High-consistency cutter passivation process and device based on flexible abrasive auxiliary force rheological polishing

Abstract

The invention discloses a high-consistency cutter passivation process and device based on flexible abrasive auxiliary force rheological polishing, and relates to the technical field of cutter passivation. The process comprises the following steps: step 1, preparing a gradient grinding material; step 2, programmable fiber flow control; 3, multi-stage gradient machining; and 4, intelligent closed-loop control. The device comprises a gradient abrasive material preparation module, a programmable fiber flow control device, a multi-degree-of-freedom machining platform, an intelligent monitoring module, a polishing solution circulation module and a protection module. Through the three-stage abrasive grain grading and programmable fiber flow control technology, magnetic particles and an external magnetic field do not need to be relied on, the agglomeration state of the polishing solution is directly damaged through fiber vibration, the fluid flow speed of a complex cutting edge area is increased, abrasive grain distribution uniformity is improved, laser confocal real-time monitoring and PID algorithm dynamic adjustment are combined, the precision is remarkably improved, and the polishing effect is good. And the method is particularly suitable for precise passivation of superhard cutters such as PCD cutters and the like.

Description

Technical Field

[0001] The present invention relates to the technical field of tool passivation, specifically to a high-consistency passivation process and device for tools based on flexible abrasive-assisted force rheological polishing. Background Art

[0002] With the continuous development of high-tech, micro-parts with complex structures are increasingly widely used in the national defense and civilian fields, and high-quality micro-tools are an important guarantee for realizing the precision micro-machining of micro-parts. After the cutting edge of the micro-tool is ground by a grinding wheel, there are inevitably microscopic defects such as notches and cracks at the edge, and there will also be micro-pits, micro-cracks, chip adhesion, and micro-burrs on the tool surfaces such as chip flutes and flank faces. During the cutting process, the sharp and defective edge is prone to tool failures such as edge chipping and tooth breakage, and the poor tool surface quality will exacerbate the friction and extrusion between the tool, chip, and workpiece, resulting in tool damage and accelerated wear. Tool passivation treatment can change the edge profile and morphology, eliminate edge defects, and improve the tool surface quality, so as to achieve the purpose of improving cutting performance, extending tool life, and improving workpiece machining quality. In addition, tool passivation treatment can also eliminate the residual stress on the cutting edge after grinding, improve the bonding strength between the coating material and the tool surface in the coated tool, and prevent coating peeling.

[0003] The invention with the publication number CN114131431A discloses a passivation method and device for micro-tools based on flexible abrasive grains and magnetic composite fluid. The cutting edge of the micro-tool is processed by using the magnetic composite fluid polishing principle, and the rheological properties of the magnetic composite fluid and the flexible abrasive grains are used to slightly remove the tool surface material, which can simultaneously achieve tool edge passivation treatment and tool surface polishing treatment, with high tool passivation accuracy and good consistency; through the multi-fixture design, batch passivation of micro-tools can be realized, and the tool passivation work and disassembly and assembly operations can be carried out simultaneously, improving the tool passivation efficiency.

[0004] As shown in the above invention, the existing device prepares flexible abrasive grains by embedding nano-diamond abrasive grains and iron oxide particles in an organic polymer elastic matrix. The preparation process involves multi-material composite and microstructure control, with a complex process and high cost. In addition, although the dispersion of abrasive grains is improved by magnetic particles, in the complex edge area, the flexible abrasive grains may still aggregate or settle due to uneven magnetic field distribution, resulting in local abrasive grain concentration differences and affecting passivation uniformity. Moreover, the existing device relies on an external magnetic field to make hydroxyl iron powder and iron oxide form a chain structure, and two sets of electromagnets, magnetic poles, and excitation power supplies need to be configured, with a large equipment volume and high energy consumption. At the same time, the precise control of the magnetic field direction and intensity is crucial for the passivation effect. If the magnetic field distribution is uneven, it may lead to unstable viscosity of the passivation liquid, and then cause inconsistent removal rates of the edge material. Summary of the Invention

[0005] Aiming at the deficiencies of the prior art, the present invention provides a high-consistency passivation process and device for cutting tools based on flexible abrasive-assisted magnetorheological polishing, which solves the existing problems.

