This research paper investigates mechanical, morphological behavior of Al6061-3%Gr, Al6061-10%TiB₂, Al6061-10%TiB₂-3%Gr and optimizes input machining parameters in abrasive assisted and straight electro chemical machining. The Hybrid ceramic composite (HCC) are reinforced with TiB₂ and Graphite. The composites are fabricated by stir casting method to achieved good mechanical property and wear resistance. This hybrid composite are highly suitable material for automobile and aerospace components. ECM is an excellent way to produce micro components with special features and this fabrication method is used for biomedical applications. Machining of HCC is very serious problems due to its hardness. The ECM is a very complex process in practice. The quality of production mainly depends on the input machining parameters. The economical and high quality of micro drill on HCC is achieved by controlling machining parameters like current, voltage, electrolyte concentration, feed rate, gap between the tool and work. Performance of abrasive assisted ECMM and straight ECMM process in terms of maximum material removal rate and minimum overcut were analysed. The maximum material removal rate is acquired through abrasive assisted ECMM process

Keywords: Al6061-10%TiB₂-3%Gr, Stir Casting, Electrochemical Machining, Over Cut, Material Removal Rate