EP3999280A1 - Abrasive articles having internal coolant features and methods of manufacturing the same - Google Patents
Abrasive articles having internal coolant features and methods of manufacturing the sameInfo
- Publication number
- EP3999280A1 EP3999280A1 EP20743355.8A EP20743355A EP3999280A1 EP 3999280 A1 EP3999280 A1 EP 3999280A1 EP 20743355 A EP20743355 A EP 20743355A EP 3999280 A1 EP3999280 A1 EP 3999280A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- abrasive article
- bonded abrasive
- feature
- fluid
- coolant
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 239000002826 coolant Substances 0.000 title claims description 107
- 238000000034 method Methods 0.000 title claims description 83
- 238000004519 manufacturing process Methods 0.000 title claims description 27
- 238000000227 grinding Methods 0.000 claims abstract description 152
- 239000012530 fluid Substances 0.000 claims abstract description 96
- 239000002245 particle Substances 0.000 claims abstract description 91
- 239000011230 binding agent Substances 0.000 claims abstract description 68
- 230000008859 change Effects 0.000 claims abstract description 8
- 230000000717 retained effect Effects 0.000 claims abstract description 4
- 230000001133 acceleration Effects 0.000 claims description 65
- 239000000463 material Substances 0.000 claims description 56
- 229910052751 metal Inorganic materials 0.000 claims description 19
- 239000002184 metal Substances 0.000 claims description 19
- 239000000654 additive Substances 0.000 claims description 18
- 229920005989 resin Polymers 0.000 claims description 16
- 239000011347 resin Substances 0.000 claims description 16
- 230000000996 additive effect Effects 0.000 claims description 14
- 239000000919 ceramic Substances 0.000 claims description 14
- 229920000642 polymer Polymers 0.000 claims description 11
- 238000010438 heat treatment Methods 0.000 claims description 7
- 239000000314 lubricant Substances 0.000 claims description 6
- 239000000843 powder Substances 0.000 description 57
- 239000010410 layer Substances 0.000 description 56
- 239000002243 precursor Substances 0.000 description 35
- 239000007788 liquid Substances 0.000 description 34
- 239000000203 mixture Substances 0.000 description 32
- 238000013461 design Methods 0.000 description 25
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 20
- 230000008569 process Effects 0.000 description 20
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 19
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 16
- 239000011521 glass Substances 0.000 description 16
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 15
- 239000003981 vehicle Substances 0.000 description 13
- 238000007639 printing Methods 0.000 description 10
- 238000005245 sintering Methods 0.000 description 10
- 238000001816 cooling Methods 0.000 description 9
- 239000000377 silicon dioxide Substances 0.000 description 9
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 8
- 238000001035 drying Methods 0.000 description 8
- 238000004088 simulation Methods 0.000 description 8
- ODINCKMPIJJUCX-UHFFFAOYSA-N Calcium oxide Chemical compound [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 7
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 7
- 239000011148 porous material Substances 0.000 description 7
- PEDCQBHIVMGVHV-UHFFFAOYSA-N Glycerine Chemical compound OCC(O)CO PEDCQBHIVMGVHV-UHFFFAOYSA-N 0.000 description 6
- JKWMSGQKBLHBQQ-UHFFFAOYSA-N diboron trioxide Chemical compound O=BOB=O JKWMSGQKBLHBQQ-UHFFFAOYSA-N 0.000 description 6
- 238000010304 firing Methods 0.000 description 6
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- LRHPLDYGYMQRHN-UHFFFAOYSA-N N-Butanol Chemical compound CCCCO LRHPLDYGYMQRHN-UHFFFAOYSA-N 0.000 description 5
- 101100054294 Oryza sativa subsp. japonica ABCG36 gene Proteins 0.000 description 5
- 101100107604 Oryza sativa subsp. japonica ABCG48 gene Proteins 0.000 description 5
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- 239000003082 abrasive agent Substances 0.000 description 5
