Electrostatic induction–based online monitoring of grinding wheel wear

Grinding is an important part of precision manufacturing, and grinding wheel wear is a crucial factor affecting the processing quality. It will be of great significance to monitor the grinding wheel wear status in real-time and provide timely warnings during processing. To realize the real-time and effective monitoring of grinding wheel wear, a new grinding wheel wear state monitoring method based on the principle of electrostatic induction is proposed. The principle of electrostatic induction in the machining process is analyzed, and two methods of grinding wheel wear surface monitoring and chip-abrasive grain monitoring are proposed. The time domain signal is processed by Fourier transform and noise reduction, and the influence of grinding wheel wear on the electrostatic signals of grinding wheel, abrasive grains, and chips is analyzed. The results of titanium alloy grinding show that with the increase in the wear degree of the grinding wheel, the electrostatic quantity of the grinding wheel increases by 5.6 times, and the number of electrostatic pulses of abrasive grains decreases by 74%. The degree of grinding wheel wear can be characterized by the electrostatic quantity of the grinding wheel and the number of electrostatic pulses of abrasive grains. In contrast, the number of electrostatic pulses of chips, the electrostatic pulse peaks of abrasive grains, and chips have no apparent relationship with grinding wheel wear. The electrostatic monitoring method can effectively monitor the grinding wheel wear state in real time and provide a new solution for the online monitoring of grinding wheel wear.