International Journal of Engineering and Advanced Technology (IJEAT)

ISSN: 2249-8958 (Online), Volume-2 Issue-2, December 2012

A Circularity Analysis of Different Clearances

in the Sheet Metal Punching Process
V Bram Armunanto, Yudit Cahyantoro NS, Kaleb Priyanto

b. The angle formed by the punch and dies.

c. The cutting pressure needed.
Abstract— Nowadays, technological development demands d. Suitable hardness of the punch and dies material.
efficiency of time and energy in all fields in order to create a e. Other demands such as the smoothness of the surface of
product that can compete in the global market. Breakthroughs
and innovations are needed merely to survive in manufacturing
the tools.
industry. Punching is the common process of using a cutting
punch and die in the manufacturing process. A variety of
physical phenomena occur in the metal cutting process such as
metal flow, friction between the material and tools, process heat
and changes in the microstructure of the material. Much
research conerning dimensions, tolerances, cutting angles and
cutting force has been carried out. This article discusses and
examines the relationship between clearance, punch and dies
circularity and circularity of the product of the punching process.
Testing has been conducted using various punches with different
diameters and different circularity conditions. The Coordinate
Measuring Machine (CMM) which has an accuracy of 1 micron
was used to measure the diameter of the punch and the dies, the
clearance and circularity of the punch and dies, and the
resulting product. The question is: is the circularity of the Figure 2 : Mould Punching Machine
product of punching affected by the clearance or by the
circularity of such tools?
Drawing annotation :
Keywords- CMM. 1. blanking punch 10. piercing plate
I. INTRODUCTION 2. blanking plate 11. pressure pad
3. ejector 12. punch base
The punching process is the process of making a hole
4. guide/ring plate 13. ejector bridge
using a machine installed with a cutter in the form of a
5. inner punch 14. base plate
punch and die set, where the machine pushes the punch to
cut the material with the dies at the bottom. 6. inner ejector pin 15. latch bolt
7. pressure pin 16. upper frame
8. backup plate 17. lower frame
9. holding ring 18. column
Clearance is the difference in size between punch and dies
in a series of punching processes, measured from one side.
The difference in size may vary due to punches and dies
having a maximum and minimum size, which means that
there are differences in the size of one punch or dies. The
amount of clearance in a process of punching ranges
between 5% - 7.5% of the thickness of the material being
Figure 1 : The Position of the Punch-Dies and Material cut. If the clearance is too small (about 3%) it can cause a
Many factors need to be considered in the punching tear in the material being cut. If the clearance is too large
process. These include: (above 10%) it can cause burr / fracture the tip.
A punch and die set can be round, square, triangular, slot
a. The dimensions of the punch and dies used.
shaped or in another particular shape. Punch and dies have a
certain size with a certain tolerance. Good clearance is a
difference in size that allows the best result from the
Manuscript published on 30 December 2012.
* Correspondence Author (s)
punching process.
V Bram Armunanto*, Mechanical Engineering, Sebelas Maret The effects of clearance on the cutting process include:
University, Surakarta, Indonesia. = the magnitude of the cutting force required.
Yudit CNS, Mechanical Engineering, Sebelas Maret University, = the lifespan of the punch as the upper cutting tool.
Surakarta, Indonesia.
Kaleb Priyanto, Mechanical Engineering Sebelas Maret University, = the lifespan of the dies as the lower cutting tool.
Surakarta, Indonesia. = the smoothness of the resulting surface / surface finish.
© The Authors. Published by Blue Eyes Intelligence Engineering and
Sciences Publication (BEIESP). This is an open access article under the
CC-BY-NC-ND license http://creativecommons.org/licenses/by-nc-nd/4.0/

Published By:
Blue Eyes Intelligence Engineering
Retrieval Number B0936112212/12©BEIESP and Sciences Publication (BEIESP)
Journal Website: www.ijeat.org 277 © Copyright: All rights reserved.
 Circularity Analysis of Different Clearance on Sheet Metal Punching Process
characteristics are essential for the suitability of the product.
In the manufacturing industry with its accuracy to the
micron meter, geometric characteristic circularity means that
dimensions and tolerances absolutely must be met, and other
associated requirements must also fit.

Figure 3 : Punching Process Faults

Figure 6 : Product Circularity

Specifications related to circularity tools and products for
the punching process with 9 mm diameter: (Ø 8-13 mm)
Fine circularity: Circularity of the punch < 0.002 mm.
Circularity of the dies < 0.002 mm.
Circularity of the product < 0.004 mm.
Middle circularity: Circularity of the punch < 0.005 mm.
Circularity of the dies < 0.005 mm.
Figure 4 : Specifications of a Punch and Die. Circularity of the product < 0.012 mm.
Rough circularity: Circularity of the punch < 0.015 mm.
Circularity of the dies < 0.015 mm.
Circularity of the product < 0.025 mm.

