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Due to the stochastic nature of the EDM process, limited knowledge of material removal mechanism as well as the progression of sparks is available. For complete utilization of the micro-EDM process, a concrete study is needed to understand the physics associated with the process such as the formation of crater, multiple-sparks generation, and overlapping of craters for uniform material removal. The scarcity of the models to simulate multi-sparks with appropriate crater overlap in the micro-EDM process is the motivation for the present work. This work presents a numerical simulation of the micro-EDM process based on the generation of multiple-sparks. The sparks are assumed to be occurring at a point of minimum inter-electrode gap (IEG) based on the arbitrary surface roughness assigned to the tool as well as the workpiece. Using the thermal ablation model as a mechanism of material removal and adopting …