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Abrasive finishing processes such as grinding, lapping or disc polishing are one of the most practical means for processing materials to manufacture products with fine surface finish, surface quality and dimensional accuracy. However, they are one of the most difficult and least-understood processes for two main reasons. Firstly, the abrasive grains present in the tool surface are randomly oriented. Secondly, they undergo complex interactions in the machining zone. Given the advances in sensor technologies, the finishing processes can now be sensorized, and the vast amount of data produced can be exploited to model and monitor the processes using Artificial Intelligence techniques. Data-driven models have turned into a hot focus in engineering with the rise of machine learning and deep learning algorithms, which have greatly spread all through the academic community. The scope of this paper is mainly to review the application of Artificial Intelligence as well as supporting sensing and signal processing techniques in modelling and monitoring on different types of abrasive processes in metal finishing. The paper gives a detailed background on the key mechanisms and defects in the different abrasive finishing process and lists the suitable sensing techniques for their monitoring. The paper reports that most of the Artificial Intelligence algorithms available are not fully exploited for monitoring and modelling in abrasive finishing and emphasizes on bridging this gap. The probable research tendency on datadriven monitoring and modelling for abrasive finishing is also forecasted.

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The residual stress distributions caused by the deep cold rolling (DCR) process, with a focus on the distributions at the boundary of the treatment zone, are examined in this study. A three-dimensional finite-element (FE) model, validated with experimental residual stress data, is used to study the effect of the process. The residual stress distribution in the crosswise direction (perpendicular to rolling direction) shows a region of tensile residual stress at the start and end of the track that may be a cause for concern. The reason for this region of tensile stress is likely to be due to the reduced treatment of the start and end zones due to the step over and the tool path taken. Other factors that cause a difference between the steady state and the transient zone of the burnished area are also investigated. It is shown that the net material movement causes larger plastic deformation in the boundary zone between the burnished and unburnished region of DCR.