In this work, titanium grade 2 alloy is evaluated for their machinability behavior using novel reciprocating wire-cut electrical discharge machining (RWEDM) by changing the wire feed rate, flow rate of dielectric, variable frequency and current as per Taguchi’s approach (L₂₇ orthogonal array) towards maximizing material removal rate (MRR) and minimizing surface roughness (SR) and kerf width (KW). A multiple attribute decision method, The Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) is implemented for simultaneous optimization of output responses. The ideal condition obtained is: wire feed of 8 mm/min, flow rate of 15 g/sec, variable frequency of 22 Hz and current density of 220 A. Analysis of Variance identifies that the influence of feed rate of wire electrode is noteworthy with a contribution of 67.12% followed by flow rate and variable frequency. Recast layer on the machined specimens is also evaluated using scanning electron microscope (SEM) images which shows lower distortion. A metaheuristic particle swarm optimization (PSO) optimization method is utilized for further optimizing the output responses and is found that the results obtained matches with the results of TOPSIS. Finally, a validation experiment is performed with ideal conditions of input parameters and verified

Keywords: Reciprocating WEDM, Titanium grade 2, TOPSIS, Molybdenum wire, PSO