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Wire electrical discharge machining is one of the important non-traditional machining processes for machining difficult to machine materials. It involves the removal of material by the discrete electric discharges produced between the inter electrode gap of continuously moving wire electrode and the work piece. The ability to produce intricate profiles on materials irrespective of the mechanical properties made this process to be widely used in industries. The present study investigates the relationship of various process parameters in WEDM of AISI 202 stainless steel with brass electrode.The experiments were planned according to Taguchi’s L18 orthogonal array and experimental models were developed. The important process parameters identified for the present study were pulse on time, peak current, pulse off time, wire feed, wire tension, dielectric flushing pressure, servo feed and gap voltage. The surface roughness of the machined surface was measured as the process performance measure. Analysis of variance test has also been carried out to check the adequacy of the developed models and to identify the level of significance of each process parameters. In addition to the developed models, ABC optimization has been performed to identify the optimum parameter combination for minimum surface roughness and the obtained optimal process parameters are peak current 11 A, pulse on time 100 μs, pulse off time 49 μs, wire feed 4 m/min, wire tension 10 N, flushing pressure 12 kg/cm2, servo feed 2100 mm/min and set gap voltage 30 V. Finally the results were verified with the experimental results and found that they are in good agreement.