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- 229910052906 cristobalite Inorganic materials 0.000 description 5
- 230000000694 effects Effects 0.000 description 5
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- 238000003892 spreading Methods 0.000 description 5
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- 229910052682 stishovite Inorganic materials 0.000 description 5
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- RTZKZFJDLAIYFH-UHFFFAOYSA-N Diethyl ether Chemical compound CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 description 4
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 4
- 239000000292 calcium oxide Substances 0.000 description 4
- 235000012255 calcium oxide Nutrition 0.000 description 4
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- 239000000395 magnesium oxide Substances 0.000 description 4
- CHWRSCGUEQEHOH-UHFFFAOYSA-N potassium oxide Chemical compound [O-2].[K+].[K+] CHWRSCGUEQEHOH-UHFFFAOYSA-N 0.000 description 4
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 4
- 229910010271 silicon carbide Inorganic materials 0.000 description 4
- KKCBUQHMOMHUOY-UHFFFAOYSA-N sodium oxide Chemical compound [O-2].[Na+].[Na+] KKCBUQHMOMHUOY-UHFFFAOYSA-N 0.000 description 4
- 239000007787 solid Substances 0.000 description 4
- 239000000243 solution Substances 0.000 description 4
- 239000002904 solvent Substances 0.000 description 4
- -1 vitreous Substances 0.000 description 4
- ZWEHNKRNPOVVGH-UHFFFAOYSA-N 2-Butanone Chemical compound CCC(C)=O ZWEHNKRNPOVVGH-UHFFFAOYSA-N 0.000 description 3
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 description 3
- 101100433746 Arabidopsis thaliana ABCG29 gene Proteins 0.000 description 3
- 101100433757 Arabidopsis thaliana ABCG32 gene Proteins 0.000 description 3
- 101100433759 Arabidopsis thaliana ABCG33 gene Proteins 0.000 description 3
- 229910052582 BN Inorganic materials 0.000 description 3
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 description 3
- 239000004593 Epoxy Substances 0.000 description 3
- XEKOWRVHYACXOJ-UHFFFAOYSA-N Ethyl acetate Chemical compound CCOC(C)=O XEKOWRVHYACXOJ-UHFFFAOYSA-N 0.000 description 3
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 3
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 description 3
- KFZMGEQAYNKOFK-UHFFFAOYSA-N Isopropanol Chemical compound CC(C)O KFZMGEQAYNKOFK-UHFFFAOYSA-N 0.000 description 3
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 3
- 101100433758 Oryza sativa subsp. japonica ABCG32 gene Proteins 0.000 description 3
- 101100054289 Oryza sativa subsp. japonica ABCG34 gene Proteins 0.000 description 3
- 101100054296 Oryza sativa subsp. japonica ABCG37 gene Proteins 0.000 description 3
- 101100107593 Oryza sativa subsp. japonica ABCG40 gene Proteins 0.000 description 3
- 101100107599 Oryza sativa subsp. japonica ABCG43 gene Proteins 0.000 description 3
- 101100107601 Oryza sativa subsp. japonica ABCG45 gene Proteins 0.000 description 3
- 101150088582 PDR1 gene Proteins 0.000 description 3
- DNIAPMSPPWPWGF-UHFFFAOYSA-N Propylene glycol Chemical compound CC(O)CO DNIAPMSPPWPWGF-UHFFFAOYSA-N 0.000 description 3
- 101100028967 Saccharomyces cerevisiae (strain ATCC 204508 / S288c) PDR5 gene Proteins 0.000 description 3
- 101100491255 Saccharomyces cerevisiae (strain ATCC 204508 / S288c) YAP1 gene Proteins 0.000 description 3
- 101100400877 Trichophyton rubrum (strain ATCC MYA-4607 / CBS 118892) MDR1 gene Proteins 0.000 description 3
- 229910001593 boehmite Inorganic materials 0.000 description 3
- 229910010293 ceramic material Inorganic materials 0.000 description 3
- 239000012700 ceramic precursor Substances 0.000 description 3
- 229910003460 diamond Inorganic materials 0.000 description 3
- 239000010432 diamond Substances 0.000 description 3
- MTHSVFCYNBDYFN-UHFFFAOYSA-N diethylene glycol Chemical compound OCCOCCO MTHSVFCYNBDYFN-UHFFFAOYSA-N 0.000 description 3
- 238000009826 distribution Methods 0.000 description 3
- 235000019441 ethanol Nutrition 0.000 description 3
- 238000001704 evaporation Methods 0.000 description 3
