The paper presents the modeling and analysis algorithm as well as the results of simulation tests with the use of FEM of the process of punching aluminum sheets used for casings. The first part presents the results enabling the correct selection of the die clearance on production lines depending on the thickness of the sheet metal. The second shows how to prepare the punch geometry in the FEM environment, taking into account the typical defects that occur as the work cycles increase. Thanks to

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... his, it was possible to determine their influence on the state of stresses and deformations as well as the quality of the cut edge. The developed numerical applications and the obtained test results can be used to design tools and optimize the punching process.