{"status":"ok","message-type":"work","message-version":"1.0.0","message":{"indexed":{"date-parts":[[2026,4,7]],"date-time":"2026-04-07T21:49:43Z","timestamp":1775598583934,"version":"3.50.1"},"reference-count":46,"publisher":"MDPI AG","issue":"12","license":[{"start":{"date-parts":[[2025,12,9]],"date-time":"2025-12-09T00:00:00Z","timestamp":1765238400000},"content-version":"vor","delay-in-days":0,"URL":"https:\/\/creativecommons.org\/licenses\/by\/4.0\/"}],"funder":[{"name":"PRR\u2014Plano de Recupera\u00e7\u00e3o e Resili\u00eancia under the Next Generation EU from the European Union","award":["C644914747-00000023"],"award-info":[{"award-number":["C644914747-00000023"]}]},{"name":"FCT\u2014Funda\u00e7\u00e3o para a Ci\u00eancia e a Tecnologia","award":["UID 00481\/2025"],"award-info":[{"award-number":["UID 00481\/2025"]}]}],"content-domain":{"domain":[],"crossmark-restriction":false},"short-container-title":["Metals"],"abstract":"<jats:p>Punching is a widely adopted cold sheet metal forming process, prized for its cost-effectiveness and high production efficiency. However, premature tool failure remains a persistent challenge, leading to increased downtime and maintenance costs. This study investigates solutions to mitigate tool failure through a combination of 3D design optimization, Finite Element Modeling (FEM), and Response Surface Methodology (RSM). Specifically, FEM was used to analyze stress distribution and deformation in the punch under varying geometric and operational parameters, while RSM optimized the design space to identify key factors influencing tool life. The findings reveal that each proposed solution, including modifications to punch geometry, clearance, and material treatment, offers distinct advantages and trade-offs. A comparative analysis of these solutions highlighted one optimal design, which was then further analyzed using FEM to predict damage progression. While this study provides a framework for reducing tool failure, experimental validation of the damage prediction model is recommended for future work to confirm the numerical results. This research aims to provide industrial practitioners with actionable insights and methodologies to enhance punch durability, ultimately reducing production interruptions and costs.<\/jats:p>","DOI":"10.3390\/met15121353","type":"journal-article","created":{"date-parts":[[2025,12,9]],"date-time":"2025-12-09T14:49:01Z","timestamp":1765291741000},"page":"1353","update-policy":"https:\/\/doi.org\/10.3390\/mdpi_crossmark_policy","source":"Crossref","is-referenced-by-count":1,"title":["Reducing Maximum Punching Force in Sheet Cold Forming: A Numerical Study of a New Punch Design (Part II)"],"prefix":"10.3390","volume":"15","author":[{"given":"Abdelwaheb","family":"Zeidi","sequence":"first","affiliation":[{"name":"Laboratoire de G\u00e9nie des Mat\u00e9riaux et Environnement (LGME), Ecole Nationale d\u2019Ing\u00e9nieurs de Sfax, University of Sfax, Route Soukra Km 3.5, P.O. Box 1173, Sfax 3038, Tunisia"}]},{"ORCID":"https:\/\/orcid.org\/0009-0001-7537-8767","authenticated-orcid":false,"given":"Mabrouka","family":"Akrout","sequence":"additional","affiliation":[{"name":"Laboratory of Electromechanical Systems, National School of Engineers of Sfax, University of Sfax, Soukra Road, Km 3.5, P.O. Box 1173, Sfax 3038, Tunisia"}]},{"ORCID":"https:\/\/orcid.org\/0000-0001-9959-6577","authenticated-orcid":false,"given":"Khaled","family":"Elleuch","sequence":"additional","affiliation":[{"name":"Laboratoire de G\u00e9nie des Mat\u00e9riaux et Environnement (LGME), Ecole Nationale d\u2019Ing\u00e9nieurs de Sfax, University of Sfax, Route Soukra Km 3.5, P.O. Box 1173, Sfax 3038, Tunisia"}]},{"ORCID":"https:\/\/orcid.org\/0000-0001-8342-5116","authenticated-orcid":false,"given":"Ant\u00f3nio","family":"Pereira","sequence":"additional","affiliation":[{"name":"Department of Mechanical Engineering, Centre for Mechanical Technology and Automation (TEMA), University of Aveiro, 3810-193 Aveiro, Portugal"},{"name":"LASI\u2014Intelligent Systems Associate Laboratory, 4800-058 Guimar\u00e3es, Portugal"}]}],"member":"1968","published-online":{"date-parts":[[2025,12,9]]},"reference":[{"key":"ref_1","doi-asserted-by":"crossref","first-page":"3","DOI":"10.1177\/0954405419855507","article-title":"Optimization of compound die piercing punches and double cutting process parameters using finite element analysis","volume":"234","author":"Shaheen","year":"2020","journal-title":"Proc. Inst. Mech. Eng. Part B J. Eng. 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