The Controlled grinding is governed by the maximum surface temperature in the wheel-workpiece interaction. In this study, we demonstrate that temperature is the significant controller on the surface characteristic grinding, the surface integrity, the productivity and the fatigue life. Moreover, high temperature generated in abrasive processes is the main factor responsible on ground surface damage and its impact on the induced consequences in grinding of AISI D2 tool steel. The combined effects of abrasive type, cooling mode according to the cutting depth, on the temperature and residual stress distribution were highlighted by exploiting FEM. Obtained numerical results were validated with the experimental ones.