- 230000008020 evaporation Effects 0.000 description 3
- FAHBNUUHRFUEAI-UHFFFAOYSA-M hydroxidooxidoaluminium Chemical compound O[Al]=O FAHBNUUHRFUEAI-UHFFFAOYSA-M 0.000 description 3
- FUJCRWPEOMXPAD-UHFFFAOYSA-N lithium oxide Chemical compound [Li+].[Li+].[O-2] FUJCRWPEOMXPAD-UHFFFAOYSA-N 0.000 description 3
- 238000003801 milling Methods 0.000 description 3
- 229920000647 polyepoxide Polymers 0.000 description 3
- ARXKVVRQIIOZGF-UHFFFAOYSA-N 1,2,4-butanetriol Chemical compound OCCC(O)CO ARXKVVRQIIOZGF-UHFFFAOYSA-N 0.000 description 2
- ARXJGSRGQADJSQ-UHFFFAOYSA-N 1-methoxypropan-2-ol Chemical compound COCC(C)O ARXJGSRGQADJSQ-UHFFFAOYSA-N 0.000 description 2
- XNWFRZJHXBZDAG-UHFFFAOYSA-N 2-METHOXYETHANOL Chemical compound COCCO XNWFRZJHXBZDAG-UHFFFAOYSA-N 0.000 description 2
- NIXOWILDQLNWCW-UHFFFAOYSA-N 2-Propenoic acid Natural products OC(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 2
- WWSJZGAPAVMETJ-UHFFFAOYSA-N 2-[4-[2-(2,3-dihydro-1H-inden-2-ylamino)pyrimidin-5-yl]-3-ethoxypyrazol-1-yl]-1-(2,4,6,7-tetrahydrotriazolo[4,5-c]pyridin-5-yl)ethanone Chemical compound C1C(CC2=CC=CC=C12)NC1=NC=C(C=N1)C=1C(=NN(C=1)CC(=O)N1CC2=C(CC1)NN=N2)OCC WWSJZGAPAVMETJ-UHFFFAOYSA-N 0.000 description 2
- SVTBMSDMJJWYQN-UHFFFAOYSA-N 2-methylpentane-2,4-diol Chemical compound CC(O)CC(C)(C)O SVTBMSDMJJWYQN-UHFFFAOYSA-N 0.000 description 2
- 238000010146 3D printing Methods 0.000 description 2
- 101100433754 Arabidopsis thaliana ABCG30 gene Proteins 0.000 description 2
- 229910052580 B4C Inorganic materials 0.000 description 2
- 239000004375 Dextrin Substances 0.000 description 2
- 229920001353 Dextrin Polymers 0.000 description 2
- IAZDPXIOMUYVGZ-UHFFFAOYSA-N Dimethylsulphoxide Chemical compound CS(C)=O IAZDPXIOMUYVGZ-UHFFFAOYSA-N 0.000 description 2
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 2
- SECXISVLQFMRJM-UHFFFAOYSA-N N-Methylpyrrolidone Chemical compound CN1CCCC1=O SECXISVLQFMRJM-UHFFFAOYSA-N 0.000 description 2
- UFWIBTONFRDIAS-UHFFFAOYSA-N Naphthalene Chemical compound C1=CC=CC2=CC=CC=C21 UFWIBTONFRDIAS-UHFFFAOYSA-N 0.000 description 2
- 229920000299 Nylon 12 Polymers 0.000 description 2
- 101100054291 Oryza sativa subsp. japonica ABCG35 gene Proteins 0.000 description 2
- 101100107595 Oryza sativa subsp. japonica ABCG41 gene Proteins 0.000 description 2
- 101150024488 PDR2 gene Proteins 0.000 description 2
- 101100321174 Saccharomyces cerevisiae (strain ATCC 204508 / S288c) YRR1 gene Proteins 0.000 description 2
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 2
- DKGAVHZHDRPRBM-UHFFFAOYSA-N Tert-Butanol Chemical compound CC(C)(C)O DKGAVHZHDRPRBM-UHFFFAOYSA-N 0.000 description 2
- 239000006061 abrasive grain Substances 0.000 description 2
- 230000003213 activating effect Effects 0.000 description 2
- 150000001298 alcohols Chemical class 0.000 description 2
- 229910000272 alkali metal oxide Inorganic materials 0.000 description 2
- 229910000287 alkaline earth metal oxide Inorganic materials 0.000 description 2
- 229920006187 aquazol Polymers 0.000 description 2
- 239000012861 aquazol Substances 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- INAHAJYZKVIDIZ-UHFFFAOYSA-N boron carbide Chemical compound B12B3B4C32B41 INAHAJYZKVIDIZ-UHFFFAOYSA-N 0.000 description 2
- BTANRVKWQNVYAZ-UHFFFAOYSA-N butan-2-ol Chemical compound CCC(C)O BTANRVKWQNVYAZ-UHFFFAOYSA-N 0.000 description 2
- WERYXYBDKMZEQL-UHFFFAOYSA-N butane-1,4-diol Chemical compound OCCCCO WERYXYBDKMZEQL-UHFFFAOYSA-N 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
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- 235000019425 dextrin Nutrition 0.000 description 2
- SWXVUIWOUIDPGS-UHFFFAOYSA-N diacetone alcohol Chemical compound CC(=O)CC(C)(C)O SWXVUIWOUIDPGS-UHFFFAOYSA-N 0.000 description 2
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- 238000005516 engineering process Methods 0.000 description 2
- 239000003822 epoxy resin Substances 0.000 description 2
- LZCLXQDLBQLTDK-UHFFFAOYSA-N ethyl 2-hydroxypropanoate Chemical compound CCOC(=O)C(C)O LZCLXQDLBQLTDK-UHFFFAOYSA-N 0.000 description 2
