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The surface roughness of Inconel 718 is predicted using a sequential discharge model for electrical discharge machining (EDM). To begin with, the EDM single pulse discharge machining process was accurately simulated using the finite-element method (FEM). The surface topography under various discharge settings, the size, and the characteristic parameters of a single-pulse crater are simulated. Second, the material defines the discharge position as the minimum gap width between the work piece’s starting surface and the electrode in the removal model. The simulation shows that the magnitude of the single-pulse discharge energy influences the crater’s form and size. A difference in discharge energy causes a divergence in the increasing crater radius, depth, and flanging height trends. On the other hand, the ultimate surface morphology of an EDM machined surface is determined by the distribution of discharge locations around the parts in the workpiece; finally, machined surfaces are inspected using the same discharge parameters. The EDM work piece’s surface morphology matches the material removal. Between simulation and experiment, there is a relative error in surface roughness around 8.26%, and there is a relative error in surface roughness.

The present paper focuses on the wire electrical discharge machining (WEDM) of titanium alloys. It can be considered as an attempt to develop two dielectrics in the WEDM significantly affects the efficiency of machining. This paper explores surface ruggedness during the processing of titanium of various dielectric fluids, including demineralized water and dielectric alumina. The findings show that dielectric alumina as a dielectric produces decreased ruggedness on the surface. Also, surface rudeness is better for demineralized water as the dielectric powder is mixed with non-conductive alumina powder. Many dielectric liquids show that surface ruggedness decreases. Alumina powder and ethylene glycol to dielectric water. A comparative surface roughness analysis for different dielectric fluids was also performed. Using surface roughness to analyze surface roughness is further studied. Conducting a further investigation to use the response surface method (RSM) on surface integrity in each type of the dielectric with the help of better. Hence, WEDM is performed on Ti-6242 to use the designer expert 10 to analysis ANOVA RSM titanium and varying dielectric fluids. From the findings, it is noted that combining non-conductive alumina powder and demineralized water has a significant impact, which decreased of WEDM machined surface of Ti-6242.

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