The simulation of acoustic emission for metal forging

In this article, physical models for acoustic emission (AE) are introduced and expressions are derived to predict AE activity from such parameters as applied stress, strain, and strain rate. These models are incorporated into a viscoplastic finite-element simulation program, and the AE event rate generated during metal-forming operations is predicted. Simulation results are presented for upsetting operations on a typical C-Mn type steel for various friction and die geometry conditions. The AE model predictions compare well with the limited available experimental results reported in the literature and demonstrate that AE signatures can be reliably simulated.