Parametric study along with selection of optimal solutions in Wire cut machining of Titanium (Gr2) N.E.ARUN KUMAR 1, a * , A.SURESH BABU 2, b and V.MUTHUKUMAR 3,C 1 Department of Mechanical Engineering, St. Joseph’s College of Engineering, Chennai, Tamil Nadu, India 1,2 Department of Manufacturing Engineering, College of Engineering Guindy, Anna University, Chennai, Tamil Nadu, India 3 Department of Mechanical Engineering, Saveetha Engineering College, Chennai, Tamil Nadu, India a nearunkumar@gmail.com, b subaceg@annauniv.edu, c vmkumar13@gmail.com Keywords: WEDM, Material removal rate, surface finish, Taguchi method. Abstract. This paper investigates the relationship of process parameters in wire electrical discharge machining of titanium alloy with brass wire as tool electrode. Wire electrical discharge machining (WEDM) is used to cut conductive metals of any hardness or that difficult to cut with conventional methods. The process performances such as material removal rate (MRR) and surface finish(R a ) were evaluated by giving specific input parameters which practiced to obtain optimal response. The difficulty in machine tool industry is to predict the expected output performance for the desired input variables by the way of conducting more number of experiments for different machining parameters, which leads to the increase in consumption of electric power, material and time. To overcome this phenomenon, parametric investigation was made on WED machining on titanium alloy by using Taguchi’s method. Introduction Wire electrical discharge machining is the most helpful non-traditional material removal process. This technique has been widely used in a modern metal working industries for producing complex profile in dies and moulds in tool and die making and also other fields like aerospace, automotive, surgical component manufacturing etc. However, there are problematic points that should be fully considered in order to enhance working accuracy [1]. In WEDM operations, material removal rate determine the economics of machining and rate of production. In setting the machining parameter, the main goal is the maximization of MRR and SF. The process variables especially electrical variables are more significant parameters in deciding response values [3]. To attain the precise and accurate machining, it is necessary to predict response values of machining to decide the input parameters to be provide. Optimum selection of process parameters is very much essential, as this is a costly process to increase production rate considerably by reducing machining time [2]. Material removal rate (MRR) and surface roughness are most important output parameters, which decide the performance of machining. In nature material removal rate increased with decreasing of surface roughness and vice versa. In WEDM by a single pass of wire we can fully remove the material from the work piece irrespective to rough cut and finished cut like conventional machining process. Hence it brings interest to optimize the process input parameters at best in combination. Each parameter may have individual capacity to determine the output parameters. Advanced Materials Research Vols. 984-985 (2014) pp 37-41 © (2014) Trans Tech Publications, Switzerland doi:10.4028/www.scientific.net/AMR.984-985.37 All rights reserved. No part of contents of this paper may be reproduced or transmitted in any form or by any means without the written permission of TTP, www.ttp.net. (ID: 125.17.181.196-07/07/14,05:59:39)