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Surface quality is one of the most important properties of the precision devices. Poor

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Wire electrical discharge machining (WEDM) process is one of the most popular method for the producing complex geometries in hard and wear resistant materials such as those used in tooling industry. This taper cutting involves in making of inclined surface, and it is particularly significant in the manufacturing of tooling that requires draft angles. In the present paper, experiments were conducted in order to find the effect of process parame-ters such as taper angle, geometrical thickness and servo voltage on response variables such as angular error and cutting speed on AISI D2 tool steel using statistical design of experiments. The experiments were planned using Central Composite design (CCD) which is part of Response Surface Methodology (RSM)involving three variables with five levels. Multi objective optimization was conducted for maximizing the Cutting speed and minimizing the angular error using genetic algorithm. The optimization procedure leads to creation of non-dominated optimal points which gave an insight regarding the optimal operating conditions of the process.