<p>In this study, wear and surface roughness on cutting surfaces were experimentally investigated to improve punch–die service life in non-round, soft, and thin sheet metals. Complex-shaped components with sharp corners are frequently used in industrial applications. In such parts, burr height and wear zones between the punch and the die tend to be higher compared to those with rounded or straight edges, emphasizing the importance of part geometry. Punch wear, which significantly affects product quality, exhibits a nonlinear relationship with the number of cutting strokes. Therefore, the condition between wear angles and surface roughness on the punch and die front surfaces was examined. Finally, the number of cutting strokes and values of surface roughness values were measured to show significant improvements in punch–die service life. Experimental results not only reveal that the punch die clearance significantly influences burr formation, but also that surface roughness and number of cutting stroke play a critical role in the evolution of burr height.</p>