In this paper, a multi-level fuzzy control (MLFC) technique is developed and implemented for a creep-feed grinding process. The grinding force is maintained at the maximum allowable level under varying depth of cut, so that the highest metal removal rate is achieved with a good workpiece surface quality. The control rules are generated heuristically without any analytical model of the grinding process. Based on the real-time force measurement, the control parameters are adapted automatically within a stable range. A National Instrument real-time control computer is implemented in an open architecture control system for the grinding machine. Experimental results show that the cycle time has been reduced by up to 25% over those without force control and by 10–20% compared with the conventional fuzzy logic controller, which indicates its effectiveness in improving the productivity of actual manufacturing processes. The effect of grinding wheel wear is also considered in the creep-feed grinding process, where the grinding force/power can be maintained around the specified value by the proposed MLFC controller as the wheel dulls gradually.
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