Int J Adv Manuf Technol (2003) 21:483–493
Ownership and Copyright
 2003 Springer-Verlag London Limited
Numerical Evaluation of the Tool Wear Influence on Metal-
Punching Processes
R. Hambli, F. Guerin and B. Dumon
ISTIA-LASQUO, Angers, France
Prediction of the influence of tool wear influence in sheet
metal blanking/punching processes is investigated in this paper
using the finite element method. In order to simulate accurately
sheet metal-cutting processes by a material shearing mech-
anism, a finite element model valid for the numerical descrip-
tion of such processes has been developed. Damage and crack
propagation has been taken into account by means of an
elastoplastic constitutive law to study the effects of the variation
of process parameters on the geometry of the sheared edges
and the evolution of the force-punch penetration. Furthermore,
a numerical investigation has been carried out to study the
effect of tool wear on burr formation.
During analysis, the initiation of a crack is assumed to
occur, at any point in the sheet metal where the damage
reaches a critical value. Crack propagation is simulated by
the propagation of a completely damaged area. This is taken
into account in the finite element model by a decrease of the
stiffness of the broken elements.
Keywords: Experiment; Finite element; Punching; Tool wear;
Wear model
1. Introduction
There are thousands of products manufactured with sheet metal
parts. The first step in forming such parts involves cutting of
the sheet into appropriate shapes by means of the physical
process of shearing. A contoured part is cut between a punch
and die in a press. Depending on the position of the sheared
surface with respect to the workpiece coordinates, various
shearing processes are used, such as punching, blanking, pierc-
ing and cutting off. Contrary to other operations, such as
stamping and folding where the aim is to deform the sheet
plastically, these operations lead to total rupture of the sheet.
Before complete rupture, the material is subjected to some
damage phenomena and crack propagation. To describe the
Correspondence and offprint requests to: R. Hambli, ISTIA-LASQUO,
62 Avenue Notre Dame du Lac, 49000 Angers, France. E-mail:
ridha.hambli@istia.univ-angers.fr
behaviour of the sheet as the operation is carried out, various
parameters may be used such as material hardening, damage
evolution and crack initiation and propoagation.
From a numerical point of view, a good description of the
sequence of the above stages requires the development of
reliable algorithms. These allow the crack initiation and propa-
gation phenomena to be modelled accurately and without com-
putational divergence.
Because tool wear changes the punch-die geometry and
clearance, the process of shearing and the form of the sheared
surface are influenced. In addition, tool wear has adverse
effects on the dimensional accuracy and surface finish of the
product. The phenomena related to wear on the tools have an
important impact on the economy of industrial metal-blanking
processes. Methodologies currently used are based mainly on
designers’ intuition and experience, which are not the most
reliable when considering the complexity of the problem. A
quantitative approach to tool wear analysis would improve
service life, leading to an important reduction in manufacturing
costs. In general, the need for regrinding of the shearing tool
is determined on the basis of allowable burr height on the
final product. Therefore, based on this criterion, the analysis
of the shearing process must take into account the influence
of tool wear in order to predict the need for tool regrinding.
A large number of experimental studies have been performed,
but relevant theoretical analysis is still rare, especially in burr
height formation.
The aim of this paper is to provide a general finite element
model allowing for the numerical simulation of the whole
punching process. The numerical results obtained by the simul-
ation were compared with experimental results to verify the
validity of the proposed finite element model in describing the
influence of tool wear.
2. Wear Model
In the metal-blanking process, the relative motion of the tool-
sheet surfaces may result in a loss of tool material through
adhesive wear [1–3]. This wear process is initiated by inter-
facial adhesive junctions that form in the contact zone [4,5].
As a normal load is applied, local pressure at the contact area
484 R. Hambli et al.
become extremely high. Therefore, the surfaces adhere together.
