{"id":8171,"date":"2026-11-02T10:00:00","date_gmt":"2026-11-02T02:00:00","guid":{"rendered":"https:\/\/maxtormetal.com\/?p=8171"},"modified":"2026-11-02T10:17:59","modified_gmt":"2026-11-02T02:17:59","slug":"shear-blade-clearance-5-10-percent-rule-setup-guide","status":"publish","type":"post","link":"https:\/\/maxtormetal.com\/ja\/shear-blade-clearance-5-10-percent-rule-setup-guide\/","title":{"rendered":"\u30b7\u30e3\u30fc\u30d6\u30ec\u30fc\u30c9\u306e\u30af\u30ea\u30a2\u30e9\u30f3\u30b9\uff1a\u30e1\u30ab\u30cb\u30ba\u30e0\u3001\u7247\u5074 vs \u7dcf\u9699\u9593\u3001\u8abf\u6574SOP\u3001\u304a\u3088\u3073\u54c1\u8cea\u7ba1\u7406\u57fa\u6e96"},"content":{"rendered":"<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"683\" src=\"https:\/\/maxtormetal.com\/wp-content\/uploads\/2026\/11\/image-2-1024x683.jpeg\" alt=\"Guillotine shear blade clearance diagram showing the horizontal gap between upper and lower blade edges at the cutting point\" class=\"wp-image-8174\" srcset=\"https:\/\/maxtormetal.com\/wp-content\/uploads\/2026\/11\/image-2-1024x683.jpeg 1024w, https:\/\/maxtormetal.com\/wp-content\/uploads\/2026\/11\/image-2-300x200.jpeg 300w, https:\/\/maxtormetal.com\/wp-content\/uploads\/2026\/11\/image-2-768x512.jpeg 768w, https:\/\/maxtormetal.com\/wp-content\/uploads\/2026\/11\/image-2-18x12.jpeg 18w, https:\/\/maxtormetal.com\/wp-content\/uploads\/2026\/11\/image-2-600x400.jpeg 600w, https:\/\/maxtormetal.com\/wp-content\/uploads\/2026\/11\/image-2.jpeg 1536w\" sizes=\"(max-width: 1024px) 100vw, 1024px\" \/><\/figure><p><strong>Quick Answer:<\/strong> Shear blade clearance is set at 5\u201310% of material thickness, measured at the cutting point. For 6 mm mild steel, that means a 0.30\u20130.60 mm gap \u2014 but the percentage is a starting range, not a final answer. Confirm the working value with a test cut on your actual material, verify clearance at three points along the blade with a feeler gauge, and treat any burr height above 5% of thickness as a trigger to recheck the gap.<\/p><p><strong>Engineering Note:<\/strong> Shear blade clearance is the perpendicular gap between the upper and lower cutting edges, expressed as a percentage of material thickness. It governs the ratio of burnished to fractured zone on the cut edge, the burr height, and the blade load per stroke. Maxtor Metal&#8217;s setup and QC workflow treats clearance as a material-specific process parameter \u2014 not a fixed machine setting \u2014 and documents it per job alongside blade condition and edge radius readings. [\u2192 <a href=\"https:\/\/maxtormetal.com\/product\/shear-blade\/\" target=\"_blank\" rel=\"noreferrer noopener\"><strong><em>See Maxtor Metal shear blade specifications and material options<\/em><\/strong><\/a>]<\/p><p>Shear blade clearance is the horizontal gap between the upper and lower blade edges at the cutting point, and on a guillotine shear it is normally set as a percentage of material thickness rather than a fixed number. Get it wrong and the cost is not abstract: strip scrap from poor edge quality accounts for 5%\u201310% of total cost of ownership \u2014 a figure that compounds across every regrind cycle.<\/p><p>The 5\u201310 percent rule is a starting range rather than a specification. Treat the machine manual as the authority, then find the working value by iterating on the actual sheet, blade sharpness and rake angle (<a href=\"https:\/\/www.ursviken.com\/how-to-calculate-the-proper-blade-clearance-for-different-materials-in-hydraulic-shears\/\" target=\"_blank\" rel=\"noreferrer noopener nofollow\"><em><strong>Ursviken<\/strong><\/em><\/a>, 2025). Note the convention split: some suppliers state blade clearance per side, others state the blade-to-blade gap, so confirm which figure the <a href=\"https:\/\/maxtormetal.com\/product\/shear-blade\/\" target=\"_blank\" rel=\"noreferrer noopener\"><strong><em>Maxtor Metal shear blade specification<\/em><\/strong><\/a> uses before you dial anything in. Maxtor Metal works to the per-side reading, which doubles the number at the gap.<\/p><blockquote class=\"wp-block-quote is-layout-flow wp-block-quote-is-layout-flow\"><p><strong>Key Takeaways<\/strong><\/p>\n\n<ul><li>Shear blade clearance is a percentage of material thickness, set at the cutting point.<\/li>\n\n<li>The 5\u201310% band is a starting range; the machine manual governs the final value.<\/li>\n\n<li>Confirm whether a published figure is blade clearance per side or the total blade-to-blade gap.<\/li>\n\n<li>Poor edge quality drives 5%\u201310% of total cost of ownership through strip scrap.<\/li><\/ul><\/blockquote><p>A note on sourcing: this guide draws on published shear-cutting references \u2014 the AHSS Guidelines, ispatguru&#8217;s shearing process documentation, and equipment-maker guidance from Ursviken and Sureay \u2014 alongside Maxtor Metal&#8217;s own shop-floor experience. Where a figure comes from an independent source it is cited as such; where it reflects a manufacturer&#8217;s internal acceptance limit, that is stated plainly so you can weigh it accordingly.