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 MECHANICAL TESTING 337

Acoustic emission testing of

surface roughness and wear caused
by grinding of ceramic materials
Periyasamy Kanakarajan, The current manufacturing trend mainly involves automation precisely
Sengottuvelu Sundaram, to offer better productivity and improved quality. In this context, on-
Arumugam Kumaravel, line monitoring of tools becomes essential. Acoustic emission is the
Materials Testing downloaded from www.hanser-elibrary.com by Hanser Verlag (Office) on April 1, 2015

Rathanasamy Rajasekar, most recognized technique used for condition monitoring of machine
Palaniappan Sathish Kumar, tools. Grinding is a material removal and surface generation process
Tamil Nadu, India employed to shape and finish components made of metals and other
Article Information materials. The research work deals with machining of CUMITUFF WR-90
Correspondence Address alumina ceramics by employing two different grinding wheels made
Assoc. Prof. P. Kanakarajan, B.E., M.E., of aluminum oxide and silicon carbide under varying depth of cut.
Department of Automobile Engineering
K. S. R. College of Engineering
Surface roughness of the machined component and wear of both
Tiruchengode grinding wheels were analyzed using acoustic emission technique. For
637215 Tamil Nadu, India
For personal use only.

a constant depth, the quality of machining has been improved for the
E-mail: kanagu.dhana@gmail.com
material grinded using silicon carbide wheel, which is inferred from
Keywords
Grinding, wear, ceramics, materials testing, low surface roughness value compared to material grinded using
acoustic emission aluminum oxide wheel.

Advanced ceramics offer resistance to wear
and thermal conductivity. Precisely due to
the above mentioned properties, they are
widely used in mechanical, electronic and
chemical (engineering) industries. Ceram-
ics are usually divided into two main
groups, namely oxide and non-oxide ce-
ramics. Ceramics are brittle and cannot
withstand large internal strains induced by
thermal expansion mismatch or thermal
transients. During sintering, shrinkage of
material takes place which cannot be
avoided. Hence, machining of ceramics af-
ter sintering is more essential to attain the
required shape and accuracy of the compo-
nent. Due to the high hardness of ceramic
materials, the final finishing operation of
the component is performed using dia-
mond wheel. Numerous research reports
addressed the material removal mecha-
nism of advanced ceramics.
Kitajima et al. [1] and Hwang et al. [2]
studied the grinding operation performed
using hard and brittle materials, especially
advanced ceramics. Inasaki [3] reported an
analysis on definite relations between
grinding forces, depth of cut, grinding en-
ergy and surface roughness.
In this modern era, sensing techniques
play a major role for monitoring machining
process at various levels in industries. AE
technology has been recognized as one of
the most promising methods for grinding
wheel wear detection and monitoring of
surface roughness. However, a high degree
of confidence and reliability in character-
izing the manufacturing process is re-
quired for any sensor to be utilized as a
monitoring tool. Traditionally, grinding
wheel and cutting tool is usually monitored
by the operator and studies have been fo-
cused to investigate the feasibility of auto-
mated tool condition monitoring.
Inasaki and Okamura [4] proved that
acoustic emission signals can be used to
monitor dressing process to produce a
grinding wheel surface of constant quality.
The tool life of the grinding wheel can be
identified by monitoring the change of am-
plitude and frequency characteristic ob-
tained from AE signal. Contact between the
grinding wheel and work piece had been
successfully detected using AE signal.
Mokbel and Massoud [5] analyzed raw AE
signals using fast Fourier transform and
correlated the AE spectral amplitudes of
different diamond wheel bond types, grit
sizes and conditions generated by using
different grinding wheel/truing ratios with
the surface of the ground mild steel speci-
mens. Iwata and Moriwaki [6] investigated
the feasibility of in-process tool wear sens-
ing using AE signals. Hwang et al. [2] ex-
amined the occurrence of severe wear loss
in grinding wheel by AE testing. The cause
was due to high-speed grinding of silicon
nitride using an electroplated single-lay-
ered diamond wheel. Tönshoff et al. [7] as
well as Kwak and Ha [8] studied the micro
and macro topography of the abrasive layer
of the grinding wheel using sensors.
Recent researches on micro grinding
have been mainly focused on assessing the
tool life and wear mechanisms, as the per-
formance of micro grinding wheels are
more sensitive to tool wear. Yin et al. [9]
studied the tool wear of the electroplated
micro grinding wheel in side grinding of

