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Abstract—This paper presents a study on the optimum calculation of exchanged grinding wheel diameter when external grinding alloy tool steel 9CrSi. In this study, the effects of the grinding process parameters including the initial grinding wheel diameter, the total dressing depth, the radial grinding wheel wear per dress, and the wheel life on the exchanged grinding wheel diameter were considered. Furthermore, the impact of cost elements including the machine tool hourly rate and the grinding wheel cost were investigated. To evaluate the effect of these factors on the optimum exchanged grinding wheel diameter, an “experiment” was designed, and a computer program was built for performing the “experiment”. Based on the results of the “experiment”, a formula for determining the optimum exchanged grinding wheel diameter was proposed.