To the group,
After monitoring the discussion for a while, I thought that I would share my
experiences. As a person who bears scars from encounters with sharp edges
inside equipment, I can state with certainty that outside CORNERS are by far
the worst offenders. Knocking off these corners at 45 degrees will eliminate
a large percentage of cut hazards, especially on small brackets. Most of the
remaining problems with edges will be caused by burrs from manufacturing
problems. Properly adjusted and sharpened punches and dies will not leave
large burrs. A punched piece of metal will have smooth edges on one side and
a sharper edge on the other. This is a normal result of the process. The
sharper edge is usually only capable of causing superficial scratches on
skin. Metal alloys that tend to develop larger burrs are generally put
through a surface sanding process after being punched. A good sheet metal
vendor can help a great deal. As for testing edge sharpness, women's
stockings (and pantyhose) are often ruined by snags. Some brands are more
susceptible than others. A piece of this material stretched over cardboard,
with thin foam or felt padding between, would make a good tester.
Scott Lacey
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