OBJECTIVE To evaluate the effect of different polishing methods on surface roughness and accuracy of cobalt-chromium castings. METHODS Five polishing methods were compared: centrifugal barrel polishing, electrical brightening, grinding, grinding+centrifugal barrel polishing and grinding+electrical brightening. 30 specimens (30 mmx 10 mm x l.5 mm) were divided into 6 groups which were cast and polished for surface roughness test.30 upper complete denture bases were cast and divided into 6 groups. The dimensional accuracy between the posterior border of the upper complete denture and model at five different positions were determined by traveling microscope measuring method respectively before and after polishing. One-way ANOVA with SPSS13.0 was used for statistical analysis. RESULTS Specimens polished by grinding+centrifugal barrel got the smoothest surface (P < 0.01) with Ra0.19 microm, compared with Ra3.38 microm before polishing. No significant difference of the posterior border gaps between the cast base and model was found (P > 0.05). CONCLUSIONS Bases polished by grinding + centrifugal barrel had the smoothest surface. There is no influence of centrifugal barrel polishing on dimensional accuracy of cast upper base.