<p>The micro-mechanisms of abrasive air jet machining for micro-textures remain unclear, particularly lacking a systematic and unified theoretical model for material removal behavior at the microscale. To gain an in-depth understanding of the micro-machining process, it is imperative to employ appropriate simulation methods for mechanistic exploration. To address these issues, this study focuses on finite element method-based simulations of the micro-texturing process on cast iron surfaces under abrasive air jet action, systematically analyzing the stress distribution and deformation characteristics of cast iron during machining. This approach aims to elucidate the micro-removal mechanisms and the formation mechanisms of geometric morphologies in abrasive air jet machining of micro-textures. Specifically, the velocity model of abrasive particles was first derived, and the velocity distribution pattern of particles within the jet stream was defined accordingly. Based on this foundation, the effects of abrasive particle shape and jet pressure on machining outcomes during single-particle impact on cast iron surfaces were analyzed. The study revealed two impact behaviors-rebound and fragmentation-when abrasive particles strike cast iron, with significant differences in material removal behavior observed for particles of varying shapes. The kinetic energy transferred to the cast iron was found to depend jointly on particle velocity and impact behavior. Furthermore, multiple abrasive particles impact finite element model verified by the experiment is conducted, uncovering three removal mechanisms and their coupled effects in abrasive air jet machining of micro-textures on cast iron surfaces.</p>