A comprehensive review on wire electrical discharge machining (WEDM), a non-traditional material removal process, is presented. WEDM is a highly advanced thermo-electric machining technique that can effectively produce parts with varying hardness or complex designs that are difficult to machine using traditional methods. It uses a non-contact material removal approach and has evolved from a simple tool-making technique to an advanced method for creating micro-scale components with high dimensional accuracy and surface finish. Despite its advantages, WEDM faces challenges such as wire damage and bending, which can reduce precision and effectiveness. The review covers various studies on WEDM, including process optimization, adaptive monitoring and control, and the impact of cutting variables like wire feed rate (F), voltage (V), wire tension (WT), and dielectric flow rate on outcomes such as material removal rate (MRR), kerf width (Kw), and surface roughness (SR). The review also discusses the application of WEDM in various industries and the development of hybrid machining techniques. It highlights the importance of optimizing WEDM parameters to achieve the desired machining performance and discusses the potential for future research in WEDM. The review emphasizes the need for further research to improve the efficiency and effectiveness of WEDM processes. The study also examines the impact of different wire materials, such as copper, brass, and coated wires, on the performance of WEDM. The review discusses the key parameters of WEDM, including pulse on time, pulse off time, servo voltage, and wire tension, and their influence on the machining process. The review also covers the different responses of WEDM, such as MRR, surface roughness, kerf width, and wire wear ratio, and their relationship with various process parameters. The review highlights the importance of monitoring and controlling the WEDM process to ensure optimal performance and quality. The study also discusses the use of advanced control systems, such as fuzzy control, adaptive control, and self-tuning adaptive control, to improve the efficiency and effectiveness of WEDM. The review concludes that further research is needed to enhance the performance of WEDM and to develop more efficient and effective machining techniques.A comprehensive review on wire electrical discharge machining (WEDM), a non-traditional material removal process, is presented. WEDM is a highly advanced thermo-electric machining technique that can effectively produce parts with varying hardness or complex designs that are difficult to machine using traditional methods. It uses a non-contact material removal approach and has evolved from a simple tool-making technique to an advanced method for creating micro-scale components with high dimensional accuracy and surface finish. Despite its advantages, WEDM faces challenges such as wire damage and bending, which can reduce precision and effectiveness. The review covers various studies on WEDM, including process optimization, adaptive monitoring and control, and the impact of cutting variables like wire feed rate (F), voltage (V), wire tension (WT), and dielectric flow rate on outcomes such as material removal rate (MRR), kerf width (Kw), and surface roughness (SR). The review also discusses the application of WEDM in various industries and the development of hybrid machining techniques. It highlights the importance of optimizing WEDM parameters to achieve the desired machining performance and discusses the potential for future research in WEDM. The review emphasizes the need for further research to improve the efficiency and effectiveness of WEDM processes. The study also examines the impact of different wire materials, such as copper, brass, and coated wires, on the performance of WEDM. The review discusses the key parameters of WEDM, including pulse on time, pulse off time, servo voltage, and wire tension, and their influence on the machining process. The review also covers the different responses of WEDM, such as MRR, surface roughness, kerf width, and wire wear ratio, and their relationship with various process parameters. The review highlights the importance of monitoring and controlling the WEDM process to ensure optimal performance and quality. The study also discusses the use of advanced control systems, such as fuzzy control, adaptive control, and self-tuning adaptive control, to improve the efficiency and effectiveness of WEDM. The review concludes that further research is needed to enhance the performance of WEDM and to develop more efficient and effective machining techniques.