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Dr. Afzaal Ahmed
Assistant Professor
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Dr. Afzaal Ahmed is an Assistant Professor in Department of Mechanical Engineering, IIT Palakkad. His research interests broadly centers on the non-coventional machining, hybrid machining, deep hole drilling, laser based surface alloying and metal additive manufacturing (AM). 

Dr. Ahmed has been involved in multiple projects funded by Agency of Science Technology and Research (A*Star), Singapore and Singapore Institute of Manufacturing Technology (SIMTech) that focussed on development and implementation of hybrid processing techniques for Large Format Machining of Nickel based superalloys. During the PhD, he developed a novel hybrid electrical discharge and arc machining process (HEDAM) for the efficient and ultrafast machining of difficult-to-cut superalloys such as Inconel 718, Ti-6Al-4V etc. His research expertise also include evaluation of machined surfaces via roughness, microhardness, microstructure with various microscopic and spectroscopic techniques like SEM, EDS, XRD, AFM, TEM and XPS.

Educational Background

PhD - Department of Mechanical Engineering, National University of Singapore (NUS), Singapore. 

M.Tech - Department of Mechanical Engineering, IIT Kharagpur, Kharagpur, (W.B), India. 

B.E -  Mechanical Engineering, Pt. Ravi Shankar Shukla University (Pt.RSSU), Raipur, (C.G),  India.  

Work Experience

Worked as Research Fellow in Advanced Manufacturing Laboratory (AML)  Department of Mechanical Engineering at NUS Singapore. The post-doc position involved working on an A*Star Singapore funded project, Large Format Machining of Inconel 718 for Oil and Gas Industry.


PG Courses

Odd Semester

ME 5013 Mechanics of Machining

Even Semester

ME 5613 Welding Technology

UG Courses

Odd Semester

ME 2280 Manufacturing Processes

ME 1130 Engineering Drawing 

Even Semester

ME 2080 Engineering Materials

Research Area
Non-conventional machining processes
Hybrid machining methods
Micro and nano machining
Ultra-precision machining
Deep hole drilling
Laser surface alloying
Laser based additive manufacturing processes
Wear and tribology studies of modified surfaces
Additional Information
Sponsored Projects

April 2020 - Funding received from Federal Bank under the scheme of Corporate Social Responsibility (CSR)

Title - Mechanical design and development of a portable emergency ventilator for COVID-19 patients

Funding Amount: INR 6,00,000 for 4 Months

Role: Principal Investigator (PI)


December 2019 -  Funding received from Science and Engineering Research Board (SERB), Government of India under the scheme of Startup Research Grant (SRG)

Title: Ultra-precision machining of brittle materials – Material micro-structural perspective and cutting edge radius effect

Funding Amount: INR 31,651,90 for 2 Years

Role: Principal Investigator (PI)

Academic Awards/Achievements

1. Received ‘Best Paper Award” for the paper titled ‘A novel approach in deep hole drilling of Inconel 718’ at the 7th International Conference of Asian Society for Precision Engineering and Nanotechnology (ASPEN) held at Seoul, South Korea in Nov 2017.
2. Received the 30th Innovation & Research Award (IRA 2016) by Faculty of Engineering (FoE) NUS Singapore in the category of ‘High Achievement’.
3. Awarded with NUS Research Scholarship for the duration of four years.
4. Secured 9th position overall & 5th in Mechanical Engineering in Pt. Ravishankar Shukla University Raipur (C.G.) at U.G. level.
5. Ranked among Nation’s top 1.6% in GATE - 2007.

6. Received St. Thomas Mission Performance Award for overall excellent academic performance.
7. Awarded Merit Scholarship for excellent academic performance in 3rd and 4th semester at U.G. level.
8. Awarded Merit Scholarship for excellent performance in 5th and 6th semester at U.G. level.
9. Awarded with Prime Minister Trophy Scholarship by SAIL for successive four years at U.G. level.

Scientific & Professional Societies
  • Professional Member of Society of Manufacturing Engineers (SME)
  • Member of American Society of Mechanical Engineers (ASME)
  • Associate Member of The Institution of Engineers (IEI), India

Book Chapters

Ahmed, A., Boban, J., & Rahman, M. A. (2022). Recent Trends in Arc Machining Processes. In B. Kuriachen, J. Mathew, & U. Dixit (Eds.), Electric Discharge Hybrid-Machining Processes (pp. 87-104): CRC Press.
Rahman, M. A., Ahmed, A., & Mia, M. (2021). Trends in electrical discharge machining of Ti-and Ni-based superalloys: macro-micro-compound arc/spark/melt process. In Micro Electro-Fabrication (pp. 63-87). Elsevier.

Ahmed, A., Rahman, M., & Kumar, A. S. (2020). Spark Erosion Based Hybrid Processes. Spark Erosion Machining: MEMS to Aerospace, 123.

Journals & Peer Reviewed Conferences


Boban, J., & Ahmed, A. (2022). Electric discharge assisted post-processing performance of high strength-to-weight ratio alloys fabricated using metal additive manufacturing. CIRP Journal of Manufacturing Science and Technology, 39, 159-174.

