Numerical and experimental analyses of punch wear in the blanking of copper alloy thin sheet

This research on punch wear resulting from the blanking of copper alloy thin sheet has been conducted by means of experimental and numerical analyses. Firstly, the experimental method has consisted in measuring punch worn profiles from replicas, and secondly in obtaining the wear coefficient by using a specific tribometer. The numerical modelling of blanking process has been developed with the finite element method to compute the mechanical fields necessary to calculate wear. Thus, the Archard formulation for abrasive wear has been programmed to compute the wear depth and the resulting punch geometry. Finally the simulation results of wear prediction have been compared to experimental ones.

► We extract punch wear profiles by means of an experimental double-print method.
► Wear coefficient measurement is provided by a specific tribometer.
► We propose an original transfer method to calculate wear depth.
► We exhibit a minimal wear zone in the punch cutting edge.
► Punch wear is more important on the lateral face.