High-consistency passivation process and apparatus for cutting tools based on flexible abrasive-assisted force-rheology polishing

Abstract

This invention discloses a high-consistency passivation process and apparatus for cutting tools based on flexible abrasive-assisted force-rheological polishing, which relates to the field of cutting tool passivation technology. The process includes the following steps: Step 1, gradient abrasive preparation; Step 2, programmable fiber flow control; Step 3, multi-stage gradient machining; and Step 4, intelligent closed-loop control. The apparatus includes a gradient abrasive preparation module, a programmable fiber flow control device, a multi-degree-of-freedom machining platform, an intelligent monitoring module, a polishing slurry circulation module, and a protection module. Through three-stage abrasive gradation and programmable fiber flow control technology, without relying on magnetic particles or an external magnetic field, the agglomeration of the polishing slurry is directly disrupted by fiber vibration, increasing the fluid velocity in complex cutting edge areas and improving the uniformity of abrasive distribution. Combined with real-time laser confocal monitoring and dynamic adjustment using a PID algorithm, the accuracy is significantly improved, making it particularly suitable for the precision passivation of superhard cutting tools such as PCD tools.

Description

Technical Field

[0001] This invention relates to the field of tool passivation technology, specifically to a tool passivation process and apparatus based on flexible abrasive-assisted force rheological polishing for high uniformity. Background Technology

[0002] With the continuous development of high technology, the application of micro-parts with complex structures in national defense and civilian fields is becoming increasingly widespread. High-quality micro-tools are crucial for achieving precision micro-machining of these parts. After grinding, the cutting edge of a micro-tool inevitably has microscopic defects such as notches and cracks. Simultaneously, the tool surface, including chip grooves and the flank face, may exhibit micro-pits, micro-cracks, grinding debris adhesion, and micro-burrs. During cutting, sharp and defective cutting edges easily lead to tool failures such as chipping and tooth breakage. Poor tool surface quality exacerbates friction and compression between the tool, chips, and workpiece, causing tool damage and accelerated wear. Tool passivation treatment can alter the cutting edge profile and morphology, eliminate cutting edge defects, and improve tool surface quality, thereby improving cutting performance, extending tool life, and enhancing workpiece machining quality. Furthermore, tool passivation treatment can eliminate residual stress on the cutting edge after grinding, enhance the bonding strength between the coating material and the tool surface in coated tools, and prevent coating peeling.

[0003] The invention disclosed in CN114131431A presents a method and apparatus for passivating micro-tools based on flexible abrasive particles and magnetic composite fluid. It uses the polishing principle of magnetic composite fluid to treat the cutting edge of the micro-tool, and utilizes the rheological properties of the magnetic composite fluid and flexible abrasive particles to remove a small amount of material from the tool surface. It can simultaneously achieve tool edge passivation and tool surface polishing, with high passivation accuracy and good consistency. The multi-fixture design enables batch passivation of micro-tools, and the tool passivation and disassembly operations can be carried out simultaneously, improving the tool passivation efficiency.

[0004] As described above, existing devices prepare flexible abrasives by embedding nano-sized diamond abrasives and iron oxide particles onto an organic polymer elastic matrix. This process involves multi-material composites and microstructure control, making it complex and costly. Furthermore, although magnetic particles improve abrasive dispersion, in complex cutting edge regions, the flexible abrasives may still aggregate or settle due to uneven magnetic field distribution, causing localized abrasive concentration differences and affecting passivation uniformity. Moreover, existing devices rely on an external magnetic field to form a chain-like structure between hydroxyl iron powder and iron oxide, requiring two sets of electromagnets, magnetic poles, and excitation power supplies, resulting in bulky equipment and high energy consumption. Simultaneously, precise control of the magnetic field direction and intensity is crucial for passivation effectiveness; uneven magnetic field distribution can lead to unstable viscosity of the passivation solution, resulting in inconsistent material removal rates at the cutting edge. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a high-consistency passivation process and apparatus for cutting tools based on flexible abrasive-assisted force rheological polishing, thus solving the existing problems.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a tool passivation process based on flexible abrasive-assisted force-rheological polishing, comprising the following steps:

[0007] Step 1: Gradient abrasive preparation: Combine 40-60 wt% of a polyhydroxy polymer base liquid with 2-20 wt% of a three-graded abrasive particles to form a shear-thickening polishing fluid, wherein 0.5-1 μm abrasive particles account for 10%-20%, 1-3 μm abrasive particles account for 50%-60%, 3-5 μm abrasive particles account for 20%-30%, and 0.1-0.5 wt% of polyoxyethylene ether dispersant is added;

[0008] Step 2, Programmable Fiber Flow Control: Utilizing fibers with a diameter of 50-200 μm and a density of 200-250 fibers / cm² 2 The flexible fiber array is subjected to vibrations of 5-100Hz, which disrupts the agglomeration of the polishing fluid and increases the fluid flow rate in the complex cutting edge area by 30%-50%.

[0009] Step 3, Multi-stage gradient processing: Rough passivation, fine passivation, and ultra-fine polishing are carried out in sequence. The material removal rate in the rough passivation stage is 5-8μm / min, the removal rate in the fine passivation stage is 2-5μm / min, and the removal rate in the ultra-fine polishing stage is ≤2μm / min. The cutting edge profile is controlled by adjusting the spindle speed at 30-120rpm and adjusting the fiber vibration parameters.

[0010] Step 4, Intelligent Closed-Loop Control: Real-time monitoring is conducted using a laser confocal sensor (resolution 0.1μm) and an acoustic emission sensor (threshold 150-200mV). The processing is automatically terminated when the radius of the blunt circle fluctuates by <±1μm and the surface roughness Ra≤10nm.

[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 adjustability of low shear viscosity (20-50 Pa·s) and high shear viscosity (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 unit method (angle with the blade edge normal is 30°-60°). The vibration frequency is 50-80Hz in the rough grinding stage and 10-30Hz in the fine grinding stage.

[0013] Preferably, the three-graded abrasive grains include diamond, boron carbide, or cubic boron nitride, wherein 500nm-1μm cubic boron nitride abrasive grains with a concentration of 8-12wt% are used for PCD tool passivation.

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

[0015] Preferably, in the gradient abrasive preparation step, a shear emulsifier is used to achieve nanoscale dispersion of abrasive particles. The shear emulsifier is equipped with a speed adjustment device and a temperature monitoring device, which can adjust the speed as needed and monitor the temperature changes 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 used to monitor the temperature of the polishing fluid and the pressure of the processing area, respectively. The temperature sensor has a measurement accuracy of ±0.5℃, and the pressure sensor has a measurement range of 0-10MPa with an accuracy of ±0.1%. The monitoring data is transmitted to the control system in real time, and the relevant parameters are automatically adjusted after being compared with the preset parameter range.

[0017] Preferably, 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 by a temperature control system. This temperature control system adopts a combination of semiconductor cooling chip and heating wire and is equipped with an overheat protection device.

[0018] This invention also discloses a tool passivation device with high uniformity based on flexible abrasive-assisted force rheological polishing, comprising:

[0019] Gradient abrasive preparation module: This includes a base liquid storage tank, a three-stage abrasive classification unit, a dynamic proportioning system, and an ultrasonic dispersion unit. The base liquid storage tank is equipped with a level sensor connected to the control system, which issues an alarm when the level is below a set value. The three-stage abrasive classification unit uses a multi-layer vibrating screen, with each layer's mesh size corresponding to different abrasive particle sizes. Efficient classification is achieved by adjusting the vibration frequency and amplitude. The dynamic proportioning system uses a high-precision mass flow meter and a proportional control valve. The ultrasonic dispersion unit uses multiple ultrasonic transducers evenly distributed within the base liquid storage tank and is equipped with a power adjustment device.

[0020] Programmable fiber flow control device: The fiber array is equipped with a micro vibration motor, and the angle adjustment bracket, which is a combination of electric push rod and rotary joint, is adapted to different cutting edge geometry. The micro vibration motor is electromagnetically driven and equipped with an independent drive circuit.

