The goal of this research work was to create guideline for Wire Electrical Discharge Machining (WEDM) of Titanium Alloy (Ti6 Al4V), using Molybdenum wire as a cutting tool. The Ti alloy possesses excellent bio compatibility to human beings, especially with tissues or bones. In general, the material of wire (electrode) is taken as brass/copper in WEDM. But in this work, Molybdenum wire is used. The main goal of this research work was to investigate the effect of various process parameters on material removal rate (MRR) while machining Ti6AL4V work piece on WEDM using Molybdenum wire. The important process parameters are pulse on time (Ton), pulse off time (Toff), peak current (IP), servo voltage (SV) and wire feed rate (WF). The optimum process parameters for maximum material removal rate (MRR) were to be determined experimentally using DOE, use of Taguchi method. The analysis of results (i, e. parametric contribution of each process parameter on MRR) was determined by ANOVA using SPSS software (Statistical Package for Social Sciences). The optimum process parameters were determined, from the graphs generated between S/N ratios to each design factors. At last, the specimen (work piece) was machined at optimum process parameters to find the improvement in MRR with acceptable surface finish (max. 3.5 μm).
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