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04 Cutting Clearance

The document discusses cutting clearance in press tools. Cutting clearance is the gap between the punch and die that allows the material to be cut. Having the proper clearance is important for tool life, part quality, and reducing stress. Optimum clearance results in a clean cut with a small burr. Insufficient clearance increases burr size, while excessive clearance reduces cut quality. The document provides formulas for calculating clearance based on material thickness and examples of determining punch and die sizes.

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gaurav deshmukh
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396 views18 pages

04 Cutting Clearance

The document discusses cutting clearance in press tools. Cutting clearance is the gap between the punch and die that allows the material to be cut. Having the proper clearance is important for tool life, part quality, and reducing stress. Optimum clearance results in a clean cut with a small burr. Insufficient clearance increases burr size, while excessive clearance reduces cut quality. The document provides formulas for calculating clearance based on material thickness and examples of determining punch and die sizes.

Uploaded by

gaurav deshmukh
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPT, PDF, TXT or read online on Scribd
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PRESS TOOLS

CUTTING CLEARANCE
Cutting clearance:
Cutting clearance is the gap
between the side of the punch and the
corresponding side of the die opening on
one side of the edge, when the punch is
entered into the die opening. It is
expressed in the amount of clearance
per side.
IMPORTANCE OF CUTTING CLEARANCE
Proper cutting clearance is necessary to:

1. Aid the life of the die.


2. Increase the quality of the piece part.
3. Improve the characteristics of piece part.
4. Reduces undue stress and wear on the cutting edges
of the tool.
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.
INSUFFICIENT CUTTING CLEARANCE:

When the cutting clearance is slightly less the condition can be identified by
greater width 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.
BURR SIDE:

The burr side is the adjacent to the break. The burr side is also called
because of a noticeable burr developed in this side. Burr should be practically
very little if the cutting clearance between the punch and die is correct and if the
cutting edges are sharp.

The burr side of the blank or slug is always towards the punch (die starts
shearing) the burr side of the punched opening is always towards the die opening.
DETERMINATION OF PUNCH AND DIE SIZE:
For Piercing:
Pierced hole size =Piercing punch size
Die = Hole size + 2 clearance.

For Blanking:
Blanking punch = Blanking size – 2 clearance.
Blanking size = Die size

For finding the cutting clearance following formula to be used.

Clearance = c X s X

 for above 3 mm clearance =


(1.5x s) x (s-0.015) x
Where

s = sheet thickness in mm
c = constant= 0.005
T max = shear strength = 80% Ultimate tensile strength in N/mm2

If we take c as 0.005 we get a Clarence which yields a better and


cleanest work piece but required a higher cutting force and considerably more
energy. If we take c as 0.01 cutting force energy as its minimum but finish will be
bad. The usual practice however is to take c as 0.01
Applying Clearance

Given diagram illustrates how to


apply clearance to obtain correct size of
hole and blank.

When the metal is punched out


from the functional part and the metal
around the opening is scrap, the die is
made to desired part size and the
clearance is subtracted from (applied to)
the punch size as shown in figure A.

when the slug is discarded and the


punched opening is functional, the required
clearance is applied (added to) the die
opening as shown in figure B.
PROBLEMS:
1. Calculating the clearance for punching a 2mm sheet. Tmax
to be assumed to be 300 N/mm2.

Clearance = c X s X

= 0.01 X 2 X

= 0.02 X

= 0.12 mm/side

Therefore clearance on one side = 0.12 mm


2. Determine the punch and die dimension for the component Given below. Sheet
thickness 0.5mm, stainless steel sheet, T max is 400 N/mm2. C = 0.01

Clearance = c X s X
= 0.01 X 0.5 X
= 0.03 mm/side
Blanking punch:
 Blanking die dimension is the same as that of component dimension.
 Piercing punch size is the size of the pierced hole.

Piercing Die:
Determine the punch and die dimension for the component Given below. Sheet
thickness 2mm MS,T max is 400N/mm2 C=0.01.
Clearance = c X s X
= 0.01 X 2.0 X
= 0.13 mm/side
 Blanking die dimension is the same as that of component dimensions.
 Piercing punch size is same as component size.

Piercing Die size = component size + clearance


= 10.00 + 0.26
= 10.26mm
ASSIGNMENTS
1.0 What will be the characteristics of the component.
1.1 When the cutting clearance is optimum.
1.2 When the cutting clearance is excessive.
1.3 When cutting clearance is in sufficient.

2.0 Fill in the blanks :


2.1 The burr side of a blank is towards the ……….. side.
2.2 The burr side of a slug is towards the ………… side.
2.3 The burr side of a punched opening is towards the ………side.
2.4 Blanking punch size is ……………
2.5 Blanking die size is ……………
2.6 Piercing punch size is ……………
2.7 Piercing die size is ……………
3.0 Determine the punch and die size to produce the following components.
1. Material : Copper
Thickness : 2mm 2. Material : Brass
Thickness : 1mm
Tmax : 350 N/mm²
Tmax : 350 N/mm²

. Material : Aluminium
Thickness : 0.3mm 4. Material : M S
Tmax : 350 N/mm² Thickness : 1.5mm
Tmax : 400 N/mm²

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