Abstract:The recent trend in miniaturisation of sensors has given micro wire electrical discharge machining (μ-WEDM) a significant amount of research attention. The underlying challenge in the selection of optimal machining parameter combination to achieve the desired surface finish, kerf width and metal removal rate has urged the disclosure of an integrated method of technique for order of preference by similarity to ideal solution (TOPSIS)-based response surface methodology (TOP-RSM). A L16 orthogonal array was used to design the experiments and multi response optimisation was performed by using the TOP-RSM approach. A confirmation test was conducted to ensure the validity of proposed approach. The response surfaces were also studied to understand the effects of individual parameters on the quality characteristics.Keywords: grey Taguchi; TOPSIS; response surface methodology; RSM; manufacturing; micro wire electrical discharge machining; μ-WEDM; optimisation.Reference to this paper should be made as follows: Santhanakumar, M., Adalarasan, R., Senthil Raj, S. and Rajmohan, M. (2017) 'An integrated approach of TOPSIS and response surface methodology for optimising the micro WEDM parameters', Int.