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

[0022] Intelligent monitoring module: integrates laser confocal sensor, acoustic emission sensor, temperature sensor and pressure sensor, adopts adaptive PID control strategy to realize automatic adjustment of polishing fluid composition and fiber vibration parameters, and has data storage and analysis functions;

[0023] Polishing fluid circulation module: includes a circulation pump, multi-stage filter and plate heat exchanger, the heat exchanger can control the polishing fluid temperature at 20-50℃;

[0024] Protective modules: These are installed around the processing area and include electric sliding protective doors, high-strength metal protective railings, and infrared sensor safety light curtains.

[0025] Preferably, the control system of the device adopts an industrial-grade PLC, which has data processing, logic 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 also supports remote monitoring and operation.

[0026] Beneficial effects

[0027] This invention provides a high-consistency passivation process and apparatus for cutting tools based on flexible abrasive-assisted force rheological polishing. Compared with the prior art, it has the following advantages:

[0028] 1. This tool high-consistency passivation process and device based on flexible abrasive-assisted force rheological polishing utilizes three-stage abrasive gradation and programmable fiber flow control technology. It eliminates the need for magnetic particles and external magnetic fields, directly breaking the agglomeration of polishing fluid through fiber vibration. This increases the fluid flow rate in complex cutting edge areas by 42% and improves the uniformity of abrasive distribution. Combined with real-time laser confocal monitoring and dynamic adjustment using PID algorithm, it achieves a passivation radius consistency deviation of ≤±5% and a surface roughness Ra≤10nm, resulting in a significant improvement in precision. It is particularly suitable for the precision passivation of superhard tools such as PCD.

[0029] 2. This tool passivation process and device based on flexible abrasive-assisted force rheological polishing uses a magnetically levitated spindle and a six-axis linkage fixture to support multi-degree-of-freedom movement of the tool. Combined with a polishing fluid circulation module, it can achieve gradient processing of rough grinding, fine grinding and ultra-fine polishing. The processing time of a single piece is reduced by more than 50% compared with existing patents. At the same time, the multi-fixture design and intelligent measurement and control system support batch processing and do not require additional magnetic field equipment. The equipment cost is reduced, energy consumption is reduced, and industrial production efficiency and economy are significantly improved. Attached Figure Description

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

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

[0032] Figure 3 This is a schematic diagram of the polishing fluid circulation module of the present invention. Detailed Implementation

[0033] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0034] See also Figure 1-3 The present invention provides the following three technical solutions:

[0035] The first implementation method: a tool passivation process based on flexible abrasive-assisted force rheological polishing, including the following steps:

[0036] Step 1: Gradient Abrasive Formulation: A shear-thickening polishing slurry is prepared by compounding a 40-60 wt% polyhydroxy polymer base liquid with a 2-20 wt% tertiary graded abrasive particles. The tertiary graded abrasive particles include diamond, boron carbide, or cubic boron nitride. For PCD tool passivation, 500 nm-1 μm cubic boron nitride abrasive particles at a concentration of 8-12 wt% are used. A shear emulsifier is employed to achieve nanoscale dispersion of the abrasive particles. This shear emulsifier is equipped with a speed adjustment device and a temperature monitoring device, allowing for on-demand adjustment. The rotation speed is adjusted and the temperature change during the emulsification process is monitored. The proportion of 0.5-1μm abrasive particles is 10%-20%, 1-3μm abrasive particles are 50%-60%, and 3-5μm abrasive particles are 20%-30%. 0.1-0.5wt% polyoxyethylene ether dispersant is added. The particle size of the polyhydroxy polymer base liquid is 5-20μm. 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: Utilizing fibers with a diameter of 50-200 μm and a density of 200-250 fibers / cm² 2 The flexible fiber array is subjected to vibration of 5-100Hz to break the agglomeration of the polishing fluid and increase the fluid flow rate in the complex cutting 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 unit method. The vibration frequency is 50-80Hz in the rough grinding stage and 10-30Hz in the fine grinding stage.

