An investigation on tool wear prediction in automotive sheet metal stamping die using numerical simulation

Prediction of tool wear in rapid production of sheet metal stamping in automobile industries is a highly challenging task as there are many control parameters involved in the production of automotive panels. This paper presents a numerical simulation methodology to investigate the effects of various processing parameters, such as the lubrication, binder pressure and surface coating, on the critical tool worn area of a certain sheet metal stamping die used in automotive production. The simulation was performed using the finite element software AutoForm™. Various contact pressure distributions and tool wear predictions at the critical tool worn section of the die-workpiece interface, using different processing parameters, were obtained in the simulation, which provide informative guidelines for the on-site production.