Wire electrical discharge machining (WEDM) is extensively used in machining of materials when precision is of major factor. Selection of optimum machining parameter combinations for obtaining higher accuracy is a challenging task in WEDM due to the presence of a large number of process variables and complex stochastic process mechanisms. In the present work, WEDM of titanium alloy (Ti6Al4V) is experimentally studied. The behavior of eight control parameters such as Ignition pulse current (A), Short pulse duration(B), Time between two pulses(C), Servo speed(D), Servo reference voltage(E), Injection pressure(F), Wire speed(G) and Wire tension(H) on surface finish was studied using Taguchi parameter design. A mathematical model is developed by means of linear regression analysis to establish relationship between control parameters and surface finish as process response. An attempt is made to optimize the surface roughness prediction model using Genetic Algorithm (GA). Optimum values of control parameters at level A1, B1, C1, D3, E1, F3, G2, H3 for the selected range and workpiece material are obtained.

Turning is a widely used metal removal process in manufacturing industry that involves generation of high cutting forces and temperature. Lubrication becomes critical to minimize the effects of these forces and temperature on cutting tool and workpiece. The conventional cutting fluids employed in machining have certain limitations with regard to their use for ecological and economic reasons. Development of lubricants that are eco friendly is acquiring importance. In this context, application of solid lubricants has proved to be a feasible alternative to the conventional cutting fluids. In the present work, Boric Acid is used as a lubricant in turning process. Variations in cutting force, tool wear, tool temperature and surface roughness are studied under different machining conditions. The results indicate that there is considerable improvement in the machining performance with Boric Acid assisted machining compared to dry and wet machining.