The friction between the sliding surfaces generates wear par-
ticles. The presence of high-hardness particles accelerates abras-
ive wear.
Tool wear is defined as the slow degradation of the blanking
tool caused by friction between tool and metal sheet [2,3].
The rate of wear is affected by parameters such as tool
material, blank part material, punch-die clearance, punch velo-
city, lubrication and material thickness. The quality of the
workpiece is governed by the state of the wear tool.
The wear resulting from the adhesive wear process has been
described phenomenologically by the Archard Eq. [2]:
V FN
Wad = =k (1)
s 3H
Wad is the worn volume per unit sliding distance, V is the
volume of the material removed by wear from the surface, k
is a material constant that expresses the probability of generat-
ing a wear particle (dimensionless), s is the sliding distance,
H is the hardness of the sheet and FN is the normal load
applied on the tool. Equation (1) shows that the hardness H
is the only material property appearing in the model. Typical
values of the wear coefficient k are given elsewhere [5,6] for
a combination of contacting materials.
A simplified expression for the volume of abrasive wear can
be given by [5]:
␤FNs
V= tan(␪) (2)
␲H
where ␤ represents that part of the asperities having the ability
to cut, and ␪ is the angle of the assumed cone-shaped asperities
for the hardest material.
If the constants of the wear models are assumed to be
constant with time, the above wear models can be rewritten as:
V = ␥wFNs (3)
where ␥w denotes a wear coefficient depending on the sliding
contact conditions and varies over the range of 10⫺2 to 10⫺7
mm2/N.
Based on previous investigations [6–10], adhesive wear
causes the cutting edges to become rounded (Fig. 1). This
would reduce the sharpness of the punch during shearing, and
increase the deformation of workpiece. Moreover, the burrs on
Fig. 1. Wear profile of blanking tool.
the parts become larger, the noise level in the press becomes
very high and the punch penetration corresponding to crack
initiation into the sheet increases.
Equation (1) employs hardness as the only material property.
Typical values of the wear cofficient k for a combination of
materials are given in Kalpakjian [5].
From a numerical point of view, at each node i of the
contact elements of the tool mesh the above Eq. can be
written as:
Vi = (␥w)i (FN)i si (4)
3. Finite Element Approach
The law describing material behaviour should allow a descrip-
tion of the different stages of the process observed experimen-
tally starting from the elastic state and ending with the final
rupture of the sheet. For this purpose, a behavioural law
including damage and failure phenomena must be chosen. In
order to predict damage evolution in the sheet metal during
blanking processes, the continuum damage mechanics approach
has been applied in this work to describe the behaviour of the
sheet using the Lemaitre damage model [11].
The algorithms generally implemented in the finite element
codes for the integration of non-linear constitutive Eq. are the
so-called radial return algorithms, which are used to solve the
equation in an incremental form. They are based on the notion
of an elastic predictor–plastic corrector, where a purely elastic
trial state is followed by a plastic corrector phase [12,13]. In
this way, an implicit algorithm has been developed which
allows for the integration of the constitutive Eq.. The inte-
gration methods of the non-linear constitutive Eq. are based
on the use of a special algorithm which solves the equation
in incremental form. For this purpose, during a small time
interval [tn, tn+1], it is assumed that the whole increment is
purely elastic; then an elastic prediction is defined as:
␴n+1
T
= ␴n + ⌬␴ (5)
Equation (5) can be written as:
冋冉 冊 册
␴n+1
T
= (1 ⫺ Dn) Cel ⑀tot ⫺ (⑀pl)n (6)
n+1
The superscipt (␴)T refers to trial test and Cel is the elastic
modulus tensor depending on the damage state of the
material [11].
The Von Mises yield function coupled with damage is
given by:
f = ␴eq ⫺ (1 ⫺ D) (␴el + ␴0) (7)
where D is the damage variable.
If this elastic prediction satisfies the yield condition, f ⬍ 0,
the prediction is true and the local procedure is completed.
Then it can be stated that:
␴n+1 = ␴Tn+1 (8)
Otherwise, this state must be corrected by means of a plastic
correction. For this purpose, the variables at increment n + 1
must satisfy the system [8]:
 Numerical Evaluation of the Tool Wear 485

