Titanium Ti-6Al-4V has become very popular materials and widely used as implants for dental, restorations and
orthodontic wires, as well as orthopedic due to their low density, high corrosion resistance and excellent mechanical
properties [1]. However these alloys were very difficult to fabricate as they are not ductile and have low fracture toughness
at room temperature [2]. Furthermore, due to its excellent strength property, it is found that it is extremely difficult to
machine by conventional method. Several researchers [3, 4] have been investigated the different aspects of machining but
no comprehensive research work has been reported so far in the field of wire electrical discharge machining of this alloy.
Hence, it is essential to introduce an alternative method in machining of this alloy.
Wire electrical discharge machining (WEDM) becomes an important non-traditional machining process due to its
competency in machining of work pieces with complex geometry and hard stiffness [5]. The material is removed by a series
of discrete electrical discharges between the wire electrode and the work piece in this process. The discharges, which are
highly focused by the dielectric medium, cause rise in the local temperatures of the work piece near the point of
introduction. The temperatures are high enough to melt and vaporize the material in the immediate vicinity of the electrical
discharges. Since, there is no mechanical contact between the work piece and the electrode, material of any hardness can be
machined as long as it is electrically conductive [6]. Due to this reason, it has dramatically increased in high application of