In the present study rotary-Electro Discharge machining of AISI D2 tool steel has been carried out using a pure copper electrode. Various response variables such as Material Removal Rate(MRR), Tool Wear Rate(TWR) and Machining Rate(MR) have been studied against the selected process variables. The selected process variables were Peak Current(I), Voltage(V), Duty Cycle and Electrode rotation(N). AISI D2 Tool Steel is air hardened, high carbon, high chromium which increases its hardness and reduces its machinability. Reduced machinability means it not economical to use conventional methods to machine AISI D2 Tool Steel. So, non-conventional methods play an important role in machining of such materials.