‫المحاضرة الرابعة عشر‬

Clearance in Sheet Metal Cutting

Clearance is a Distance between punch cutting
edge and die cutting edge
 Typical values range between 4% and 8% of
sheet thickness
 If the clearance too small, fracture lines
pass each other, causing double burnishing
and larger force
 If the clearance too large, metal is pinched
between cutting edges and excessive burr
results
 Clearance in Sheet Metal Cutting

FIGURE 20.5 Effect of clearance: (a) clearance too small

causes less-than optimal fracture and excessive forces; and
(b) clearance too large causes oversized burr. Symbols v
and F indicate motion and applied force, respectively.
Clearance in Sheet Metal Cutting
 Recommended clearance is calculated by:
c = at
where c = clearance; a = allowance; and t =
stock thickness
 Allowance a is determined according to type of
metal
Sheet Metal Groups Allowances

Metal group a
1100S and 5052S aluminum alloys, all 0.045
tempers
2024ST and 6061ST aluminum alloys; 0.060
brass, soft cold rolled steel, soft
stainless steel

Cold rolled steel, half hard; stainless 0.075

steel, half hard and full hard
Punch and Die Sizes for blanking
 For a round blank of diameter Db:
 Blanking punch diameter = Db ‑ 2c
 Blanking die diameter = Db
where c = clearance
Punch and Die Sizes for punching
 For a round hole of diameter Dh:
 Hole punch diameter = Dh
 Hole die diameter = Dh + 2c
where c = clearance
 Punch and Die Sizes

Figure 20.6 Die size

determines blank
size Db; punch size
determines hole
size Dh.; c =
clearance
 Angular Clearance
Purpose: allows slug or blank to drop through die
 Typical values:= 2.5 to 1.5 on each side

Figure 20.7
Angular
clearance.
 Cutting Forces
Important for determining press size (tonnage)
F=StL
where S = shear strength of metal; t = stock
thickness, and L = length of cut edge
 Example

Around disk of 150-mm diameter is to be blanked from

a strip of 3.2-mm, half-hard cold-rolled steel whose
shear strength = 310 MPa. Determine (a) the
appropriate punch and die diameters, and (b)
blanking force.
Other sheet metal cutting Operation

FIGURE 20.8 (a) Cutoff

and (b) parting.
 Slotting, Perforating and Notching

FIGURE 20.9 (a) Slotting, (b) perforating, (c) notching and seminotching.
Symbol v indicates motion of strip
Trimming process

Trimming process.
 Trimming,

 Trimming is a cutting operation performed on

a formed part to remove excess metal and
establish size. A typical example in sheet
metalwork is trimming the upper portion of a
deep drawn cup to leave the desired
dimensions on the cup.
 Shaving

Shaving process
Shaving & Beveled Tooling
 Shaving

 Shaving is a shearing operation performed

with very small clearance to obtain accurate
dimensions and cut edges that are smooth
and straight. Shaving is typically performed
as a secondary or finishing operation on
parts that have been previously cut.
 Fine Blanking

fine blanking proocess

 Fine Blanking
 Fine blanking is a shearing operation used to blank
sheet-metal parts with close tolerances and smooth,
straight edges in one step, as illustrated in Figure. At
the start of the cycle, a pressure pad with a V-shaped
projection applies a holding force Fh against the work
adjacent to the punch in order to compress the metal
and prevent distortion. The punch then moves down
with a slower-than-normal velocity and smaller
clearances to provide the desired dimensions and cut
edges. The process is usually reserved for relatively
small sheet thicknesses.
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