The fluid magnetic abrasive (FMA) is a new type of precision finishing abrasives, which is typically prepared by dispersing the magnetic particles, nonmagnetic abrasives, surfactants in a non-magnetizable carrier liquid. As the functional particles, the characteristics of magnetic particles have a great impact on the properties of FMA. In our experiment, the micron-sized carbonyl-iron (CI) particles (typical size: 3 μm–5 μm) are found to be ideally suited for the preparation of FMA. In this paper, the selections of micron-sized carbonyl-iron particles suitable for the FMA, the preparation techniques, the finishing mechanism and finishing process are presented. Some key parameters of FMA that may affect the finishing efficiency and the final surface roughness are analyzed theoretically. The experimental results are discussed as well in this paper.

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