57 (2015) 4  © Carl Hanser Verlag, München  Materials Testing

 338 MECHANICAL TESTING
porcelain and zirconia. Various types of
grinding process signals, data feature ex-
traction methods and detection algorithms
had been developed for wear monitoring of
grinding wheel subjected to several appli-
cations. Byrne et al. [10] identified grind-
ing force as the important parameter for
indirect and continuous monitoring of tool
wear. Feng et al. [11] studied the variation
in stiffness and wear of tool upon end
grinding of ceramic materials using pro-
cess signals such as grinding force, grind-
ing system vibration, acoustic emission
signal and spindle load .Counts, hits and
energy are essential parameters for AE sig-
nal analysis. Grinding can be considered as
Materials Testing downloaded from www.hanser-elibrary.com by Hanser Verlag (Office) on April 1, 2015
a process with energy release. A rough sur-
face has high surface energy and a smooth
surface has low surface energy. Han and
Wu [12] focused on energy variation dur-
ing analyzing the relationship between the
AE signal and surface quality of the ma-
chined component. Hsu et al. [13] made an
extensive analysis on the machining char-
acteristics such as material removal rate,
machined surface roughness of wafers,
kerf width, steel wire wear and flatness.
For personal use only.
Tsai et al. [14] used the concept of fracture
machining technique to develop the ma-
chining of selected ceramic materials. A
smooth surface on alumina substrate was
successfully produced by adopting fracture
machining technique. A focused CO2 laser
was used to scribe a crack network on the
material surface and a defocused CO2 laser
was applied throughout the scribed lines.
This study provides a valuable methodol-
ogy to the grinding of ceramic and moti-
vates the improvement of the conventional
laser machining in surface quality.
This publication presents an investiga-
tion on grinding of alumina ceramic using
aluminum oxide (Al2O3) and silicon carbide
(SiC) wheels. By varying depth of cut and
by introducing acoustic emission parame-
ters, the following parameters like energy,
amplitude of grinding wheel wear and sur-
face roughness of ceramics were studied.
The experiments were conducted on hori-
zontal surface grinding machine. Ulti-
mately, the relationship between tool wear
and AE parameters were accomplished.
Acoustic emission technique
AE is the prime technique in the field of
non-destructive testing (NDE) which has
shown a very high potential for material
characterization and damage assessment
in conventional as well as non-conven-
tional materials. Acoustic emission is the
class of phenomenon where transient elas-
tic waves are generated by the rapid re-
lease of energy from localized sources
within a material. In other words acoustic
emission refers to the stress waves gener-
ated by dynamic processes in materials.
Emission occurs as a release of a series of
short impulsive energy packets. Thus, the
energy released travels as a spherical wave
front and can be picked from the surface of
a material using highly sensitive transduc-
ers usually electromechanical type. It is
converted into electrical signal on suitable
processing and analysis, which reveals
valuable information of the source causing
energy release.
Sources of acoustic emission include
many different mechanisms of deformation
and fracture. Sources that have been identi-
fied in metals include moving dislocations,
slip, twinning, grain boundary sliding, crack
initiation, crack growth, etc.. Other mecha-
nisms like leaks, cavitations, friction,
growth of magnetic activation domains,
movement of magnetic domain wells, phase
transformations also fall within definition
and are detectable by acoustic emission
equipment. These sources are termed as
secondary or pseudo sources.
The sensor is the heart of any acoustic
detection system. An acoustic emission
sensor is a device which generates an elec-
trical signal when it is stimulated by an
acoustic wave. An ideal sensor would pro-
duce a voltage-time curve identical to am-
plitude-time curve of the wave at the point
where the sensor is located. Acoustic emis-
sion sensors can be based upon different
physical principles. The signals can be gen-
erated by electromagnetic devices such as
phonograph pickups or piezoelectric de-
vices. Piezoelectric crystals are generally
used as sensor elements in commercially
available acoustic emission system. The
calibration gives the frequency/sensitivity
Figure 1: Schematic
illustration of the
experimental setup
curve for a given sensor, i. e., frequency re-
sponse of the sensor to the acoustic waves.
The strength of AE signals is normally
very weak and requires more amplifica-
tion. Hence, a preamplifier follows the
transducer and both together form the
front-end of the AE instrumentation. The
preamplifiers are used
• to amplify the small sensor signals so
that it may be transmitted over long sig-
nal cables. The signal is typically ampli-
fied 100 or 1000 times (40 or 60 dB) by
using special low noise amplifiers.
• to match high impedance of sensors to
low impedance of signal cable (typically
20 kK ohms to 50 ohms). Low impedance
cables pickup less airborne electrical in-
terference.
• to provide a means of common mode re-
jection to reduce electrical pickup from
sensor and sensor cable.
The desirable characteristics for a good AE
preamplifier are low noise, moderately
high gain, low output impedance, good dy-
namic range, high stability, good common
mode rejection and input impedance
matching to the sensor.
A filter is a passive or active network
which discriminates between different fre-
quencies, that it provides ‘transmission’
over any desired range of frequencies and
high degree of attenuation for all other
ranges. Depending on noise considerations
the operating bandwidth frequency is cho-
sen. So, filters are designed for different
bandwidths and can be plugged to pream-
plifiers to meet the specific requirement.
The conditioned (amplified and filtered)
AE signals are processed in order to do one
or more of the following:
• specify the amount of AE activity by
number
• accept AE signals of interest and reject
all others
• identify some characteristics of the sig-
57 (2015) 4
 MECHANICAL TESTING 339

