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Because of its excellent mechanical qualities and weldability, titanium alloy is used in many different biomedical applications. Wire electrical discharge machining may be used to machine materials with such greater strengths and intricate forms. Using Taguchi-Data Envelopment Analysis-based Ranking (DEAR) approach and zinc-diffused coated brass wire electrode to improve Titanium alloy machining was the goal of this research project. The quality metrics that were taken into consideration were sur-face roughness, kerf width, and material removal rate. Among the selected factors, with an error of 2.7%, the optimal configuration of input factors was determined to be 130 µs (Ton), 40 µs (Toff), 50 V (SV), 6 A (IP), and 8 Kg (WT). Due to its relevance in the process of deionization, the Ton is the high-est influential parameter for creating quality measurements.

The surface measures of machined titanium alloys as dental materials can be enhanced by adopting a decision-making algorithm in the machining process. The surface quality is normally characterized by more than one quality parameter. Hence, it is very important to establish multi-criteria decision making to compute the optimal process factors. In the present study, Taguchi−Grey analysis-based criteria decision making has been applied to the input process factors in the wire EDM (electric discharge machining) process. The recast layer thickness, wire wear ratio and micro hardness have been chosen to evaluate the quality measures. It was found that the wire electrode selection was the most influential factor on the quality measures in the WEDM process, due to its significance in creating spark energy. The optimal arrangement of the input process parameters has been found using the proposed approach as gap voltage (70 V), discharge current (15 A) and duty factor (0.6). It was proved that the proposed method can enhance the efficacy of the process. Utilizing the computed combination of optimal process parameters in surface quality analysis has significantly contributed to improving the quality of machining surface.