In metalwork, plastic forming and machining sharp right angle or 90-degree corners are always associated with risks. These sharp corners pose a potential for damaging the corners themselves or the handlers involved in moving the product. To address this issue, two main features are utilized: chamfers and bevels. Chamfer and Bevel might sound very much alike, but there are certain differences between the two.
In this article, we will analyze the core differences between chamfers and bevels. Moreover, it will comprise their geometric characteristics, how they are manufactured, and other related features. Read on for more useful information on this topic!
Understanding Chamfers
A chamfer refers to a cut made on a workpiece along its edge. Usually, this cut takes place between two adjacent surfaces being perpendicular to each other. Normally the chamfers are made at 45 degree angle. Importantly, this cut does not run through the thickness of the material between two parallel surfaces.
Chamfered edges perform several tasks during the manufacturing process. They successfully eliminate sharp edges to improve safe handling. Also, chamfering enhances the appearance of the machined components. Moreover, chamfers make it easier for the various parts to be joined together. Chamfer mills and chamfer planes are the most common means used in chamfer manufacturing.
Understanding Bevels
A beveling is a cutting technique indicating an inclined surface between two flat surfaces. They also incorporate a sloped edge to help with workpiece assembly and provide both aesthetics and safety solutions.
However, while chamfers are cuts that go halfway, beveled edges are cuts that go the full length. Therefore in the case of forming beveled edges, it is expected that more material is taken compared to forming chamfered edges.
Such bevel angles may also differ depending on one application or another. Nevertheless, the most common beveled angles are 45 degrees.
Now let’s look further at the differences between chamfers and bevels.
Chamfer vs. Bevel: Measurement Methods
To quantify such features, the optical comparators and chamfer gauges are common equipment used by professionals.
An optical comparator has the incorporation of a magnifying lens for visibility. This tool makes it easy to measure angled surfaces. It’s available in both hand and electronic form, but the electronic version is more efficient.
Chamfer gauges contain a spring-loaded plunger having an anvil. The anvil is placed on the inclined plane to facilitate quantitative measurements. These may be mechanical or digital or maybe computerized for CNC kind of installations.
A bevel protractor is only limited to measuring bevel angles. These rotary protractors are assembled with a circular scale in between two rotary blades. Normally, these protractors are placed on the bevel surface adjacent to the blade.
In contrast, chamfers are measured by a chamfering ruler. This ruler is a stainless steel tool. It has an L-shape and contains two scales perpendicular to each other. It’s a typical tool for determining chamfer angles and lengths, with relative ease.
Chamfer vs. Bevel: Connotation
In some cases, it is possible to observe that the bevel edges of workpieces are inclined toward one another and connect parallel planes.
Oppositely, chamfering always seems like cuts/cutting. Therefore, the formation of chamfer requires cutting some material.
Chamfer vs. Bevel: Shape
These two features are distinguished by shape and geometry. Chamfers are normally produced at 45 degrees. Usually, used to connect adjacent surfaces.
Bevels can be of any degree. Although bevels of 45 degrees are usually more frequently used. As compared to chamfers, bevels are between parallel surfaces.
By chamfering all the sharp corners of a workpiece(square), the inner shape becomes an octagonal shape. On the other hand, a fully beveled prismatic jobpiece has a rhombus shape.
Chamfer vs. Bevel: Machining Means
Chamfers and bevels are common features of a part design. However, the machining techniques used are different.
Specially, beveled edges may need certain tools. For example, plate beveling machines are used for flat/plane surfaces. Pipe bevelers are used on pipes and tubes only.
While chamfers are usually undertaken with standard end milling machines. On the lathe machines, rotary broaching is often employed for creating chamfers on cylindrical billets.
Chamfer vs. Bevel: Functions
Chamfers and bevels are applied for appearance and functionality. Safety is the primary purpose of chamfer. Even if it has other uses in the construction world. By eliminating exposed edges, chamfers act to minimize injury hazards. Moreover, they improve articles’ appearance such as mirrors and glass-top tables.
Chamfers can reduce stress concentration. Therefore, they help increase the load-carrying capability. Fitted parts have beveled edges. They form bevel joints. Even though, in particular cases, these help smooth interfacings between two or more parts.
Why design chamfers and bevels for parts?
When chamfers and bevels are comprehended, new questions arise as to the role they play. These features are essential in most sectors of the economy. They affect the functional and the ornamental aspects in several considerations.
1. Provide Safety
The primary reason for chamfers and bevels is safety. They are dangerous and sharp edges may cause cuts. They also can catch on loose garments.
Chamfering reduces the thickness of sharp corners by cutting to have a lesser edge. This reduces injury risks. For instance, while designing the countertops, the edges are chamfered to avoid accidents. Nonetheless, bevels can result in a sharpened point on the other corner. Therefore, bevels are not well-suited for the parts that are in frequent use. Nevertheless, beveling is useful in maintaining close tolerances between the joining surfaces.
2 Assembly and Disassembly
Bevels and chamfers are fundamental to assemblies where one part fits into another. Some components are joined by chamfered edges before being joined together. When added together, the edges are at a 90-degree angle, with a secret seam. The heads of many nuts and bolts are chamfered. Eliminating sharp edges improves their durability and maneuverability characteristics. Some of the edges on the fasteners had been made sharp and could break under wrench force.
Slopes that are beveled to some extent greatly help in parts joining. For instance, when trying to join two long wooden surfaces, bevels are of great help. They enhance access, contact, and fastening resistant forces.
3 Decorative Purpose
Chamfers and bevels are central to the designs. Smooth edges make machined parts appearance look better than when they have sharp edges. The lack of sharp edges conforms to better engineering and design. For example, in woodworking, chamfers sometimes enhance product appearance. They produce neat, classy lines for the final finish.
4 Fit & Alignment
Angled edges make assemblies optimally work. Because these ensures correct fit into each other seamlessly. Tapered edges increase the potential for flawless fits when joining parts. Rounding shape edges that fit well with other parts to form a beveled shape. In intricate structures, for instance, wooden frames of racks, beveled elements are well-suited and interlock well allowing easy fastening.
5 Reduced Friction
Chamfers and bevels raise smooth ridges. Ultimately it diminishes rubbing. Reduced surface roughness is crucial in sliding parts to improve wear protection. In the automobile manufacturing sector, bevels are used in the creation of bevel gears. They provide correct teeth geometry for interaction, which eliminates wear and energy loss. Moreover, prevents brake squeal, noise, and other unwanted frictions.
6 Manufacturability
Bevels and chamfers are normally applied after component manufacturing. These features also lead to increased time and costs of machining. However, if necessary, the introduction of chamfers or bevels in the initial design phase can be vital. This approach makes it possible to avoid secondary machining.
Using special dies offers the added advantage of creating integrated bevels and chamfers directly at machine shops. It will save time and money. Higher tolerance levels can lead to longer machining times and increased costs. In addition, chamfering can reduce the time that is taken to perform machining of right angles.
Conclusion
In conclusion, bevels and chamfers are indispensable on the edges. They increase the appearance, mechanical properties, fit, and safety of the component. These features are popular across industries including machining, automotive, and electronics industries. Their basic surface treatments significantly improve the aesthetics, as well as the utilitarian features of machined parts.
To get the best beveled or chamfered edges, Tops Precision has the best manufacturing facility. Call us now for a no-obligation free quote today!