[0006] To achieve the above objectives, the present invention is realized through the following technical solutions: A high-consistency passivation process for cutting tools based on flexible abrasive-assisted magnetorheological polishing, comprising the following steps:

[0007] Step 1, gradient abrasive preparation: Compound a shear-thickening polishing fluid by mixing a polyhydroxy polymer base liquid accounting for 40-60 wt% with a three-stage graded abrasive accounting for 2-20 wt%, wherein the abrasive particles of 0.5-1 μm account for 10%-20%, the abrasive particles of 1-3 μm account for 50%-60%, the abrasive particles of 3-5 μm account for 20%-30%, and add 0.1-0.5 wt% of a polyoxyethylene ether dispersant;

[0008] Step 2, programmable fiber flow control: Apply vibrations of 5-100 Hz using a flexible fiber array with a diameter of 50-200 μm and a density of 200-250 roots / cm 2 to break the agglomerated state of the polishing fluid and increase the fluid flow rate in the complex edge region by 30%-50%;

[0009] Step 3, multi-stage gradient processing: Carry out rough passivation, fine passivation, and superfine polishing processing in sequence. The material removal rate in the rough passivation stage is 5-8 μm / min, the removal rate in the fine passivation stage is 2-5 μm / min, and the removal rate in the superfine polishing stage is ≤2 μm / min. Coordinate and control the edge profile by controlling the spindle speed at 30-120 rpm and adjusting the fiber vibration parameters;

[0010] Step 4, intelligent closed-loop control: Use a laser confocal sensor (resolution 0.1 μm) and an acoustic emission sensor (threshold 150-200 mV) for real-time monitoring, and automatically terminate the processing when the fluctuation of the blunt radius is <±1 μm and the surface roughness Ra ≤ 10 nm.

[0011] Preferably, the particle size of the polyhydroxy polymer base liquid is 5-20 μm, and the concentration is dynamically adjusted by a screw pump to achieve continuous adjustment of the low-shear viscosity of 20-50 Pa·s and the high-shear viscosity of 150-250 Pa·s.

[0012] Preferably, the programmable fiber array is made of nylon or carbon fiber, and the arrangement angle is optimized by the discrete element method (the included angle with the edge normal is 30°-60°). The vibration frequency in the rough grinding stage is 50-80 Hz, and the vibration frequency in the fine grinding stage is 10-30 Hz.

[0013] Preferably, the three - stage graded abrasive grains include diamond, boron carbide or cubic boron nitride. Among them, when the PCD tool is passivated, cubic boron nitride abrasive grains with a size of 500 nm - 1 μm are used, and the concentration is 8 - 12 wt%.

[0014] Preferably, in the multi - stage gradient machining, the shear rate in the rough passivation stage is controlled at 150 - 200 s⁻¹, in the fine passivation stage is 50 - 100 s⁻¹, and in the super - fine polishing stage is 20 - 50 s⁻¹.

[0015] Preferably, in the step of preparing the gradient abrasive, a shear emulsifier is used to achieve the nano - scale dispersion of the abrasive grains. The shear emulsifier is equipped with a rotational speed adjusting device and a temperature monitoring device, and can adjust the rotational speed as needed and monitor the temperature change during the emulsification process.

[0016] Preferably, in the intelligent closed - loop control step, the intelligent monitoring module further includes a temperature sensor and a pressure sensor, which are respectively used to monitor the temperature of the polishing liquid and the pressure in the machining area. The measurement accuracy of the temperature sensor reaches ±0.5 °C, the measurement range of the pressure sensor is 0 - 10 MPa, and the accuracy reaches ±0.1%. The monitoring data is transmitted to the control system in real time and the relevant parameters are automatically adjusted after comparing with the preset parameter range.