<\/p><h2 class=\"wp-block-heading\" id=\"6c4e00f0-4f13-4b7f-81c6-26a595708094\">Edge mechanics<\/h2><div class=\"wp-block-image\"><figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"749\" height=\"468\" src=\"https:\/\/maxtormetal.com\/wp-content\/uploads\/2023\/10\/shearing-blade5-\u526f\u672c11.jpg\" alt=\"Shear blade Edge mechanics\" class=\"wp-image-4807\" srcset=\"https:\/\/maxtormetal.com\/wp-content\/uploads\/2023\/10\/shearing-blade5-\u526f\u672c11.jpg 749w, https:\/\/maxtormetal.com\/wp-content\/uploads\/2023\/10\/shearing-blade5-\u526f\u672c11-300x187.jpg 300w, https:\/\/maxtormetal.com\/wp-content\/uploads\/2023\/10\/shearing-blade5-\u526f\u672c11-18x12.jpg 18w, https:\/\/maxtormetal.com\/wp-content\/uploads\/2023\/10\/shearing-blade5-\u526f\u672c11-600x375.jpg 600w\" sizes=\"(max-width: 749px) 100vw, 749px\" \/><\/figure><\/div><p>Shear blade clearance decides how a cut fails, and that failure is what produces either a clean edge or a burr. The mechanism is worth understanding because it explains why the recommended band moves with material and thickness rather than staying fixed.<\/p><p><em>In short: clearance controls the split between smooth burnish and rough fracture on the cut edge \u2014 understanding this mechanism is what turns the 5\u201310% band from a guess into a tuning range.<\/em><\/p><h3 class=\"wp-block-heading\" id=\"f8781d01-737e-43ac-9f62-3af657aee62e\">Burnish and fracture zones<\/h3><p>A sheared edge is not one surface. It is four zones stacked through the material thickness: rollover, where the blade first contacts and plastically deforms the sheet into a rounded, bent region; the burnish or shear zone, a smooth band formed while the blade compresses and rubs the material; the fracture or rupture zone, a rougher angled region where the crack propagates; and the burr, thin elongated metal pushed out at the exit edge (<a href=\"https:\/\/www.ispatguru.com\/shearing-process-and-shears\/\" target=\"_blank\" rel=\"noreferrer noopener\"><em><strong>is<\/strong><\/em><\/a><a href=\"https:\/\/www.ispatguru.com\/shearing-process-and-shears\/\" target=\"_blank\" rel=\"noreferrer noopener nofollow\"><em><strong>patguru<\/strong><\/em><\/a>, 2019; <a href=\"https:\/\/ahssinsights.org\/forming\/cutting\/shear-affected-zone\/\" target=\"_blank\" rel=\"noreferrer noopener\"><em><strong>AHSS Guidelines<\/strong><\/em><\/a>, 2021).<\/p><h3 class=\"wp-block-heading\" id=\"0a1a8e0c-5396-4c19-a8a6-e1bd578606bf\">Rollover and burr formation<\/h3><p>Clearance sets the split between the smooth and rough portions of that edge. The burnish zone ends where crack initiation begins, so penetration depth equals rollover height plus burnishing zone height. The rough fracture zone then grows with ductility, thickness and clearance, which means a larger clearance shrinks the burnish share, enlarges the fracture share, and pushes more material into the burr (ispatguru, 2019).<\/p><h3 class=\"wp-block-heading\" id=\"59b69566-ec75-42d2-a44a-4bb89d86638d\">Force, rake, and clearance interplay<\/h3><p>The general shearing range runs from 2% to 10% of material thickness, and the correct point inside that range depends on the workpiece. Harder materials and greater thickness need larger clearance. Set it too wide and the edge comes out rounded and distorted with a burr and a higher shearing load; set it too tight and the blade leaves a double cut, sometimes called secondary shearing. Ductile material produces a taller burr at any given clearance (ispatguru, 2019).<\/p><p>That is the mechanism behind the band. The next section turns it into numbers.<\/p><h2 class=\"wp-block-heading\" id=\"8082f27c-854c-434e-8cb5-0b7ed98ae1a6\">The 5\u201310% rule<\/h2><p>The 5\u201310 percent rule says the shear blade clearance should sit between 5% and 10% of the metal thickness you are cutting. That band is the starting point for mild steels, not a universal setting, and the <a href=\"https:\/\/ahssinsights.org\/forming\/cutting\/cutting-blanking-shearing-trimming\/\" target=\"_blank\" rel=\"noreferrer noopener\"><em><strong>AHSS Guidelines<\/strong><\/em><\/a> note that published recommendations place mild-steel die clearance at 5% to 10% of metal thickness. The same source flags a convention trap worth settling before you touch the machine: for punched holes, those figures are per-side values. Vendor charts on the open web often frame the identical 5%\u201310% band as the total blade-to-blade gap instead. Confirm which convention your chart uses before you convert a number into a shim stack, because a 10 mm mild-steel cut reads as 0.5\u20131.0 mm per side under one reading and 0.5\u20131.0 mm total under the other.<\/p><p><em>In short: the 5\u201310% band is a defensible starting range for mild steel, not a universal answer \u2014 the working value must be confirmed by test cut on the actual material, and the convention (per side vs total gap) must be established before any number is set.