CUTTING CLEARANCE

Cutting clearance

 It is the gap between a side of a punch and the corresponding side of the die
opening on one side of the edge, when punch is entered into the die opening

 If the cutting clearance is more than the specified limit, excessive burrs will be
present along the cut

 General cutting clearance = 0.06 x t

 Cutting Clearance

 Expressed as the amount per side.

 Proper cutting clearance is necessary for longer tool life.

 Quality of the piece part also depends on proper cutting

clearance.
EFFECT OF CUTTING CLEARANCE
 OPTIMUM CUTTING CLEARANCE:

Fig shows the blank or slug made under optimum cutting conditions.

The edge radius (die roll) is the result of initial plastic deformation, which occurred
during the first stage of plastic shear action.

•Highly burnished cut band results from the second stage (penetration) of shear action.

•The width of the cut band is approximately 1/3rd of the thickness of stock material.

•The balance of the cut is the break, which results from the third stage (fracture) of the
shearing action.
EXCESSIVE CUTTING CLAERANCE:

• In this the large gap between the punch and die cutting edges allows the stock
material to react to the initial pressure on a manner approaching that of forming
rather than cutting.
• Therefore the edge radius becomes larger and the cut band becomes smaller.
• The break shows greater irregularities due to tearing.
• When the break occurs, large burrs are present at the break edge.
• Residual incomplete fracture may sometimes be found in the finished parts.
 EXCESSIVE CLEARANCE

R
R
D
D

CC

The inset fig shows the effect of excessive clearance

•Roll over Radius R is considerably larger than when correct clearance has
being applied.

•Burnished band D is narrower

•The break off angle is excessive.

•A burr C is left on the blank.

EXCESSIVE CLEARANCE

Fig-1 shows cutting edges of punch

and die in partial penetration

Cracks have begun to form in

opposite direction.

Fig-2, Continued downward descent

of the punch causes elongation an
widening of cracks.

Their alignment is fairly good.

EXCESSIVE CLEARANCE

Fig-3.

At the bottom of stroke, separation has occurred leaving

the characteristic blank edges, as shown in inset fig.

When the die is provided with excessive clearance, less

pressure is required to effect cutting of material.
INSUFFICIENT CUTTING CLEARANCE:

• When the cutting clearance is slightly less the condition can be identified
by greater width & irregularity of the cut band.

• Because of steeper angle between the punch and die cut edges, the
resistance of the stock material to fracture is increased.

• In case of excessive clearance the burr results from dragging of the

material. While insufficient clearance compressive forces cause the burr.
INSUFFICIENT CLEARANCE

The fig. shows the effect of insufficient

clearance.

•Radius R is smaller than when correct

clearance is applied

•A double burnished band D is formed on

the blank edge

•The break off angle B is smaller than

when correct clearance is applied.

•Greater pressure is required for producing

the blank.
Referring to the above fig. it shows
INSUFFICIENT CLEARANCE

Fig – 1 shows cutting edges of a punch and die in partial penetration.

Obviously the cracks that have appeared at the punch and die sides will
not meet when extended because the clearance is insufficient.
 INSUFFICIENT CLEARANCE

Fig-2 shows the continued downward descent causes elongation

of the cracks.

The uncut area between them will be broken in secondary

fracture.
 INSUFFICIENT CLEARANCE

Fig-3 At the bottom of the stroke the secondary fracture has

occurred and a second burnished band has been produced on the
blank edge and on the strip(ref. encircled fig.)
What is BURR?

BURR:

“A rough ridge, edge, protuberance, or area, as that left on metal after cutting,
drilling, punching, etc.; in stamping it occurs in cutting dies because of the clearance
between punch and die”.
BURR SIDE:
This generally refers to the side or face of a blank or other stamping which
 

comes in direct contact with the punch in a blanking operation, and the side
or face of a blank or other stamping which comes in direct contact with the
die in piercing or perforating operation

Burrs should be practically non-existent if the cutting clearance between the punch
and the die is correct and if the cutting edges are sharp. In fact, when a die is
running in production, the degree of burr on the piece parts is an indication whether
the die is ready for sharpening

The burr side of a blank or slug is always toward the punch. The burr side of a
punched opening is always toward the' die opening.
HR : Roll-over depth.
HS : Sheared edge.
HF : Fracture depth.
Hb : Burr height.
φ : Fracture angle.
 SHEAR
ROLL OVER

FRACTURE

PUNCH or
UPPER KNIFE

ROLL OVER

DIE or
LOWER KNIFE
FRACTURE

ROLL OVER SHEAR

IMPORTANCE OF CUTTING CLEARANCE

Proper cutting is necessary to

Aid the life of die

Increase the quqlity of piece part
Improve the charateritics of the piece part
Reduce the undue stress and wear on the cutting edges of the cutting
member.
Relationship of Piece Part and Die Size.

“When pierced or blanked piece parts are measured, the measurement

Is made at the cut band ie smooth surface of the sheared area.”
 CUTTING CLEARANCE
Cutting Clearance Calculation.

The ideal clearance can be calculated by the following formula

Clearance = C x s x T max
10

Where C is a constant
= 0.005 for very accurate component
= 0.01 for normal components
s = sheet thickness in mm
T max = shear strength of the stock material in N/mm2.
OR T max = shear strength = 80% of the ultimate tensile
strength of the material
DETERMINATION OF PUNCH AND DIE SIZE:

Cutting clearance should be expressed in terms of percentage of stock

material thickness per side. It varies wrt the properties of the material

Ex:
Mica, fiber, Plastics requires less cutting clearance than any of the material.

For Piercing:

Piercing punch size = Pierced hole size(as given component drg)

Die = Hole size + 2 clearance.

For Blanking:

Blanking punch = Blanking size – 2 clearance.

Blanking size = Die size

ANGULAR CLEARANCE
&
LAND
The inner walls of the die opening are
usually made striaght through
as the blanks or slugs tend to get
jammed inside which may result undue
stress build up and may lead to
breakage of punch & die.

To avoid such a situation the die

opening are kept straight only to small
amount from the cutting edges. This
straight wall around the die opening
Is called LAND
Angular clearance

 It is a draft or taper applied to the

side walls of the die opening in
order to relieve the internal
pressure of the blank or slug as it
passes through the opening

 Soft materials require greater

angular clearance than hard. Soft
material above 3mm thickness
require more angular clearance.
 The normal value of angular clearance is 1.5° per side.

 Dies for materials like silicon steel and stainless steel are provided with
angular clearance from the cutting edge.(No land is provided).

 These materials are abrasive in nature and tend t bell-mouth the die opening
rapidly if land is provided.