Little information is available about the corner shape and size produced in electrochemical drilling of blind holes. On this account prediction of the complete anode shape analytically, in ECD, is not possible. This paper reports the experimental findings regarding the shape and size of the corners copied, in the anode during electrochemical drilling of blind holes using a tool of specified geometry. An equation evolved by regression analysis of experimental data has been suggested for this purpose. With a view to improve results, an equation based on dimensional analysis has also been presented. Finally, a comprehensive mathematical model accounting for the independent, higher order, and the interaction effects of different important process parameters on the yield (anode radius) has been proposed and its adequacy has been tested by the analysis of variance and accuracy against experimental data.

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