[0017] Preferably, during the machining process, the temperature of the polishing liquid in the contact area between the fiber array and the polishing liquid is maintained at 20 - 50 °C through a temperature control system. This temperature control system uses a combination of a thermoelectric cooler and a heating wire, and is equipped with an overheat protection device.

[0018] The present invention also discloses a tool high - consistency passivation device based on flexible abrasive - assisted magnetorheological polishing, including:

[0019] Gradient abrasive preparation module: It includes a base liquid storage tank, a three - stage abrasive grading unit, a dynamic proportioning system and an ultrasonic dispersion unit. The base liquid storage tank is equipped with a liquid level sensor, which is connected to the control system and issues an alarm when the liquid level is lower than the set value; the three - stage abrasive grading unit uses a multi - layer vibrating screen, and the aperture of each layer of sieve mesh corresponds to abrasive grains of different particle sizes, and high - efficiency grading is achieved by adjusting the vibration frequency and amplitude; the dynamic proportioning system uses a high - precision mass flowmeter and a proportional regulating valve; the ultrasonic dispersion unit uses multiple ultrasonic transducers evenly distributed in the base liquid storage tank and is equipped with a power regulating device;

[0020] Programmable fiber flow control device: The fiber array is equipped with a micro - vibration motor, and the angle - adjusting bracket combined with an electric push rod and a rotary joint adapts to different cutting edge geometric features. The micro - vibration motor is electromagnetically driven and is equipped with an independent drive circuit;

[0021] Multi - degree - of - freedom machining platform: The magnetic levitation spindle uses five - degree - of - freedom magnetic levitation technology, the six - axis linkage fixture uses a modular design, each axis is driven by a high - precision servo motor, and position feedback is carried out through a grating scale;

[0022] Intelligent monitoring module: Integrated with a laser confocal sensor, an acoustic emission sensor, a temperature sensor, and a pressure sensor, it adopts an adaptive PID control strategy to automatically adjust the polishing liquid components and fiber vibration parameters, and has data storage and analysis functions;

[0023] Polishing liquid circulation module: Includes a circulation pump, a multi-stage filter, and a plate heat exchanger. The heat exchanger can control the temperature of the polishing liquid at 20 - 50 °C;

[0024] Protection module: Set around the processing area, including an electric sliding protection door, a high-strength metal protection fence, and an infrared induction safety light curtain.

[0025] Preferably, the control system of the device uses an industrial-grade PLC, which has data processing, logical operation, and control functions. It can adjust the operating parameters of each module in real time according to the data of the intelligent monitoring module to ensure the stability and consistency of the process. At the same time, it supports remote monitoring and operation.

[0026] Beneficial effects

[0027] The present invention provides a high-consistency passivation process and device for tools based on flexible abrasive-assisted magnetorheological polishing. Compared with the prior art, it has the following beneficial effects:

[0028] 1. For the high-consistency passivation process and device for tools based on flexible abrasive-assisted magnetorheological polishing, through a three-stage abrasive grading and programmable fiber flow control technology, without relying on magnetic particles and an external magnetic field, it directly destroys the agglomerated state of the polishing liquid through fiber vibration, increasing the fluid velocity in the complex edge area by 42%, improving the uniformity of abrasive distribution. Combining laser confocal real-time monitoring with PID algorithm dynamic adjustment, the deviation of the roundness radius consistency is ≤ ±5%, and the surface roughness Ra ≤ 10 nm. The accuracy is significantly improved, especially suitable for precision passivation of super-hard tools such as PCD.

