Cutting is one of the most frequently carried out metal forming processes. One of the basic parameters of this process is the clearance value. The clearance is the difference between dimensions of the punch and the die, usually related to sheet thickness. The amount of clearance affects on geometry and quality of the material cut surface. The cut surface can be divided into the area of rollover, burnish, fracture and burr. Of these areas, only rollover and burr is visible on the sheet surface. In this paper, the authors proposed a method allowing to determine the clearance based on the rollover area measurement. By means of the camera and experimental lighting, it was possible to measure the size of the rollover area without making sheet cross-sections. Proposed vision system allows fast measurements of the rollover area and determines the associated clearance. The experimental measurements were carried out on a deep drawing steel DC04 with a thickness of 1 mm and 2 mm.Keywords: Cutting process, clearance, rollover area, vision system
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