<p>Chip morphology has been utilized as a potential source to predict the performance of the grinding process. But, grinding chips are tiny enough that their morphology cannot be identified with bare eyes during operation. Instead, the process could be run with optimum settings that will generate desired chips. This paper focuses on the effect of process parameters on chip type and chip size to get suitable chips that may be used as an indication of desired response values. As grinding chips are small in size, scanning electron microscope (SEM) images were captured for an enlarged view of the chips. SEM images were then calibrated, and their sizes were measured using image pro software. The measurements showed that when the spindle speed and/or infeed rise, chip sizes increase as well. Besides, the application of cutting fluids through minimum quantity lubrication (MQL) produced smaller chips, better surface quality, and around 30 times lower temperatures than flood cooling environment. It was also observed that large chips were associated with higher temperatures and greater wheel loading. Aspect ratios of the chips were calculated to quantify the range for different chip types. Finally, it was found that 1500 r.p.m. spindle speed, 10&#xa0;µm infeed, and MQL environment were the optimum process settings that minimize the chip size while performing surface grinding of Al/SiC-MMC. Consequently, it can be anticipated, based on current and prior research, that these optimal settings will yield the minimal temperature, cutting force, and wheel loading.</p>