Abstract: This paper analysed the wear failure modes of a high- speed corrugating roll, indicating that its dominant wear mode is abrasive wear produced by the SiO2 particles embeded in the paper, showing the characteristics of strain fatigue abrasive wear on the bottom of flutes and both sliding and strain fatigue abrasive wear on the top of crowns. The locations for maximum wear are always on these two places, and the wear volume at both end parts of corrugating roll is larger than at its center, that is obviously different with what are reported in literatures. The authors consider that the main reason is due to the gradual reduction of roll diameter at its center in service, which will damage the uniform distribution of stress on the roll surface along its full length and accelerate the wear at its end parts. Therefore the repairing of corrugating roll flutes must be carried out before the complete vanishing of the protruding diameter at its center, and the times of repairing are also limited, because the fatigue-induced permanent damage will become the main source of roll failure after several times of repairing.