[0029] 2. For the high-consistency passivation process and device for tools based on flexible abrasive-assisted magnetorheological polishing, the device uses a magnetic levitation spindle and a six-axis linkage fixture, supports multi-degree-of-freedom movement of the tool, and cooperates with the polishing liquid circulation module to achieve gradient processing of rough grinding, fine grinding, and super-fine polishing. The single-piece processing time is shortened by more than 50% compared with the existing patents. At the same time, the multi-fixture design and intelligent measurement and control system support batch processing, and no additional magnetic field equipment is required, reducing equipment costs and energy consumption, and significantly improving the industrial production efficiency and economy. Description of the drawings

[0030] Figure 1 It is a schematic process flow diagram of the present invention.

[0031] Figure 2 It is a schematic hardware architecture diagram of the intelligent measurement and control system of the present invention.

[0032] Figure 3 This is a schematic diagram of the principle of the polishing liquid circulation module of the present invention. Specific embodiments

[0033] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0034] Refer to Figures 1-3 , the present invention provides the following three technical solutions:

[0035] The first embodiment: A high-consistency passivation process for cutting tools based on flexible abrasive-assisted force rheology polishing, including the following steps:

[0036] Step 1: Gradient abrasive preparation: Compound a shear-thickening polishing liquid by mixing a polyhydroxy polymer base liquid accounting for 40-60 wt% with a three-stage graded abrasive accounting for 2-20 wt%. The three-stage graded abrasive includes diamond, boron carbide or cubic boron nitride. When passivating a PCD cutting tool, cubic boron nitride abrasive particles with a size of 500 nm - 1 μm are used, with a concentration of 8-12 wt%. A shear emulsifier is used to achieve nano-scale dispersion of the abrasive particles. The shear emulsifier is equipped with a rotational speed adjustment device and a temperature monitoring device, and the rotational speed can be adjusted as needed and the temperature change during the emulsification process can be monitored. Among them, the abrasive particles with a size of 0.5-1 μm account for 10%-20%, the abrasive particles with a size of 1-3 μm account for 50%-60%, and the abrasive particles with a size of 3-5 μm account for 20%-30%. And 0.1-0.5 wt% of polyoxyethylene ether dispersant is added. The particle size of the polyhydroxy polymer base liquid is 5-20 μm, and the concentration is dynamically adjusted by a screw pump to achieve continuously adjustable low-shear viscosity of 20-50 Pa·s and high-shear viscosity of 150-250 Pa·s.

[0037] Step 2: Programmable fiber flow control: Apply vibrations with a frequency of 5-100 Hz using a flexible fiber array with a diameter of 50-200 μm and a density of 200-250 roots / cm 2 to break the agglomerated state of the polishing liquid and increase the fluid flow rate in the complex edge area by 30%-50%. The programmable fiber array is made of nylon or carbon fiber, and the arrangement angle is optimized by the discrete element method. The vibration frequency is 50-80 Hz in the rough grinding stage and 10-30 Hz in the fine grinding stage.

[0038] Step 3. Multi-stage gradient machining: Coarsening passivation, fine passivation, and superfine polishing are carried out in sequence. The material removal rate in the coarsening passivation stage is 5 - 8 μm / min, the removal rate in the fine passivation stage is 2 - 5 μm / min, and the removal rate in the superfine polishing stage is ≤2 μm / min. By controlling the spindle speed at 30 - 120 rpm and adjusting the fiber vibration parameters, the edge profile is synergistically regulated. The shear rate in the coarsening passivation stage is controlled at 150 - 200 s⁻¹, 50 - 100 s⁻¹ in the fine passivation stage, and 20 - 50 s⁻¹ in the superfine polishing stage.

[0039] Step 4. Intelligent closed-loop control: A laser confocal sensor (resolution 0.1 μm) and an acoustic emission sensor (threshold 150 - 200 mV) are used for real-time monitoring. When the fluctuation of the blunt radius is < ±1 μm and the surface roughness Ra ≤ 10 nm, the machining is automatically terminated. The intelligent monitoring module also includes a temperature sensor and a pressure sensor, which are respectively used to monitor the temperature of the polishing liquid and the pressure in the machining area. The monitoring data is transmitted to the control system in real time and the relevant parameters are automatically adjusted after comparing with the preset parameter range.