[0038] Step 3, Multi-stage gradient processing: Roughing, fine passivation, and ultra-fine polishing are carried out sequentially. The material removal rate is 5-8 μm / min in the roughing stage, 2-5 μm / min in the fine passivation stage, and ≤2 μm / min in the ultra-fine polishing stage. The cutting edge profile is controlled by adjusting the spindle speed at 30-120 rpm and adjusting the fiber vibration parameters. The shearing rate is controlled at 150-200 s⁻¹ in the roughing stage, 50-100 s⁻¹ in the fine passivation stage, and 20-50 s⁻¹ in the ultra-fine polishing stage.

[0039] Step 4, Intelligent Closed-Loop Control: Real-time monitoring is achieved using a laser confocal sensor (resolution 0.1μm) and an acoustic emission sensor (threshold 150-200mV). Processing is automatically terminated when the radius of the blunt circle fluctuates by less than ±1μm and the surface roughness Ra ≤ 10nm. The intelligent monitoring module also includes a temperature sensor and a pressure sensor, which are used to monitor the temperature of the polishing fluid and the pressure of the processing area, respectively. The monitoring data is transmitted to the control system in real time, and the relevant parameters are automatically adjusted after being compared with the preset parameter range.

[0040] In an embodiment of the present invention, the processing process maintains the temperature of the polishing slurry in the contact area between the fiber array and the polishing slurry at 20-50°C through a temperature control system. The temperature control system adopts a combination of semiconductor cooling chip and heating wire and is equipped with an overheat protection device.

[0041] The second implementation method: a tool passivation device based on flexible abrasive-assisted force rheological polishing, comprising:

[0042] The gradient abrasive preparation module includes a base liquid storage tank, a three-stage abrasive classification unit, a dynamic proportioning system, and an ultrasonic dispersion unit. The base liquid storage tank is equipped with a level sensor connected to the control system, which issues an alarm when the level is below the set value. The three-stage abrasive classification unit uses a multi-layer vibrating screen, with each layer of screen mesh corresponding to abrasive particles of different sizes. Efficient classification is achieved by adjusting the vibration frequency and amplitude. The dynamic proportioning system uses a high-precision mass flow meter and a proportional control valve. The ultrasonic dispersion unit uses multiple ultrasonic transducers evenly distributed within the base liquid storage tank and is equipped with a power adjustment device.

[0043] Programmable fiber flow control device: The fiber array is equipped with a micro vibration motor, and the angle adjustment bracket, which is a combination of electric push rod and rotary joint, is adapted to different cutting edge geometry. The micro vibration motor is electromagnetically driven and 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, the six-axis linkage fixture adopts a modular design, each axis is driven by a high-precision servo motor, and the position feedback is achieved through a grating ruler.

[0045] Intelligent monitoring module: It integrates 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 composition and fiber vibration parameters, and has data storage and analysis functions.

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

[0047] Protective modules: These are installed around the processing area and include electric sliding protective doors, high-strength metal protective railings, and infrared sensor safety light curtains.

[0048] In an embodiment of the present invention, the control system of the device adopts an industrial-grade PLC, which has data processing, logic 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 supports remote monitoring and operation.

[0049] Third implementation method: Example

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

[0051] I. Process Parameters

[0052] Polishing slurry formula:

[0053] The mixture consists of 50 wt% polyhydroxy polymer base liquid (particle size 10 μm) + 3-5 μm diamond abrasive particles (25%) + 1-3 μm diamond abrasive particles (55%) + 0.5-1 μm diamond abrasive particles (20%) + 0.3 wt% polyoxyethylene ether, with a viscosity of 180 Pa·s at γ = 100 s⁻¹.

[0054] Fiber flow control parameters:

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

[0056] Machining platform parameters:

[0057] Magnetic levitation spindle speed: 100rpm for rough grinding, 60rpm for fine grinding, and 40rpm for ultra-fine polishing; Six-axis fixture tilt angle: 45° for rough grinding and 30° for fine grinding.

[0058] II. Processing procedure

[0059] Gradient abrasive formulation:

[0060] The abrasive particles are graded by a three-stage vibrating screen, the base liquid concentration is precisely controlled by a screw pump, and ultrasonic dispersion for 3 minutes ensures uniform distribution of the abrasive particles.

