Titanium Grade 5 (T16AIW) is generously utilised in space research, biomedical research, defence research etc., its due to superior of mechanical and chemical properties. Titanium material is high resistance, exotic, temperature resistive, conductive and high strength it gives maximum precision and accuracy. The objective of the manuscript is to predict achieve process parameters in Wire Electric Discharge Machine (WEDM) such as Ton, Toff, voltage, current, wire feed and wire tension and the output characteristics such as high material removal rate and low surface roughness by using Response Surface Methodology (RSM). Initially the titanium material is cutting in WEDM machine by varying the load from minimum to maximum for optimizing the level without wire breakage. It is analysed the material which give high response due to Ton, Toff, voltage and peak current. The wire feed rate is kept as constant 1 m/min for the purpose of wire consumption and the wire tension also kept in constant range. The optimal design is carried by response surface design using distance-based optimahty with 31 design points for the four factors, with cube points 16, center points in cube is 7 and axial points is 8 with null center points of axial. Then the design is optimized with 20 optimal design for comparison of smallest and largest distance between the optimal ranges. © 2022 Elsevier B.V., All rights reserved.