f=0 (9) -Dw = ␥w P -s (19)

␴n+1 ⫺ (1 ⫺ Dn) Cel(⑀n + ⌬⑀ ⫺ ⑀pl
n ⫺ ⌬⑀ ) = 0
pl
(10) The wear depth Dw can be expressed in the following inte-
gral form:
⌬Η␣ = h␣(⌬⑀ij, (␴ij)n+1, H␣ij ) (11)
where H␣, ␣ = 1, 2, %, n, is a set of scalar state variables
and h␣ is the hardening law for H␣.
Dw = ␥w 冕 0
S
P -s (20)
Within the displacement formulation of FEM, the global This Eq. can discretised as follows:
equilibrium Eq. to be satisfied at each instant tn+1 can be

冘冘
n m
written in the general form [12]:
Dw = ␥w P ⌬s (21)
F(Un+1) = 0 (12) i=1 j=1

where Un+1 is the displacement field at step (n + 1). where m is the total number of time steps ⌬t, and n indicates
If this non-linear problem is solved iteratively by the Newton the total number of nodes at the punch-part contact area.
method, at each global iteration r the following Eq. can Within a time interval [tn, tn+1], the wear prediction algorithm
be written: leads to the following form of incremental wear depth:
r
F(Un+1 ) + (Krn+1) (Ur+1
n+1 ⫺ Un+1) = 0
r
(13) (Dw)n+1 = (Dw)n + ␥wPn+1 (sn+1 ⫺ sn) (22)
where where (•)n and (•)n+1 denote the approximation of the variable
values at increment n and n + 1.
Krn+1 = 冉 冊 冕
∂F
∂U
r

n+1
=
⍀
BT Jn+1
r
B d⍀ (14)

B is the strain-displacement matrix and Jrn+1 is the Jacobien 4. Numerical Modelling of Damage and
tensor obtained by: Ductile Fracture

Jrn+1 = 冉冊
∂␴
∂⑀
r

n+1
(15) During sheet metal-shearing operation, the part is subjected to
complex operations such as deformation, hardening and crack
The adhesive wear model (Eq. (3)) can be expressed in initiation and propagation. The theoretical modelling of such
incremental form: processes is very difficult due to the complexity of describing
the different stages of the whole shearing process starting from
(16) the elastic stage and ending with the total separation of the
-V = ␥w -FN -s sheet metal (Fig. 2).
Accurate knowledge of the failure process is essential for
dV and dFN can be expressed as:
the selection of a suitable damage model. In the case of sheet
-V = -Dw -⍀ (17) blanking by the shearing processes, numerous authors have
studied the different physical mechanisms leading to the final
-FN = P -⍀ (18)
rupture, and proposed their own models. Dos Santos and
dDw is the depth of the wear, d⍀ is the contact area, and P Organ [14] carried out a visioplastic study of a rectangular-
the normal contact pressure acting on the tool. bar cropping operation. They analysed the deformation of a
By substituing Eqs (17) and (18) into Eq. (16), we obtain: pattern engraved on the surface of the sheared area of the

Fig. 2. Different stage of the blanking process, after Hambli [9].

