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The present study focuses on experimental modelling of travelling wire electrochemical spark machining process using coupled methodology comprising Taguchi methodology and response surface methodology. Experiments were conducted on Pyrex glass workpiece using L27 orthogonal array considering applied voltage, pulse on-time, pulse off-time, electrolyte concentration and wire feed velocity as input parameters and material removal rate, surface roughness (Ra) and kerf width (Kw) as output parameters. The multi-response optimization is also pe rformed using a coupled analysis comprising grey relational analysis and principal component analysis. The optimal process parameter setting demonstrates the enhancement of material removal rate by 154% and reduction of surface roughness and kerf width by 21% and 11%, respectively, against the initial parameter setting.

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