In this article, the acoustic emission technique has been used to study a well-known surface damage mechanism, known as galling, during experimental simulation of sheet metal forming process. Results illustrated that the galling starts with relatively low-amplitude acoustic emission waves, corresponding to the elastic–plastic deformation of surface asperities (stage I), followed by a continually graduate rise in the acoustic emission activities related to the sheet material transfer to the slider tool along with lump growth (stage II), and ended to some waves with the highest amplitude and energy corresponding to the severe plowing and rupture of the friction junctions (stage III).
SchedinE. Galling mechanisms in sheet metal forming operations. Wear1994; 179: 123–128.
2.
Gaard A. Wear in sheet metal forming. Licentiate Thesis, Karlstad University, Sweden, 2008.
3.
van der Heide E, Huisin 't Veld AJ and Schipper DJ. The effect of lubricant selection on galling in a model wear test. Wear 2001; 251: 971–979.
4.
PodgornikBHogmarkbSPezdirnikJ. Comparison between different test methods for evaluation of galling properties of surface engineered tool surfaces. Wear2004; 257: 843–851.
SkareTThilderkvistPStahlJE. Monitoring of friction processes by the means of acoustic emission measurements—deep drawing of sheet metal. J Mater Process Technol1998; 80–81: 263–272.
7.
SatoshiIMasayukiSTatsuhiroJ. The relationship between AE and dissipation energy for fretting wear. Tribol Int2009; 42: 236–242.
8.
YangMManabeaKHayashiK. Data fusion of distributed AE sensors for the detection of friction sources during press forming. J Mater Process Technol2003; 139: 368–372.
9.
JolliffeIT. Principal component analysis, 2nd ed. New York: Springer Series in Statistics, 2002.
10.
SchedinELehtinenB. Galling mechanisms in lubricated systems: a study of sheet metal forming. Wear1993; 170: 119–130.
11.
de Rooij MB. Tribological aspects of unlubricated deep drawing processes. PhD Thesis, University of Twente, Enschede, 1998.
12.
Woska R. Influence of selected surface layers on the friction and wear behavior in deep drawing. PhD Thesis, TU Darmstadt, Germany, 1982.
13.
SindiCTNajafabadiMAEbrahimianSA. Fracture toughness determination of heat treated AISI D2 tool steel using AE technique. ISIJ Int2011; 51: 305–312.
14.
ThompsonBDYoungRPLocknerDA. Observations of premonitory acoustic emission and slip nucleation during a stick slip experiment in smooth faulted Westerly granite. Geophys Res Lett2005; 32: L10304–L10304.
15.
FerrerCSalasFPascualM. Discrete acoustic emission waves during stick–slip friction between steel samples. Tribol Int2010; 43: 1–6.