486 R. Hambli et al.
Fig. 3. Grid deformation of material points during blanking process,
after Stegeman et al. [16].
testing bar. They demonstrated, by means of observation, that
the rupture is of a ductile nature and that the cracks generated
by the cropping process follow an “S” or double “S” profile,
parallel to the direction of maximum intensity of the shear
stress. These results correspond to those obtained by Wong
and Das [15] with regard to crack initiation.
In their investigation dealing with a planar blanking process,
Stegeman et al. [16] used CCD camera records in order to
quantify the displacement of material points at the sheared
surface (Fig. 3). One can observe the grid deformation in the
clearance zone of the tool.
The metal-cutting operation depends on the damage caused
to the material. The accurate knowledge of the material failure
process is an essential stage in the selection of a damage
model. In the case of sheet blanking by the shearing processes,
numerous authors have studied the different physical mech-
anisms leading to the final rupture and proposed their own mod-
els.
The damage phenomenon, described by initiation and growth
of cavities and microcracks into material induced by large
deformations in metals, has been extensively studied in order
to predict the evolution of ductile damage into structures
subjected to plastic loading [17–19]. In order to predict when
a structure will undergo rupture, numerous authors have pro-
posed their own criteria. In the isotropic case, these failure
Fig. 4. Rupture of the sheet, after Hambli [9].
criteria are scalar functions involving stresses and/or strains,
which depend on physical and mechanical parameters. They
are usually identified by performing rheological tests on speci-
mens. The failure is modelled by a mathematical function
which is supposed to represent the physical behaviour of the
material, and occurs when the function reaches a critical value.
Examining the faces of the sheared edge, Jana and Ong
[20] confirmed that the blanked edge exhibits microscopic
hemispherical holes which characterise ductile fracture. Starting
from a different approach which states that the moment when
cracks initiate the hydrostatic pressure ␴H is negative at the
cutting edges of the tools, Kasuga et al. [21] proposed a
theorical model for damage propagation. They showed that the
cracks which begin at the cutting edges of the die and the
punch grow and spread in the direction of the material where
␴H is minimal. In their work, McClintock [17] and Rice and
Tracey [19] have demonstrated that the void enlargement rate
is amplified over the strain rate by a factor rising exponentially
with the ratio of hydrostatic stress to the equivalent stress. The
results suggest a rapidly decreasing fracture ductility with
increasing hydrostatic pressure.
As a conclusion from the aforementioned work, a damage
law must take into account the equivalent plastic strain and
the hydrostatic pressure value ␴H. Such a law would be suitable
for describing the damage evolution of the material before final
rupture, especially when the deformation process is affected by
a hydrostatic pressure field. Recently, an analytical study and
experimental tests [8,9] showed that the physical mechanisms
leading to the complete failure of the sheet material can be
described as follows: first, due to the penetration of the punch
into the sheet, cracks initiate at the cutting edges “A” and “B”
of the tools (Fig. 4). Secondly, the cracks propagate when and
where Rice and Tracey’s fracture criteria value exceeds a
critical value, and thus progressively cut the material fibres
one after the other.
 Numerical Evaluation of the Tool Wear 487

Fig. 5. Three-dimensional representation of Le Maître’s damage law.

Fig. 6. Schematic diagram of the approach used.

The damage phenomenon described by initiation and growth

of cavities and microcracks into material induced by large
deformations in metals has been extensively studied in order
Ḋ =
Dc 2
⑀R ⫺ ⑀D 3冋(1 + v) + 3(1 ⫺ 2v) 冉 冊册
␴H
␴eq
2
2
(⑀eq)n -⑀˙ eq

to predict ductile damage evolution into structures subjected ␴H

when ⱖ0 (23)
to plastic loading. ␴eq
The damage law used in this paper to describe the stages
␴H
corresponding to crack initiation and the propagation is of the Ḋ = 0 when ⬍0 (24)
Lemaitre type [11]. ␴eq
According to the approach proposed by Lemaitre, the iso- This model depends upon material constants for damage propre-
tropic damage law, which is valid for any loading path, is ties, the hardening exponent n and the Poisson ratio v.
written in incremental form:
488 R. Hambli et al.

Fig. 7. Axisymmetric model of punching operation.

Fig. 8. Mesh used for the finite element model.

⑀D is the threshold strain at which damage initiates, ⑀R is

the strain value at fracture and ⑀eq the plastic strain. Dc is the
critical damage value at fracture.
Identification of this model consists of the quantitative evalu-
ation of the five coefficients Dc, ⑀R, ⑀D, ␯ and n by mean of
tensile tests of each material [22,23]. This model is represented
in Fig. 5.
Figure 6 shows the flow chart of the method used for crack
propagation analysis. First, at a given punch displacement step
n, the behaviour law coupled with damage allows for the
computation of the damage value at each finite element of the
mesh. During the analysis, the initiation of a crack is supposed
to occur at any point in the metal sheet where the damage
reaches its critical value Dc. The crack propagation is simulated Fig. 9. (a) Damage contour and (b) Von Mises stress contour.
by the propagation of a completely damaged area. This method
leads to the decrease in stiffness of the completely damaged
elements. The rheological constants for the damage law associated
with the Lemaitre model were found to be ⑀D = 0., ⑀R = 0.85,
Dc = 0.4.
4. Numerical Simulation of a Punching In this study, the tool is modelled by adopting a rigid body
Operation hypothesis and the contact surface laws are defined by a
Coulomb friction model with a friction coefficient value of 0.1.
The problem studied here consists of an axisymmetric punching The meshing of the model is carried out by means of 1480
operation on a metal sheet with 3.5 mm thickness (Fig. 7). quadrangular four-node axisymmetric elements. Figure 8 shows
The corresponding strain hardening law takes the non- how the meshing is used.
linear form: During the analysis, crack initiation occurs at any point in
the structure where the damage reaches its critical value Dc.
␴ = ␴el + K⑀neq (25)
Crack propagation is simulated by the propagation of a com-
The mechanical characteristics of the material obtained by a pletely damaged area. This is taken into account in the FEM
tensile test are given in Table 1. by a decrease in the rigidity of the elements concerned.
 Numerical Evaluation of the Tool Wear 489

Table 1. Material characteristics.