[0040] In the embodiment of the present invention, during the machining process, the temperature control system maintains the temperature of the polishing liquid in the contact area between the fiber array and the polishing liquid at 20 - 50 °C. The temperature control system adopts a combination of a thermoelectric cooler and a heating wire, and is equipped with an overheat protection device.

[0041] The second embodiment: A high-consistency passivation device for cutting tools based on flexible abrasive-assisted forced rheological polishing, comprising:

[0042] Gradient abrasive preparation module: It includes a base liquid storage tank, a three-stage abrasive grading unit, a dynamic proportioning system, and an ultrasonic dispersion unit. The base liquid storage tank is equipped with a liquid level sensor, which is connected to the control system and gives an alarm when the liquid level is lower than the set value; the three-stage abrasive grading unit uses a multi-layer vibrating screen, and the aperture of each layer of sieve mesh corresponds to abrasive grains of different particle sizes, and efficient grading is achieved by adjusting the vibration frequency and amplitude; the dynamic proportioning system uses a high-precision mass flowmeter and a proportional regulating valve; the ultrasonic dispersion unit uses multiple ultrasonic transducers evenly distributed in the base liquid storage tank and is equipped with a power regulating device.

[0043] Programmable fiber flow control device: The fiber array is equipped with a micro vibration motor, and the angle adjustment bracket composed of an electric push rod and a rotary joint adapts to different edge geometric features. The micro vibration motor is electromagnetically driven and is equipped with an independent drive circuit.

[0044] Multi-degree-of-freedom machining platform: The magnetic levitation spindle adopts five-degree-of-freedom magnetic levitation technology, and the six-axis linkage fixture adopts a modular design. Each axis is driven by a high-precision servo motor, and position feedback is carried out through a grating scale.

[0045] Intelligent monitoring module: Integrated with a laser confocal sensor, an acoustic emission sensor, a temperature sensor, and a pressure sensor, it adopts an adaptive PID control strategy to automatically adjust the polishing fluid components and fiber vibration parameters, and has data storage and analysis functions.

[0046] Polishing fluid circulation module: Includes a circulation pump, a multi-stage filter, and a plate heat exchanger. The heat exchanger can control the temperature of the polishing fluid at 20 - 50 °C.

[0047] Protection module: Set around the processing area, including an electric sliding protection door, a high-strength metal protection fence, and an infrared induction safety light curtain.

[0048] In an embodiment of the present invention, the control system of the device uses an industrial-grade PLC, which has data processing, logical operation, and control functions. It can adjust the operating parameters of each module in real time according to the data of the intelligent monitoring module to ensure the stability and consistency of the process, and at the same time support remote monitoring and operation.

[0049] The third embodiment: Example

[0050] Example 1: High-consistency passivation of cemented carbide end mills

[0051] I. Process parameters

[0052] Polishing fluid formula:

[0053] Polyhydroxy polymer base liquid 50 wt% (particle size 10 μm) + 3 - 5 μm diamond abrasive grains (25%) + 1 - 3 μm diamond abrasive grains (55%) + 0.5 - 1 μm diamond abrasive grains (20%) + polyoxyethylene ether 0.3 wt%, viscosity 180 Pa·s at γ = 100 s-1.

[0054] Fiber flow control parameters:

[0055] Carbon fiber array (diameter 100 μm, density 220 roots / cm 2 ), vibration frequency 60 Hz, amplitude 0.6 mm in the rough grinding stage, frequency 20 Hz, amplitude 0.3 mm in the fine grinding stage, and the angle with the cutting edge normal is 45°.

[0056] Processing platform parameters:

[0057] Magnetic levitation spindle speed: 100 rpm in rough grinding, 60 rpm in fine grinding, 40 rpm in superfine polishing; six-axis fixture inclination angle: 45° in rough grinding, 30° in fine grinding.

