Narrow Brass Tubing - Smothing Out Cut Ends

1. Cut the tubing with a jeweler's saw. Use about a #2 or finer blade for that diameter. That alone will create a nice flat edge. Alternatively, use a Dremel or Flex shaft machine with a cut-off wheel -- not as good, but a Jeweler's saw takes lots of practice until you stop breaking blades.
2. File the end flat to rid the burrs. If you hold the tube in a pin vice you can put a nice chamfer in a second. Alternatively, a touch with a rubber abrasive wheel on a flex shaft machine or dremel will do nicely.
3. Use a jeweler's conical or bud burr, about 2.5 mm in diameter. Dremel also sells these (overpriced, but okay for one time buy). DO NOT use it in a machine. Put the burr in a pin vice and make a pass or two for the inside chamfer. You might also use a #2 center drill -- that you can hold in fingers because the shank is bigger -- a twist or two and you've got a nice chamfer on the inside.

The entire process I described takes less time than it takes you to read the above. I'd make them up in a mini production line -- one operation at a time and do a few dozen at a time.

Boris

I do this with a very small carbide countersink, and simply put a chamfer inside the ends. Typically I dress the outer edges with a fine jewlers file.

Jim

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chuck the tube up in your drill press, crank the rpms up, roll up a small piece of fine emory cloth & insert it into the end of the tube

Do you have a lathe? If not, you now have an excuse to get one. If (when) you do, cut the tubing in the lathe with a really sharp parting tool and then touch up the inside with a sharp countersink to remove what little burr will be there.

If you want to flare the end a little, you could do it with the work spinning and a tool that looks like a rivet set for hollow end rivets in the tailstock.

Ted

I was wondering how long it would take for someone to suggest this, the best possible solution to this simple problem! I agree! I've deburred such items that way as long as I can remember.

Harold

Cut it with a dremmil tool and you will have very little to polish. Use the thin cut off tools.