The technological challenges faced by any industry in machining OHNS steel in the use of tools and die by conventional processing techniques point to tool wear rate and poor surface finish. To overcome these, Electrical Discharge Machine (EDM) process, an inevitable Unconventional Machining process is used in the precision and micro component manufacturing industries. Here an attempt has been made to machine OHNS material with a lately developed copper titanium diboride (Cu-TiB2) of 16% wt of TiB2 is prepared through powder metallurgy route which enhances the shortcomings obtained in conventional techniques. The experiment models are made to optimize through statistical Response Surface Methodology (RSM). The experiments were conducted by considering the effect of pulsating direct current, pulse time ON, and pressure flushing. Then, ANOVA is executed to predict the impact of each parameter and its significance concerning the output responses of roughness (SR) and Volume of Material removed (MRR). The equation developed for each output response and then the optimum process parameters obtained in the desirability based multi-objective optimization using RSM. The minimum surface roughness and maximum material removal rates are attained at 14 A, 16(μs) and 0.6 MPa. Then the confirmation experiments were carried to validate the model and it is witnessed that the error percentage attained was within the satisfactory range. © Published under licence by IOP Publishing Ltd.