• • Halbach array with 11 permanent magnets generates a maximum magnetic induction of 192 mT and uniform central field distribution, with measured average of 150.2 mT, ensuring uniform force on ZrO2 during polishing and reducing edge defects.
• • Magnetic shear thickening polishing slurry with 4% carbonyl iron powder at 150 mT exhibits the highest peak viscosity and broadest stable thickening range, optimizing the synergistic magnetorheological-shear thickening effect for enhanced material removal.
• • Polishing speed increase raises shear rate and forms more abrasive-containing particle clusters, boosting MRR; excessive or insufficient polishing angle disrupts slurry flow, while workpiece rotation at moderate speed ensures uniform force but excessive rotation diverts slurry and weakens shear thickening.
• • After 60 min of HMSTP, ZrO2 surface roughness Ra decreased from 601 nm to 11 nm and MRR reached 7.26 μm/h; compared to conventional STP without magnetic field, Ra reduced by 85.6% and MRR increased by 1.33 times, demonstrating significant industrial potential for high-efficiency, low-damage ceramic polishing.