II. PUNCH AND DIES USED FOR TESTING

5.1 5.2 5.3

Figure 5 : Resulting Pieces of the Punching Process.

Figure 5.1: resulting pieces of a small clearance.

Figure 5.2: resulting pieces of a suitable clearance.
Figure 5.3: resulting pieces of a large clearance..
Figure 7 : Punch and Dies
The following table shows the thickness of the material used One die and three punches made of SpKNL and XW5 of
and the amount of clearance in the process of cutting sheet varying tolerances were used for testing. All of punch and
metal in accordance with DIN 1623. dies diameters were 9 mm. The tools used met
manufacturing standards related to surface smoothness =
Material N6, hardness of the end product HRC = 62 and occuring
Nr Spring Back Clearance
Thickness corner formations. The tools used and their specifications
1 0,10 mm 0,010 mm 0,02 mm are shown in table 2.
2 0,25 mm 0,020 mm 0,04 mm
Min Ø Max Ø Circularity Clearance
3 0,40 mm 0,025 mm 0,06 mm Tool Name
(mm) (mm) (mm) (mm)
4 0,63 mm 0,030 mm 0,08 mm
5 1,00 mm 0,050 mm 0,11 mm Dies 01 9.326 9.328 0.008 ---
6 1,25 mm 0,055 mm 0,13 mm Punch 01 9.005 9.006 0.007 0.161
7 2,00 mm 0,080 mm 0,25 mm
8 2,50 mm 0,100 mm 0,28 mm Punch 02 9.012 9.012 0.014 0.158
9 3,20 mm 0,120 mm 0,30 mm Punch 03 9.017 9.018 0.022 0.155
10 4,00 mm 0,130 mm 0,35 mm
Table 2: Analysis of Tools Used.
Table 1 : Material – Spring Back - Clearance

Circularity / roundness is a cross-section calculated from the

difference between the nearest and farthest distance to a
point on the outside of the circle from the center. Geometric
Published By:
Blue Eyes Intelligence Engineering
Retrieval Number B0936112212/12©BEIESP and Sciences Publication (BEIESP)
Journal Website: www.ijeat.org 278 © Copyright: All rights reserved.
 International Journal of Engineering and Advanced Technology (IJEAT)
ISSN: 2249-8958 (Online), Volume-2 Issue-2, December 2012
III. DESIGN ANALYSIS OF PUNCH AND DIES a. The thickness of the material.
b. The type of material.
A. Modelling of the Punch
c. The dimensions of the material to be cut.
The punch is the male part of the cutting tool and works d. The types of material for the cutting tools.
with an up and down movement from above. The shape of e. The surface finish and cutting results.
the surface intersection depends on the shape desired.
For industry using conventional machinery of this type,
feeding, cutting speed or strokes per minute are not the
main objective.
B. Specific Requirements
In industries that use Fine and Progressive Stamping
Dies, speed and product performance are essential. The
surface smoothness of the tools, the centricity, cylindricity
and circularity of the punch and dies are also very important.
We can imagine that with a movement of materials and
tools at a speed of about 500 strokes per minute, if demands
outside of these dimensions are neglected, tools will quickly
Figure 8 : Punch Tools. wear out, the product will not perfect, or tools may break
Specifications applicable to the punch size: because the hole is not round / off center.
Piercing punch, d1 = d + f Fulfilling the demands of the tools and equipment in the
Blanking punch, D1 = D – f – 2c punching process is expected to reduce the number of errors
and reject products which will both increase productivity
d1 : punch diameter for piercing process. and create a precise mold development that meets all the
d : piece diameter from the piercing process. requirements of the industry in all fields.
f : material spring-back.
D1 : punch diameter for the blanking process. V. RESULTS AND DISCUSSION
D : piece diameter from the blanking products.
A. Figures and Tables
2c : 2x clearance between punch-dies.
After running multiple tests, the results of the punching
B. Modelling of the Die process can be observed in the following table :
The die is the female cutting part located on the under Øpunch,mm Ø Dies,mm Ø Product Product
No
side. It has notching hole profiles in a similar shape to that (circularity) (circularity) (mm) Circularity
of the punch. The die form can be made as an intact die 9.033 0.014mm
plate or plate insert or mounted in a circuit of holders. 9.006 9.328 9.042 0.016mm
1
(0.007mm) (0.008mm) 9.036 0.017mm
9.041 0.018mm
9.049 0.021mm
9.012 9.328 9.042 0.024mm
2
(0.014mm) (0.008mm) 9.043 0.028mm
9.045 0.032mm
9.053 0.029mm
9.018 9.328 9.052 0.033mm
3
(0.022mm) (0.008mm) 9.053 0.034mm
9.056 0.035mm
Figure 9 : Die Tools.
Table 3 : Diameter and Circularity of the Product.
Specifications applicable to the die size:
From the test results can be computed average circularity
Piercing die, d2 = d + f + 2c
product and made the following table:
Blanking die, D2 = D – f
d2 : die diameter for the piercing process.
d : piece diameter from the piercing processs.
F : material spring-back.
D2 : die diameter for the blanking process.
D : piece diameter from the blanking product.
2c : 2x clearance between punch-dies.

