To successfully establish the ELID-grinding, it is important to properly se
lect the electrolytic condition according to grinding conditions. Currently
, the selection of electrolytic condition is mainly dependent on the operat
or's experience, which is one of difficulties preventing the successful app
lication of ELID technique. In this study, an in-process measurement system
of the insulating layer using two gap sensors-a capacitance type and an ed
dy current type-are developed and the change of the thickness of insulating
layer during ELID grinding is detected. Evaluation experiments show the po
ssibility to control the electrolytic condition through the in-process meas
urement of the layer status.