EDM has become an important and cost-effective method of machining extremely tough and brittle electrically conductive materials. It is widely used in the process of making mould/dies, automobile and electronics industries where intricate complex shapes need to be machined in very hard materials. The work piece material selected in this experiment is AISI 304 Stainless steel taking into account its wide usage in industrial applications and it is very difficult to machine by conventional machining. The tool material selected in this experiment is copper based on the good electrical conductivity compared to other tool materials like brass, tellurium copper and graphite. In this work, the influence of variable process parameters such as pulse current, pulse on time, pulse off time, discharge current, gap distance and machining time over performance characteristics like material removal rate, tool wear rate, and different aspects of surface integrity for AISI 304. Stainless steel such as topography of machined surface, MRR, Tool Wear Rate, and surface will be investigated. The variations of material removal rate, tool wear rate versus input machining parameters will be optimized by using Response Surface Methodology which allows us to get best output characteristics.