We drill a lot of these bars......


Attachment 504034

.....and use an angle grinder to debur the ends to approx 6mm concave rad - does the job but not very consistent and a nasty job.
Looking at corner rounding tools but its cost prohibitive - £30-40 a tip and copper is abrasive
So thinking of a custom tool more like a wood working tool with clamped carbide strips (maybe 4 @ 10x3x50 ish) so the rough corner rad can be easily reground and the strip advanced.

Does that sound feasible or is grinding a 6mm +/-0.5 corner rad in carbide just expensive and £30-40 a tip is reasonable?

Any thoughts gratefully received, cheers