[0061] Flow field initialization:

[0062] The fiber array vibrates at 60Hz for 30s, breaking up the agglomeration of the polishing fluid and increasing the fluid velocity in the tooth root region to 0.8m / s (0.56m / s in the traditional process).

[0063] Multi-stage processing:

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

[0065] Fine grinding (15-35 min): Adjust the spindle tilt angle to 30°, increase the blunt radius from 30 μm to 50 ± 2 μm, and improve the contour accuracy by 40%;

[0066] Ultra-fine polishing (35-50 min): 0.5 μm abrasive particles are used, and the fiber vibrates at low frequency. The final 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 Ra = 8.2nm and the blunt radius fluctuation is < ±1μm for three consecutive measurements, the system automatically stops processing.

[0069] III. Effect Verification

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

[0071] Efficiency indicators: Single-piece processing time is 50 minutes, which is 60% shorter than traditional force rheological polishing.

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

[0073] Example 2: Precision passivation of PCD micro drill bits

[0074] I. Process Parameters

[0075] Polishing slurry formula:

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

[0077] Fiber flow control parameters:

[0078] Ultrafine nylon fibers (50μm in diameter, 250 fibers / cm) 2 The vibration frequency is 15Hz, the amplitude is 0.3mm, and the angle with the drill bit tip is 30°.

[0079] Machining platform parameters:

[0080] The magnetic levitation spindle speed is 50 rpm, the six-axis fixture is fixed at a tilt angle of 30°, and spindle rotation is disabled (micro-drill tip orientation machining).

[0081] II. Processing procedure

[0082] Gradient abrasive formulation:

[0083] The nanoscale vibrating screen is used to classify 500nm cubic boron nitride abrasive particles, and the low viscosity base fluid ensures fluid penetration in the micro-drill tip area.

[0084] Flow field initialization:

[0085] The fiber vibrates at a low frequency for 10 seconds to avoid overload impact on the micro-drill tip caused by high frequency vibration, and the fluid flow rate at the tip is increased by 35%.

[0086] Multi-stage processing:

[0087] Coarse grinding (0-20 min): Removes micro-chipping on the cutting edge, material removal rate is 3 μm / min, and Ra decreases from 120 nm to 40 nm;

[0088] Fine grinding (20-50 min): The tip profile is gradually trimmed by fine adjustment of fiber vibration and spindle tilt angle, and the final blunt radius is 25±1μm, Ra=9.5nm.

[0089] III. Effect Verification

[0090] Accuracy specifications: The deviation of the tip blunt radius is ±4%, which meets the precision machining requirements of Φ0.3mm micro drills.

[0091] Processing stability: In the micro-hole processing of aluminum alloys, the hole diameter accuracy reaches ±5μm, which is 50% higher than that of the traditional electrolytic method.

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

[0093] Furthermore, all content not described in detail in this specification is existing technology known to those skilled in the art, and the model parameters of each electrical appliance are not specifically limited; conventional equipment can be used.

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

[0095] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A tool passivation process with high uniformity based on flexible abrasive-assisted force rheological polishing, characterized in that, Includes the following steps: Step 1: Gradient abrasive preparation: Combine 40-60 wt% of a polyhydroxy polymer base liquid with 2-20 wt% of a three-graded abrasive particles to form a shear-thickening polishing fluid, wherein 0.5-1 μm abrasive particles account for 10%-20%, 1-3 μm abrasive particles account for 50%-60%, 3-5 μm abrasive particles account for 20%-30%, and 0.1-0.5 wt% of polyoxyethylene ether dispersant is added; Step 2, Programmable Fiber Flow Control: Utilizing fibers with a diameter of 50-200 μm and a density of 200-250 fibers / cm² 2 The flexible fiber array is subjected to vibrations of 5-100Hz, which disrupts the agglomeration of the polishing fluid and increases the fluid flow rate in the complex cutting edge area by 30%-50%. Step 3, Multi-stage gradient processing: Rough passivation, fine passivation, and ultra-fine polishing are carried out in sequence. The material removal rate in the rough passivation stage is 5-8μm / min, the removal rate in the fine passivation stage is 2-5μm / min, and the removal rate in the ultra-fine polishing stage is ≤2μm / min. The cutting edge profile is controlled by adjusting the spindle speed at 30-120rpm and adjusting the fiber vibration parameters. Step 4, Intelligent Closed-Loop Control: Using a laser confocal sensor and an acoustic emission sensor for real-time monitoring, the processing is automatically terminated when the radius of the blunt circle fluctuates by less than ±1μm and the surface roughness Ra is less than 10nm.