[0058] II. Processing process

[0059] Gradient abrasive preparation:

[0060] The abrasive grains are classified by a three-stage vibrating screen, the concentration of the base liquid is precisely controlled by a screw pump, and ultrasonic dispersion is carried out for 3 min to ensure uniform distribution of the abrasive grains.

[0061] Flow field initialization:

[0062] The fiber array vibrates at 60 Hz for 30 s to break the agglomerated state of the polishing liquid, and the fluid flow velocity in the tooth root area is increased to 0.8 m / s (0.56 m / s in the traditional process).

[0063] Multi-stage processing:

[0064] Rough grinding (0 - 15 min): Remove the burrs on the edge, the Ra is reduced from 180 nm to 25 nm, and the material removal rate is 6 μm / min;

[0065] Fine grinding (15 - 35 min): Adjust the spindle inclination angle to 30°, the blunt radius is increased from 30 μm to 50 ± 2 μm, and the profile accuracy is improved by 40%;

[0066] Ultra-precision polishing (35 - 50 min): Use 0.5 μm abrasive grains and low-frequency vibration of the fiber. Finally, Ra = 8.2 nm and the blunt radius is 50.3 ± 1.8 μm.

[0067] Intelligent monitoring:

[0068] The laser confocal sensor scans in real time. When the Ra = 8.2 nm is measured continuously three times and the fluctuation of the blunt radius < ±1 μm, the system automatically stops processing.

[0069] III. Effect verification

[0070] Quality index: The consistency deviation of the blunt radius is ±3.6%, Ra = 8.2 nm, meeting the aerospace processing requirements (Ra ≤ 10 nm).

[0071] Efficiency index: The single-piece processing time is 50 min, which is 60% shorter than that of the traditional magnetorheological polishing.

[0072] Life test: When turning stainless steel workpieces, the tool life reaches 300 minutes, which is 300% higher than that of the traditional process.

[0073] Example 2: Precision passivation of PCD micro-drills

[0074] I. Process parameters

[0075] Polishing liquid formula:

[0076] Low-viscosity polyhydroxy polymer base liquid 40 wt% + 500 nm cubic boron nitride abrasive grains (10%) + polyoxyethylene ether 0.2 wt%, viscosity 100 Pa·s at γ = 100 s-1.

[0077] Fiber flow control parameters:

[0078] Ultra-fine nylon fiber (diameter 50μm, density 250 fibers / cm 2 ), vibration frequency 15Hz, amplitude 0.3mm, angle with the drill tip 30°.

[0079] Processing platform parameters:

[0080] Magnetic levitation spindle speed 50rpm, six-axis fixture fixed inclination angle 30°, spindle rotation disabled (micro-drill tip oriented machining).

[0081] II. Processing process

[0082] Gradient abrasive preparation:

[0083] Using a nanoscale vibrating screen to classify 500nm cubic boron nitride abrasive grains, and a low-viscosity base fluid to ensure fluid penetration in the micro-drill tip area.

[0084] Flow field initialization:

[0085] The fiber vibrates at a low frequency for 10s to avoid overloading the micro-drill tip by high-frequency vibration, and the fluid flow rate at the tip increases by 35%.

[0086] Multi-stage processing:

[0087] Rough grinding (0 - 20min): Remove micro-cracking at the cutting edge, material removal rate 3μm / min, Ra decreases from 120nm to 40nm;

[0088] Fine grinding (20 - 50min): Gradually trim the tip profile through fiber vibration and fine adjustment of the spindle inclination angle. Finally, the blunt radius is 25 ± 1μm, Ra = 9.5nm.

[0089] III. Effect verification

[0090] Accuracy index: The deviation of the tip blunt radius is ±4%, meeting the precision machining requirements of a Φ0.3mm micro-drill.

[0091] Processing stability: In the machining of aluminum alloy micro-holes, the hole diameter accuracy reaches ±5μm, a 50% improvement compared to the traditional electrolysis method.

