How to achieve a clean edge when shortening small screws using a Dremel Cut off Blade Dremel EZ S

I am using a Dremel 38mm EZ SpeedClic cut-off wheel to shorten 8BA steel screws to size but the leading edge is throwing up a burr preventing an easy running fit onto the test nut. The problem can be overcome by running the screw into an 8BA die but I have never had to to do this when using a piercing saw as the resulting cut face is always clean and free to accept the test nut. Am I using the wrong type of cut-off blade or is there something else I should be aware of? The srew is being firmly held in a dedicated chuck with zero wobble.

I assume you are running the spindle, i.e. the screw is rotating..

If you can you swing the Dremel over slightly ( I mean ever so slightly) to give a (barely) convex top to the end of the screw, it ought to clean it up as it goes..?

PS I use these wheels to 'nick' and shape HSS / carbide - if your steel is a bit soft, try slowing the Dremel a bit..

Edited By DiogenesII on 21/06/2022 21:07:43

The screw in the chuck remains stationary, the Dremel being run at high speed to provide the necessary torque without stalling the motor.

Make a plate of the same thickness as the wanted screw length. Drill and tap 8BA holes, insert screws and file to length. The end of the screw is automatically cleaned when the screw is unscrewed.

Andrew

As DII says rotate the lathe spindle it should help. Why not use a chamfer tool. I shorten 12 and 14 ba screws and finish off with a chamfer tool and have occasionally used a graver but it takes a bit of practice.

Why not take off the burr and add a small chamfer with a fine tooth or diamond file ?

Put a nut on the screw before cutting then screw it off after.

Edited By Hopper on 22/06/2022 00:39:53

Rotating the screw by hand with the chuck key whist feeding the Dremel will do way with the burr

Hi Dave - Just tried out rotating the screw by means of a mandrel mounted handle whilst running the Dremel which has given a burr free end face with easy acceptance of the test nut. Problem solved I would have said. Thanks for the tip.