EDM is a popular non-traditional machining method extensively utilized for shaping hard materials with intricate geometries. By serving as a medium for electrical discharge, offering cooling, and assisting in the removal of debris, the dielectric fluid used in EDM is essential to the machining process. In order to analyze widely utilized dielectrics, such as EDM oil, this article uses Taguchi’s L27 orthogonal array experimental design. An Electronica ELEKTRA PULS SS-35 ZNC EDM machine with a copper tool and a gunmetal work piece were used. To comprehend their impact on machining performance, variations in parameters including current, voltage, and pulse on time were methodically examined. The results clarified the complex interaction between the cathode and electrode. ANOVA (analysis of variance) was used to examine key performance variables such as surface roughness, tool wear rate, and material removal rate. Through the use of the knowledge acquired from this study, researchers and engineers may efficiently optimize EDM operations to get improved surface quality and efficiency. This work advances the field of EDM technology and offers helpful recommendations for EDM oil dielectric in real-world machining scenarios.