Chamfers

A chamfer is a transitional edge formed between two intersecting surfaces of a part, typically created by cutting away the sharp corner to produce a beveled edge. It is usually specified as a straight cut at a designated angle, most commonly 45 degrees, and a defined width. Chamfers differ from bevels in that a bevel may refer to any edge cut at an oblique angle, whereas a chamfer specifically shortens and angles the edge at the joint rather than across the entire thickness. A fillet, by contrast, is a rounded corner rather than a straight edge.

Chamfers are defined by two main parameters: an angle and a depth or width. A common specification is 2 mm by 45°, meaning a 2 mm chamfer measured along the edge at a 45-degree angle. Chamfers can be symmetric, affecting both sides of an edge equally, or asymmetric for specific fits or clearances. They may be external, on the outside of a feature, or internal, such as at a hole entrance or slot.

Applications and purposes include easing assembly, deburring sharp edges, improving safety by removing knife-like edges, and providing a lead-in for fasteners. Chamfers can slightly reduce sharpness and stress concentration compared with a square edge, though a rounded fillet is typically more effective for fatigue resistance.

Manufacturing and inspection methods encompass milling, turning, drilling deburring, and grinding to create the chamfer, followed by inspection with calipers or gauges. In technical drawings, chamfers are indicated with the width and angle notation, for example “2 x 45°” or “3 mm x 45°,” to ensure consistent fabrication and fit.