- 239000000945 filler Substances 0.000 description 2
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- VKYKSIONXSXAKP-UHFFFAOYSA-N hexamethylenetetramine Chemical compound C1N(C2)CN3CN1CN2C3 VKYKSIONXSXAKP-UHFFFAOYSA-N 0.000 description 2
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- 238000007641 inkjet printing Methods 0.000 description 2
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- 150000002576 ketones Chemical class 0.000 description 2
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- 229920002907 Guar gum Polymers 0.000 description 1
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B55/00—Safety devices for grinding or polishing machines; Accessories fitted to grinding or polishing machines for keeping tools or parts of the machine in good working condition
- B24B55/02—Equipment for cooling the grinding surfaces, e.g. devices for feeding coolant
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D18/00—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
- B24D18/0072—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for using adhesives for bonding abrasive particles or grinding elements to a support, e.g. by gluing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D5/00—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting only by their periphery; Bushings or mountings therefor
- B24D5/10—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting only by their periphery; Bushings or mountings therefor with cooling provisions, e.g. with radial slots
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D7/00—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting otherwise than only by their periphery, e.g. by the front face; Bushings or mountings therefor
- B24D7/10—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting otherwise than only by their periphery, e.g. by the front face; Bushings or mountings therefor with cooling provisions
Definitions
- the abrasive particles, bond precursor, and, usually, the pore inducer are typically dry blended together.
- the temporary organic binder solution is then added to wet out the grain mix.
- the blended mix is then placed in a hardened steel mold treated with a mold release agent and pressed to reach a predefined volume.
- the pressed part is then removed from the mold in a green stage and put in a furnace to be heated until the binder is fully formed.
- the present disclosure provides a bonded abrasive article.
- the bonded abrasive article has abrasive particles retained within a binder in an active grinding layer.
- the bonded abrasive article also has an internal reservoir configured to receive a fluid.
- the bonded abrasive article also has a feature configured to change a property of the fluid.
- the bonded abrasive article also has a delivery feature configured to deliver to fluid to a contact zone.
- the present disclosure provides a method of making a bonded abrasive article.
- the method includes manufacturing an abrasive article preform.
- the abrasive article preform has an internal reservoir configured to receive a fluid from an external source.
- the abrasive article preform also includes a delivery feature configured to deliver the fluid to a contact area.
- the method also includes heating the abrasive article preform to provide the bonded abrasive article.
- the method also includes providing an acceleration feature into the internal reservoir. The acceleration feature accelerates a flow of the fluid from the internal reservoir to the delivery feature.
- the present disclosure provides a method of using a bonded abrasive article. The method includes contacting the bonded abrasive article to a workpiece.
- abrasive articles with such systems may reduce or even prevent surface burning and / or damage to a workpiece subsurface during an abrading operation.
- FIG. 2 illustrates an abrasive article with an internal coolant feature in accordance with accordance with embodiments herein.
- FIGS 3A-3D illustrate different acceleration feature designs in accordance with embodiments herein.
