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Cutting Clearance Calculation
Cutting Clearance Calculation
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The intentional gap provided between punch and die for proper shearing of
material is known as clearance. It is always expressed in amount of clearance per
side between the cutting edges of punch and die. The amount of cutting clearance
is depends upon the sheet thickness and type of material. Soft or ductile material
should have lesser die clearance because it may flow into the gap and the hard or
thick material required more die clearance for proper shearing process.
The quality of piece part and tool life both depends upon the amount of
clearance. The clearance provided between punch and die may be optimum,
insufficient and excessive which seriously effect the tool life and part quality.
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Insufficient clearance:-
Insufficient die clearance reduces the burr on the component but seriously effect
the tool life. It blunts or wear/tear the cutting edges of punch and die which
increases the resharpening frequency of blunt punches and die. Thus the
maintenance cost of tool is increased. Insufficient die clearance produces very
small roll over radius and more than one cut bends during the metal shearing
process.
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Excessive cutting clearance :
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In excessive cutting clearance, a large rollover radius & heavy burr is produced
and the length of cut bend is negligible. Here tool life is increased but product
quality is very poor. To remove this excess burr, shaving operation is necessary.
Sheet thickness
Cutting clearance in %
' t ' in mm
of sheet thickness
<1 2.5 - 4 %
1 - 3 5 - 8 %
3 - 5 8 - 10 %
sheet thickness
Cutting clearance in %
' t ' in mm
of sheet thickness
<1 4 - 5 %
1 - 3 6 - 8 %
3 - 6 8 - 15 %
In blanking operation the die is a responsible member, so the size of die is equal
to the size of given blank / component and the size of punch is calculated by
subtracting the clearance all around from the size of die.
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Example:
Determine the sizes of punch and die for given washer.
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Size of die = Size of punch + clearance all around.
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2/1/22, 12:07 PM Cutting clearance calculation
Blanking operation:
In blanking operation die is a responsible member.
therefore,
Size of die = Size of blank.
Size of die = dia. 100 mm
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Er. KD Singh
I am a tool designer. I share my knowledge and experience on this platform.
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expiation is very good and its very use full learners thanks
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