Ti-6Al-4V alloys are one of the toughest materials to machine using conventional machining process due to its high too wear ratio and high elevating cutting temperature. Owing to its fatigue resistance, excellent corrosion resistance, high strength to weight ratio and good thermal behavior, Ti-6Al-4V became a most important material to propose a proper modeling and machining for different types of applications. In this research study, Ti-6Al-4V was machined using Wire Electrical Discharge Machining under various process parameters like pulse on time TON, pulse off time TOFF, Wire feed, Servo Gap voltage and cutting speed. The approach is based on the Box Behnken method to optimize the WEDM process parameter for efficient machining. After the machining, multiple responses were examined such as kerf taper geometries (θ) and material removal rate (MRR). The topographies of different cutting surface regions were analyzed using SEM (Scanning electron microscopy investigation). The experimental results indicate that pulse on time, wire feed and servo gap voltage increases to increase the kerf taper ratio in Ti-6Al-4V machining. It was also observed that MRR increase with high pulse on time TON, low pulse off time TOFF and low servo voltage in the selected environmental conditions. By those multiple responses, it was evident that quality of cutting surface of Ti-6Al-4V at optimum condition obviously depends on different process parameter significantly. © 2018 Elsevier Ltd.