Round a steel edge question

[dml66]

I'd like to round the end of a mild steel bar like I did the aluminum prototype beside it in the picture.

The aluminum one was done on a table-mounted router with a ball-bearing quarter round bit.

I don't have a mill: I do have a mini-lathe, drill press, bench grinder, metal cutting bandsaw, and metal dry cutting chop saw.

Any ideas for a way to take the vertical sharp edge off the steel bar somewhat like the aluminum?

Thanks

 

[woodchucker]

A file. look up filing on youtube to learn how to file rounded sections.

 

[deakin]

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[Jim F]

Feller at work has 1 of these.

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[Larry$]

Use one of your saws to rough it out. Bench grinder to get closer & files to finish.

 

[markba633csi]

That's one operation that a standard milling machine can't do easily-
Pretty much have to saw and then grind/file like Larry$ said

 

[Larry$]

That's one operation that a standard milling machine can't do easily-

--- without a rotary table!

 

[francist]

This is where I find my disc sander/grinder very useful. Yes I can file outside corners like this too but the disc just goes way faster and makes a nice edge.

 

[projectnut]

I use either a belt or disk sander. The grinder will also work. If using the grinder, I would first mark the material you want to remove using a radius gauge and felt marker. It makes it much easier to free hand a radius when you have a pattern to follow.

 

[Shotgun]

Mount the part on your cross-slide with the corner to be rounded on top and the the quarter-round bit in the chuck. Router bits are carbide and will cut steel. They just don't last long, and you can't push them hard at all. You might want to do most of the round with the bench grinder, and then clean it up on the lathe.