This research paper focus on the machinability studies of Ti6Al4V material during electrical discharge machining (EDM) process. Discharge time, current, and discharge voltage are taken as input process variables. Experiments are conducted on Ti6Al4V material to explore the effect of these input variables on material removal rate (MRR), surface roughness, thickness of white layer and microcracks taken as output variables. The machined components are analyzed using three-dimensional surface topography and scanning electron microscope micrographs. It is found, by increasing discharge time and current, MRR and thickness of white layer is increased whereas surface finish gets worsened. Microcracks, blow holes, and redeposition of workpiece as debris are perceived on machined workpiece. A modified equation is proposed to estimate diameter of crater taking into account the discharge energy and latent heat of vaporization of workpiece material. Compared with experimental data, the proposed equation predicts diameter of crater an error of 16.89%. © 2019, © 2019 Taylor & Francis.