Investigation of Galling Wear Using Acoustic Emission Frequency Characteristics

Lubricants - Tập 8 Số 3 - Trang 25
Vignesh V. Shanbhag1, Bernard Rolfe1, Michael P. Pereira1
1School of Engineering, Faculty of Science, Engineering and Built Environment, Deakin University, Waurn Ponds 3216, Australia

Tóm tắt

In the sheet metal stamping process, during sliding contact between the tool and sheet, it is expected that severe events such as tool wear or fracture on the sheet generate acoustic emission (AE) burst waveforms. Attempts have been made in the literature to correlate the AE burst waveform with the wear mechanisms. However, there is a need for additional studies to understand the frequency characteristics of the AE burst waveform due to the severity and progression of the galling wear. This paper will determine the AE frequency characteristics that can be used to monitor galling wear, independent of the experimental process examined. The AE burst waveforms generated during the stamping and scratch tests are analysed in this paper to understand the change in the AE frequency characteristics with the galling severity. These AE burst waveforms were investigated using the Hilbert Huang Transform (HHT) time-frequency technique, band power, and mean-frequency. Subsequently, these AE frequency features are correlated with the wear behaviour observed via high-resolution profilometer images of the stamped parts and scratch surfaces. Initially, the HHT technique is applied to the AE burst waveform to understand the influence of wear severity in the power distribution over the wide AE frequency range. Later, the AE bandpower feature is used to quantitatively analyse the power in each frequency interval during the unworn and worn tool conditions. Finally, the mean-frequency of AE signal is identified to be able to determine the onset of galling wear. The new knowledge defined in this paper is the AE frequency features and wear measurement feature that can be used to indicate the onset of galling wear, irrespective of the processes examined.

Từ khóa


Tài liệu tham khảo

Ubhayaratne, 2017, Audio signal analysis for tool wear monitoring in sheet metal stamping, Mech. Syst. Signal Process., 85, 809, 10.1016/j.ymssp.2016.09.014

ASTM (2013). Standard Terminology Relating to Wear and Erosion, ASTM. ASTM G40-13.

Challen, 1979, An explanation of the different regimes of friction and wear using asperity deformation models, Wear, 53, 229, 10.1016/0043-1648(79)90080-2

Pereira, 2012, Wear at the die radius in sheet metal stamping, Wear, 274, 355, 10.1016/j.wear.2011.10.006

Shanbhag, V.V., Rolfe, B.F., Arunachalam, N., and Pereira, M.P. Understanding the source of acoustic emission signals during the wear of stamping tools. IOP Conf. Ser. Mater. Sci. Eng., 2018.

Schedin, 1994, Galling mechanisms in sheet forming operations, Wear, 179, 123, 10.1016/0043-1648(94)90229-1

Krakhmalev, 2007, Galling resistance and wear mechanisms-cold work tool materials sliding against carbon steel sheets, Tribol. Lett., 26, 67, 10.1007/s11249-006-9186-5

Karlsson, 2012, Galling resistance and wear mechanisms for cold-work tool steels in lubricated sliding against high strength stainless steel sheets, Wear, 286, 92, 10.1016/j.wear.2011.04.002

Sindi, 2013, Tribological behavior of sheet metal forming process using acoustic emission characteristics, Tribol. Lett., 52, 67, 10.1007/s11249-013-0193-z

Hase, 2012, Correlation between features of acoustic emission signals and mechanical wear mechanisms, Wear, 292, 144, 10.1016/j.wear.2012.05.019

Shanbhag, 2019, Understanding galling wear initiation and progression using force and acoustic emissions sensors, Wear, 436, 202991, 10.1016/j.wear.2019.202991

Ge, 2004, Fault diagnosis using support vector machine with an application in sheet metal stamping operations, Mech. Syst. Signal Process., 18, 143, 10.1016/S0888-3270(03)00071-2

Bassiuny, 2007, Fault diagnosis of stamping process based on empirical mode decomposition and learning vector quantization, Int. J. Mach. Tools Manuf., 47, 2298, 10.1016/j.ijmachtools.2007.06.006

Krantz, 2003, Wear and frictional behaviour of high strength steel in stamping monitored by acoustic emission technique, Wear, 255, 1471, 10.1016/S0043-1648(03)00197-2

Shanbhag, 2018, Investigating galling wear behaviour in sheet metal stamping using acoustic emissions, Wear, 414, 31, 10.1016/j.wear.2018.07.003

Filippov, 2017, Acoustic emission study of surface deterioration in tribocontacting, Appl. Acoust., 117, 106, 10.1016/j.apacoust.2016.11.007

Filippov, 2017, Vibration and acoustic emission monitoring the stability of peakless tool turning: Experiment and modeling, J. Mater. Process. Technol., 246, 224, 10.1016/j.jmatprotec.2017.03.030

Filippov, 2018, Microstructural, mechanical and acoustic emission-assisted wear characterization of equal channel angular pressed (ECAP) low stacking fault energy brass, Tribol. Int., 123, 273, 10.1016/j.triboint.2018.03.023

Hokkirigawa, 1988, The effect of hardness on the transition of the abrasive wear mechanism of steels, Wear, 123, 241, 10.1016/0043-1648(88)90102-0

(2017, January 21). IF-MeasurementSuite 5.1. Available online: https://www.ita-polska.com.pl/upload/documents/IF-MeasureSuite_5.1_ProductInfo_EN1.pdf.

(2020, February 10). Acoustic Emission Sensor Specifications. Available online: http://www.atgndt.com/wp-content/uploads/2016/01/vallen-ae-sensors.pdf.

Peng, 2005, A comparison study of improved Hilbert-Huang transform and wavelet transform: Application to fault diagnosis for rolling bearing, Mech. Syst. Signal Process., 19, 974, 10.1016/j.ymssp.2004.01.006

Peng, 2005, An improved Hilbert-Huang transform and its application in vibration signal analysis, J. Sound Vib., 286, 187, 10.1016/j.jsv.2004.10.005

(2019, September 07). Bandpower. Available online: https://au.mathworks.com/help/signal/ref/bandpower.html.

(2019, September 07). Meanfreq. Available online: https://au.mathworks.com/help/signal/ref/meanfreq.html.

Schedin, 1993, Galling mechanisms in lubricated systems: A study of sheet metal forming, Wear, 170, 119, 10.1016/0043-1648(93)90358-S

Voss, 2017, A new methodology for measuring galling wear severity in high strength steels, Wear, 390, 334, 10.1016/j.wear.2017.09.002

Krakhmalev, 2008, Wear mechanisms in deep drawing of carbon steel-correlation to laboratory testing, Tribotest, 14, 1, 10.1002/tt.49

Li, 2002, A brief review: Acoustic emission method for tool wear monitoring during turning, Int. J. Mach. Tools Manuf., 42, 157, 10.1016/S0890-6955(01)00108-0

Schipper, 2001, Analysis of material transfer from a soft workpiece to a hard tool: Part I—Lump growth model, J. Tribol., 123, 469, 10.1115/1.1308009

Thông tin
Thông tin xuất bản

Lubricants

Tập 8 Số 3

25

Thông tin tác giả