Material E (MPa) ␯ ␴el (MPa) Rm (Mpa) K (MPa) n A (%)

1060 Steel 200000 0.29 250 530 1048 0.196 0.3

Four geometric tool shapes were chosen corresponding to:

쐌 A new die with Rusd = 0.01 mm.

쐌 A new punch with Rusp = 0.01 mm.
쐌 Three punchs with different edge radii Rusp = {0.06, 0.12,
0.2} mm.

Fig. 10. Illustration of the wear volume of the blanking tool.
5. Results and Discussion
Experiments using a 4000 kN hydraulic press equipped with
electrical gauges and force transducer were performed in order
to verify the validity of the proposed FEM.
Several calculations were performed in order to compare the
numerical results with experimental data. The influence of tool
wear on the punching force and on the evolution of the sheared
profiles was accounted for by changing the values of the edge
radii Rusp and Rusd (Fig. 7).
Figure 9(a) and (b) shows the damage distribution and the
Von Mises stress contour, respectively, within the sheet for a
punch penetration of about 70%. The calculation gives a
damage distribution more localised in the punch-die clearance.
Figure 9(b) clearly shows that the maximum equivalent stress
value is very small (40 MPa) in the clearance zone. This is
due to the fact that the broken finite elements have no stress-
carrying capacity when they reach the critical damage value Dc.
The evolution of the radius of the cutting edge of the tool
is related to wear volume evolution, which can be described
by Eq. (19). The geometrical relation which exists between
the radius Rusp and the wear volume V is shown in Fig. 10.

Fig. 11. Punching force versus punch travel for four wear states: (a) simulation; (b) experiment.
490 R. Hambli et al.

Based on the wear configuration of Fig. 10, the volumetric

wear resulting from the adhesive wear process versus the wear
radius can described by:
5␲ 3␲
V= (Rusp)3 + Rp (Rusp)2 (26)
r 2
It is known that the variation of the volumetric wear is linear
over the sliding length. Based on this result and neglecting the
tool-grinding period at the begining of production, it can be
assumed that the volumetric wear of the tool is linear for
production quantity. The tool wear radius over time can be
obtained using the wear model (Eq. (19)) as:

␲
冘
3 n
r␲
(Rusp)3 + Rp (Rusp)2 = Kus FN s (27)
4 2 1=1

where n is the total number of blanking cycles.

A comparison between the results obtained by the finite
element simulation and those obtained by experiment can be
seen in Fig. 11(a) and (b), respectively.
In Fig. 11(a), the evolution of the punching forces relative
to punch penetration for different simulations is shown.
When the material damage is taken into account, it is
possible to simulate the punch penetration up to 80% of the
sheet thickness, in spite of a large mesh distortion.
The experimental plots in Fig. 11(b) show that for the
various states of punch wear there is no difference between the
maximum blanking loads. Nevertheless the punch penetration
corresponding to crack initiation in the sheet material increases
with an increase in punch wear. This is due to a relative Fig. 13. Predicted and experimental blanked profiles corresponding to
two states of punch wear: (a) Rusp = 0.01 mm; (b) Rusp = 0.2
increase in the contact area between the punch and the sheet. (clearance = 10%).
The punch penetration evolution corresponding to the crack
initiation against the wear parameter Rusp obtained by experi-
damage laws, in describing the influence of punch wear on
ments on 1060 steel and the FEM simulations, have been
the mechanical results in the blanking operation.
plotted in Fig. 12.
The failure of the sheet presented in Fig. 13 is obtained for
The two blanked profiles obtained by finite element calcu-
a punch displacement of about 70% of the sheet thickness. It
lation and experiment, corresponding to a new punch with a
can be observed that the distortion of the mesh is restricted
cutting edge radius Rusp = 0.01 mm and a used punch with
to a small area near the die-punch clearance.
Rusp = 0.2 mm, are shown in Fig. 13(a) and (b), respectively.
Figure 14 shows the evolution of the burr height according
As expected, in the case of a used punch, the profile of the
to the punch wear radius obtained by experiments in the sheet-
part boundary is of bad quality due to the presence of a burr.
metal blanking operation for a 1060 steel. This curve is
The numerical results compared with the experimental ones
compared with that obtained by the FEM calculations corre-
show the reliability of the FEM, according to the aformentioned
sponding to different edge radii of the punch.
It can be shown that the predicted and experimental values
are in good agreement, with deviations of 15%.

