A New Analytical Model for Tool Life in Metal Stamping

Abstract

<p> Tool life during the precision stamping of stainless steel sheet (AISI 301) has been studied with particular emphasis on reduction in the punch diameter and part hole size due to tool wear. Two analytical models for predicting tool life in terms of number of quality parts that could be stamped between two re-grindings have been proposed using a combination of Archard's wear model and punching force. The proposed tool life models have been verified by experiment trials with a round M2 punch and die. The trials were carried out on a precision progressive die in an industrial environment.</p> <p> The first tool life model calculates the pierced hole diameter variation for a given tool from sheet material properties and gives an estimation of number of parts that could be stamped for a given tolerance on a hole size. The second tool life model calculates number of parts with respect to the allowed burr height. Both of the proposed models are derived using sheet material properties such as sheet thickness, strength coefficient (K), strain hardening index (n) and material elongation (A); process parameters such as die clearance and friction coefficient; punch characteristics such as normalized wear rate, punch diameter and punch edge radius. Finite element analysis was also employed to simulate the hole piercing process to predict burr height. The results from the proposed tool life models, FE modeling and the experiments are in good agreement.</p>