Coupled Abrasive and Fatigue Wear Modeling of Blanking Punches for Prediction of Wear Using Linear and Nonlinear Wear Models

Repeated blanking operations cause progressive degradation of punch edges, leading to dimensional inaccuracies, burr formation, and premature tool failure. This study proposes a coupled abrasive–fatigue wear modeling framework for estimating the lifetime of punches under long-term repeated blanking process. Abrasive wear was modeled using a modified Archard wear formulation, whereas fatigue-induced wear was represented using an extended Lemaitre damage model capable of capturing cyclic damage accumulation within the elastic regime. An adaptive finite element framework incorporating wear-driven geometry updating and element deletion techniques was developed to simulate progressive punch edge degradation during repeated blanking operations. The proposed methodology was applied to an AISI D2 punch and AISI 430 sheet metal under long-term cyclic blanking conditions. The results of finite element analysis demonstrated that the conventional linear wear model predicted gradual wear evolution, whereas the coupled nonlinear wear model effectively captured accelerated wear propagation after approximately 300,000 blanking cycles due to fatigue-induced material detachment. The predicted wear depth evolution showed good agreement with the experimental results, with a maximum relative error below 7%. In addition, the proposed wear update method using accumulated cycles enabled faster wear prediction than long-term blanking experiments.