[0092] In summary, through process innovation and device coordination, the present invention constructs a full-process high-precision control system of "material removal - profile forming - surface refinement", significantly improving the tool passivation quality and efficiency, and providing key technical support for high-end equipment manufacturing.

[0093] At the same time, the content not described in detail in this specification belongs to the well-known prior art in the art, and the model parameters of each electrical appliance are not specifically limited, and conventional equipment can be used.

[0094] It should be noted that in this text, relational terms such as first and second are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the term "comprising", "including" or any other variant thereof is intended to cover non-exclusive inclusion, such that a process, method, article or device comprising a series of elements not only includes those elements but also includes other elements not expressly listed, or further includes elements inherent to such process, method, article or device.

[0095] Although the embodiments of the present invention have been shown and described, those of ordinary skill in the art can understand that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A tool high-consistency passivation process based on flexible abrasive-assisted magnetorheological finishing, characterized in that, It includes the following steps: Step 1, gradient abrasive preparation: Compound a shear thickening polishing liquid by mixing a polyhydroxy polymer base liquid accounting for 40 - 60 wt% with a three - stage graded abrasive accounting for 2 - 20 wt%. Among them, the abrasive particles with a size of 0.5 - 1 μm account for 10% - 20%, the abrasive particles with a size of 1 - 3 μm account for 50% - 60%, and the abrasive particles with a size of 3 - 5 μm account for 20% - 30%. And add 0.1 - 0.5 wt% of polyoxyethylene ether dispersant; Step 2. Programmable fiber flow control: Apply vibrations with a frequency of 5 - 100 Hz to a flexible fiber array with a diameter of 50 - 200 μm and a density of 200 - 250 fibers / cm 2 to break the agglomerated state of the polishing liquid and increase the fluid flow rate in the complex edge region by 30% - 50%; Step 3, multi - stage gradient processing: Carry out rough passivation, fine passivation, and ultra - fine polishing processing in sequence. The material removal rate in the rough passivation stage is 5 - 8 μm / min, the removal rate in the fine passivation stage is 2 - 5 μm / min, and the removal rate in the ultra - fine polishing stage is ≤2 μm / min. Coordinate and control the edge profile by controlling the spindle speed at 30 - 120 rpm and adjusting the fiber vibration parameters; Step 4, intelligent closed - loop control: Use a laser confocal sensor and an acoustic emission sensor for real - time monitoring. When the fluctuation of the blunt radius is <±1 μm and the surface roughness Ra ≤ 10 nm, the processing is automatically terminated.

2. The high-consistency passivation process for cutting tools based on flexible abrasive-assisted magnetorheological polishing according to claim 1, wherein: The particle size of the polyhydroxy polymer base liquid is 5 - 20 μm, and the concentration is dynamically adjusted by a screw pump to achieve continuously adjustable low - shear viscosity of 20 - 50 Pa·s and high - shear viscosity of 150 - 250 Pa·s.

3. The high-consistency passivation process for tools based on flexible abrasive-assisted magnetorheological finishing according to claim 1, characterized in that: The programmable fiber array is made of nylon or carbon fiber, and the arrangement angle is optimized by the discrete element method. The vibration frequency in the rough grinding stage is 50 - 80 Hz, and in the fine grinding stage is 10 - 30 Hz.

4. The high-consistency passivation process for cutting tools based on flexible abrasive-assisted magnetorheological finishing according to claim 1, wherein: The three - stage graded abrasive includes diamond, boron carbide or cubic boron nitride. Among them, when passivating a PCD tool, cubic boron nitride abrasive particles with a size of 500 nm - 1 μm are used, and the concentration is 8 - 12 wt%.

5. The high-consistency passivation process for cutting tools based on flexible abrasive-assisted magnetorheological polishing according to claim 1, characterized in that: In the multi - stage gradient processing, the shear rate in the rough passivation stage is controlled at 150 - 200 s⁻¹, in the fine passivation stage is 50 - 100 s⁻¹, and in the ultra - fine polishing stage is 20 - 50 s⁻¹.

