Electrochemical machining (ECM) provides the alternative to traditional or conventional machining processes without a workpiece, with high material removal rates, irrespective of diverse mechanical properties of the workpiece. Even though ECM has a great potential, the process is still not fully explored and its research is in proce phenomena such as electrochemistry, mass transfer, heat transfer and hydrodynamics taking place simultaneously and leads to different material removal rate at each point on the anode surface (Workpiece). Due to this it is profile accurately in ECM process. This problem is considered for investigation by developing a Multiphysics simulation model for ECM hole making process and the effect of tool geometry on generated anode profile is stu dimensional control and performance of the electrochemical machining process. For development of Multiphysics simulation model for the tool design in ECM hole making process, finite element analysis (FEA) software, COMSOL is used becaus capability to couple various phenomena in ECM process in a single model for better accuracy.ECM performance characteristics namely; overcut and height of spike generated is predicted by simulation and the accuracy and capability. The predicted and experimental results agreed well and the developed innovative simulation model provides complete visualization and understanding of the ECM process.