In this study, an experimental study was carried out to examine the effect of different clearances on smooth-sheared depth, burr height and blanking force. Aluminium sheet metals with 0.8, 1, and 1.5 mm thicknesses were used in the experiments. These experiments were carried out in circular blanking dies to 6, 8, 10, and 12 nun diameters. Six different clearances (0.009, 0.064, 0.12, 0.175, 0.231 and 0.287 mm) were used for every material and diameter. The results of the experiment show that burr, smooth-sheared and punch force is strongly related to the clearance value. The results are in agreement with the results of previous theoretical and experimental work in the literature. (C) 2005 Elsevier Ltd. All rights reserved.