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Electrochemical micromachining (ECMM) is a promising and economical process that can machine hard-to-machine metals with high material removal rate and good surface integrity. In this work, an attempt has been made to develop a novel atomized electrolyte flushing technique to enhance mass transport. An atomizer is employed for supplying pressurized micro-droplets of electrolyte on the workpiece surface which leads to the formation of a thin and mobile fluid film. This thin film of electrolyte, moving with a high velocity helps in overcoming the problems associated with jet flushing such as radial overcut, stray corrosion, and usage of a large volume of electrolyte for machining. Numerical simulations of atomized electrolyte-based ECMM are carried out by considering a thin electrolyte film in the interelectrode gap to predict the evolution of anode profile on SS304 workpiece. Experimental observations suggest …