IV. MANUFACTURING REQUIREMENTS

A. General Requirements
For the manufacturing industry in general, dimensions and
the tolerances are the two key factors. Clearance between
the punch and dies are major factors associated with:

Published By:
Blue Eyes Intelligence Engineering
Retrieval Number B0936112212/12©BEIESP and Sciences Publication (BEIESP)
Journal Website: www.ijeat.org 279 © Copyright: All rights reserved.
 Circularity Analysis of Different Clearance on Sheet Metal Punching Process
[6] J.B Moerbani, “Punching Tools 1 and 2,” ATMI Polytechnic Lab.,
ATMI Solo Press, Indonesia 2005, pp. 7-14.
[7] B Sudibyo and Djunarso, “Tolerance,” ATMI Polytechnic Lab. ATMI
Solo Press, Indonesia, 1991.
[8] VB Armunanto, “Industrial Metrology” ATMI Polytechnic Lab.,
ATMI Solo Press, Indonesia, 2004.
[9] D. Brokken, “Numerical Modelling of Ductile Fracture in Blanking”
PhD Thesis, Eindhoven University of Technology, Netherland, 1999.
[10] Chang T.M. “Shearing of Metal Blanks” Institute of Metals, 1951. pp.
393-414.
[11] Xiao Jingrong and Jiang K, “Stamping Technology” Mechanical
Industry Press, Beijing, 1993. pp 137-143.

V Bram Armunanto Magister Mechanical Engineering, Sebelas Maret

University, Surakarta, Indonesia, Industrial Metrology HandBook for
Polytechnic ATMI, Manual Book for Small Measuring Tools.

Yudit Cahyantoro NS Magister Mechanical Engineering, Sebelas

Maret University, Surakarta, Indonesia.
Table 4 : Tools Clearance – Product Circularity Graph. Kaleb Priyanto Magister Mechanical Engineering, Sebelas Maret
University, Surakarta, Indonesia.

Table 5 : Tools – Product Circularity Graph.

VI. CONCLUSION
Figure 10 : Raskin Punching Machine.
The results of the analysis of the punching process and
measurements are as follows:
1. The circularity of the product is smaller than the
clearance between the punch and dies.
2. The circularity of the product is always greater than the
circularity of the punch and dies.
3. The diameter of the product hole is always larger than
the diameter of the punch.
4. The diameter of the product hole is always smaller than
the diameter of the dies.
5. Increasingly tight / small clearance between the punch
dies does not guarantee the product circularity punching
the smaller / stable. Figure 11 : CMM Measuring Machine.
6. The main effect on the product’s circularity is the
circularity of the tools used, the punch and die.
As such, while it was previously assumed that the tolerance
and size of the punch and die were the main determinant of
product circularity, this research indicates that the circularity
of the punch and die are in fact the more influential factors.

REFERENCES
[1] Donald F Eary, “Techniques of Pressworking Sheet Metal Prentice -
Hall, Inc., Englewood Cliffs, New Jersey 1974, pp. 15–24.
[2] Hermann W Pollack, Tool Design, Reston Publishing Company, Inc.,
Virginia, 1976, pp. 23–35.
[3] Donaldson Lecain Gold, Tool Design, Tata Mc Graw – Hill
Publishing Company Ltd., New Delhi, 1978, ch. 4.
[4] Heinrich L Hilbert, “Stanzereitechnik,” Schneidende Werkzeuge, Carl
Hanser Verlag, Muenchen, 1971.
[5] J R Paquin, “Die Design Fundamentals,” Industrial Press Inc., 200
Madison Avenue, New York, N.Y.10016, 1962.
Anthony Davidson, “Handbook of Precision Engineering, Vol.10.
N.V Philips, Gloeilampenfabrieken, London, 1974.

Published By:
Blue Eyes Intelligence Engineering
Retrieval Number B0936112212/12©BEIESP and Sciences Publication (BEIESP)
Journal Website: www.ijeat.org 280 © Copyright: All rights reserved.