In this study, a flexible grind-polishing tool was innovatively fabricated, and a two-dimensional (2D) vibration-assisted machining device was developed. Based on these, a 2D vibration-assisted grind-polishing composite machining method was proposed, which significantly improved the surface quality and processing efficiency in the precision machining of GH4169 nickel-based superalloy. The macroscopic stress-deformation relationship of the self-made grind-polishing wheel was investigated through static compression testing, and the forces on asperities were analyzed at the microscale. Further, the material removal mechanisms of embedded/free dual abrasive grains were explored at the sub-microscale, ultimately leading to the development of a multiscale material removal model. Subsequently, a series of polishing experiments was conducted to validate the effectiveness of the proposed model, which revealed that, at the same frequency, both material removal rate (MRR) and surface roughness gradually decreased with increasing phase. As the vibration frequency increases, the MRR significantly increases and the surface roughness significantly decreases. Ultrasonic vibration offers certain advantages that are typically not achievable with low-frequency excitation. The transitional boundary region becomes increasingly flat with increasing vibration frequency. Based on the experimental results, an innovative characterization coefficient for MRR was proposed. This study provides a theoretical model and experimental basis for the removal mechanism of vibration-assisted polishing and extends the simplified characterization coefficient of the MRR.
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