To control the process parameters using two-stage atomization and rapid solidification, and get the spherical magnetic abrasive with excellent performance, and improve the stability of the preparation processes system. Through the analysis of the atomization and rapid solidification process, it was designed which were the two-stage atomizer, the device and system of cool water supply, pneumatic conveying device and control system, atomized water-cooled chambers. The numerical analysis of the two-stage atomizer under different pressure ratios was carried out, through the FLUENT fluid analysis software. It is concluded that the uniform velocity flow field is obtained when the atomization pressure is 1.2 MPa and the lower atomization pressure is 2.5 MPa. On the basis of the existing design, the operability of the process system was verified by experiments, and the spherical abrasive particles were embedded in the spherical surface of the iron matrix.