Influence of control parameters on tool wear for sheet metal stamping die with various die radius arc profiles

Prediction of tool wear pattern for sheet metal stamping die for processing of advanced high strength steel (AHSS) parts is a highly challenging task in automotive applications as there are many control parameters involved in the production. It is important to understand the impact of these control parameters in order to predict and enhance the tool life of stamping dies. This article presents a numerical simulation methodology to analyze the influences of various control parameters such as the lubrication coefficient, binder holder force, clearance between die and punch, and blank thickness on tool wear pattern of a sheet metal stamping die with different die radius arc profiles. An equation consisting of adhesive wear and abrasive wear was developed and utilized in a numerical model for wear pattern and the simulations were performed using the finite element software Abaqus 6.8. The numerical model was validated by a series of channel bending tests. The results suggest that various control parameters have different impacts on the tool wear of die radius, depending on the specified die radius profile. However, for a certain die radius arc profile, the variation of control parameters has limited effects on the locations of first and second peaks of tool wear work over die radius. To minimize tool wear, it would be necessary to optimize the shape for a particular combination of circular and elliptical profiles in relation to the control parameters instead of only varying the control parameters themselves