HVOF thermal spray coatings of WC-10Co-4Cr cermets are widely used to protect materials from corrosion, wear and to restore worn components in a variety of industrial environments such as petroleum and gas, petrochemical, steel industries, aerospace, gas turbines, textile industries and automotive industries. The as-sprayed coatings of thermal spray techniques generally result in high level of surface roughness. In carbide cermet coatings especially, such as WC-Co based coatings, the surface roughness in the as-sprayed form is higher than the acceptable values for many applications. Therefore, the carbide coating surfaces are to be finished suitably in order to achieve desirable surface roughness and dimensional tolerance. The grinding, however, may change the coating properties. The main objective of this thesis is to examine the effect of grinding on adhesion strength and surface properties of WC-10Co-4Cr coating and to determine the optimal grinding parameters. In this research, the fundamental grinding parameters are depth of cut, ap, feed rate, vw, and cutting speed, vs. According to the results of X-ray diffraction analysis, decarburization of WC has occurred during thermal spray process, but the grinding process did not result in any phase transformations in the coating. Based on the mathematical model, the as-ground average surface roughness depends not only on the depth of cut, feed rate and cutting speed, but also on the depth of cut and cutting speed interaction and on the feed rate and cutting speed interaction. The values of grinding force ratio for all the grinding experiment conditions remain almost constant. It suggests that the wheel topography approximately was unchanged in all experimental conditions. Also, as the maximum undeformed chip thickness, hm, increases, the specific energy shows a decreasing trend because of the effect of hm on the material removal mechanisms. The material removal during grinding of WC–10Co–4Cr coating was via both brittle fracture and ductile flow modes, and the most of the energy was consumed by ductile flow mode due to plowing. There is a little increase in the porosity content of coating after grinding due to mechanical loading. The residual stress of as-sprayed WC-10Co-4Cr coating was compressive indicating that the mismatch and peening rather than quenching component have a decisive role in the final direction of the residual stress. Also, the compressive residual stresses were increased with increasing distance from the coating surface due to the increased effect of thermal mismatch and peening stresses. There was a significant increase in the compressive residual stress of coating surface after grinding because of the mechanical-plastic deformation due to the Hertzian loads. Adhesion and cohesion strength and microhardness of the coating were improved after grinding because of the increased compressive residual stress. The optimum grinding parameters have been determined using desirability function approach, and finally, the optimum process parameters for surface grinding of HVOF coatings of WC-10Co-4Cr cermets have been determined as ap=10.73µm, vw=550mm/s and vs=30.45m/s. Key Words WC-10Co-4Cr coating, grinding, force, roughness, material removal mechanism, residual stress, microhardness, adhesion strength