Fig. 12. Punch penetration at rupture versus the wear radius Rusp. Fig. 14. Evolution of the burr height versus the punch wear radius.

Fig. 15. Approach used for tool wear analysis and the need for tool
regrinding.
The flow chart of Figure 15 explains how the program can
be used for prediction of the need of tool regrinding in two
steps. In the first step, one can compute the burr height versus
the tool wear radius variation. In the second step, it possible
to assess the need for regrinding by comparing the critical
burr height and the predicted height. This analysis is very
helpful for improving the reliability of the shearing tool and
to determine the need for tool repair or change.
Fig. 16. Crack propagation versus punch penetration.
Numerical Evaluation of the Tool Wear 491
The different simulations that we have performed indicated
that, due to the punch penetration into the sheet, cracks initiate
at the cutting edges of the tools. Secondly, the cracks propagate
in the same direction as the punch penetration. This is illus-
trated by the curves in Fig. 16.
These curves correspond to the relative crack propagation
depth (expressed as a percentage of sheet thickness) versus
the relative punch displacement obtained by experiment and
simulation in the cases of a new and a used punch.
Crack initiation and propagation can be accurately predicted
without computational divergence. From the moment of crack
initiation to the complete rupture of the sheet, experimental
and numerical results are always in good agreement.
The two curves are sufficiently close to conclude that the
procedure, which we propose to simulate crack initiation and
propagation, gives good results.
The quality of the final product is measured by the accuracy
of the final geometry of the blanked part. Springback is proved
to be one of the major formability concerns in sheet metal
forming. Springback refers to the deformation induced in a
blanked metal sheet once the blanking tool has been removed,
after final separation of the part. Springback deformation is
produced mainly by the bending energy accumulated in the
sheet during the blanking process.
In this work, sheet springback analysis using both damage
models is studied by computing the displacement of the top
right corner node (Ref. Sp of Fig. 17).
Figure 18 shows springback evolution during the blanking
process obtained by experiment and simulation with a new
punch (Rusp = 0.01 mm) and a used punch (Rusp = 0.2 mm).
It can be observed that the springback of the sheet is larger
with the worn punch then with the new one. The predicted
and experimental curves are in good agreement.
6. Conclusion
In the investigation, a finite element model for the simulation
of blanking/punching processes has been developed. The mod-
elling takes into account the influence of tool wear on burr
height evolution. In general, the need for regrinding of the
492 R. Hambli et al.
Fig. 17. Springback of the sheet computed by node Sp displacement.
Fig. 18. Node Sp (of Fig. 17) displacement versus punch penetration.
shearing tool is determined on the basis of allowable burr
height on the final product. The proposed finite element model
predicts the need for tool regrinding; therefore, it possible to
predict the burr height corresponding to the wear radius of the
tool. This wear analysis is very helpful for improving the
reliability of the shearing tool and for determining the required
tool repair or tool change.
Numerical simulation of damage evolution and crack
initiation and propagation has been described by means of the
continuum damage approach using the Lemaitre damage model.
Crack initiation and propagation can be predicted accurately
without computational divergence from the moment of crack
initiation to the complete rupture of the sheet. The experimental
and numerical results are always in good agreement throughout
the simulation.
ABAQUS/standard routines, which account for the contact
law between tool and sheet and incremental computations
strategy, give good results when compared to the experimental
ones. For relative punch penetrations up to 100%.
From a practical point of view, the simulation can provide
useful information about the influence of the leading parameters
in the fine blanking process on the quality of the blanked parts.
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