Effect of Process Parameters on Surface Roughness in Wire EDM of Titanium Alloys

wire electrical discharge machining (wire EDM) is broadly hired for precision machining of tough-to-cut substances together with titanium alloys, which find widespread use in aerospace, biomedical, and chemical processing industries, floor integrity, in particular surface roughness, plays a critical role in the overall performance and sturdiness of additives made from titanium alloys. This examine systematically investigates the have an impact on of key twine EDM parameters—spark modern-day, pulse-on time, pulse-off time, twine tension, and flushing stress—on the ensuing surface roughness of Ti-6Al-4V specimens. A full-factorial experimental layout became employed to isolate the effects of character parameters and their interactions. floor roughness measurements (Ra) have been received the use of a touch profilometer, and statistical evaluation together with analysis of variance (ANOVA) was performed to discover the maximum substantial individuals to surface end. The outcomes reveal that better spark modern-day and longer pulse-on instances increase surface roughness, whereas optimized pulse-off instances and greater flushing pressure make a contribution to smoother surfaces by using enhancing debris evacuation. wire anxiety exhibited a slight impact, mostly thru its impact on wire stability and spark gap consistency. A predictive regression version with R² = 0.92 changed into advanced for Ra as a function of the method parameters, enabling practitioners to choose parameter units that yield goal surface fine. This work offers actionable recommendations for optimizing twine EDM of titanium alloys to obtain preferred surface integrity even as preserving machining efficiency. Key Words: Wire EDM, surface roughness, Ti-6Al-4V, process parameters, statistical modelling