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Time series analysis of tool wear in sheet metal stamping using acoustic emission

Shanbhag, Vignesh Vishnudas, Pereira, Michael, Rolfe, Bernard and Arunachalam, N 2017, Time series analysis of tool wear in sheet metal stamping using acoustic emission, in IDDRG 2017 : Materials modelling and testing for sheet metal forming : Proceedings of the 36th IDDRG Conference 2017, IOP Publishing, Bristol, Eng., pp. 1-8, doi: 10.1088/1742-6596/896/1/012030.

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Title Time series analysis of tool wear in sheet metal stamping using acoustic emission
Author(s) Shanbhag, Vignesh VishnudasORCID iD for Shanbhag, Vignesh Vishnudas orcid.org/0000-0002-3900-0388
Pereira, MichaelORCID iD for Pereira, Michael orcid.org/0000-0002-7885-5901
Rolfe, BernardORCID iD for Rolfe, Bernard orcid.org/0000-0001-8516-6170
Arunachalam, N
Conference name International Deep Drawing Research Group. Conference (36th : 2017 : Munich, Germany)
Conference location Munich, Germany
Conference dates 2017/07/02 - 2017/07/06
Title of proceedings IDDRG 2017 : Materials modelling and testing for sheet metal forming : Proceedings of the 36th IDDRG Conference 2017
Editor(s) Volk, Wolfram
Publication date 2017
Series International Deep Drawing Research Group Conference
Start page 1
End page 8
Total pages 8
Publisher IOP Publishing
Place of publication Bristol, Eng.
Keyword(s) sheet metal stamping
acoustic emission
science & technology
technology
engineering, manufacturing
engineering
materials science
Summary Galling is an adhesive wear mode that often affects the lifespan of stamping tools. Since stamping tools represent significant economic cost, even a slight improvement in maintenance cost is of high importance for the stamping industry. In other manufacturing industries, online tool condition monitoring has been used to prevent tool wear-related failure. However, monitoring the acoustic emission signal from a stamping process is a non-trivial task since the acoustic emission signal is non-stationary and non-transient. There have been numerous studies examining acoustic emissions in sheet metal stamping. However, very few have focused in detail on how the signals change as wear on the tool surface progresses prior to failure. In this study, time domain analysis was applied to the acoustic emission signals to extract features related to tool wear. To understand the wear progression, accelerated stamping tests were performed using a semi-industrial stamping setup which can perform clamping, piercing, stamping in a single cycle. The time domain features related to stamping were computed for the acoustic emissions signal of each part. The sidewalls of the stamped parts were scanned using an optical profilometer to obtain profiles of the worn part, and they were qualitatively correlated to that of the acoustic emissions signal. Based on the wear behaviour, the wear data can be divided into three stages: - In the first stage, no wear is observed, in the second stage, adhesive wear is likely to occur, and in the third stage severe abrasive plus adhesive wear is likely to occur. Scanning electron microscopy showed the formation of lumps on the stamping tool, which represents galling behavior. Correlation between the time domain features of the acoustic emissions signal and the wear progression identified in this study lays the basis for tool diagnostics in stamping industry.
ISSN 1742-6588
Language eng
DOI 10.1088/1742-6596/896/1/012030
Field of Research 091006 Manufacturing Processes and Technologies (excl Textiles)
091309 Tribology
02 Physical Sciences
09 Engineering
Socio Economic Objective 861205 Sheet Metal Products
HERDC Research category E1 Full written paper - refereed
ERA Research output type E Conference publication
Copyright notice ©2017, V. Vignesh Shanbhag et al.
Free to Read? Yes
Use Rights Creative Commons Attribution licence
Persistent URL http://hdl.handle.net/10536/DRO/DU:30102962

Document type: Conference Paper
Collections: Institute for Frontier Materials
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Every reasonable effort has been made to ensure that permission has been obtained for items included in DRO. If you believe that your rights have been infringed by this repository, please contact drosupport@deakin.edu.au.