Sheet metal forming operations are widely used in the industry because of their ability to produce complex shapes at higher production rates. These operations utilize high stresses to plastically deform workpiece in the desired geometry. For reliable performance, punch design and operating parameters can play significant role. To investigate the tool wear finite element (FE) based numerical methodology was developed in this study. Tool wear is one of the main causes of tool failure and process deviation in the punching operation. Research in the past has covered process parameters and effects of wear on the die plate. However, little research focused on the effects of wear on the punch itself. In this paper a full analysis of the punching process was performed, giving an understating of the effects of tool rounding due to wear on various punching parameters, while focusing on the evolution of wear on the punch in all cases. It was found that wear accelerates as the punch's bluntness is increased. It was also identified that most of the wear is expected on the radius on the punch as opposed to its face, and the full punch diameter will be affected by the abrasive wear between the sheet metal and the punch as opposed to only the striking edge. However, it was also seen that in cases of highly worn-out punches, the wear on the side can be decreased due to the increased deformation of the sheet metal which occurs due to the blunt punch.

钣金成型操作在工业中被广泛使用，因为它们能够以更高的生产率生产复杂的形状。这些操作利用高应力使工件塑性变形为所需的几何形状。对于可靠的性能，冲头设计和操作参数可以发挥重要作用。为了研究刀具磨损有限元 (FE)，本研究开发了基于数值方法。刀具磨损是冲压作业中刀具失效和工艺偏差的主要原因之一。过去的研究涵盖了工艺参数和模具磨损的影响。然而，很少有研究关注磨损对冲头本身的影响。在本文中，对冲压过程进行了全面分析，低估了由于磨损导致的刀具倒圆对各种冲压参数的影响，同时重点关注所有情况下冲头磨损的演变。发现随着冲头的钝度增加，磨损会加速。还确定大部分磨损预计发生在冲头的半径上，而不是其表面​​，整个冲头直径将受到金属板和冲头之间磨料磨损的影响，而不仅仅是冲击边缘。然而，我们还发现，在冲头磨损严重的情况下，由于冲头钝化会增加金属板的变形，因此可以减少侧面的磨损。还确定大部分磨损预计发生在冲头的半径上，而不是其表面​​，整个冲头直径将受到金属板和冲头之间磨料磨损的影响，而不仅仅是冲击边缘。然而，我们还发现，在冲头磨损严重的情况下，由于冲头钝化会增加金属板的变形，因此可以减少侧面的磨损。还确定大部分磨损预计发生在冲头的半径上，而不是其表面​​，整个冲头直径将受到金属板和冲头之间磨料磨损的影响，而不仅仅是冲击边缘。然而，我们还发现，在冲头磨损严重的情况下，由于冲头钝化会增加金属板的变形，因此可以减少侧面的磨损。