Multi-Sensor Monitoring of Wheel Wear During CBN Grinding of Crankshaft Steel

Journal article, 2025

Monitoring grinding wheel wear is crucial for optimising dressing intervals and workpiece surface integrity. Grindability tests were conducted on a through-hardened, micro-alloyed C38 steel, using a multi-sensor approach to analyse forces and acoustic emission (AE) under varying grinding aggressiveness and wheel micro-topographies. The acquired data enabled the identification of features sensitive to wheel wear progression. For all investigated conditions, a worn wheel (duller micro-topography) led to higher forces and instantaneous energies of the AE Intrinsic Mode Functions. The frequency spectra obtained by Fast Fourier and Hilbert-Huang transforms also revealed distinct differences as wheel wear progressed.