© 2020 Elsevier LtdPunching is recognized to be useful in sheet cold forming. To the best of our knowledge, researchers have been interested just in thin ones. That is why the interest of this paper is in premature AISI D2 punch damage in case of thick S500 MC plettac. Several techniques such as optical microscopy, Energy dispersive spectroscopy (EDS), Vickers hardness and scanning electron microscopy (SEM) were used in order to extract failure causes. The obtained results showed that back-up plate, corrosion, wear and fatigue as well as head punch cracking, scaling, mating and inflation lead to a short-life service. Microstructures characterizations exhibit fractured chromium carbides and lamellar pearlite bending during head tool and back-up plate contact.