Abstract:To manufacture quality products at lowest cost in industries, optimization is an effective technique which can be Electrochemical micro-machining (EMM) appears to be very promising as a future micromachining technique, since in many areas of applications it offers several advantages, which include higher machining rate, better precision and control, short lead time and a wide range of materials that can be machined.In this work, the shape evolution in through-mask electrochemical micromachining (ECMM) process is investigated numerically and experimentally. The effect of process parameters on the anode shape was demonstrated by Finite Element Method using COMSOL Multiphysics software. With finite element method (FEM), the anodic evolution process is predicted and effects of stray current also have been identified. The validation experiment is conducted and the hole drilling procedure is observed. The FEM calculation predicted model is in good agreement with experimental model. With the sets of experiments and Finite element analysis simulation, the optimized set and the formulation of the electrolyte in through-mask ECMM are achieved.