2. The tool high-consistency passivation process based on flexible abrasive-assisted force rheological polishing according to claim 1, characterized in that: 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 adjustability of low shear viscosity (20-50 Pa·s) and high shear viscosity (150-250 Pa·s).

3. The tool high-consistency passivation process based on flexible abrasive-assisted force rheological polishing 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 unit method. The vibration frequency is 50-80Hz in the rough grinding stage and 10-30Hz in the fine grinding stage.

4. The tool high-consistency passivation process based on flexible abrasive-assisted force rheological polishing according to claim 1, characterized in that: The three-graded abrasive grains include diamond, boron carbide, or cubic boron nitride, wherein 500nm-1μm cubic boron nitride abrasive grains with a concentration of 8-12wt% are used for PCD tool passivation.

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

6. The tool high-consistency passivation process and apparatus based on flexible abrasive-assisted force rheological polishing according to claim 1, characterized in that: In the gradient abrasive preparation step, a shear emulsifier is used to achieve nanoscale dispersion of abrasive particles. The shear emulsifier is equipped with a speed adjustment device and a temperature monitoring device, which can adjust the speed as needed and monitor the temperature changes during the emulsification process.

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

8. The tool high-consistency passivation process based on flexible abrasive-assisted force rheological polishing 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 by a temperature control system. The temperature control system adopts a combination of semiconductor cooling chip and heating wire and is equipped with an overheat protection device.

9. A tool high-consistency passivation device based on flexible abrasive-assisted force-rheological polishing, based on the tool high-consistency passivation process based on flexible abrasive-assisted force-rheological polishing as described in any one of claims 1-8, characterized in that, include: Gradient abrasive preparation module: This includes a base liquid storage tank, a three-stage abrasive classification unit, a dynamic proportioning system, and an ultrasonic dispersion unit. The base liquid storage tank is equipped with a level sensor connected to the control system, which issues an alarm when the level is below a set value. The three-stage abrasive classification unit uses a multi-layer vibrating screen, with each layer's mesh size corresponding to different abrasive particle sizes. Efficient classification is achieved by adjusting the vibration frequency and amplitude. The dynamic proportioning system uses a high-precision mass flow meter and a proportional control valve. The ultrasonic dispersion unit uses multiple ultrasonic transducers evenly distributed within the base liquid storage tank and is equipped with a power adjustment device. Programmable fiber flow control device: The fiber array is equipped with a micro vibration motor, and the angle adjustment bracket, which is a combination of electric push rod and rotary joint, is adapted to different cutting edge geometry. The micro vibration motor is electromagnetically driven and equipped with an independent drive circuit. Multi-degree-of-freedom machining platform: The magnetic levitation spindle adopts five-degree-of-freedom magnetic levitation technology, the six-axis linkage fixture adopts a modular design, each axis is driven by a high-precision servo motor, and position feedback is provided by a grating ruler; Intelligent monitoring module: integrates laser confocal sensor, acoustic emission sensor, temperature sensor and pressure sensor, adopts adaptive PID control strategy to realize automatic adjustment of polishing fluid composition and fiber vibration parameters, and has data storage and analysis functions; Polishing fluid circulation module: includes a circulation pump, multi-stage filter and plate heat exchanger, the heat exchanger can control the polishing fluid temperature at 20-50℃; Protective modules: These are installed around the processing area and include electric sliding protective doors, high-strength metal protective railings, and infrared sensor safety light curtains.

10. The tool high-consistency passivation device based on flexible abrasive-assisted force rheological polishing according to claim 9, characterized in that: The control system of the device adopts an industrial-grade PLC, which has data processing, logic 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 also supports remote monitoring and operation.

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