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This paper deals with the inter-relationship between workpiece-tool interface temperature and wear at the flank face of the cutting tool during machining hardened alloy steels using carbide-cutting tools. The temperature developed during machining is critical for analysis since it effects wear of the cutting tool and increases the surface roughness of the machined surface. The interface temperature generated during machining will depend on the machining parameters and geometrical parameters chosen for a particular material. Experiments are designed based on Taguchi's Design of Experiment, for seven input parameters varied through three levels, an L₁₈ Orthogonal array is chosen. The output responses are analyzed based on Signal-to-Noise ratio and statistical tool like Analysis of Variance. The relationship between the responses is analyzed and the optimum input parameters determined will reduce the …