Analysis of chip size distribution using image processing technology to estimate wear state of cylindrical grinding wheel

In theory, the chip shape distribution changes with the wearing of a grinding wheel in both sur-face and cylindrical grinding processes. However, the relationship between the chip shape distri- bution and wear has not been verified experimentally and quantitatively under any of the grinding techniques. To this end, in this work, chips from repeated cylindrical grinding processes are col-lected. It is noted that the workpiece surface becomes rougher with each repetition. The images of the individual chips, obtained using a particle tracking system are analyzed, and the results indicate that the proportion of small chips and slender chips, respectively known as melted and flow chips, increases when the grinding wheel is worn, which is in contrast to the implications of the established theory. •Focusing on chips to estimate grinding wheel wear.•Developing a device to collect chips during grinding procedure.•Measuring perimeter and area of an enormous number of chips by optical method.•Relationship between chip size and wheel wear revealed here differs from prevailing knowledge.