The magnetic abrasive finishing (MAF) process is well known because of its high efficiency in yielding a mirror gloss finish zone. However, this process yields unevenness, which is often evident on the workpiece surface. So in this paper, we observe the characteristics of the polishing force and contact condition for these three different iron particle shapes and for different particle numbers, using a force sensor and a high-speed camera. The relationship between the particle shape and the polishing force is also explored in an attempt to construct a predictive model for the polishing force. It is found that the force variation can be reduced by adjusting the particle shape and number, which effectively reduces the damage caused when the brush approaches the workpiece surface.
