Cutting clearance calculation:-

Cutting clearance is calculated either by using the formula

or in percentage of sheet thickness which are based on
experimental results.

• Cutting clearance calculate by using a formula :-

                                                  
Cutting clearance  C :-
                     _________
 C = c x t x √ T max/10      mm /side
                         
where,
    c = constant
    c = 0.01     (for normal work)
    c = 0.005    (for very accurate work)
    t = sheet thickness in mm
    T max = ultimate shear strength in  N/mm^2

  

• Cutting clearance in percentage of sheet

thickness:-

Material Cutting clearance in %

      of sheet thickness
M.S 2.5 - 5 %
ALUMINIUM 1 - 1.5 %
BRASS 1.5 - 3 %

Cutting clearance for blanking is also calculated as:

For soft materials:

Sheet thickness Cutting clearance in %

 ' t '  in mm         of sheet thickness
<1 2.5 - 4 %
1-3 5-8%
3-5 8 - 10 %

For hard materials:

sheet thickness  Cutting clearance in %

 ' t '  in mm        of sheet thickness
<1 4-5%
1-3 6-8%
3-6 8 - 15 %





Sizes of die and punch in blanking and piercing
operation:

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.

Size of die = Size of blank

Size of punch = Size of die - cutting clearance all around

In piercing operation the punch is a responsible member,

so the size of punch is equal to the size of hole and the size
of die is calculated by adding the clearance all around in the
size of punch.
 

Size of punch = Size of hole

Size of die = Size of punch + clearance all around.