<p>The grinding temperature is the most significant parameter affecting surface characteristics, integrity, productivity and workpiece fatigue life. The thermal stresses generated by the grinding process are the main causes of residual tensile stresses. However, we have also demonstrated that it can be possible to identify the improvement in surface characteristics and integrity of ground surfaces AISI D2 tool steel by knowing the grinding temperature range. The present study therefore describes the combined effects of abrasive type, cooling mode and cutting grinding depth (ACC) on grinding temperature evolution and residual stress distribution using experimental and numerical simulation approaches on grinding wheel/workpiece interaction. Furthermore, our result revealed a strong correlation between the measured and simulated values of the temperature and residual stress profiles and a significant effect of temperature on the fatigue life. Also, we have deduced that the decrease in hardness is due to a surface softening phenomenon, which would suggest that the high strains intent to accelerate the kinetics of martensite decomposition at relatively low temperatures. These findings can be used to predict surface and fatigue characteristics as well as integrity in relation to temperature or ACC combinations.</p>