Evaluation of acoustic emission for monitoring wire drawing process

Acoustic emission (AE) technology is sensitive to high frequency waves generated in physical mechanisms as friction contact and plastic deformation, both present in the wire drawing process. In this regard, experimental measurements with this technology have been conducted to wire drawing in an industrial environment, in order to prove the technology validity to monitor this manufacturing process. The correlation of the results with the parameters defining the operation (as drawing speed, die temperature or lubricant type) and production (e.g. wire diameter, die status or incidences) intends to stablish the main aspects to develop a correct monitoring for this application. Due to the complexity of the wire drawing and the interrelated parameters, tendencies in AE signal have been assessed under certain conditions in base to the experimental results. The study developed in tests with controlled-parameters for same single wire reel reveals a clear correlation between AE amplitude and lubricant chemical composition, as well as between AE amplitude and die temperature. Furthermore, the employment of another wire material or different die set makes the analysis more complex, revealing AE spectral variations and patterns that reflect slight changes of the process.