International Journal of Applied Engineering Research ISSN 0973-4562 Volume 5 Number 13 (2010) pp. 2325–2338 © Research India Publications http://www.ripublication.com/ijaer.htm Multi Response Optimization of Machining Parameters of Wire-EDM using Grey Relational Analysis in the Taguchi Method V. Muthu Kumar 1 , A. Suresh Babu 2 , R. Venkatasamy 3 and M. Raajenthiren 4 1 Reasearch Scholar, Anna University, Chennai. 2 Lecturer, Departmentof Manufacturing Engineering, Anna University, Chennai. 3 Professor, Department of Mechanical Engineering, Saveetha Engineering College, Chennai. 4 Professor, Department of Chemical Engineering, Anna University, Chennai. Abstract This paper presents a study on optimizing the process parameters of wire electrical-discharge machining (Wire-EDM) process for machining Titanium Alloy (Ti-6AL-4V). Wire-EDM process parameters namely pulse on time, pulse off time, wire feed and gap voltage were optimized with the considerations of metal removal rate (MRR), Surface Roughness (Ra) and kerf width (k). Wire electrical-discharge machining (Wire-EDM) was carried out using 0.25 mm diameter brass wire in Electronica Ecocut machine. Grey Relational Analysis with Taguchi method was used to optimize the machining parameters of Wire-EDM. A grey relational grade was obtained from the grey relational analysis and based on this grade, optimum levels of parameters have been identified and percentage contribution of the parameters which are affecting the responses were determined by ANOVA. Confirmation test was conducted to validate the test result. Experimental results have shown that the responses in Wire-EDM process can be improved effectively by selecting the optimal levels of control factors through the Grey-Taguchi method. Keywords: Wire-EDM - Taguchi method - Grey Relational Analysis - Titanium alloy - Grey-Taguchi method - ANOVA. Introduction Wire electrical discharge machining (Wire-EDM) is an important non-traditional machining process, widely used in the aerospace, precision die industry, nuclear and