Blanking tool wear modeling using the finite element method

One of the main objectives of the numerical process design in metal forming is to develop adequate tool design and establish process parameter in order to increase tool life and to improve part quality and complexity while reducing manufacturing cost. The prediction of tool wear in sheet metal blanking/punching processes is investigated in this paper using the finite element method. A wear prediction model has been implemented in a finite element code in which the tool wear is a function of the normal pressure and some material parameters. 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. Furthermore, a numerical investigation has been carried out to study the effect of tool wear on the burr formation.