******George, the number 1 choice is not to remove the fillet radius at all
to begin with, BUT when you HAVE TO, as in our application, all possible
precautions should be taken into consideration hence, cut the largest RADIUS
you can possibly fit in, an .040 to .060 RADIUS ground on the c'bore/end mill
is the max size for us. FYI, this radius actually serves as a bridge to
prevent stresses from gathering and having a party in the corners and wreak
havoc.....This is general common practice especially in the Aerospace and
Nuclear Industry.

Butch, Do you think shot peening after the machining would help prevent 
stress concentrations? Bill Jepson

 
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