Just for clarity I will be using the ASME Y14.5 standard (section 1.8.16) for chamfer dimensioning. That is, where the called out dimension is the opposite or adjacent side of a triangular chamfer, and not the hypotenuse.

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The importance of holes on a cnc machined parts is no less than the threads. Parts are usually made to assemble with other ones. When it talks about assembly, the standards tolerances below takes important roles on it. In other words, the relationship between the two mating parts could be determined by "fitting". Generally speaking, there are three kinds of fitting below:

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So I dug into how to get Fusion360 to make back (backside, bottom chamfering, etc.) chamfers. And unfortunately, it’s not simple or straight forward. And in all honesty, the information seems to be stagnant out there. The best resource for Fusion 360 I’ve found has been NYC CNC, great guys and very informative content. They have a great, although dated, video ( https://youtu.be/HsBR2_6h4mM ) of how they have tackled the problem of back side chamfering if you want to see where I am starting from.

First challenge is finding a backside chamfering tool which fits your part and has adequate reach. I am using Iscar’s MultiMaster upper and bottom chamfering tools (MM HDF100-090-2T05). You can use whatever tool you want, but check the following:

A transition fitting is known as a slip or push fit for the mating parts. This kind of fitting is usually required a highly accurate alignment or tolerance between the mating parts. Under a transition fitting, the mating parts could perform a fitting without excess play or movement in the assembly.

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The slide fitting is so called clearance fit or loose mating. The mating parts with a slide fitting could slide in and out without any restriction. A grinding process would be helpful to optimize the surface quality on the mating parts to slide freely between each other.

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Now here is the clever bit, to get Fusion to recognize the tool as a back chamfer tool we need to define the tool compensation point. Normally, this point is the revolves centerline at the lowest Z height. But we don’t want that so we need to tell Fusion where we want to compensate the tool point.

Besides, considering an optimize performance on fixing the bearing into the hole, the hole finished with burnishing process could provide a firm and consistence surface quality. You could refer to Sandy Munro's comments on the motor of Tesla Model S Plaid at 8'28''.

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Recently I found myself with the issue of needing to chamfer a part feature, but I couldn’t reach it with the traditional chamfering approach.

Whatever tool you’re using you need to bring it into Fusion360. Iscar makes it very easy as they have files package for every tool. If your tool of choice doesn’t have a 2D file, you can always draw it from scratch using provided dimensions. You can also setup a parametric template to use in the future if you’re so inclined.

How is Bilateral Upper Extremity abbreviated? BUE stands for Bilateral Upper Extremity. BUE is defined as Bilateral Upper Extremity rarely.

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This is where this method really shines, when we use our new form tool and create a 2D contour or Trace or pocket for chamfering we don’t need to apply any hacky work arounds in the “stock to leave” box or play with the contour height selection, or even need to make a template tool path, it just works! Select the 2D or 3D contour that requires a chamfer and you’re good.

Some caveats however, if your tool diameter is very close to the minimum cutting radius be sure to use feed optimization option. If your tool diameter is also close to the minimum cutting radius, avoid steep Z height changes along 3D contours. You get a “step” in the tool path and may cause gouging. Additionally, if the solid model has the chamfers modeled in, you’ll need to create another form tool with the compensation point at the lower cutting edge.

When we create the form tool we select the tool profile we created, select the axis of rotation (arrow points down), and most importantly select the compensation point we just created. And that’s it! The new form tool is in your tool library.

Front and backchamfer tool

On the same plane, create a new sketch and draw out HALF of the tool’s profile with the sketch origin being on the tool’s centerline.

An interference fitting is so called press fit, tight fit or friction fit. It is usually used in fixing the bearing on to a shaft or a hole, a dowel pin into a hole. It may sometimes use to assembly spare parts into a single unit to reduce the raw material and production cost.

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