In a previous paper, the acoustic emission (AE) signal emitted from a Minster1 #3 punch press was completely characterized and effects of stock hardness were examined. The AE signal emitted during punching was found to consist of three components: initial impact, shear fracture and rupture. Effects of stock hardness on the AE signal were then examined in terms of relative timing and amplitude of these three components and an excellent correlation was found between AE count and stock hardness. As a continuation, effects of stock thickness, tool size and tool wear are examined in this report. Similar to the previous study, their effects are investigated qualitatively in terms of relative timing and amplitude of the AE component and quantitatively in terms of AE count. Again good correlations are found between these process variables and the AE signals.

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