A fillet is a rounded corner that removes sharp edges or corners on a manufactured part. It is typically used to improve the appearance and safety of the part, as well as to increase its strength and durability. A chamfer is a beveled edge used to remove sharp edges or corners on a manufactured part. It is typically used to improve the appearance and safety of the part, as well as to make it easier to assemble and fit into other components. The main difference between a fillet and a chamfer is their shape – a fillet has a rounded corner, while a chamfer has a beveled edge.
|Differences between Fillet and Chamfer
|Fillet makes the material handling safer.
|The sharp edges of chamfer can cause injury.
|Fillet can avoid sharp edges from hurting people. Internal features often use fillet.
|Holes use chamfers for lead-ins. Chamfer is often used for external features.
|If it is milling, relatively speaking, the cost of fillet is higher than that of chamfer.
|The cost of chamfer is slightly cheaper when the part is cut by hand.
|Curved edges are not very easy to make. Unless a ball end mill is used for machining complex shapes, it is more time-consuming than chamfer.
|Chamfer takes less time to process than fillet.
|Different cutting tools are required to machine fillets of different radius.
|Chamfers of diffrent sizes can be machined with one cutting tool.
|Fillet is preferred when coating is required.
|There are still sharp edges at the chamfer, and the coating is easy to peel off.
|Fillet shares stress over a larger radius, preventing deformation of the part.
|Stress is concentrated on a part, which can easily cause deformation of the material.
Fillets are typically used on corners where two surfaces meet at a sharp angle, while chamfers are used on edges where the surfaces meet at an angle.