International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.2, No.4, November 2013 37              Somashekhar S. Hiremath 1 Vidyadhar H. M. 2 and Makaram Singaperumal 3 1,3 Department of Mechanical Engineering, Indian Institute of Technology Madras, Chennai-600036, Tamil Nadu. INDIA. 2 Mechanical Engineer, Purchase in charge, Dubai Aluminium (DUBAL), Jebel Ali, Dubai, UAE. ABSTRACT Manufacturing processes converts the raw materials into functionally usable goods. This conversion process adds value to them. Over the last few years, surface machining has assumed a greater importance in manufacturing. In recent years, surfaces are being engineered to make surface texture more suitable to the required specified functions. Finish machining of the external surfaces and easily accessible internal surfaces to specification can be accomplished by traditional processes. However, with the exception of lapping, most of these processes are nonflexible in nature and cannot access internal surfaces of intricate shapes. For this type of problems extrusion honing can be a viable solution. Extrusion honing is a process to deburr, polish and radius difficult-to-reach surfaces. The process can be applied to an impressive range of finishing operations that provide uniform, repeatable, predictable results. In this process, the small quantities of work material are removed by flowing semi solid, abrasive dispersed putty, under pressure through or across workpiece material. Abrasive flow machining was developed in 1960s as a method to deburr, polish, and radius difficult to reach surfaces with required surface finish. So in this paper an attempt has been made to develop a prototype model of a Abrasive Flow Machine (AFM) with various sensors to monitor process parameters. Experimentation was carried out on various engineering materials and studied the quality characteristics-surface finish achieved on various kinds of workpieces. It was shown that a very high surface finish is achieved as the experiments were carried out for more number of passes and even small intricate cavities available on internal surface of the workpiece was machined to high quality surface finish. Also the obtained results show that this process completely removes all traces of thermal recast layers remaining after spark erosion processes. KEYWORDS Abrasive Flow Machine, Carrier Medium, Viscoelastic Polymer,Surface Roughness and Characterization 1. INTRODUCTION Abrasive finishing processes use a large number of multi point or random cutting edges for effective removal of material at smaller chip sizes than in the finishing methods that use defined cutting edges. Machining at small chip sizes allows improved surface finish, closer tolerances, more localised control, generation of more intricate surface features. For producing small chip sizes, abrasive processes are more suitable than processes with defined cutting edges. By mixing abrasive grains with some bond material or matrix material small cutting edges can be delivered directly to the machining area. The ability of the abrasive processes to produce closer tolerances has enhanced product performance; greater consistency of the processes has made it more