- FIGS. 5A-5D illustrate grinding wheels with multiple internal coolant delivery systems made in accordance with embodiments herein.
- FIG. 6 illustrates a method of manufacturing an abrasive article using additive manufacturing in accordance with embodiments herein.
- FIGS. 7-9 illustrate abrasive articles with internal coolant delivery systems made using additive manufacturing in accordance with embodiments herein.
- FIGS. 10-22D illustrate abrasive articles and fluid flow therethrough as illustrated in the Examples. Repeated use of reference characters in the specification and drawings is intended to represent the same or analogous features or elements of the disclosure. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art, which fall within the scope and spirit of the principles of the disclosure. The figures may not be drawn to scale.
- Powder bed binder jetting is an additive manufacturing, or "3D printing" technology, in which a thin layer of a powder is temporarily bonded at desired locations by a jetted liquid binder mixture.
- that binder mixture is dispensed by an inkjet printing head, and consists of a polymer dissolved in a suitable solvent or carrier solution.
- the binder is a powder which is mixed with the other powder, or coated onto the powder and dried, and then an activating liquid, such as water or a solvent mixture, is jetted onto the powder, activating the binder in select areas.
- the printed powder layer is then at least partially dried and lowered so that a next powder layer can be spread.
- the powder spreading, bonding and drying processes can be repeated until the full object is created.
- the object and surrounding powder is removed from the printer and often dried or cured to impart additional strength so that the now hardened object can be extracted from the surrounding powder.
- coolant reduces mechanical, thermal and chemical impact between an abrasive particle and the workpiece being abraded.
- Lubricant reduces friction between the materials and cools the grinding process area by absorbing and transporting heat generated during grinding away from the process area. If sufficient coolant is not present, the risk of surface burning and / or damage to the subsurface of the workpiece being abraded is high.
- One goal of abrasive article design is to manage coolant delivery, both too and from a work area, so that enough coolant is available to an active grinding area as needed. As discussed below, embodiments of the present invention achieve this by modifying the abrasive article design. For example, some embodiments use internal coolant features designed to capture coolant from an external source and deliver it to an active grinding area.
- FIGS. 1A-1E illustrate prior art methods of providing coolant to an abrasive process.
- Internal grinding processes such as process 10 of FIG. 1A, illustrate challenges for coolant delivery.
- nozzles such as nozzle 12 are used to direct cooling into an internal grinding area.
- space for nozzles 12 are limited and the contact length between the abrasive article and the workpiece is high.
- the quantity of coolant reaching the active grinding zone is not enough to sufficiently cool the grinding area, maintain sufficient lubrication, and flush away abraded material.
- Nozzle 40 is designed such that an outlet 42 substantially contacts abrasive wheel 41.
- a significant drawback of a separate nozzle structure is the need for the nozzle to be close to the grinding zone, as illustrated in FIG. 1D, without taking up space occupied by the abrasive article.
- it may be possible to deliver a sufficient quantity of coolant through a nozzle it is often difficult to deliver the coolant consistently to the right place.
- Abrasive article 50 has a plurality of coolant features 52 within the grinding wheel surface. Grooves 52 can capture the coolant and retain it, with some still present as the abrasive article abrades the surface.
- Coolant is delivered through the specially designed grinding wheel center (e.g. through a shaft or adapted connection feature) and then passes through the grinding wheel through holes in the abrasive layer.
- a specially designed grinding wheel spindle e.g. through a shaft or adapted connection feature
- Embodiments described herein solve the coolant delivery problem by driving coolant to an abrading contact zone without the need for a special spindle. Some embodiments accomplish this by collecting fluid from the standard environment such that the fluid is captured from a supply, accelerated through a design feature within the grinding wheel, and then redistributed to the grinding zone through openings in an active layer of the grinding wheel. The openings may be located to take advantage of acceleration by the design feature(s).
- FIG. 2 illustrates an abrasive article with an internal coolant feature in accordance with an embodiment of the present invention.
- Abrasive article 200 has a plurality of features that help to provide coolant to an abrading site.
- article 200 has an active grinding surface layer 210 configured to abrade a surface of a workpiece.
- abrasive properties of the active grinding layer can be customized, for example diameter, height, abrasive thickness, grit size, etc.
- Abrasive article 200 also has an internal bore 220, configured to allow abrasive article 200 to be mounted on a machine shaft.