<\/em><\/p><h3 class=\"wp-block-heading\" id=\"b6c29c0a-3fe0-41f4-85e7-0ba14ad35705\">Material-based bands<\/h3><figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"683\" src=\"https:\/\/maxtormetal.com\/wp-content\/uploads\/2026\/11\/image-1-1024x683.jpeg\" alt=\"A per-material clearance chart for carbon, stainless, HSLA, aluminum with %t bands\" class=\"wp-image-8173\" srcset=\"https:\/\/maxtormetal.com\/wp-content\/uploads\/2026\/11\/image-1-1024x683.jpeg 1024w, https:\/\/maxtormetal.com\/wp-content\/uploads\/2026\/11\/image-1-300x200.jpeg 300w, https:\/\/maxtormetal.com\/wp-content\/uploads\/2026\/11\/image-1-768x512.jpeg 768w, https:\/\/maxtormetal.com\/wp-content\/uploads\/2026\/11\/image-1-18x12.jpeg 18w, https:\/\/maxtormetal.com\/wp-content\/uploads\/2026\/11\/image-1-600x400.jpeg 600w, https:\/\/maxtormetal.com\/wp-content\/uploads\/2026\/11\/image-1.jpeg 1536w\" sizes=\"(max-width: 1024px) 100vw, 1024px\" \/><\/figure><p>The band widens as the material gets stronger. The AHSS Guidelines put the range at roughly 6% for mild steel, rising to 16% or higher once tensile strength passes 1400 MPa, and note that ISO 16630 hole-expansion testing specifies 12% punch-to-die clearance while optimal clearance for advanced high-strength steel appears to be approximately 15%. Treat those as directional anchors rather than a lookup table: they come from a technical body&#8217;s guidance program, and the underlying figure is a historical baseline rather than a recent test series.<\/p><p>For AHSS and UHSS applications where standard D2 blades are reaching their clearance and wear limits, see the <a href=\"https:\/\/maxtormetal.com\/tungsten-carbide-inlaid-shear-blades-ahss-roi-guide\/\" target=\"_blank\" rel=\"noreferrer noopener\"><em><strong>tungsten carbide inlaid shear blades ROI guide for AHSS lines<\/strong><\/em><\/a> for a full TCO comparison.<\/p><h3 class=\"wp-block-heading\" id=\"21141697-24f4-476f-98c1-841485cbd3a1\">When to deviate<\/h3><p>Deviate upward when the material work-hardens or when edge quality matters more than tool life. Deviate downward only when your press capacity is the binding constraint, since tighter clearance raises cutting force. The honest position is that 5%\u201310% is a starting point you tune from, not an answer you inherit.<\/p><h3 class=\"wp-block-heading\" id=\"583d233e-13ae-47f7-a523-ee65a19cd66c\">Parallelism and thickness effects<\/h3><p>Clearance is only as good as its consistency along the blade. A machine set to 8% at the ends but drifting to 11% mid-blade will burr in the middle and shear cleanly at the edges, which is why parallelism is checked separately from the nominal gap. Thicker stock amplifies the same error: the absolute gap grows with thickness, so a fixed mechanical misalignment becomes a larger percentage deviation.<\/p><h2 class=\"wp-block-heading\" id=\"cc562ceb-869a-4d28-ac05-6044dacbf96d\">Setup SOP<\/h2><p>A repeatable shear blade clearance setup follows one sequence: baseline the gap, verify parallelism, lock, test cut, iterate. The steps below assume the machine is locked off, the blades are clean and correctly seated, and you have a feeler gauge set, a dial indicator with a magnetic base, and scrap of the material you are about to run. Budget 30 to 45 minutes for a first setup on a machine you do not know well.<\/p><p><em>In short: measure clearance at three points along the blade before every setup change, verify parallelism within 0.02 mm, lock the adjusters, then iterate from a test cut \u2014 the sequence matters because locking adjusters commonly shifts the gap.<\/em><\/p><h3 class=\"wp-block-heading\" id=\"f8d0196f-b130-4a8d-a9aa-f2f38a3b7f1b\">Feeler gauge baseline<\/h3><figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"683\" src=\"https:\/\/maxtormetal.com\/wp-content\/uploads\/2026\/11\/image-1024x683.jpeg\" alt=\"Dial indicator mounted to sweep blade length for parallelism and clearance calibration\" class=\"wp-image-8172\" srcset=\"https:\/\/maxtormetal.com\/wp-content\/uploads\/2026\/11\/image-1024x683.jpeg 1024w, https:\/\/maxtormetal.com\/wp-content\/uploads\/2026\/11\/image-300x200.jpeg 300w, https:\/\/maxtormetal.com\/wp-content\/uploads\/2026\/11\/image-768x512.jpeg 768w, https:\/\/maxtormetal.com\/wp-content\/uploads\/2026\/11\/image-18x12.jpeg 18w, https:\/\/maxtormetal.com\/wp-content\/uploads\/2026\/11\/image-600x400.jpeg 600w, https:\/\/maxtormetal.com\/wp-content\/uploads\/2026\/11\/image.jpeg 1536w\" sizes=\"(max-width: 1024px) 100vw, 1024px\" \/><\/figure><p>Set the upper blade to its lowest position and insert the feeler gauge stack at the left end, center, and right end of the blade. Three points is the minimum; add points every 500 mm on blades longer than 2 m. Adjust the gap until the gauge drags with light resistance rather than passing freely or binding. Record all readings before touching anything else, because the spread across those points tells you whether you are correcting clearance or parallelism.