If the clearance is too large, the slug will show a rough fracture plane C and a small burnish zone B. The larger the clearance, the greater the angle between the fracture plane C and the burnish zone B. Excess clearance makes a hole with large rollover A and fracture C so that the profile is somewhat pointed with a thin burr D.
When clearance is too large, tool life is reduced. About Us. For best results, 90 PSI of clean dry air is recommended. Are your tools made in the USA? Yes, Patco Air Tools is a proud manufacturer of high-quality American made tools. How often should I oil your tools? Can I use another source of power besides air? What types of wheels can I use for grinding? Featured New Product. This is especially prevalent when nibbling.
Fully guided systems guide the punch tip and thus eliminate punch tip deflection. A guided system produces higher-quality parts with greater interval between regrinds. This is especially noticeable at high press speeds and when punching hard materials such as stainless steel. By design, guided tool systems are more robust and components last longer. Optimizing the die clearance is the single most important contribution to punching success.
Using a clearance that is too large leads to large burrs and poor part quality. Using a clearance that is too tight results in parts with poor edge quality, reduces tool life, and leads to more frequent tool component replacement.
Achieving the optimal die clearance improves edge quality, tool life, and regrind interval and reduces cost per hit. Achieving the correct die clearance is easy, once you understand the punching process. Most punch press tooling is used for making holes in metals that have a crystalline structure with a fracture plane a line of weakness. The metal's crystalline structure defines the precise angle of the fracture plane. As the punch penetrates the material, it induces the fracture in the upper and lower surfaces of the material and pushes it into the die.
When the die has the correct clearance, the upper and lower fractures connect. This frees the slug, releasing the punching force, and discharges the slug with maximum efficiency and minimum force. A common mistake is to specify a clearance that is too tight, in the hope that it will improve the edge quality. Nothing could be further from the truth.
When the die clearance is too tight, the upper and lower fractures essentially miss each other. The only way to complete the punching process is for the punch to continue to push the slug into the die and rip the material apart.
The punch eventually produces a hole, but the ripping action results in poor edge quality and significantly more force on the punch tip. The extra force of the punch tip increases the wear, reduces the interval between regrinds, and increases tool replacement costs see Figure 5. The optimal die clearance depends on the type and thickness of the workpiece material see Figure 6. One of the easiest ways to determine the punching operation's efficiency is to look at the slugs. The slug is a mirror image of the hole.
A slug provides evidence that tells you if the clearance is appropriate for the application. The burnished land is the shiny or polished surface below the rollover that is created when the punch initially penetrates the material. When the clearance is correct, the burnished land is approximately one-third the material thickness. The dull surface below the burnished land is the fracture plane.
When the die clearance is correct and the machine is properly aligned, the burnished land and fracture plane are consistent around the slug's periphery. If the burnished land is uneven, then the tool probably is misaligned. If the burnished land is rough and extends more than one-third the material thickness, then the clearance is too tight see Figure 7. A good slug means more than just good parts. It also indicates the tool is operating at maximum efficiency, the interval between regrinds is maximized, and tooling costs are minimized.
Proper tool maintenance includes timely lubrication according to the tooling manufacturer's recommendations, sharpening using grinding equipment designed for the job, and regular maintenance of the punch press to ensure turret alignment.
Tooling manufacturers can design tooling for maximum longevity. Tooling that is designed to mitigate punching forces has a longer interval between sharpenings compared with tooling that doesn't have these features. You will find both overstocked and reconditioned items discounted for quick sale. Vogel has long used UPS as our primary transportation provider. For larger palletized… Read More ». You have excellent customer service and I wish every company that we deal with was as customer service oriented as you have been.
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