Crack propagation in AISI D2 punch: a comparative study of FEM and XFEM methods

Abstract

Abstract This study examines crack initiation and propagation in AISI D2 punch tools subjected to cyclic and impact loading using the Finite Element Method (FEM) and the Extended Finite Element Method (XFEM). FEM analysis is employed to identify stress concentration areas and potential failure points, while XFEM facilitates efficient simulation of crack growth paths without the need for re-meshing. The Johnson–Cook constitutive and damage models are applied to accurately capture the elastoplastic behavior and fracture characteristics of AISI D2 under realistic industrial punching conditions. Results show that crack evolution occurs in distinct stages, from stable propagation to catastrophic failure, closely linked to Von Mises stress and plastic strain accumulation. These numerical predictions are corroborated by microstructural observations in failed punch head. The study also highlights the superior ability of XFEM to predict crack trajectories compared to conventional FEM, providing valuable insights into fracture mechanisms. The findings offer practical guidance for improving punch tool design through geometry optimization, material selection, and surface engineering. Furthermore, this research emphasizes the critical role of predictive numerical modeling in extending tool life, minimizing downtime, and enhancing reliability in industrial sheet metal forming processes.