- abrasive article 200 has an internal reservoir 230 configured to collect coolant from an external source.
- an acceleration feature 240 Located within internal reservoir 230 is an acceleration feature 240 configured to accelerate coolant.
- Acceleration feature 240 in the embodiment illustrated in FIG. 2, is a turbofan. However, other possible designs for acceleration feature are specifically contemplated, some of which are discussed within. Acceleration feature 240 is designed to use the rotation of grinding wheel 200 to increase the speed and / or pressure of provided coolant to ensure that it is delivered to an active grinding area.
- Abrasive article 200 may be have a vitreous, metal-based or resin bond that holds abrasive particles in place within a bond matrix. While some of the discussion below focuses on the example of a vitreous bonded abrasive article, it is expressly contemplated that other binders, such as metal -based bond or a resin-based bond, are also possible in some embodiments of the present invention.
- Abrasive article 200 also includes openings 250 in the abrasive layer that drive coolant, accelerated by acceleration feature 240, to a contact zone. Additionally, channels 260 distribute coolant throughout the surface area of grinding wheel 200. Illustrated in FIG. 2 are circular openings 250 and curved channels 260. However, it is also expressly contemplated that other suitable shapes and designs may be possible, or even desired, based on the parameters of an abrading operation.
- Abrasive article 200 is designed to utilize an external coolant source to collect coolant, using reservoir 230, and distribute it to a work zone, using openings 250 and grooves 260, at a desired speed and pressure, achieved through acceleration feature 240.
- FIG. 2 illustrates one embodiment where acceleration feature 240 is formed of the same ceramic material as abrasive layer 210. This can be achieved, for example, using additive manufacturing to build acceleration feature into abrasive article 200. However, it is expressly contemplated that acceleration feature can be made from a different material as well and inserted later, for example.
- FIGS 3A-3D illustrate different internal acceleration feature designs in accordance with embodiments of the present invention.
- Acceleration features 310, 320, 330 and 340 in one embodiment, comprise polyamide 12, sold under the tradename NYLON®, and are configured to fit within an abrasive grinding wheel 350, as illustrated in FIG. 3D.
- acceleration features 310, 320, 330 and / or 340 may be constructed to fit within internal reservoir 230 instead of acceleration feature 240.
- FIGS. 3A-3D illustrate polyamide-based acceleration features, other suitable materials may also be used. Acceleration features 310, 320, 330, and 340 will not contact a workpiece, or be ground, as part of an abrading operation.
- acceleration feature inserts 310, 320, 330 and 340 can be made using a separate process and later insert into an abrasive grinding wheel.
- Acceleration feature designs can be varied, as illustrated in the examples of FIGS 3A-3F.
- Acceleration features may contain one or more blades.
- blades may resemble those used in axial fans, centrifugal fans, turbo fans, axial pumps, centrifugal pumps and turbo chargers. Additionally, in some embodiments, the blades can be straight, or curved clockwise or counterclockwise. Additionally, in some embodiments, the blades are twisted. Each blade may extend along a length of the internal reservoir. Each blade may extend, as a solid structure, from the internal bore to the active grinding layer, effectively separating a reservoir into a plurality of reservoir portions, in one embodiment. However, in another embodiment, each blade only extends partway into reservoir. Each blade may have a flat surface or a curved surface.
- Acceleration feature 310 includes a plurality of blades 302, each of which curves counterclockwise outward from an internal bore 304 to an abrasive layer (e.g. at reference numeral 306).
- each blade 302 has a variable thickness and is thinnest at the connection point to bore 304 and thickest at the connection point to an abrasive layer (e.g at reference numeral 306).
- acceleration feature has eight blades 302. However more blades 302, or fewer, may also be present. Blades 302 are configured to extend along an entire length 308 of an internal reservoir.
- Acceleration feature 320 includes a plurality of blades 312 that extend from an internal core 314 to the abrasive layer (e.g.
- blades 312 in acceleration feature 320 extend substantially straight from an internal core 314 to an abrasive layer (e.g. at reference numeral 316), they do not extend straight along a length 318 of the abrasive article. Instead, each blade in acceleration feature has a twisted surface as it extends along a length of abrasive article. Additionally, each blade 312 has a length longer than an abrasive article length 318, as it curves around the internal bore.
