The short answer Burr height is set by die clearance first, then by punch sharpness. Hold clearance at 4 to 8 percent of thickness for carbon steel, specify a maximum burr height per edge, and treat rising burr as the trigger to regrind: a die that made 0.03 mm burrs can reach 0.15 mm after 50,000 hits. What a burr actually is Every sheared edge has up to four zones, and the burr is the last o...

The short answer Multiply the total cut perimeter in millimetres by the sheet thickness and by the material's shear strength in kilograms per square millimetre, then divide by 1,000 for metric tons. Add 20 to 30 percent for tool wear, then check the press can deliver that force near bottom dead centre. The formula, term by term Every cutting operation in a press, whether it is blanking, pierci...

The short answer Blanking cuts a shape with 5 to 10 percent clearance per side, leaving rollover, a 30 to 50 percent shear band, a torn fracture zone and a 0.1 to 0.3 mm burr. Fine blanking clamps the strip, cuts at 0.5 to 1 percent clearance and yields an 85 to 100 percent sheared edge. What each process does to the edge Both processes use a punch and a die, and both produce a part in a singl...

The short answer Custom stamping suits almost anything that can be cut or formed from flat sheet: automotive brackets, electrical terminals, EMI shield cans, washers and shims, heat-sink fins, appliance panels. The shared conditions are a sheet form, a thickness under about 6 mm, a simple 2D or formed shape, and volume above roughly 10,000 parts a year. The one condition every stamped part sha...

The short answer Stamping forms parts from sheet in a die at 30 to 1,500 strokes a minute; CNC machining cuts them from solid at 5 to 60 minutes a part. Stamping carries a die cost of 3,000 to 30,000 dollars and wins above roughly 5,000 to 10,000 parts a year; CNC carries almost no tooling and wins below that. Where the two cost structures come from The two processes are not variations on a th...