Finite element prediction of blanking tool cost caused by wear

The total cost of a blanked part is determined by a large number of factors, including the material cost, manufacturing costs. Predicting the manufacturing costs of a blanked part requires accurate estimation of tool cost caused by wear. The aim of this paper is to develop a finite element model allowing for the numerical prediction of the blanking tool life which allows for the evaluation of the cost rate of blanking tool caused by wear needed to assess the total cost of a blanked part. A wear prediction model has been implemented in the finite element code Abaqus in which the tool wear is a function of the normal pressure and some material parameters. In the present work, the tool is modeled as rigid body hypothesis, and the wear variables are computed in the contacting elements. The altered tool contact surface and contact pressure tool shapes are updated iteratively to simulate wear over a long period of time of about 100,000 cycles. A damage model is used in order to describe crack initiation and propagation into the sheet. The distribution of the tool wear on the tool profile is obtained and compared to industrial observations.