<p>Abrasive flow machining (AFM), one of the several mechanical non-conventional machining (NCM) techniques, is a non-conventional machining technique utilized for varied surface finishing and polishing applications. In this work, we examine the effects on surface finish quality of three process factors in Abrasive Flow Machining (AFM): the number of cycles, extrusion pressure, and abrasive grain size, in combination. An unconventional finishing method called AFM is very useful for improving the surface finishes of internal channels in IC engines and precision-required components, especially in aerospace applications. The experimentation focuses on SS 430 material and evaluates finish quality and machining time. Grey relation analysis and the Taguchi technique are used in the study for optimization. The research attempts to comprehend these elements’ impact on surface finish by methodically altering them, offering insights into the ideal circumstances for AFM. This study not only advances knowledge of AFM’s use in aerospace and IC engine applications, but it also provides a useful approach for adjusting process variables to effectively provide better surface finishes.</p>