<\/p><h3 class=\"wp-block-heading\" id=\"21195531-f9bc-4871-ad36-1ef8cc40b7f9\">Dial indicator calibration<\/h3><p>Mount the dial indicator on the lower blade and sweep the upper blade through its stroke, recording readings at several positions along the length. Blades should sit within <strong>0.02 mm<\/strong> of each other, and the gap needs immediate recalibration once it exceeds that. Note what kind of number this is: there is no single ISO standard that sets a shear-blade parallelism limit, so <strong>0.02 mm is Maxtor Metal&#8217;s internal acceptance target<\/strong>, not an industry-mandated figure. The relevant general framework is dimensional and geometric tolerancing \u2014 <strong>ISO 286<\/strong> defines the IT tolerance grades used for precision blade geometry (IT6 for cutting-edge position, parallelism to the holder reference face, and flatness; IT7 for length, width, and mounting-hole position), and <strong>ISO 2768<\/strong> supplies general tolerances where a drawing carries no individual callout. Treat the 0.02 mm as a tighter-than-general shop specification built on that framework (<strong><em><a href=\"https:\/\/www.iso.org\/standard\/45975.html\" target=\"_blank\" rel=\"noreferrer noopener\">ISO 286-1:2010<\/a>; <a href=\"https:\/\/www.iso.org\/standard\/7748.html\" target=\"_blank\" rel=\"noreferrer noopener\">ISO 2768<\/a><\/em><\/strong>). The reason such a tight target is worth holding is mechanical: on a <strong>3,000\u20134,000 mm blade, a 0.1\u20130.15 mm deviation across the length is enough to produce visible taper<\/strong> on the cut edge (consistent with precision blade geometry standards under ISO 286 \/ ISO 2768). Lock the adjusters and re-check the gap at the same three points; locking commonly shifts it.<\/p><h3 class=\"wp-block-heading\" id=\"fceabce8-faa9-4431-97a5-c39c16c05fc4\">Test cut and iteration<\/h3><p>Run a slow test cut on scrap and read the edge. Burrs or tearing mean the gap is too large; rubbing or excessive tightness means it is too small. Change clearance in small increments and re-cut rather than adjusting several variables at once, then log the final gap, the material grade and thickness, and the indicator readings against the job number so the next setup starts from a known point.<\/p><p>Each regrind removes material from the blade thickness. For the shim calculation method that compensates for this dimensional change and restores correct overlap after each cycle, see the <a href=\"https:\/\/maxtormetal.com\/regrinding-thickness-reduction-compensation-shim-guide\/\" target=\"_blank\" rel=\"noreferrer noopener\"><strong><em>regrinding thickness reduction compensation and shim stack guide<\/em><\/strong><\/a>.<\/p><blockquote class=\"wp-block-quote is-layout-flow wp-block-quote-is-layout-flow\"><p><strong>Verify your result:<\/strong> the test cut should shear cleanly with no visible taper along its length, and a repeat indicator sweep should hold the gap within 0.02 mm after the adjusters are locked.<\/p><\/blockquote><h2 class=\"wp-block-heading\" id=\"94f21d07-a8b5-44ce-8a67-d406389a43c2\">Field case: correcting excessive burr on 6 mm S355<\/h2><div class=\"wp-block-image\"><figure class=\"aligncenter size-full is-resized\"><img loading=\"lazy\" decoding=\"async\" width=\"722\" height=\"672\" src=\"https:\/\/maxtormetal.com\/wp-content\/uploads\/2023\/10\/cutting-blade-knife6.jpg\" alt=\"sheeter-knives\" class=\"wp-image-5679\" style=\"width:652px;height:auto\" srcset=\"https:\/\/maxtormetal.com\/wp-content\/uploads\/2023\/10\/cutting-blade-knife6.jpg 722w, https:\/\/maxtormetal.com\/wp-content\/uploads\/2023\/10\/cutting-blade-knife6-300x279.jpg 300w, https:\/\/maxtormetal.com\/wp-content\/uploads\/2023\/10\/cutting-blade-knife6-13x12.jpg 13w, https:\/\/maxtormetal.com\/wp-content\/uploads\/2023\/10\/cutting-blade-knife6-600x558.jpg 600w\" sizes=\"(max-width: 722px) 100vw, 722px\" \/><\/figure><\/div><p>The clearest way to see why 5\u201310% is a starting rule and not a fixed answer is to walk through a commissioning-style troubleshooting case. This is a <strong>representative field case built on documented industry practice<\/strong> rather than a measured customer study: the machine, material and measurement sequence reflect how this problem typically appears on a hydraulic guillotine shear, and the underlying rules \u2014 the 5\u201310% band, the ~10% structural-steel practice, and multi-point feeler-gauge verification \u2014 are all publicly documented.<\/p><p><em>In short: this case demonstrates that a clearance value can sit inside the published 5\u201310% range and still produce unacceptable edge quality \u2014 the percentage is the starting calculation, and the cut edge is the verification tool.<\/em><\/p><h3 class=\"wp-block-heading\" id=\"4edccff3-3764-46d3-b465-2323930eb473\">The situation<\/h3><figure class=\"wp-block-table\"><table><tbody><tr><th>Parameter<\/th><th>Value<\/th><\/tr><tr><td>Application<\/td><td>Hydraulic guillotine shear<\/td><\/tr><tr><td>Material<\/td><td>S355 structural steel<\/td><\/tr><tr><td>Nominal thickness<\/td><td>6.0 mm<\/td><\/tr><tr><td>Measured thickness<\/td><td>5.94\u20136.06 mm across the test sheets<\/td><\/tr><tr><td>Blade<\/td><td>Hardened cold-work tool-steel shear blades<\/td><\/tr><tr><td>Initial clearance<\/td><td>~0.30 mm<\/td><\/tr><tr><td>Target window<\/td><td>~0.30\u20130.60 mm (5\u201310% starting rule)<\/td><\/tr><\/tbody><\/table><\/figure><p>The problem appeared after the machine was switched from thinner sheet to 6 mm structural steel. The operator kept the previous clearance setting rather than recalculating the gap from the new material thickness \u2014 a common error where clearance is treated as a fixed machine setting instead of a material-dependent process parameter. The first test cuts showed a noticeably larger burr on the underside of the cut edge, a relatively short burnished zone, and a more irregular fracture zone. The operator suspected dull blades and considered replacing them.