Based on the grey relational analysis, this work proposes an effective approach for optimizing various injection moulding parameters on the wear behaviours of ultra-high molecular weight polyethylene (UHMWPE) with diverse performance characteristics. The injection moulding parameters are melting temperature, injection velocity and compaction time. The experimental data were used to calculate wear parameters, such as coefficient of friction, wear rate and hardness. Thirty runs were carried out using the response surface design to determine the optimal factor level condition. The graph and the response table in each level of the parameters are generated with help of grey relational grade. In addition to that, bovine serum is taken, which acts as a lubricant, and the sample hardness is tested. The results showed that there is an impact on the wear behaviour due to the contact load and melt temperature of UHMWPE. According to the grey relational grade, level 2 of injection moulding parameters has a greater effect than levels 1 and 3. With the help of a scanning electron microscope, the worn-out morphologies of samples were studied. Plastic deformation, ploughing, scratching, ironing and fatigue wear are the major wear processes of our study.