Fabrication process for noncircular vacuum seal

In fabricating a sealing flange assembly useful for oval-like and other noncircular access openings in vacuum equipment, wherein the flange assembly includes relatively hard metallic flange members having opposed, mating surfaces at least a portion of which are chamfered to define a V-shaped notch therebetween and a relatively soft metallic sealing member disposed in the notch under compression against said chamfered surfaces to effect sealing action, the steps of:

• (a) milling the mating surface of each flange member to provide the chamfered sealing surface of the desired noncircular configuration and characterized by a grooved surface profile essentially devoid of tool chatter marks and metal folds resulting from tool mark roll-over which represent nonsealable surface defects when the soft sealing member is compressed thereagainst, such milling being effected by an end mill having a central axis of rotation aligned substantially normal to said mating surface to insure uniform chamfer at arcuate as well as linear portions of the sealing surface and also to prevent harmful tool chatter marks on the sealing surface at the transition between linear and arcuate portions, said end mill including at least one cutting edge oriented at such an angle relative to the central mill axis that the desired degree of chamfer is produced when the aligned end mill is brought into cutting engagement with the mating surface, said milling being conducted in a plurality of cutting passes the latter of which are sufficiently limited in the depth of cut to substantially preclude formation of harmful metal folds on the surface resulting from tool mark roll-over;
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• (b) assembling the machined flange members and soft sealing member so that the mating surfaces, including the chamfered sealing surfaces, are in working relationship, the sealing member being disposed between said chamfered surfaces in the notch defined thereby, and compressing the assembly to press the soft sealing member into and against the opposed as-milled chamfered surfaces and thereby establish a vacuum tight seal, intimate contact between the sealing member and chamfered sealing surfaces being facilitated by the absence of nonsealable chatter marks and metal folds on said as-milled surfaces.