<\/p><h3 class=\"wp-block-heading\" id=\"88133dc2-3a93-43b7-abe9-ec80deb96d22\">Attempt 1 \u2014 replace the blades (rejected)<\/h3><p>The first response was to suspect blade wear. Inspection, however, showed the cutting edges were still serviceable \u2014 no significant chipping or abnormal rounding. Replacing the blades without correcting the clearance would have treated the symptom rather than the process condition, so the next step was to verify the actual gap.<\/p><h3 class=\"wp-block-heading\" id=\"a7e78a58-8ad8-45d7-bd1b-78e25dd92cd2\">Measurement sequence<\/h3><p>The machine was stopped and isolated per the site&#8217;s maintenance procedure. Blade seats were cleaned and checked for trapped scale, chips and debris. Sheet thickness was measured at several points with a micrometer rather than trusting the nominal 6 mm designation. Clearance was then measured at the left, center and right portions of the cutting length with calibrated feeler gauges. The machine manufacturer&#8217;s definition of clearance was used throughout the adjustment. This multi-point approach follows published shear-machine guidance, which requires clearance verification at several points along the blade rather than assuming the machine&#8217;s nominal setting equals the actual gap \u2014 Mittler Bros. and other shear manuals specify checking left, center and right with feeler gauges, and the Australian Steel Institute notes that optimum clearance depends on both material properties and thickness.<\/p><h3 class=\"wp-block-heading\" id=\"3cfe1565-a036-4f4f-ab80-e0cf07b74ae6\">Attempt 2 \u2014 keep the 5% setting (insufficient)<\/h3><p>After measurement, the initial gap was approximately 0.30 mm \u2014 about 5% of the measured 6 mm thickness:<\/p><p><code>6.0 mm \u00d7 5% = 0.30 mm<\/code><\/p><p>That value was technically inside the general 5\u201310% starting range, yet edge quality remained unsatisfactory. This is the key point: <strong>a value can sit inside the published percentage range and still not be the optimum setting for a particular machine-and-material combination.<\/strong> Clearance is also affected by blade condition, blade geometry, machine rigidity, alignment, and the mechanical properties of the workpiece. Betenbender&#8217;s shear guidance makes the same observation for steel work \u2014 roughly 10% of thickness usually gives a good cut edge, and clearance may be increased for harder or thicker material, but not beyond about 15%.<\/p><h3 class=\"wp-block-heading\" id=\"c4fde7bf-9b3c-4d2d-bec0-8e3da396308c\">Attempt 3 \u2014 increase clearance (resolved)<\/h3><p>Clearance was increased progressively toward approximately <strong>0.50\u20130.55 mm<\/strong>, corresponding to roughly <strong>8\u20139%<\/strong> of the 6 mm material thickness, then a fresh test cut was made under the same material and machine conditions. Edge quality improved visibly. The important caveat: this is not a claim that 0.50 mm is universally correct for S355 \u2014 it is simply the working setting found in this troubleshooting example. Published material studies make the same point about clearance being material-specific: voestalpine&#8217;s ALFORM technical data compares 4%, 10% and 16% clearance on 3 mm ALFORM 700 M and shows the cut-section geometry changes markedly with the ratio, with excessive clearance increasing burr and edge denting while reducing the shearing-zone share.<\/p><h3 class=\"wp-block-heading\" id=\"caaddfe9-3881-4e25-a953-33aba3962373\">Effect, recorded honestly<\/h3><p>Rather than inventing precise burr-height numbers, a credible record notes the observable change:<\/p><figure class=\"wp-block-table\"><table><tbody><tr><th>Parameter<\/th><th>Initial condition<\/th><th>After adjustment<\/th><\/tr><tr><td>Material<\/td><td>S355<\/td><td>S355<\/td><\/tr><tr><td>Nominal thickness<\/td><td>6 mm<\/td><td>6 mm<\/td><\/tr><tr><td>Measured thickness<\/td><td>5.94\u20136.06 mm<\/td><td>5.94\u20136.06 mm<\/td><\/tr><tr><td>Clearance<\/td><td>~0.30 mm<\/td><td>~0.50\u20130.55 mm<\/td><\/tr><tr><td>Clearance ratio<\/td><td>~5%<\/td><td>~8\u20139%<\/td><\/tr><tr><td>Blade condition<\/td><td>Serviceable<\/td><td>Same<\/td><\/tr><tr><td>Test batch<\/td><td>Same heat \/ comparable material<\/td><td>Same<\/td><\/tr><tr><td>Burr<\/td><td>Pronounced \/ unacceptable<\/td><td>Visibly reduced<\/td><\/tr><tr><td>Cut edge<\/td><td>Irregular fracture zone<\/td><td>More uniform fracture<\/td><\/tr><tr><td>Blade change<\/td><td>Not required<\/td><td>Not required<\/td><\/tr><\/tbody><\/table><\/figure><p>If a team wants to make this rigorous, the fields worth adding are burr height (mm), rollover height (mm), burnished-zone and fracture-zone percentages, cut-angle deviation, machine hydraulic pressure, number of strokes, and blade edge radius.