The main difficulties regarding producing non-equal sided shapes such as parallelogram slots,airofoil grooves, elliptical holes, etc. are due to non equal gap distribution allover the machined surface.Such difficulty can restrict ECM industrial applications on a large scale. The scope of the present paper comprises an analytical and experimental model for studying various probabilities to overcome such difficulty and presents suitable recommondations for such practical situation. Experimental and theoretical results revealed that there is a significant improvement in both dimensional accuracy and power consumption obtained by the use of the proposed model. It has been found that in the present case. improving in accuracy and power consumption of about 21% and 28% respectively was obtained.