The objective of the present work is to use a suitable method that can optimize the process parameters like pulse on time (TON), pulse off time (TOFF), wire feed rate (WF), wire tension (WT) and servo voltage (SV) to attain the maximum value of MRR and minimum value of surface roughness during the production of a fine pitch spur gear made of copper. The spur gear has a pressure angle of 20⁰ and pitch circle diameter of 70 mm. The wire has a diameter of mm and is made of brass. | Comparison of optimization techniques for MRR and surface roughness in wire EDM process for gear cutting