<p>Small-size polishing is a potential polishing method, and its removal efficiency, resolution, and stability are the key factors determining its machining capability. In this study, the material removal characteristics of the small-size polyurethane polishing wheel were investigated both theoretically and experimentally. A tool influence function (TIF) prediction model was established based on finite element simulation and kinematics theory, and the effects of different process parameters on the stability of the TIF as well as the material removal rate (MRR) were investigated. Meanwhile, the stable material removal ability of the small-size polyurethane polishing wheel was verified by multi-point discrete processing experiments and surface continuous polishing experiments, with the peak removal depth varying within 2.5%, and the processed surface roughness reaching Sa 0.894 nm. The results reveal the relationship between TIF and process parameters and give the optimal process parameters for obtaining high surface quality and stable material removal. This study provides theoretical guidance for the determination of the polishing process parameters of a double-axis polyurethane wheel tool, which is significant for promoting the application of the small-size polyurethane polishing wheel in the field of small-size polishing.</p>