Multi-Response Optimization and Surface Integrity Characteristics of Wire Electric Discharge Machining α-Phase Ti-6242 Alloy

The current research aims to optimize wire electric discharge machining parameters with multi-objectives while machining contemporary titanium alloy. Wire electric discharge machining analysis was conducted by varying the key machining parameters, viz. pulse ON time, pulse OFF time, voltage and wire feed rate. Based on preferred parameters, Taguchi orthogonal array is designed and the optimal parameter combination for minimal surface roughness and material removal rate is identified. Results reveal that material removal rate increases with increase in pulse ON time and surface roughness found to be minimized with increase voltage and wire feed rate. Multi-objective optimization was carried through Technique for Order of Preference by Similarity to Ideal Solution methodology that helps in attaining optimal combination that results in maximum material removal rate (2.84 mm 3 /min) and minimum surface roughness (2.43 μm). Traces of deterioration and deep crater were observed over the machined surface when machining parameters like voltage and pulse ON time are high.