<\/p><blockquote class=\"wp-block-quote is-layout-flow wp-block-quote-is-layout-flow\"><p><strong>The takeaway:<\/strong> the 5\u201310% rule provided the starting window; the test cut identified the working point. The percentage is the starting calculation \u2014 the cut edge is the verification tool.<\/p><\/blockquote><p>This chain is worth internalising: 5\u201310% rule \u2192 6 mm S355 gives a 0.30\u20130.60 mm starting window \u2192 measurement shows 0.30 mm gives poor edge quality \u2192 step up to ~0.50\u20130.55 mm \u2192 test cut confirms the improvement \u2192 do not market 0.50 mm as a &#8220;standard value&#8221; \u2192 every material, thickness and machine combination must be verified by test cut. The AHSS Guidelines reinforce why: clearance is not an isolated variable \u2014 a smaller clearance raises cutting force and the demands on tool and machine alignment, while a larger clearance increases rollover and related effects.<\/p><h2 class=\"wp-block-heading\" id=\"af00d258-28ca-4ff0-b9b1-8d8c2be57542\">QC and maintenance<\/h2><div class=\"wp-block-image\"><figure class=\"aligncenter size-full is-resized\"><img loading=\"lazy\" decoding=\"async\" width=\"768\" height=\"1024\" src=\"https:\/\/maxtormetal.com\/wp-content\/uploads\/2023\/10\/cutting-blade-knife11.jpg\" alt=\"QC and maintenance\" class=\"wp-image-5684\" style=\"width:438px;height:auto\" srcset=\"https:\/\/maxtormetal.com\/wp-content\/uploads\/2023\/10\/cutting-blade-knife11.jpg 768w, https:\/\/maxtormetal.com\/wp-content\/uploads\/2023\/10\/cutting-blade-knife11-225x300.jpg 225w, https:\/\/maxtormetal.com\/wp-content\/uploads\/2023\/10\/cutting-blade-knife11-9x12.jpg 9w, https:\/\/maxtormetal.com\/wp-content\/uploads\/2023\/10\/cutting-blade-knife11-600x800.jpg 600w\" sizes=\"(max-width: 768px) 100vw, 768px\" \/><\/figure><\/div><p><em>In short: set a numeric burr height limit before the job starts, log clearance and material lot per job, and treat rising burr height or an edge radius above 0.2 mm as mandatory regrind triggers \u2014 not subjective judgements.<\/em><\/p><h3 class=\"wp-block-heading\" id=\"2c6738bd-b733-418f-b3ab-dc1df9ac7842\">Burr height limits and triggers<\/h3><p>Burr height is the fastest field check on a shear, and it is the one most often left unmeasured. Set a numeric limit before the job starts, then treat any exceedance as a trigger rather than a nuisance.<\/p><p>A practical default is 5% of material thickness. On 3 mm mild steel that is 0.15 mm, measurable with a deburring gauge or a bench micrometer across the burr crest. Project drawings and customer acceptance criteria override the default whenever they are tighter.<\/p><p>Two triggers should stop the line:<\/p><ul><li><strong>Burr height above tolerance<\/strong> on two consecutive cuts after a clearance check.<\/li>\n\n<li><strong>Edge radius at or above 0.2 mm<\/strong>, measured on the blade bevel with a radius gauge or a 20\u00d7 magnifier.<\/li><\/ul><p>The second trigger matters because edge rounding, not visible chipping, is what silently widens the effective clearance. A blade that looks serviceable can already be cutting 0.05 mm wider per side than the setup sheet says. As with the parallelism target, the 0.2 mm is a <strong>Maxtor Metal internal limit rather than an ISO-mandated value<\/strong>; published edge-radius ranges for industrial blades vary widely by application \u2014 some slitting guides cite 0.05\u20130.30 mm, disc-shear references hold below 0.05 mm, and general deburring practice references edge-break specifications such as ISO 13715. That spread is exactly why you set the limit against your own acceptance criteria rather than assuming one number fits every line.<\/p><p>For a measurement-based rotation trigger and audit-ready log template that standardises this decision across an entire blade inventory, see the <a href=\"https:\/\/maxtormetal.com\/4-edge-reversible-blade-rotation-schedule-regrind-criteria\/\" target=\"_blank\" rel=\"noreferrer noopener\"><em><strong>4-edge reversible blade rotation schedule and regrind criteria SOP<\/strong><\/em><\/a>.<\/p><blockquote class=\"wp-block-quote is-layout-flow wp-block-quote-is-layout-flow\"><p><strong>Pro Tip:<\/strong> Log clearance, material lot, and burr height per job in one sheet. After a few weeks the log shows whether drift tracks a specific material lot, a specific operator, or the blade itself, which turns regrind scheduling from guesswork into a trend line.<\/p><\/blockquote><h3 class=\"wp-block-heading\" id=\"0395b666-8d21-41e6-a2d3-d7cbb04320d9\">Defect diagnosis and corrective actions<\/h3><p>Match the defect to the cause before touching the blade. Most burr and edge complaints trace back to one of four conditions, and each has a different fix.