Method of Monitoring of the Grinding Process with Lapping Kinematics Using Audible Sound Analysis
More details
Hide details
Department of Manufacturing and Production Engineering, Gdansk University of Technology, Faculty of Mechanical Engineering and Ship Technology, Poland
Submission date: 2022-11-20
Final revision date: 2022-12-07
Acceptance date: 2022-12-07
Online publication date: 2022-12-09
Publication date: 2022-12-22
Corresponding author
Mariusz Deja   

Department of Manufacturing and Production Engineering, Gdansk University of Technology, Faculty of Mechanical Engineering and Ship Technology, G. Narutowicza, 80-233, Gdansk, Poland
Journal of Machine Engineering 2022;22(4):71-81
Utilising microphones as audible sound sensors for monitoring a single-side grinding process with lapping kinematics is presented in the paper. The audible sound generated during grinding depended on the cutting properties of electroplated tools with D107 diamond grains and different thicknesses of the nickel bond. The tool wear affected the obtained technological effects such as material removal rate and the surface roughness of Al2O3 ceramic samples. The relationship between the quantities that characterise the sound signal and the surface roughness of machined surfaces was examined with the use of spectral analysis of the sound signal in the frequency domain with a focus on the Ra parameter. The decreasing amplitude indicated a better surface finish, down to Ra = 0.23 µm. The developed method and the obtained results will facilitate the practical use of the electroplated tools in the lap-grinding technology without interrupting the process before obtaining the required surface roughness.
MALKIN S., GUO, C., 2007, Thermal Analysis of Grinding, CIRP Annals – Manufacturing Technology, 56/2, 760–782.
BARYLSKI A., DEJA M., 2010, Finishing of Ceramics in a Single-Disk Lapping Machine Configuration, Solid State Phenomena, 165, 237–243.
ZAK K., GRZESIK W., 2017, Metrological Aspects of Surface Topographies Produced by Different Machining Operations Regarding their Potential Functionality, Metrology and Measurement Systems, 24/2, 325–335.
DEJA M., 2010, Simulation Model for the Shape Error Estimation During Machining with Flat Lapping Kinematics, ASME, International Manufacturing Science and Engineering Conference, 1, 291–299.
UHLMANN E., HOGHE T., 2012, Wear Reduction at Double Face Grinding with Planetary Kinematics, Production Engineering, 6/3, 237–242.
KHOSHAIM B.A., XU Z., MARINESCU D.I., 2015, Chapter 9 – ELID Grinding with Lapping Kinematics, Handbook of Ceramics Grinding and Polishing (Second Edition), William Andrew Publishing, Boston, 394–448, ISBN 9781455778584,
DEJA M., LICHTSCHLAG L., UHLMANN E., 2021, Thermal and Technological Aspects of Double Face Grinding of C45 Carbon Steel, Journal of Manufacturing Processes, 64, 1036–1046.
SANCHEZ L.E.A., JUN N.Z.X., FIOCCHI A.A., 2010, Surface Finishing of Flat Pieces when Submitted to Lapping Kinematics on Abrasive Disc Dressed Under Several Overlap Factors, Prec. Engineering, 35/2, 355–363.
DEJA M., 2012, Correlation Between Shape Errors in Flat Grinding, Journal of Vibroengineering, 14/2, 520–527.
DEJA M., LIST M., LICHTSCHLAG L., UHLMANN E., 2019, Thermal and Technological Aspects of Double Face Grinding of Al2O3 Ceramic Materials, Ceramics International, 45/15, 19489–19495.
AI C.S. et al., 2012, The Milling Tool Wear Monitoring Using the Acoustic Spectrum, International Journal of Advanced Manufacturing Technology, 61/5–8, 457–463.
RUBIO E.M., TETI R., 2009, Cutting Parameters Analysis for the Development of a Milling Process Monitoring System Based on Audible Energy Sound, Journal of Intelligent Manufacturing, 20/1, 4354.
LU M.C., KANNATEY-ASIBU JR., E., 2004, Flank Wear and Process Characteristic Effect on System Dynamics in Turning, Journal of Manufacturing Science and Engineering – Transactions of the ASME, 126/1, 131–140.
SALGADO D.R., ALONSO F.J., 2007, An Approach Based on Current and Sound Signals for in-Process Tool Wear Monitoring, International Journal of Machine Tools and Manufacture, 47/14, 2140–2152.
DEJA M., LICOW R., 2021, A Pilot Study to Assess Manufacturing Processes Using Selected Point Measures of Vibroacoustic Signals Generated on a Multitasking Machine, The International Journal of Advanced Manufacturing Technology, 115/3, 8078–22.
DEJA M., 2014, Vertical Vibration Reduction and Audible Sound Analysis in Surface Grinding with Electroplated Tools, Journal of Measurements in Engineering, 2/2, 80–85.
SHI Z., MALKIN S., 2006, Wear of Electroplated CBN Wheels, ASME J. Manufacturing Science and Engineering, 128/1, 110–118.
LIPINSKI D., KACALAK W., 2016, Metrological Aspects of Abrasive Tool Active Surface Topography Evaluation, Metrology and Measurement Systems, 23/4, 567–577.
HWANG T.W., EVANS C.J., WHITENTON E.P., MALKIN S., 2000, High Speed Grinding of Silicon Nitride with Electroplated Diamond Wheels, Part 1: Wear and Wheel Life, J. Manufacturing Science and Engineering, 122/1, 32–41.
UPADHYAYA R.P., FIECOAT J.H., 2007, Factors Affecting Grinding Performance with Electroplated CBN Wheels, CIRP Annals – Manufacturing Technology, 56/1, 339–342.
ZAWADA-TOMKIEWICZ A., SCIEGIENKA R., 2011, Monitoring of a Micro-Smoothing Process with the Use of Machined Surface Images, Metrology and Measurement Systems, 18/3, 419–428.
SUTOWSKI P., NADOLNY K., KAPLONEK W., 2012, Monitoring of Cylindrical Grinding Processes by Use of a Non-Contact AE System, Int. J. Precis. Eng. Manuf. 13/10, 1737.
SUTOWSKI P., 2012, Surface Evaluation During the Grinding Process Using Acoustic Emission Signal, Journal of Machine Engineering, 12/4, 23–34.
DEJA M., 2013, Selected Problems of Grinding with Lapping Kinematics, Publishing House of Gdansk University of Technology, Monography 143.
DEJA M., ZIELINSKI D., 2020), Wear of Electroplated Diamond Tools in Lap-Grinding of Al2O3 Ceramic Materials, Wear, 460, 203461.
KORZYNSKI M., 2018, Methodology of the Experiment. Planning, Implementation and Statistical Analysis of the Results of Technological Experiments, Publisher House: Wydawnictwo WNT, 277, (in Polish).
Journals System - logo
Scroll to top