Finite element analysis for the wear of Ti–N coated punch in the piercing process

This paper describes a computer modeling scheme using the finite element method in order to investigate the wear mechanism and to predict the wear profile of Ti–N coated tool in the piercing process according to the volume of production. Archard’s wear model is reformulated in an incremental form to predict tool wear and then the wear depth on the tool is calculated at each step in the deformation using the results of finite element analysis, taking in consideration the sliding velocity and normal pressure over the contact area. To analyze the quantitative wear of the tool, wear coefficients of the coated and the inner layer of tool are determined by the result using a wear test, such as pin-on-disk wear test. To verify the effectiveness of the suggested scheme, the scheme is applied to wear analysis on punch during piercing process in multi-stage forming process of piston pin and simulation results are compared with experimental ones. It is known that the simulation results are in good agreement with those obtained experimentally.