This paper outlines a strategy for evaluating the planar contact zone geometry generated by circular brush contact with a flat workpiece. Parameters which characterize the contact zone are identified and obtained for a range of brush operating conditions. Special attention is given to examining the effect of brush width distortion on contact zone geometry for orthogonal brushing operations. Shape functions are identified as an appropriate means for evaluating filament tip motion within the contact zone and, subsequently, are used for illustrating the growth of brush width distortion associated with quasi-static brush-workpiece contact.

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