Most Mechanical Engineers Misunderstood this simple Feature

Published: 17 May 2026
on channel: Master Mechanical DESIGN

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In this video, we revisit one of the most debated DFMA suggestions from the previous video- undercut relief at stepped shaft shoulders.

Many engineers suggested that a simple chamfer on the mating hole can solve the same problem more easily and economically.

So, in this video, we will discuss:
• why shaft shoulder fillets are created during machining
• why undercut reliefs are used
• undercut vs chamfer approach
• assembly and manufacturing considerations
• and where each method actually makes sense in real engineering
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Chapters:
00:00 Undercut vs Chamfer fitment
01:09 Common argument
02:07 Assumptions clarity
02:49 Corner radius during turning
04:27 Chamfer method
05:49 Undercut relief Reason 1
08:06 Undercut relief Reason 2
09:55 Undercut relief Reason 3
11:57 Undercut relief Reason 4
12:44 Conclusion

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#DFMA
#mechanicaldesign #Machinedesign #Mechanical #Solidwork #Mechanicalengineering #mastermechanicaldesign

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