Edge passivation of triangular turning inserts using silicone rubber magnetoelastic abrasives: Simulation and experiment

• A double-disk magnetic blunting method using silicone-based magnetoelastic abrasives is proposed for precision turning tools. • EDEM simulations reveal that disk spacing, tool rotation direction, and speed significantly influence abrasive behavior and edge wear. • Optimal parameters (22 mm spacing, 2500 rpm, alternating rotation) were identified and experimentally validated. • Post-blunting edge profiles show improved smoothness, consistency, and reduced surface defects. • The method provides a controllable and efficient solution for high-quality tool edge preparation. Precision edge preparation is crucial for enhancing the performance and longevity of high-precision cutting tools, yet achieving uniform blunting for complex tool geometries remains challenging with conventional methods. This study addresses the edge passivation of tungsten carbide triangular precision turning inserts (TNGG160404L-F) and proposes a double-disk magnetic passivation method based on silicone rubber magnetoelastic abrasive particles. A passivation process model was established using EDEM discrete element simulation to systematically investigate the influence of tool rotation direction, rotational speed, and disk spacing on abrasive particle behavior, edge collision force, cumulative energy, and wear volume. Simulation results indicate that reducing disk spacing significantly increases material removal rate. The wear volume at 20 mm spacing is 3.58 times greater than that at 26 mm. Both collision force and wear volume peak at a tool rotational speed of 2500 rpm. Adopting an alternating forward and reverse rotation strategy effectively improves edge passivation uniformity. Based on simulation optimization, the optimal parameter combination—alternating forward/reverse rotation, 22 mm disk spacing, and 2500 rpm rotational speed—was selected for experimental verification. Experimental results show that after passivation, the edge profile transitions from irregular to smooth, with front and rear face passivation amounts reaching consistent values of 1.5–2.0 µm. The edge contour becomes smoother and flatter, surface consistency increases, and defects such as burrs and scratches are significantly reduced. These findings confirm effective edge quality control, providing theoretical and experimental support for optimizing magnetic passivation processes for high-precision cutting tools.