Jithinraj, E. K., Ahmed, A., & Boban, J. (2022). Improving the surface integrity of additively manufactured curved and inclined metallic surfaces using thermo-electric energy assisted polishing. Surface and Coatings Technology, 446, 128803.

Boban, J., Ahmed, A., Jithinraj, E. K., Rahman, M. A., & Rahman, M. (2022). Polishing of additive manufactured metallic components: retrospect on existing methods and future prospects. The International Journal of Advanced Manufacturing Technology, 121, 83-125.

Ellappan, S., Ahmed, A., & Rahman, M. A. (2022). Cutting edge radius effect on the surface integrity of orthogonal turned aluminium alloy Al6082 with different initial microstructure. Procedia CIRP, 108, 636-641.

Boban, J., & Ahmed, A. (2022). Electric discharge assisted post-processing of internal surfaces fabricated using metal additive manufacturing. Paper presented at the 22nd International Conference & Exhibition, Geneva, Switzerland. pp 275-278.


Jibin Boban, Afzaal Ahmed, Ashwani Assam. (2021). Effect of recirculation zone on debris evacuation during EDM deep hole drilling. Procedia CIRP, 102, 393-398.

Ahmed, A., Boban, J., & Rahman, M. (2021). Novel EDM deep hole drilling strategy using tubular electrode with orifice. CIRP Annals, 70(1), 151-154.

Payaningal, T., Kuriachen, B., Kumar, D., Ahmed, A., & ML, J. (2021). Effect of heat treatment and electric discharge alloying on the tribological performance of Selective Laser Melted AlSi10Mg. Journal of Tribology, 1-21.

Boban, J., & Ahmed, A. (2021). Improving the surface integrity and mechanical properties of additive manufactured stainless steel components by wire electrical discharge polishing. Journal of Materials Processing Technology, 291, 117013.


Boban, J., Ahmed, A., Rahman, M. A., & Rahman, M. (2020). Wire electrical discharge polishing of additive manufactured metallic components. Procedia CIRP, 87, 321-326.

Rahman, M. A., Rahman, M., Mia, M., Gupta, M. K., Sen, B., & Ahmed, A. (2020). Investigation of the specific cutting energy and its effect in shearing dominant precision micro cutting. Journal of Materials Processing Technology, 116688.


Ahmed, A., Tanjilul, M., Rahman, M., & Kumar, A. S. (2019). Ultrafast drilling of Inconel 718 using hybrid EDM with different electrode materials. The International Journal of Advanced Manufacturing Technology, 1-14.

Ahmed, A., Lew, M. T., Diwakar, P., Kumar, A. S., & Rahman, M. (2019). A novel approach in high performance deep hole drilling of Inconel 718. Precision Engineering, 56, 432-437.

2018 & Before

Ahmed, A., Tanjilul, M., Fardin, A., Wong, Y. S., Rahman, M., & Kumar, A. S. (2018). On the design and application of hybrid electrical discharge and arc machining process for enhancing drilling performance in Inconel 718. The International Journal of Advanced Manufacturing Technology, 99(5), 1825-1837.

Ahmed, A., Fardin, A., Tanjilul, M., Wong, Y. S., Rahman, M., & Kumar, A. S. (2017). A comparative study on the modelling of EDM and hybrid electrical discharge and arc machining considering latent heat and temperature-dependent properties of Inconel 718. The International Journal of Advanced Manufacturing Technology, 1-9. 

Tanjilul, M., Ahmed, A., Kumar, A. S., & Rahman, M. (2018). A study on EDM debris particle size and flushing mechanism for efficient debris removal in EDM-drilling of Inconel 718. Journal of Materials Processing Technology, 255, 263-274. 

Ahmed, A., Dhakar, B., Kaul, R., Palai, R., Roy Choudhury, A., & Chatterjee, S. (2017). Hardfacing of AISI304 steel: fabrication of oxide-boride-nitride ceramic matrix composite layer by laser-assisted high temperature chemical reaction. Transactions of the IMF, 95(4), 207-216. 

Ahmed, Afzaal. "Deposition and Analysis of Composite Coating on Aluminum Using Ti–B4C Powder Metallurgy Tools in EDM." Materials and Manufacturing Processes 31.4 (2016): 467-474. 

Afzaal Ahmed, Mustafizur Rahman, A. Senthil Kumar; A novel approach in deep hole drilling of Inconel 718; The 7th International Conference of Asian Society for Precision Engineering and Nanotechnology, 14-17 Nov 2017, Seoul, South Korea.

Afzaal Ahmed, S. B. Sabtu, M. Rahman, A. S. Kumar; EM drilling of Inconel 718 using copper tube electrode; The 14th International Conference of the European Society for Precision Engineering and Nanotechnology (euspen); 2-4 June 2014, Dubrovnik, Croatia.

Afzaal Ahmed, Syafiq Ab Rahman, A.S. Kumar, M. Rahman; Enhanced surface integrity and dimensional accuracy in micro-EDM drilling using D-shaped electrode; 4M 10th International Conference 08-10 October, San Sebastian, Spain 2013.

Afzaal Ahmed, A.S. Kumar, M. Rahman;. An experimental investigation of micro-EDM drilling capability for Inconel 718 against SUS 304 stainless steel in deionized water; 9th International Conference on Micro Manufacturing (ICOMM), Singapore 2014.