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Due to heavy competitions in manufacturing and marketing, the industries are prompted to manufacture products that are better, long-lasting and dependable and a new material revolution in this regard has become inevitable. As an impact of the revolution, the families of difficult-to machine materials like high carbon high chromium die steel, stainless steel and super alloys have expanded. Experimental results analysed by ANOVA indicate the improved performance of ECM. The developed mathematical models provide a good relationship between the selected influencing factors and the objectives due to higher values of R2. The confirmatory experiments were conducted for both GA and Firefly algorithm and the results reveal that the actual performance deviates from the predicted one by 2 to 4% only. Hence, the developed mathematical models can be used for obtaining maximum MRR and minimum surface roughness of HCHCr die steel. The performance of Firefly algorithm is better when compared to genetic algorithm. Firefly algorithm performs well in all the selected machining parameters on maximum MRR and minimum surface roughness condition.