Abrasive flow machining process provides a high level of surface finish and close tolerances with an economically acceptable rate of surface generation for a wide range of industial components. Abrasive flow machining (AFM) is one of the widely used advanced finishing processes in which a small quantity of work material is removed by flowing semisolid abrasive-laden putty over the workpiece surface to be finished. AFM is popular for finishing and deburring of difficult –to-access areas,complex passage to high quality. This process is also used for radusing,produsing compressive residual stresses ,and removal of recast layer. For the control of abrasive fow machining process,it is important to understand main effect and interaction effect of process parameters.in the present work ,the effects of different process parameters, such as number of cycles,concentration of abrasive,abrasive mesh size and gap between workpiece and mandrel on the response reduction in surface roughness(Ra value) are studied. The preliminary experiments are conducted to select the ranges of variables by using single-factor experimental technique. The media used for the present experimentation is a mixture of Bentonite (carrier), and silicon carbide (abrasive particle),and water (lubricant). A statistical 1 2 *3 3 full factorial experimental technique is used to find out main effect ,interaction effect and contribution of each variable to the machined workpiece surface roughness. Levels of machining parameters selecting consist mesh number (70,100), number of cycles (15,25,40), concentration of abrasive (40,50,60%), gap between workpiece and mandrel (1.5,2,2.5mm). The effects of machining parameters on surface finish have been experimentally analysed. Experiments were performed on aluminum as work material. The significant machining parameters and the optimal combinations of the machining parameters were identified by ANOVA (analysis of variation) response graph. Based on the present result, parameters such as mesh number and gap between mandrel and workpiece has inverse effect on reduction in surface roughness (Ra value), However parameters such as cycle and concentration of abrasive have straight effect on reduction in surface roughness (Ra value) and material removal. Key words: AFM, mesh number, cycles, concentration, gap