The article provides a comprehensive review of wire electrical discharge machining (WEDM), a non-traditional material removal process that effectively produces parts with varying hardness and complex designs. WEDM, which emerged in the mid-1960s, has evolved from a simple tool-making technique to an advanced method for creating micro-scale components with high dimensional precision and surface finish. The process relies on the principles of electro-discharge machining (EDM) and uses a continuous moving wire electrode to achieve high precision and accuracy. However, the potential for wire damage and bending has limited its full potential and affected precision and efficiency. The review covers a wide range of investigations, including variable optimization and the assessment of various influences on machining efficiency and accuracy. It emphasizes adaptive monitoring and control systems, such as fuzzy logic, wire breakage adaptive control, and self-tuning adaptive control, to improve the WEDM process. The article also discusses the impact of different wire materials, dielectric types, and flushing techniques on WEDM performance. Key parameters such as pulse on time, pulse off time, peak current, servo voltage, wire tension, and dielectric flow rate are analyzed for their effects on material removal rate (MRR), surface roughness (SR), and kerf width. The review highlights the importance of process optimization and control for achieving optimal results in WEDM, including the use of design of experiments (DOE) methods like Taguchi's method and response surface methodology (RSM). The article concludes by discussing future research directions, emphasizing the need for further advancements in WEDM to address challenges such as wire breakage, surface quality, and dimensional accuracy.The article provides a comprehensive review of wire electrical discharge machining (WEDM), a non-traditional material removal process that effectively produces parts with varying hardness and complex designs. WEDM, which emerged in the mid-1960s, has evolved from a simple tool-making technique to an advanced method for creating micro-scale components with high dimensional precision and surface finish. The process relies on the principles of electro-discharge machining (EDM) and uses a continuous moving wire electrode to achieve high precision and accuracy. However, the potential for wire damage and bending has limited its full potential and affected precision and efficiency. The review covers a wide range of investigations, including variable optimization and the assessment of various influences on machining efficiency and accuracy. It emphasizes adaptive monitoring and control systems, such as fuzzy logic, wire breakage adaptive control, and self-tuning adaptive control, to improve the WEDM process. The article also discusses the impact of different wire materials, dielectric types, and flushing techniques on WEDM performance. Key parameters such as pulse on time, pulse off time, peak current, servo voltage, wire tension, and dielectric flow rate are analyzed for their effects on material removal rate (MRR), surface roughness (SR), and kerf width. The review highlights the importance of process optimization and control for achieving optimal results in WEDM, including the use of design of experiments (DOE) methods like Taguchi's method and response surface methodology (RSM). The article concludes by discussing future research directions, emphasizing the need for further advancements in WEDM to address challenges such as wire breakage, surface quality, and dimensional accuracy.