The authors developed a finite element model for electric discharge machining (EDM) that utilizes a Gaussian heat source. The model takes into account the spark radius and the energy distribution factor, which are both dependent on the pulse on time and pulse current. The model also incorporates latent heat, specific heat, and temperature-dependent thermal conductivity properties. The authors emphasize the paucity of study on simulating EDM of hybrid composites utilizing the energy distribution factor as a function of performance parameters, which adds novelty to the research. This study used an aluminum-based hybrid composite reinforced with micro and varying percent of nano SiC particles due to their strength-enhancing properties. The L9 orthogonal array was used for experimental design.A parametric analysis was conducted to investigate the effects of SiC nanoparticle percentage, pulse current, and pulse on time on material removal rate (MRR) and surface roughness (SR). The simulation results were compared with experimental data from previous study. The findings revealed that an increase in the percentage of SiC nanoparticles, pulse current, and pulse on time resulted in a higher MRR. Furthermore, these factors initially caused an increase in SR, followed by a subsequent decrease. Notably, the pulse current exhibited the greatest impact on both MRR and SR, while the pulse on time was the second most significant factor for MRR and the least influential factor for SR. Increasing the percentage of SiC nanoparticles in the Al-based hybrid composite had the least effect on MRR but emerged as the second most influential factor for SR. In summary, the simulation results aligned with the outcomes of prior experimental investigations.