<p>Tool edge preparation can eliminate edge defects and customize edge geometry to improve cutting performance, which has become essential in the manufacturing of high performance tools. Developing a novel edge preparation process is particularly urgent as the quality and controllability of edge preparation become increasingly demanding. This study presents a process for preparing carbide tool edges using magnetorheological fluids containing abrasives. An equivalent multiphase flow simulation of the preparation process is developed to investigate the interaction between the abrasive and the tool edge, and the mechanism and critical conditions for material removal are elucidated. Response surface methodology was employed to investigate the effects of the process parameters on the edge material removal amount and surface quality. The results show that magnetorheological preparation is a reliable edge treatment method that significantly improves the edge surface quality, achieving a surface roughness of 0.15&#xa0;μm and an increase in the edge radius of approximately 1.48&#xa0;μm/min in the optimization experiment. Normal force-assisted shear scraping of the abrasive particles is the dominant mechanism for edge material removal, and an appropriate abrasive particle area ratio ensures edge material shear failure. Adjusting the process parameters can change the material removal amount and surface roughness. This study contributes to a deep understanding of the magnetorheological preparation mechanism of cemented carbide tool edges and will provides an invaluable reference for determing process preference and achieving controlled tool edge preparation.</p>