<p>The puncture resistance of rubber materials is a critical performance indicator, especially in applications requiring high durability and reliability. Traditional experimental research methods are costly and time-consuming, particularly when systematic studies under various conditions are needed. To address these issues, this paper proposes a finite element method that integrates hyperelastic constitutive modeling with cohesive zone theory, enabling effective simulation of stress distribution and damage evolution in rubber materials during puncture processes. The study employs a hyperelastic model to describe the mechanical behavior of rubber and uses cohesive elements to simulate damage mechanisms and the evolution of contact damage during puncture. By simulating the insertion of a steel needle into rubber, the relationship between needle displacement and puncture force under different needle tip angles, puncture speeds, and rubber thicknesses was analyzed. To validate the simulation results, a dedicated experimental platform was designed and tests were conducted. The experimental data showed good agreement with the numerical simulation results, confirming the accuracy of the method. The study finds that the puncture force is influenced by the needle tip angle, puncture speed, and rubber thickness, with the needle tip angle and rubber thickness having a significant impact on the maximum puncture force, while the effect of puncture speed is relatively minor. This approach reduces the cost and time of traditional testing while providing in-depth information, such as stress distribution and internal damage mechanisms, which are difficult to obtain experimentally.</p>