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off time (Toff), input power (IP), and servo voltage (V). material removal rate (MRR), kerf
width, surface roughness, overcut, topography of the surface, microstructure, cutting
speed, EDX analysis, white layer thinness, and dimensional deviation are all performance
metrics that are measured. The findings of the experiments indicate that the pulse

on time is the most critical parameter for all response parameters and that Zn-coated
brass wire is the best wire material for machining both workpiece materials. The titanium
content, according to the thermal evaluation, has a higher heat flux than the SAILMA 350
material. The main cut to trim cuts indicates that the SAILMA 350 material is more robust
and has a smoother surface than Titanium. The cutting pace reduced when the main cut
became a trim cut. Increased overcut. The dimensional deviation is minimized during the
primary cut to trim cuts. Trim cuts have fewer surface topographical features such as
crests, valleys, holes, minor gaps, and surface cuts compared to main cuts. Three tests
are conducted to determine the thickness of the white layer. Multiple trim cuts increase
the surface quality, as evidenced in the Surfaceintegrity result. The research concluded
that SAILMA 350 material is superior to Titanium for manufacturing aerospace and
automotive industry components, and that machining SAILMA 350 material to obtain
high-quality, low-cost components using zinc-coated brass wire is preferable.

Key words: SAILMA 350. Titanium, trim cut, multiple trim cuts, Surface Integrity, EDX,
Temperature destitution, heat flux, Half Hard brass wire, Zn coated wire

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