Find the correct per-side punch-to-die clearance for your material and thickness to control burr height and edge quality.
Clearance is the gap per side between punch and die. The right amount lets the fractures from the punch and die meet cleanly, giving a good edge at minimum tonnage and tool wear.
Clearance is set as a percentage of thickness, and that percentage rises with material hardness — soft aluminum runs tight, hardened steel runs loose.
Formula: Clearance per side = % × Material Thickness
Die clearance is the gap per side between the punch and die. It is typically expressed as a percentage of material thickness, commonly 5-12% depending on material.
Too little clearance causes secondary shear, excessive tonnage, and rapid tool wear; too much causes large burrs and edge rollover.
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