Integrated measurement of tool wear in punching processes using a pneumatic gauging system

Punching is an essential production process for manufacturing large volumes of uniform, cost-effective parts. Despite its widespread use, the efficiency and quality of this process are highly sensitive to numerous parameters, many of which are not fully understood. Achieving optimal, reproducible, and transparent process control, it is crucial to have a detailed understanding of the wear condition of the punching tool. Currently, direct methods for measuring tool wear are unavailable, leading to reliance on indirect measurements through physical surrogate variables. These techniques predominantly focus on indirectly monitoring the quality of the punched parts after processing. In this study, we developed an innovative pneumatic gauging system capable of periodically measuring punch wear directly. We demonstrate the feasibility of integrating a measurement nozzle into the cutting tool, which enables direct assessment of the cutting edge wear. Additionally, we have developed a dedicated measuring transducer and conducted a comparative analysis against an industrial standard. Our methodology includes a comprehensive calibration process within the punching operation. To validate our approach, we performed a series of tests and cross-validation to demonstrate that tool wear degradation can be effectively measured. We explored the potential of this monitoring approach for predicting tool wear. Our findings indicate that real-time measurement of the punch’s cutting edge wear in punching and blanking operations is achievable, which paves the way for advancements in process control and maintenance. • Pneumatic gauging enables precision measurement of punch wear during manufacturing. • System integrates directly into tools, with a compact design and fast response time. • Data density enhances the precision and predictive capabilities of wear analysis. • The system monitors punch breakage by detecting pressure drops in real time. • The method facilitates denser data collection, enabling integration with AI systems.