Electroplated wheels have excellent formability and shape holding capacity which make it more and more widely used in complex curved surface grinding. But the researches on the surface integrity influenced by wheel wear is insufficient. Therefore

the surface topography feature of cantilever plunge grinding were studied and the roughness changing with wheel wear were recorded when the rectangular specimens with high stiffness and a kind of motor stator vane with weak stiffness were grinded. The result show that the appropriate wear can make the roughness fell by 35%. But the wear has little influence on surface hardness and residual stress. The weak stiffness of aero-engine blade can increase the roughness. The appropriate wear not only can make the blade top edge roughness reduce by 64% but also can weaken the influence on roughness by stiffness and improve the uniformity of surface integrity. So the wear of electroplated wheels can be estimated by workpiece roughness. The conclusion can help select the wheels with appropriate wear for finish grinding. It contributes to decrease the roughness of workpiece and improve the uniformity of surface integrity.