What is the difference between chamfer and fillet?
If you are looking for CNC machines for your product, you must be confused by this question. In the era of rapid Internet development, you can easily get a lot of answers in your browser (such as Google). These answers will usually simply describe chamfer as a chamfer or bevel, and simply explain fillet as a fillet, etc.
But these descriptions are only based on the appearance of the parts. As an engineering designer, you need to deeply understand the differences between them and the application scenarios.
Fortunately, all about chamfer and fillet and more will be covered in this article.
What are chamfer and fillet?
Chamfering is a process of softening the corners of objects with sharp corners or edges. The more common method is to process a right-angled corner into a 45-degree angled surface. But chamfers can also be made at any common angle. Chamfers help reduce stress concentrations, but admittedly, they don’t disperse stress as well as fillet. This characteristic also determines that chamfers are not suitable for use in parts that need to withstand high stress, but are more commonly used to assist part assembly.
A fillet is an inner or outer edge that has been rounded. Fillets, like chamfers, contribute to the mechanical performance and aesthetics of a part. During casting, using fillets can help you improve the manufacturability of your castings, as it facilitates the removal of the part after forming. Smooth rounded edges allow parts to slide out easily compared to sharp edges.
What are the differences between chamfer and fillet?
After understanding the definitions of chamfer and fillet, you also need to understand the difference between chamfer and fillet so that you can use them accurately.
This section will list the differences between chamfer and fillet in table form so that you can better understand.
| Chamfer | Fillet | |
| Use | The chamfering of the orifice plays the role of leading in, and the chamfering is often used for external features | To avoid hurting people with sharp edges, use fillet for internal features |
| Machining Cost | It is cheaper when parts are cut by hand | If it is milling, the cost is much higher than that of chamfering |
| Machining Time | Chamfering takes less time | Time-consuming than chamfering (the processing time is shorter when the round-end milling cutter is already used for processing complex shapes) |
| Cutting tool | Chamfers of different sizes can be machined with one tool | Special cutting tools are required to fillet the fish. This is because it has a different radius. Therefore, the type of radius you want to make determines the cutting tool you must use. |
| Coating | There are still sharp edges at the chamfer and the coating will peel off more easily | If the coating is required, fillets are preferred |
| Stress concentration | The stress is more concentrated on the part, and the part will deform more easily | Fillet can use larger radii to share the stress and prevent component deformation, best for external parts |
| Safety | Chamfering can soften sharp edges, but there are still sharp edges that can cause injury | Compared with chamfering, fillet makes the process of handling materials safer |
When do you need a chamfer and fillet?
The correct choice of fillet or chamfer can not only help you save costs but also better ensure product quality. Here, we will introduce several scenarios for choosing fillet or chamfered, so that you can better know how to choose.
Part Edges
In order to avoid no one getting hurt while checking or using it, sharp edges to chamfers may not be your best choice. In this case, a fillet that rounds the corners of all components would be a better choice.
Outside Edges
Depending on the needs of the design, you can choose fillet or chamfer. If aesthetics are not an issue, you can simply choose to chamfer to resolve sharp edges. So you won’t get hurt while using this component.
But if you need an elegant look, fillets are a better choice. However, the size of the radius should be considered. The larger the radius selected, the better the design, since large radius fillets prevent stress.
On the Hole
Fillets are not recommended if your design requires holes into which fasteners such as screws or bolts are pushed. This way the bolt or screw cannot be easily inserted. In this case, you need to use chamfers. The pointed edge will help the dowel go into the hole more easily. It will also facilitate the fastening process.
More Q&A about Chamfer and Fillet
Q1: Does a Chamfer Angle Must be 45 Degrees?
No, it’s just that 45 degrees is commonly used. But you can specify any angle, even the length of the face.
Q2: Are rounded-edge designs stronger than chamfers?
Yes, fillets are a stronger edge design than chamfers. They make the part more visually appealing than chamfers and are safer because there are no edges. Fillet also greatly improve the load-carrying capacity and fatigue resistance of the part.
Q3: Is a chamfer the same as a taper?
No, a chamfer is not the same as a taper. Taper is the gradual reduction in size over a specified length. The chamfer is only applied to the edge where two faces of the part meet.
Q4: Are fillets the same as beveled?
No, fillets are not the same as beveled. A fillet is a rounded edge between two adjacent surfaces, while a bevel is a diagonal cut that joins two parallel surfaces.
Q5: What factors need to be considered when choosing chamfers and fillets?
When selecting fillets and chamfers, you need to consider such as machining time, cost, attractive force, rate of rusting, etc.
Conclusion
By reading this article, you can clearly understand the difference between chamfering and filleting and how to choose filleting and chamfering. Familiar with the definition difference between chamfer and fillet in engineering, not only can help you choose the most suitable process and design for the project but also help you better achieve cost-effective high-quality design.
