<p>Owing to the superior characteristics of EN-24 steel alloy, has been utilized in high-strength and wear-resistance requiring engineering applications, however, these characteristics pose a machining challenge for the specimen. Concurrently, electrical discharge machining, an advanced machining, approach has exhibited enhanced productivity, improved quality, and cost-effectiveness when contrasted with auxiliary machine practices. Therefore, in this research, the advanced machining approach was exploited for investigating the machining attributes of EN-24 steel alloy, further, a comprehensive optimization approach was employed. A systematic optimization investigation was performed with gap voltage, peak current, pulse on time, and powder concentration as crucial processing parameters. Correspondingly, the analytical tool, response surface methodology, has been operated for establishing a correlation between the process parameters and experimental outcomes, i.e., material removal rate and tool wear rate. A high R² value for material removal rate and tool wear rate, the experimental responses considered; of 98.62% and 80.11% was observed, respectively. Subsequently, grey relational analysis was employed to identify optimal electrical discharge machining parameters, which were determined to be 10 A of peak current, 100 µs of pulse on time, 60 V of gap voltage, and 6 g of powder concentration. The optimal settings amplified the material removal rate, diminishing the tool wear rate and successively enhancing productivity and precision in the machined parts by relegating tool degradation. Additionally, tool wear and the cost efficiency were advanced by utilizing a brass electrode with an aluminum-mixed dielectric. The advances discussed in this research offer reliability and cost-effective resource use, improving overall efficiency and precision in industrial applications.</p>