Honing is traditionally a rigid process meant for the finishing of plane internal features. Intricate features involving varying cross sections, bends and irregularities require flexible abrasive processing to obtain high quality surface. Extrusion honing (EH) is a flexible abrasive process. It removes material in small quantities by forcing an abrasive mixed polymeric medium across internal passages. It can be used to finish components such as valves, hydraulic sleeves, I.C. engine manifolds and also parts used in biomedical applications [1-4]. It removes recast layers left by the EDM process and induces compressive residual stresses in surface layers of material which enhances fatigue strength of the surface [5]. It can process a selected passage or many passages of one or more components. Multiple holes, stepped passages and tapered holes can be finished with this process. Removal of sharp corners enhances the edge quality. It is a proven, reliable and accurate method that provides consistent results [6,7].
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