Abstract
The aim of this study is to conduct a comprehensive comparative analysis of the stress-strain state of a restored busbar punching tool in order to improve its durability and performance. An overview of existing industrial methods for restoring punches and dies was carried out, including surfacing, welding, hard-facing, and thermal treatment approaches. The analysis showed that although these methods are widely used, each of them has inherent advantages and limitations related to cost, technological complexity, and the resulting service life of the tool. To overcome these challenges, a novel restoration technique is proposed, which involves replacing the worn working part of the busbar punching tool with a carbon steel insert. Numerical modeling of the stress-strain state of the restored tool was performed using the ANSYS software suite. The finite element simulations allowed for a detailed investigation of stress distribution, deformation patterns, and contact force distribution in the critical working zones of the tool under operational loads. The obtained results made it possible to identify the most heavily loaded regions of the structure, to compare them with the original tool design, and to assess the effectiveness of the proposed restoration method. The study demonstrated that the use of a carbon steel insert not only reduces localized stress concentrations but also contributes to extending the operational reliability and service life of the busbar punching tool. The findings of this research provide a practical contribution to the modernization and repair of punching tools, offering an economically viable and technically effective alternative to full tool replacement