<p>Surface quality is highly important to improve the design tolerance of various industrial components. This is achieved only in the last stage of production process, where a precise machining is utilized to finish the surface by using simple grinding tool. Estimated finishing forces are applied by the grinding tool on the surface to be finished. This may further cause a non-uniform surface roughness by producing some defects over the workpiece surface. To overcome this problem, magnetorheological finishing processes are taking place to finish different shapes of materials even after grinding operation. These processes use magnetorheological polishing fluid with which finishing takes place under abrasion mechanism. In this research, an optimization study is evaluated in order to study the effect of different parameters i.e. workpiece rotation, volume of concentration of SiC abrasive particles and electrolyte iron powders (EIPs) to determine the % change in Ra value. Total 20 experimentations have been performed according to the plan of experimentation with magnetorheological cylindrical type finishing process. The results revealed that the optimum parameters—workpiece rotation of 800 rpm, SiC abrasive concentration of 20 vol%, and EIP concentration of 20 vol%—led to a 70 % reduction in surface roughness (Ra) after 40 minutes of finishing. Additionally, scanning electron microscopy (SEM) and circularity measurements were conducted to evaluate the improvement in surface morphology and the enhancement in geometric precision of the cylindrical workpiece.</p>