• • IWP-1 flexible tools at 2 mm compression and 60 A Shore hardness achieve Ra = 0.033 μm, a 56% improvement over IWP-2's best Ra = 0.075 μm, enabling precision polishing of BK7 glass without surface damage.
• • IWP-2 tools at 2 mm compression and 35 A hardness deliver a material removal rate ηMRR = 0.0558 mm³/min, balancing pre-polishing throughput with acceptable surface finish (Ra = 0.075 μm) for industrial scaling.
• • Coupling Hertzian contact theory, Preston equation, and effective abrasive count yields a corrected removal function that quantitatively links tool topology to removal footprint, reducing trial-and-error in tool design by providing a predictive model.
• • CFD-DPM/DEM simulations confirm that IWP internal channels and surface depressions increase slurry circulation and abrasive accessibility in the contact zone, mitigating abrasive starvation and improving polishing uniformity.