6. The high-consistency passivation process and device for cutting tools based on flexible abrasive-assisted magnetorheological finishing according to claim 1, characterized in that: In the step of gradient abrasive preparation, a shear emulsifier is used to achieve nano - level dispersion of the abrasive particles. The shear emulsifier is equipped with a speed regulating device and a temperature monitoring device, and the speed can be adjusted as needed and the temperature change during the emulsification process can be monitored.

7. The high-consistency passivation process for cutting tools based on flexible abrasive-assisted magnetorheological finishing according to claim 1, characterized in that: In the step of intelligent closed - loop control, the intelligent monitoring module also includes a temperature sensor and a pressure sensor, which are respectively used to monitor the temperature of the polishing liquid and the pressure in the processing area. The monitoring data is transmitted to the control system in real time and the relevant parameters are automatically adjusted after comparing with the preset parameter range.

8. The high-consistency passivation process for tools based on flexible abrasive-assisted magnetorheological finishing according to claim 1, characterized in that: During the processing, the temperature of the polishing liquid in the contact area between the fiber array and the polishing liquid is maintained at 20 - 50 °C through a temperature control system. This temperature control system uses a combination of a semiconductor refrigeration sheet and a heating wire, and is equipped with an overheat protection device.

9. A tool high-consistency passivation device based on flexible abrasive-assisted magnetorheological finishing, and a tool high-consistency passivation process based on flexible abrasive-assisted magnetorheological finishing according to any one of claims 1-8, characterized in that It includes: Gradient abrasive preparation module: It includes a base liquid storage tank, a three-stage abrasive grading unit, a dynamic proportioning system, and an ultrasonic dispersion unit. The base liquid storage tank is equipped with a liquid level sensor, which is connected to the control system and issues an alarm when the liquid level is lower than the set value. The three-stage abrasive grading unit uses a multi-layer vibrating screen, and the aperture of each layer of screen corresponds to abrasive grains of different particle sizes, and efficient grading is achieved by adjusting the vibration frequency and amplitude. The dynamic proportioning system uses a high-precision mass flowmeter and a proportional regulating valve. The ultrasonic dispersion unit uses multiple ultrasonic transducers evenly distributed in the base liquid storage tank and is equipped with a power regulating device; Programmable fiber flow control device: The fiber array is equipped with a micro vibration motor, and the angle adjustment bracket composed of an electric push rod and a rotary joint is adapted to different cutting edge geometric features. The micro vibration motor is electromagnetically driven and is equipped with an independent drive circuit; Multi-degree-of-freedom processing platform: The magnetic levitation spindle uses five-degree-of-freedom magnetic levitation technology, and the six-axis linkage fixture uses a modular design. Each axis is driven by a high-precision servo motor, and position feedback is carried out through a grating ruler; Intelligent monitoring module: It integrates a laser confocal sensor, an acoustic emission sensor, a temperature sensor, and a pressure sensor, and uses an adaptive PID control strategy to automatically adjust the components of the polishing liquid and the fiber vibration parameters, and has data storage and analysis functions; Polishing liquid circulation module: It includes a circulation pump, a multi-stage filter, and a plate heat exchanger, and the heat exchanger can control the temperature of the polishing liquid at 20 - 50 °C; Protection module: It is set around the processing area and includes an electric sliding protection door, a high-strength metal protection fence, and an infrared induction safety light curtain.

10. The high-consistency passivation device for cutting tools based on flexible abrasive-assisted magnetorheological finishing according to claim 9, wherein: The control system of the device uses an industrial-grade PLC, which has data processing, logical operation, and control functions. It can adjust the operating parameters of each module in real time according to the data of the intelligent monitoring module to ensure the stability and consistency of the process, and at the same time supports remote monitoring and operation.

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