Optimization of Positioning of an Acoustic Emission Sensor for Monitoring Hot Forging

Abstract

Optimization of a sensor location for effective characterization of a hot forging process using acoustic emission (AE) signals is discussed in this paper. Acoustic emission signals generated during forging operations on an aluminium alloy were recorded using three sensors simultaneously by mounting them on the top bolster, bottom bolster, and bottom die of the press. The AE signals with maximum sensitivity could be detected with a sensor attached to the bottom die in preference to the other positions. Using AE parameters, the forging process could be differentiated into three regions, i.e., 1) yielding of the workpiece material, 2) intermediate deformation region, and 3) filling of the die. The results show that the optimum position of the AE sensor for monitoring hot forging is found to be the bottom die of the forging press.

A review of the application of acoustic emission techniques for monitoring forming and grinding processes

“…As part of the collaborative programme with HAL, Bangalore, AE monitoring of hot forging process has been carried out by the authors to determine the optimum location of the AE sensor for monitoring the forging process [19]. The other objectives of this study were to characterise the forging process and also to study the feasibility of detecting lubrication breakdown during forging.…”

System for Real-time Measurement and Monitoring of Forging Force of Screw-forming Machine

“…The acoustic emission (AE) technique is a prospective lossless audio online detection method applicable for identifying damage in the metal forming process. Mukhopadhyay et al (4) employed AE signals to effectively inspect the surface characteristics of a workpiece during hot forging and to optimize the sensor position. They installed three sensors on the top beam, bottom beam, and bottom mold of a press-brake bending machine to simultaneously record the acoustic signals emitted during bending.…”