See the attached image. I have about two dozen plates, 3/4" thick aluminum with a 3/8" chamfer around the edge. Previously I did this with a 3/16" square end mill & I 'stairstepped' down in about .020" increments. Then, I sanded the steps out. Sanding took a lot more time & effort than I had anticipated. Is there a better way to do this on my WorkBee? I have a .250" diameter x 45° chamfer bit, but it doesn't seem right for this. Maybe something like this: Amana Tool 45704 Carbide Tipped V Groove 90 Deg x 1/2 D x 1/2 CH x 1/4 Inch SHK Router Bit maybe not that exact bit, but something similar that's appropriate for aluminum. I could take out most of the material with a square end mill, then clean it up with this? Or is there something different or better that I don't know about? & I'm using a Dewalt router so i can only go down to around 16000RPM. Thanks...
I recall seeing someone use a chamfer bit with spiral flutes, that will give less tool pressure and a much better finish. I think it was this guy... nyccnc chamfer - YouTube
One of those videos deals specifically with large chamfers like mine - different ways to do it & pros & cons of each. I'm just going to try a ball end mill & step down the chamfer with it. It's basically the same thing I did before, but the ball end mill should result in a better finish & less cleanup. Hopefully none.
I recommend stepping down with a flat end mill for roughing, then step up with the ball end for finishing, ball ends do not cut well on the tip of the tool.
