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AISI P20 tool steel is commonly used for engineering of die holders, rails, plastic molds, wear strips, bolsters, shafts, and backers. When normally heated and sub-cooled, it experiences metallurgical modifications. Because the essential aspect of the "wire-electro discharge machine (WEDM)" is product finishing, this research examines the parametric responses when machining parent metal and sub-cooled metal (AISI P20). Thus, it is always necessary to choose a proper parametric arrangement for reaching maximum material removal rate (MRR), cutting speed with minimum surface roughness (SR), and kerf width. The effects of pulse on time, wire speed, discharge current, wire tension, and flushing pressure on individual machining reactions are also discussed in this study. An orthogonal array was created using Taguchi's mixed experimental approach. The measurement alternatives and ranking according to compromise solution (MARCOS) method, the Honey Badger Algorithm, and the Taguchi-MARCOS method are engaged to obtain the important machining constraints and the optimal parametric settings for each response. When compared to the parent material, sub-cooled material has a greater cutting speed, SR, kerf breadth, and MRR. Here, cutting speed, MRR, and fitness were maximized along with minimization of SR and kerf width using the Honey Badger Algorithm as compared to both the MARCOS and Taguchi-MARCOS methods. According to ANOVA, for both parent and sub-cooled material, discharge current was the most significant and influential factor. The sub-cooled material's machined surface contains smaller deposits and more spherical globules than the parent material, which has bigger melted deposits. [ABSTRACT FROM AUTHOR]