VILLA MACHINE ASSOCIATES INC.

Trusted Manufacturing For Tight Tolerances And Tough Materials

DESIGN FOR MANUFACTURING: CHAMFER VS RADIUS

by: Matthew Viau on Oct 15, 2015


When it comes to an edge break on your components a chamfer is always going to be easier to machine. As we see in the pictures below, a chamfer tool has some leeway for error, on both the top of the cut and the side. This allows us to "touch off the tool and go" so to speak. The radius cutter (fillet), as seen opposite the chamfer, leaves very little room for error. The cutter must be calibrated axially and radially separately, otherwise the cutter may dig into the part if it is down or in too far, or conversely truncate the radius if it is too far away. On top of that radius cutters are only good for one radius. A 1/4" chamfer cutter (a very popular size) can cut a little baby 0.005" chamfer or a big 0.100" chamfer with the same cutter. None of this means you can't have radii, it just means you should to be judicious about whether the cost justifies the result.

TL;DR - Chamfers are cheaper than radii when it comes to edge breaks.

design for manufacturing fillet vs bevel design for manufacturing fillet vs bevel

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