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Prototypical development of a sensory tool holder for in-situ process monitoring for high-speed internal cylindrical grinding (Projectnumber: KK 5072208 PK0)

The use of sensor-based tool holders for process analysis and especially for process monitoring in the manufacturing processes of milling, drilling and turning has established itself in recent years as the most powerful measuring strategy. By measuring the process forces as well as the disturbance variables influencing them in the tool holder as the non-wearing component closest to the process, a maximum resolution can be achieved. However, this requires that the sensors and microelectronics integrated in the holder can resist the high loads. For processes with geometrically undefined cutting edges, such as internal peel grinding, sensory tool holders are currently not available. For this process in particular, there is enormous potential for increasing performance and process stability through the use of suitable process monitoring with the assistance of in-process measurement technology.

Internal cylindrical grinding is an established manufacturing process for bore machining of hardened steels for the production of bearing and gear components. However, the engagement conditions are complex and the tools are very compliant during internal machining due to the slim, cantilevered tool body. These aspects represent a major challenge in process control. As a result, dimensional and shape deviations often occur in the workpiece, leading to rejects or demanding remachining. Increasing process monitoring is considered a necessary basis for reducing manufacturing deviations in the future with the use of suitable compensation strategies. However, there is currently no suitable, industrially applicable measuring technology on the market that is suitable for internal grinding processes under high speed conditions.

The aim of this project is to develop a sensory high-speed tool holder that enables process monitoring of internal grinding under high-speed and high-performance conditions. Through the combination of process know-how and innovative measurement technology, a production technology is to be raised to a new performance class, which is characterised by increased efficiency in the form of reduced process times and thus by considerable cost and energy savings. Measurement technology, used as an analysis tool in process development and also in industrial process set-up, but especially in real-time monitoring during the process, is a way to achieving the necessary performance ranges in the form of high material removal rates and product quality at the same time.


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Location & approach

From A1

Take exit Kreuz Dortmund/Unna to merge onto A44 toward Dortmund, which changes into the B1. Exit Dortmund-Dorstfeld toward Universität (onward see map).

From A 45

Exit Dortmund-Eichlinghofen toward Universität (onward see map).

Alternatively, you can calculate the route here: Google Maps.


Arrival by Deutsche Bahn to Dortmund or Bochum central station.

From Dortmund central station, take the S1 city train in the direction of Düsseldorf to the "Dortmund Universität" station (7 minutes journey time).

From Bochum central station, take the S1 city train in the direction of Dortmund to the "Dortmund Universität" station (14 minutes journey time).

The city train runs regularly every 20 minutes in both directions.  From the city train station, take the Skytrain (S-Universität stop) to the Campus Süd stop (1 stop, runs every 10 minutes).

From Dort­mund Airport

By taxi to TU Dortmund University, Campus South (approx. 20 min and 30 €, see  Map)

From Düsseldorf Airport

Take the city train S1 in the direction of Dortmund to the "Dortmund-Universität" station (approx. 60 min). From here, take the Skytrain in the direction of Campus South or Eichlinghofen (runs every 10 minutes and takes approx. 3 min.).


The H-Bahn is one of the hallmarks of TU Dort­mund Uni­ver­sity. There are two stations on North Campus. One (“Dort­mund Uni­ver­si­tät S”) is directly located at the suburban train stop, which connects the uni­ver­si­ty directly with the city of Dort­mund and the rest of the Ruhr Area. Also from this station, there are connections to the “Technologiepark” and (via South Campus) Eichlinghofen. The other station is located at the dining hall at North Campus and offers a direct connection to South Campus every five minutes.


The facilities of TU Dort­mund Uni­ver­sity are spread over two campuses, the larger Campus North and the smaller Campus South. Additionally, some areas of the uni­ver­si­ty are located in the adjacent “Technologiepark”.

Site Map of TU Dort­mund Uni­ver­sity (Second Page in English).