Grinding machine Cutting tool

Table size 1675 mm Aluminum oxide grinding AA46/54
wheel specification K5 V8
Working surface of table 600 × 200 mm
Diameter 150 mm
Maximum height admitted
Width 13 mm
between table and new 300 mm
grinding wheel Bore 31.75 mm
Longitudinal traverse Silicon carbide grinding
650 mm GC 60 K5 V8
of table wheel specification
Diameter 150 mm
Maximum cross
Figure 2: Pictorial view of the experimental setup 225 mm
table traverse Width 13 mm
Maximum vertical wheel Bore 31.75 mm
300 mm
head traverse Work piece
nal that will help to determine the type H.P (horse power) CUMITUFF WR-90 alumina 150 mm × 100
2 HP
of AE source of wheel head motor ceramic mm × 20 mm
• obtain a number which is proportional to
Table 1: Specifications of the grinding machine, cutting tool and work piece
Materials Testing downloaded from www.hanser-elibrary.com by Hanser Verlag (Office) on April 1, 2015

the energy in AE
• locate the source of AE

Experimental procedure
The schematic and pictorial view of experi-
mental setup is shown in the Figures 1 and 2.
The experiments are conducted by AVRO
horizontal surface grinding machine along
with pre-amplifier, AE sensor, digital stor-
age oscilloscopes and computer. The Ta-
For personal use only.
grinding machine, cutting tool, work piece
and properties of ceramics, respectively.
AE instrument. The AE signal recording
is carried out using physical acoustic emis-
sion byLocan Acoustic Emission analyzer
(4 channels). A piezoelectric transducer is
used as sensor. The transducer is properly
coupled to the surface with a highly viscous
ing AE transmission to the AET monitor by
a preamplifier. The Locan Acoustic Emis-
sion analyzer is a computerized data acqui-
sition system designed to perform data ac-
quisition, data display and data analysis.
Procedures. The sensor had been coupled
to the specimen using couplant and secured
with insulation tape. The sensor was con-

bles 1 and 2 contain the specifications of couplant in order to avoid signal loss dur- nected to the AE monitor by preamplifier

WR99.5 nominal WR96 nominal WR90 nominal WR85 nominal

Properties Units Test
99.5 % Al2O3 96 % Al2O3 90 % Al2O3 85 % Al2O3
Mechanical properties
Color Ivory White White White – –
Density 3.89 3.72 3.60 3.41 g/cc ASTM C20-83
Hardness 83 80 79 73 R45N ASTM E 18
Surface finish
Profilometer
As fired 0.9 1.6 1.6 1.6 Micrometers
(0.75 mm cut off)
Ground 0.5 1.3 0.5 1.0 cla
Polished 0.1 0.3 0.1 0.2
Water absorption 0 0 0 0 % ASTM C373-72
Elastic modulus 20 °C 372 303 276 221 GPa ASTM C848-78
Stiffness/Weight 20 °C 96 81 77 65 GPa/g/cc –
Compressive strength 20 °C 2620 2068 2482 1930 MPa ASTM C773-82
Tensile strength 25 °C 262 193 221 155 MPa ASTM TEST 4
Thermal property
1750 1700 1500 1400 °C No load
Maximum use temperature
Wear & chemical property
Corrosion 0.01 – 0.03 0.04 mg/cm2/day 95 %H2SO4@20 °C*
Resistance 0.1 – 0.50 1.00 95 %H2SO4@100 °C*
Impingement 0.47 0.63 0.45 1.00 – **
Rubbing – 0.75 0.36 1.00 – **
* Chemical Resistance – although all CUMITUFF ceramics are highly resistant to chemical attack it is recommended that specific application data are
obtained from CUMI prior to design finalization to ensure optimum ceramic selection.
** Wear Resistance – impingement tests are run using a dry fused alumina, abrasive rubbing tests are run using a dry 240 grit fused alumina abrasive.
Table 2: Properties of the ceramics

