Wire Electric Discharge Machining (WEDM) is extensively used for machining of complex shapes in the field of die and mould making, medical, aerospace and automobile industries. Improper selection of WEDM process parameters setting can affect the machining efficiency and surface roughness due to arcing phenomenon that lead by discharge point of focus. Present study has been made to optimize the process parameters such as pulse on time, pulse off time, pulse current, servo voltage and wire tension during machining of Ti-6Al-4V titanium alloy by WEDM process using Response Surface Methodology. The analysis of variance (ANOVA) was carried out to study the effect of process parameters on process performance i.e. kerf width. The mathematical models are also developed for kerf width and validated with the experimental results. Further, the machined surface of kerf was examined by using scanning electron microscope (SEM). The experimental results reveals that, as the pulse on time/ pulse duration, input power, server voltage and wire tension increases, and the kerf width also increases. This paper highlights the importance of process parameters on surface roughness and surface topography of wire electric discharge machined kerf surface.

Full text: IJEIR_1941_Final.pdf