Chamfer Dimensions on pressed parts

[bilbat]

I have a stainless steel bushing (1/4" diameter) being pressed into an aluminium bore. At times the bushing becomes misaligned and a burr is "rolled" at the leading edge of the bore. What should the dimensions of the leading chamfers (bore and shaft) be to maximize alignment/minimize burr? Physics and experience tells me the steeper the better but I can not find supporting documentation (so site references please!). Thanks.

 

[jbel]

The easiest way to do this is to actually step down to a smaller diameter and use that for a lead. For instance, a 1/2" OD by 1/2" long bushing. At the leading edge of the bushing (the end that will be pressed in first), grind a step diameter of 0.498"-0.499". This only needs to be about 1/8" wide. Then lightly chamfer this diameter (less than 0.015&quot. When you are ready to assemble, the bushing will enter into the aluminum plate the distance of the stepped diameter and you will have perfect axial alignment. Then just press it in.