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I have two filleted corners that are not at 90deg on an aluminium part. I want to measure the radius of the fillet, but I don't have fancy radius measuring tools, only calipers.

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Is there any way I can measure the fillet radius of those corners using only calipers or maybe other common tools ?

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I use low tech things for that kind of stuff. Bottle caps, jar lids, rolls of tape, 5 gallon buckets, whatever may fit the curve I am trying to measure. Once I find one that fits the curve, I measure the diameter and divide for the radius. There is a formula for finding diameter if you can set a straightedge or at least create a straight line between 2 points of an arc.

I will need to find it and add it later. It is very simple, and I used to use it a lot...

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Jack's idea is probably the best practical solution. The problem is that measurement precision becomes increasingly more critical as the radius being measured decreases. Obviously, when dealing with a fillet, we're talking about very small dimensions. A measurement error of 1/16" results in a substantial calculation error.

Calculators such as this one do the math for you, but you need accurate measurements from the tangent points and from where they cross in space.

  • The link you have is the very same formula I use. I has served me very well over the years. – Jack Apr 25 '16 at 19:24
  • "The resource you are looking for has been removed, had its name changed, or is temporarily unavailable." (link is down) – Nicu Surdu Oct 5 '18 at 15:25

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