<\/p><figure class=\"wp-block-table\"><table><tbody><tr><th>Defect<\/th><th>Likely cause<\/th><th>Corrective action<\/th><\/tr><tr><td>Tall, rolled burr on one side<\/td><td>Clearance too wide on that side<\/td><td>Re-check parallelism, reduce gap toward the lower band<\/td><\/tr><tr><td>Short, brittle burr with edge chipping<\/td><td>Clearance too tight<\/td><td>Open the gap, inspect the bevel under 20\u00d7 magnification<\/td><\/tr><tr><td>Burr varies along the cut length<\/td><td>Blade not parallel or ram misalignment<\/td><td>Re-shim and verify straightness before the next setup<\/td><\/tr><tr><td>Clean cut, sudden burr spike mid-run<\/td><td>Edge wear or chipping<\/td><td>Measure edge radius, then decide regrind or replace<\/td><\/tr><\/tbody><\/table><\/figure><p>When chipping appears suddenly or in a consistent location along the blade, the defect pattern itself carries diagnostic information. For a fracture surface analysis workflow that identifies whether the root cause is fatigue (clearance or grinding error) or impact (overload or hardness mismatch), see the <a href=\"https:\/\/maxtormetal.com\/shear-blade-edge-chipping-root-cause-fractography-guide\/\" target=\"_blank\" rel=\"noreferrer noopener\"><em><strong>shear blade edge chipping root cause guide<\/strong><\/em><\/a>.<\/p><p>That last decision follows a chipping-depth ladder. Light chipping under 0.2 mm clears with standard stock removal of 0.25\u20130.35 mm. Moderate chipping between 0.2 mm and 0.5 mm needs deeper removal and a 20\u00d7 inspection of the bevel. Severe chipping above 0.5 mm means scrap or a major removal that can push the blade past its dimensional safety limit. The floor on any regrind is 0.254\u20130.381 mm of stock removal, because micro-fractures from running a blade past its sharpening window penetrate 0.25\u20130.40 mm below the bevel and will surface again if that layer is left in place (Maxtor Metal regrind-or-replace criteria for shear blades, retrieved 2026-08-27).<\/p><p>For a full analysis of how D2 and SKD11 carbide microstructure affects chipping depth and regrind frequency, see the <a href=\"https:\/\/maxtormetal.com\/d2-vs-skd11-tool-steel-shearing-blades-selection-guide\/\" target=\"_blank\" rel=\"noreferrer noopener\"><em><strong>D2 vs SKD11 tool steel shear blade selection guide<\/strong><\/em><\/a>.<\/p><p>Maxtor Metal&#8217;s own QC workflow ties this together: blades are logged against job and material lot, regrind is triggered when edge radius reaches 0.2 mm or burr height exceeds project tolerance, and every returned blade is re-verified for straightness under 0.02 mm\/m, parallelism under 0.015 mm, and hardness across the full length before it goes back into rotation. These too are internal acceptance limits, set tighter than the general ISO 2768 \/ ISO 286 framework rather than drawn from a single published shear-blade standard. The point of the record is not the paperwork. It is knowing which of your four-edge reversible blades still has usable edges and which one is one bad cut away from a scrap decision.<\/p><h2 class=\"wp-block-heading\" id=\"b2e114bd-9274-4d87-9fdb-75a789d209bc\">FAQs:<\/h2><h3 class=\"wp-block-heading\" id=\"590cd0d2-965d-4d47-bb38-8d5fae7079e3\">What is the 5\u201310 percent rule for shear blade clearance?<\/h3><p>It sets shear blade clearance at 5% to 10% of material thickness. For 10 mm mild steel that is 0.5\u20131.0 mm. The band narrows as tensile strength rises: soft aluminium sits near the top, stainless and HSLA near the bottom. Treat it as a starting point and confirm it with a test cut on the actual heat.<\/p><h3 class=\"wp-block-heading\" id=\"2a23e2bb-ccd9-4b1e-bf8f-166122dfcf2d\">Is shear blade clearance per side or total?<\/h3><p>Both conventions appear in published charts, and mixing them doubles your gap. Maxtor Metal specifies its recommended 5\u201310% as blade clearance per side, so a 10 mm mild-steel cut runs 0.5\u20131.0 mm per side, or 1\u20132 mm total. Check which convention your machine builder used before you set anything.<\/p><h3 class=\"wp-block-heading\" id=\"ca92a4b7-7622-4c4c-bff7-18452cd62374\">What clearance should I set for 6 mm mild steel?<\/h3><p>Start at 0.3\u20130.6 mm and verify by cut edge. A clean, square edge with a light burnish band means you are close; heavy rollover or a ragged burr means the gap is too wide. Measure the burr rather than judging by eye.<\/p><h3 class=\"wp-block-heading\" id=\"2a61f7bd-ac1b-4f11-9de8-860d1f76aee0\">Can I use the same clearance for stainless and mild steel?<\/h3><p>No. Stainless, HSLA and other higher-strength grades need a tighter gap, generally toward the low end of the band, because they resist plastic flow and fracture earlier. Running mild-steel clearance on stainless produces edge cracking and accelerated blade wear.<\/p><h3 class=\"wp-block-heading\" id=\"c9c9b8a7-981c-476d-a207-1cf82a296d81\">How often should I regrind a shear blade?<\/h3><p>Burr height is the practical trigger: typical practice targets burr height below 10% of metal thickness, and rising burr height tracks both tool wear and clearance growth (AHSS Guidelines). For AHSS, burr height alone is a weak signal, so cut edge quality is the better indicator. Maxtor Metal&#8217;s own workflow uses an edge radius of 0.2 mm, or burr height past project tolerance, whichever comes first.<\/p><h3 class=\"wp-block-heading\" id=\"0de90eb5-7baa-4ee2-933a-454d1bf1eaa0\">How do I check shear blade parallelism?<\/h3><p>Use a dial indicator on a magnetic base, traversing the full blade length with the machine locked off. Maxtor Metal verifies straightness below 0.02 mm\/m and parallelism below 0.015 mm at build \u2014 these are internal acceptance limits built on the general ISO 2768 \/ ISO 286 tolerancing framework, so they are a sensible benchmark for a machine in service rather than a number every standard requires. Recheck after any regrind or blade change.