The numerical and optimal thermal analysis of Casson fluid flow over a wedge is investigated in this work. To perform numerical and sensitivity analysis we have convert third order non-linear PDEs into set of ODEs by using similarity transformations along with boundary conditions. These equations are simulated using numerical technique Keller Box method and then compared the values of skin friction coefficient and Nusselt number with those existing in literature and found excellent agreement. Then by using these numerical data we have performed sensitivity analysis by using Response Surface Methodology (RSM). ANOVA tables are generated and developed a correlations between input parameters and output responses. The coefficient of determination for output responses skinfriction coefficient and Nusselt number are 96.50% and 99.51% respectively which shows the best fitted correlations. Finally, we have performed sensitivity analysis which reflects that skinfriction coefficient is more sensitive to Falkner–Skan exponent (m) and there is no effect of Prandtl number (Pr) on skinfriction coefficient. It is also concluded that Nusselt number is sensitive to Prandtl number (Pr) and obtains its optimum value with variation in Prandtl number (Pr).
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