57 (2015) 4
 340 MECHANICAL TESTING

Digital vernier height Digital vernier height Depth Wear in Final Results and discussion
Grinding wheel
gauge reading (h1) gauge reading (h2) of cut diameter diameter
material
(mm) (mm) (mm) (mm) (mm) The experiment was conducted on WR-90
252.96 252.92 0.005 0.08 149.88 alumina ceramics using Al2O3 and SiC
252.92 252.86 0.01 0.12 149.76 wheel. Prior to experiment both wheels
were dressed. Machining was carried out
Aluminum oxide 252.86 252.77 0.015 0.18 149.58
on WR-90 alumina ceramics for depth of
252.77 252.64 0.02 0.26 149.32 cut ranging from 0.005 mm to 0.025 mm.
252.64 252.48 0.025 0.32 149.00 Table surface of surface grinder had been
252.97 252.95 0.005 0.04 149.93 taken as the reference level for tool wear
measurement.
252.95 252.90 0.01 0.10 149.83
Wear of Al2O3 and SiC wheels for differ-
Silicon carbide 252.90 252.83 0.015 0.14 149.69 ent depths of cut is illustrted in Table 3.
252.83 252.72 0.02 0.22 149.47 For the depth of cut of 0.025 mm, the wear
252.72 252.59 0.025 0.26 149.21 of aluminum oxide wheel is comparatively
higher than of silicon carbide wheel. In
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Table 3: Al2O3 and SiC wheel wear for different depths of cut such case, silicon carbide wheel is highly
preferable due to minimum wheel wear.
The amplitude, energy and surface
and the machining process was carried out. The grinding wheel wear had been meas- roughness of Al2O3 and SiC wheel for dif-
The monitor receives the AE signals and fi- ured using digital vernier height gauge. Sur- ferent depths of cut is shown in the Fig-
nally records them, when the grinding ac- face roughness of WR-90 alumina ceramics ures 3, 4 and 5. Gradual increase in depth
tion gets stabilized during grinding process. was measured using Surfcorder. of cut, i. e., 0.005, 0.01, 0.015, 0.02 and
For personal use only.

Figure 3: Amplitude of Al2O3 and SiC wheel for different depths of cut Figure 4: Energy of Al2O3 and SiC wheel for different depths of cut

Figure 5: Surface roughness for different depths of cut using Al2O3 and SiC wheel Figure 6: Amplitude versus wear of Al2O3 and SiC wheel

