Grinding is one of the most important finishing operations in the manufacturing process. But, same as any other process, it faced with limitations. In this study, to overcome the limitations of the conventional grinding process, it is combined with the chemical machining process. As a result, hybrid machining process “Grinding Assisted Chemical Etching (GACE)” introduced. To assess the superiority of the GACE process with conventional grinding, several experiments have been conducted and effect of chemical etchant in wheel life parameters (G-ratio and wheel loading) and surface quality, compared with conventional grinding. To reach a better investigation, the results of GACE process were analyzed by Taguchi’s experimental design method. In this paper, the impact of the two effective factors, chemical- work and material removal rate (MRR), on output parameters such G-ratio, wheel loading and surface roughness were discussed. The results indicated that by applying the GACE method, wheel life parameter may significantly improve, and according to SEM image and surface roughness test, it is obvious that GACE process provides a smoother surface than grinding. Eventually, the optimized mode of input parameter’s (chemical work and MRR) which achieves efficient outputs (wheel life and surface quality) of GACE process was discussed.
