This paper presents a novel variant of electrical discharge machining (EDM) called Rotary tool-Rotary workpiece EDM (RT-RW-EDM), (along one axis) which enhances the flushing conditions during the machining process. The study focuses on investigating the effects of tool rotation, workpiece rotation, and tool shape as process parameters on material removal rate (MRR), tool wear rate (TWR) and Surface roughness (SR). A full factorial L27 orthogonal array for the design of experiments. Copper tool and Al-10%SiCmicro-2%SiCnano workpiece were used. 27 workpiece samples were prepared by powder metallurgy. The results showed that tool rotation had a significant impact on MRR and TWR and was the most contributing factor in MRR and TWR while the second most contributing factor in surface roughness (SR). The best MRR and minimum TWR were achieved at zero rpm tool rotation, while the minimum SR was observed at 500 rpm tool rotation. Workpiece rotation was the second-best contributing parameter affecting MRR, TWR, and the least contributing parameter for SR. The best MRR and minimum SR were achieved at 800 rpm of workpiece rotation, while the minimum TWR was observed at 900 rpm of workpiece rotation. Tool shape was found to be the least contributing factor in both MRR and TWR but the most contributing factor in SR. The slotted shaped tool provided the highest MRR, simple shaped tool provided the lowest TWR, and the least SR. Additionally, the interaction between tool rotation and workpiece rotation was found to be the most contributing factor for MRR. The study used artificial neural networks (ANN) and particle swarm optimization for predictive modelling and optimization of the results. The desirability function analysis showed that the best performance measures in terms of max MRR, minimum TWR, and SR were obtained at 500 rpm of tool rotation, 900 rpm of workpiece rotation, and slotted tool shape. This research contributes to the development of EDM and highlights the importance of flushing parameters in achieving optimal machining conditions.