INTELLIGENT GRINDING SYSTEMS WHICH ARE SMART ENOUGH TO ACHIEVE REAL-TIME OPTIMAL CONTROL OF GRINDING OPERATIONS REQUIRE MONITORING OF THE PROCESS WITH SENSORS WHICH CAN WITHSTAND A HARSH PRODUCTION ENVIRONMENT. THE ONLY RELIABLE SENSORS READILY AVAILABLE FOR IN-PROCESS MONITORING OF CYLINDRICAL GRINDING OPERATIONS ARE POWER MONITORS AND SIZE (DIAMETER) GAGES. IN THIS PAPER, IT IS SHOWN HOW SIGNALS FROM THESE TWO SENSORS CAN BE UTILIZED ON AN INTERNAL CYLINDRICAL GRINDER INTERFACED TO A PC FOR PROCESS MONITORING. THE POWER MONITOR CAN BE USED FOR GAP ELIMINATION AT THE BEGINNING OF THE CYCLE, TO CONTROL THERMAL DAMAGE TO THE COMPONENT BEING GROUND, AND TO IDENTIFY THE EFFECTIVE DULLNESS OF THE WHEEL BEING USED. IN ADDITION TO DIRECTLY MONITORING THE PART DIAMETER, THE IN- PROCESS SIZE GAGE CAN ESTIMATE THE G-RATIO AND THE TIME CONSTANT OF THE GRINDING SYSTEM.