57 (2015) 4

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Figure 7: Energy versus wear of Al2O3 and SiC wheel
0.025 mm shows subsequent enhancement
in amplitude, energy and surface rough-
ness for both Al2O3 and SiC wheels. Depth
of cut of 0.025 mm depicts maximum am-
plitude and energy level for silicon carbide
wheel compared to aluminum oxide wheel.
These results exhibit higher emission and
energy for harder than softer grinding
For personal use only.
wheel material. The surface roughness of
WR-90 alumina ceramics is found to be
comparatively low to machining with sili-
con carbide wheel. From the inferred re-
sults, silicon carbide wheel is best suited
for achieving higher amplitude, energy and
better surface finish.
The amplitude and energy for different
wheel wear and surface roughness (Ra) val-
ues of Al2O3 and SiC wheels are depicted in
the Figures 6 to 9. The results show a grad-
ual increment in amplitude and energy for
different wheel wear (0.02, 0.04, 0.05,
0.06, 0.07, 0.09, 0.11, 0.13 and 0.16 mm)
and Ra values (0.1, 0.2, 0.3, 0.4, 0.5, 0.6,
0.8, 0.9 and 1.1 µm). Maximum wheel wear
of 0.16 mm and surface roughness of
57 (2015) 4
Figure 8: Amplitude versus surface roughness of Al2O3 and SiC wheel
1.1 µm render maximum amplitude and
energy for silicon carbide wheel compared
to aluminum oxide wheel. For same surface
roughness of work piece material, ampli-
tude and energy level are higher for harder
grinding wheel. As the structure of the tool
material becomes hard and brittle, the phys-
ical phenomenon tends to a linear raise in
amplitude and energy levels. However, the
amplitude of the surface roughness is in-
versely related and the same was clearly
justified by the experimental results.
Conclusions
In this research work, an excellent rela-
tionship between the tool wear and AE pa-
rameters were obtained, which has been
analyzed by the experiments conducted in
a horizontal surface grinding machine.
Based on the experimental results, the
acoustic emission parameters are found to
be higher and show less wear for harder
grinding wheel (SiC) material than softer
material (Al2O3). Enhancement in ampli-
Figure 9: Energy versus
surface roughness of
Al2O3 and SiC wheel
MECHANICAL TESTING 341
tude and energy of both grinding wheels
has been obtained with increase in depth of
cut, wheel wear and surface roughness of
work piece material. Good machining qual-
ity during grinding operation has been
achieved using silicon carbide wheel. The
conclusion is drawn from the attainment of
low surface roughness value for the grind-
ing operation carried out using SiC wheel
compared to Al2O3 wheel by maintaining a
constant depth of cut. It affirms that acous-
tic emission technique can be used as an
effective on-line tool and process monitor-
ing system.
References
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Study on mechanism of ceramics grinding,
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 2 T. W. Hwang, E. P. Whitenton, N. N. Hsu,
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the discrete wavelet decomposition, Interna- schleißes infolge Schleifens von keramischen Werkstoffen. Der gegen-
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Materials Testing
57 (2015) 4, pages 337-342
© Carl Hanser Verlag GmbH & Co. KG
ISSN 0025-5300
The authors of this contribution
Prof. Periyasamy Kanakarajan, born in 1967,
completed his Bachelor degree of Mechanical En-
gineering at Kongu Engineering College, Tamil
Nadu, India, in 1991. He obtained his Master de-
gree at K. S. Rangasamy College of Technology,
Tamil Nadu, India, in 2008. Currently, he is work-
ing as Associate Professor in the Department of
Automobile Engineering at K. S.R College of Engi-
neering, Tiruchengode, India.
Dr. Sengottuvelu Sundaram, born in 1960,
holds a PhD in Mechanical Engineering from
Sathyabama University, Chennai, Tamil Nadu, In-
dia, in 2010. He obtained his MSc.Tech. degree in
Maintenance Engineering and Management from
Indian Institute of Technology Madras, Chennai,
India, in 1998, and Bachelor degree of Mechani-
cal Engineering from Government College of En-
gineering, Salem, India, in 1990. Currently, he is
working as Principal at Vidyaa Vikas College of
Engineering and Technology, Tamil Nadu, India.
Dr. Arumugam Kumaravel, born in 1969,
holds a PhD in Mechanical Engineering from the
Indian Institute of Technology, Madras, India, in
2008. He obtained his MSc.Tech. degree in Indus-
trial Tribology from the Indian Institute of Tech-
nology, Madras, India, in 2004 and his BE in Me-
chanical Engineering from Government College of
Engineering, Salem, India, in 1990. He is working
as Professor in the Department of Mechanical En-
gineering at K. S.Rangasamy College of Technol-
ogy, Tamil Nadu, India.
Dr. Rathanasamy Rajasekar, born in 1982, ob-
tained his MSc and PhD degrees in Materials Sci-
ence in 2008 and 2011, respectively, at the In-
dian Institute of Technology, Kharagpur, India.
He gained his post-doctoral research experience
during 2011 and 2012 in the Department of Poly-
mer & Nano Engineering at Chonbuk National
University, South Korea. Since 2012, he has been
working as an Associate Professor in the Depart-
ment of Mechanical Engineering at Kongu Engi-
neering College, India.
Palaniappan Sathish Kumar, born in 1991, fin-
ished his Bachelor degree in Engineering (Me-
chanical stream) at University College of Engi-
neering Villupuram (a constituent college of
Anna University – Chennai), Tamil Nadu, India,
in 2012. He absolved his Master of Engineering at
Kongu Engineering College, Tamil Nadu, India, in
the discipline of CAD/CAM in 2014.

57 (2015) 4

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