Nowadays, electrical discharge machining process is successfully employed to machining hard titanium alloys compared to other non-conventional machining processes. The generation high temperature is utilized to melt and vaporize the hard titanium alloy during electrical discharge machining. The process parameters are highly influenced on the machining performance and need to be studied for optimum results. In the present research, the hard Ti-6Al-2Sn-4Zr-2Mo alloy was machined by EDM process and machining characteristics such as material removal rate, tool wear rate and surface roughness were analyzed statistically to get the optimum performance. The experiments were carried out based on the Taguchi orthogonal array method. From the statistical analysis of experimental results, the most significant parameters were identified as peak current, pulse on time and voltage. In addition to that SEM analysis was used to characterize the machined surface. The results of SEM analysis indicated that craters, surface cracks, globules and recast layer present on the machined surface.

The Ti-6Al-2Sn-4Zr-2Mo alloy was machined using the wire electrical discharge machining (WEDM) method in this research. The consequences of input values like pulse on duration, wire tension, and wire feed on metal removal rate (MRR) and surface roughness (SR) have indeed been observed. After conducting 27 experiments using Taguchis L27 type of research technique, empirical designing and analysis of variance (ANOVA) were performed. For process optimization, the Taguchi technique, which is based on the grey relational analysis approach, is used. The results show that a material removal rate of 0.293mm³/min was obtained with factors of 10µs pulse on duration, 7m/min of wire feed, and 12g of wire tension (the higher the better), and surface roughness of 2.129µm was obtained with factors of 6µs pulse on duration, 3m/min of wire feed, and 8g of wire tension (the lower the better). The percentage of errors between results obtained and grey relational analysis (GRA) predicted results varies around 6. Wire electrical discharge machining with Ti-6242 alloy to optimum conditions resulted in better MRR and surface integrity with good surface finish and integrity as evidenced by a substantial reduction in the crack formation, lumps, and accumulated surfaces.