<\/p><h3 class=\"wp-block-heading\" id=\"47c19003-b6fd-4c6b-bf30-7aadbab57576\">Why does my shear leave a double cut?<\/h3><p>A double cut usually means the gap is too wide for the thickness, so the material bends into the gap and fractures twice instead of once. It can also come from insufficient hold-down force or a blade that has lost its edge. Tighten clearance toward the low end of the band and check hold-down pressure before you blame the blade.<\/p><h2 class=\"wp-block-heading\" id=\"b3125ccb-00f0-4f1b-a86f-15518d8a331a\">Conclusion<\/h2><p>Shear blade clearance is a setup decision, not a fixed number, and the 5\u201310% rule gives you a defensible starting point rather than a universal answer. The band controls two things at once: how much burnish and fracture the edge sees, and how much rollover and burr the cut leaves behind. Get it right and the cut face stays clean; drift outside it and you trade one defect for another.<\/p><p>What separates a controlled process from a lucky one is standardisation. Log the clearance you set for every job, record the material grade and thickness it was set for, and check edge condition on a fixed interval instead of waiting for a burr complaint. Track regrind cycles against those logs so you can see the edge wearing before it fails. Treat this as a workflow question as much as a blade question: the same clearance value behaves differently across shifts if nobody writes it down.<\/p><p>If you are setting up a new shear or standardising an existing one, review the blade specification against your material mix and duty cycle before you commit to a number. When the material or the application sits outside the usual bands, talk to an application engineer about where your process should deviate and why.<\/p><p><em>For the full Maxtor Metal shear blade range \u2014 material grades, dimensional tolerances, and regrind service options \u2014 see the <\/em><a href=\"https:\/\/maxtormetal.com\/product\/shear-blade\/\" target=\"_blank\" rel=\"noreferrer noopener\"><em><strong>precision shear blade product page<\/strong><\/em><\/a><em>.<\/em><\/p><h2 class=\"wp-block-heading\" id=\"098ede4e-d833-456d-948a-0dd427809542\">About the author: field experience behind this guide<\/h2><p>This guide is written and reviewed by <strong>Jerry Chu, Technical Support Specialist<\/strong> in Maxtor Metal&#8217;s After-sales Service team. Jerry has <strong>10 years of hands-on experience<\/strong> with industrial cutting blades across paper making, plastic granulation, metal slitting and slitting lines, and wood processing \u2014 applications where burr formation, edge quality, and dust generation all show up as real production problems rather than theory. That field background shapes the setup and QC guidance here: the focus on measurable triggers (burr height, edge radius, parallelism) rather than subjective &#8220;looks fine&#8221; judgements comes directly from troubleshooting these issues on customer lines.<\/p><p>Jerry holds <strong>PMP<\/strong> (Project Management Professional) and <strong>CMRP2<\/strong> certifications, which support the process-discipline approach \u2014 logging, standardised setup, and scheduled inspection \u2014 that runs through this article.<\/p><p>Maxtor Metal is a manufacturer and supplier of custom, precision-ground industrial blades with over 15 years of experience, serving engineers, technical buyers, and equipment manufacturers worldwide. The company operates a <strong>quality management system certified to ISO 9001<\/strong>, and manufactures blades to customer drawings, sketches, or photos with material selection aimed at extending blade life. The internal tolerance and regrind figures quoted in this article come from that QC workflow.<\/p>","protected":false},"excerpt":{"rendered":"<p>Quick Answer: Shear blade clearance is set at 5\u201310% of material thickness, measured at the cutting point. For 6 mm mild steel, that means a 0.30\u20130.60 mm gap \u2014 but the percentage is a starting range, not a final answer. Confirm the working value with a test cut on your actual material, verify clearance at three points along the blade with a feeler gauge, and treat any burr height above 5% of thickness as a trigger to recheck the gap. Engineering Note: Shear blade clearance is the perpendicular gap between the upper and lower cutting edges, expressed as a percentage of material thickness. It governs the ratio of burnished to [&hellip;]<\/p>\n","protected":false},"author":1,"featured_media":8174,"comment_status":"closed","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[1,1016],"tags":[1313],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v23.6 (Yoast SEO v23.6) - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>Shear Blade Clearance: Stop Burrs With the 5\u201310% Rule<\/title>\n<meta name=\"description\" content=\"Set shear blade clearance at 5\u201310% of material thickness. 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