The grafting of methyl methacrylate (MMA) onto ultra-high-molecular-weight polyethylene (UHMWPE) and chromic acid etched UHMWPE was conducted with a preirradiation method in air in the presence of a Mohr salt and sulfuric acid. The grafted samples were characterized by Fourier transform infrared (FTIR) spectroscopy, a gravimetric method, differential scanning calorimetry, scanning electron microscopy (SEM), and interfacial bonding strength measurements. The FTIR results showed the presence of ether and carbonyl groups in the MMA-grafted UHMWPE (MMA-g-URMWPE) samples. The Taguchi experimental design method was used to find the best degree of grafting (DG) and bonding strength. The efficient levels for different variables were calculated with an analysis of variance of the results. SEM micrographs of MMA-g-UHMWPE samples showed that with increasing DG and chromic acid etching, the MMAg-UHMWPE rich phase increased on the surface; this confirmed the high interfacial bonding strength of the grafted samples with bone cement. The grafting of the MMA units onto UHMWPE resulted in a lower crystallinity, and the crystallization process proceeded at a higher rate for the MMA-g-UHMWPE samples compared to the initial UHMWPE; this suggested that the MMA grafted units acted as nucleating agents for the crystallization of UHMWPE. (C) 2009 Wiley Periodicals, Inc. J Appl Polym Sci 116: 886-894,2010