Prediction of tool wear in the blanking process using updated geometry

Predicting the die and tool replacement time in the blanking process is very important in terms of product quality and cost efficiency. In order to predict tool life, tool wear must be observed constantly and the product defect rate must be analyzed. In this study, a procedure to predict tool life during the blanking process is proposed. Tool wear is represented with the modified Archard wear model and the Lemaitre damage model for ductile fracture. These models express abrasive and fatigue wear, respectively. The surface geometry of a tool is updated based on the computed amount of wear to describe the phenomenon of realistic wear. Through the blanking process, the amount of wear that is measured and calculated is compared. The difference was found to be 7.2%. Using the calculated wear result, the tool replacement time was predicted and the wear prediction procedure was validated by performing a series of procedures using other process conditions.