- Acceleration feature 330 includes a plurality of blades 322 that do not completely extend from an internal bore 324 to an abrasive layer (e.g. at reference numeral 326). Each blade has some curvature and experiences some twisting along the length 328 of the abrasive article. Blades 322 of acceleration feature 330 also, as shown in FIG. 3C each contain two distinct portions, with portion 322A extending perpendicular to an edge of the abrasive article and portion 322B has some curvature along length 328.
- Acceleration feature 340 includes a plurality of blades 332 extending radially outward from an internal bore 334 to an abrasive layer (e.g. at reference numeral 336). Blades 332 extend perpendicularly from a surface of bore 334 along a length 338 of abrasive article 350.
- Embodiments discussed thus far illustrate an abrasive grinding wheel that can collect coolant from an external source and provide it to an active grinding area using a single acceleration feature, either build into a grinding wheel or inserted prior to an abrasive operation.
- many abrasive operations require coolant to be delivered to multiple locations, and may require coolant be delivered at different speeds and / or pressures at different locations.
- FIGS. 4A-4F illustrate a grinding wheel with multiple internal coolant delivery levels in accordance with an embodiment of the present invention.
- FIGS. 4A and 4B illustrate a grinding wheel used to create a threaded workpiece and will be discussed together.
- abrasive wheel 400 is illustrated with only three threads 412 and two internal reservoirs 404, 414 for fluid collection and distributions, it is expressly contemplated that, in other embodiments, more internal reservoirs are possible. For example, 3, 4, 5, 6, 7 or even 8 fluid levels may be present on a single abrasive wheel. These reservoirs can be interconnected together or separate from each other.
- Abrasive wheel 400 has an active layer 410 that can be customized based on the needs of an abrasive operation.
- abrasive wheel 400 has an active layer 410 with three threads. However more, or fewer threads, are also possible.
- Abrasive wheel 400 also has an internal bore 420 sized to fit a machine shaft.
- One or more reservoirs 404, 414 are also present within abrasive wheel 400 to collect fluid provided from an external source.
- Abrasive wheel 400 also has multiple acceleration features 440. Acceleration features 440 are located at the required levels to accelerate the fluid to the contact zone. Acceleration occurs based on the rotation of the grinding wheel during operation. Acceleration features are, in one embodiment, designed to provide the fluid at a desired speed and / or pressure based on the abrasive application. As illustrated in FIGS. 4A-4E, the acceleration feature may be a centrifugal fan, with a plurality of blades 402, in one embodiment.
- Abrasive wheel 400 also has one or more openings 450 to drive the accelerated fluid to the contact zone. Openings 450 are illustrated as having a rectangular shape in FIGS. 4A and 4B, however other designs are also possible. Additionally, while abrasive wheel 400 is illustrated as not having fluid channels along the surface, in some embodiments fluid channels (such as those described with respect to FIG. 2) can be added to threaded surface 410.
- abrasive wheel 400 may also be designed differently in other embodiments.
- reservoir 404 could be bigger or smaller.
- Reservoir 404 could also incorporate an acceleration feature 440 with more blades 402. Acceleration feature 440 could be shaped differently.
- blades 402 may extend completely, or only partially, from bore 420 to an internal edge of grinding surface 410.
- Openings 450 could be round, square or another tortuous shape. Additionally, openings 450 can be placed at several heights within the grinding zone, for example in each distributing groove, or in a subset of distributing grooves.
- FIGS. 4A-4B illustrate an abrasive wheel 400 with a built-in acceleration feature 440.
- the acceleration feature may also be manufactured separately, as described above with respect to FIG. 3, for example. This may allow for acceleration feature 440 to be made of a different material, for example a polymer, a ceramic or a metallic material.
- FIGS. 4C-4F illustrate another embodiment where abrasive wheel 400 is a double ball bearing outer ring grinding wheel.
- FIG. 4C illustrates an embodiment of a double ball bearing outer ring grinding wheel 450.
- FIG. 4D illustrates an upper level 470 of double ball bearing outer ring grinding wheel 450.
- FIG. 4E illustrates a lower level 480 of the double ball bearing outer ring grinding wheel 450.
- FIG. 4F illustrates an angular cut-away view 490 of the double ball bearing outer ring grinding wheel 450.
- FIGS. 5A-5D illustrate abrasive articles with multiple internal coolant delivery systems made in accordance with embodiments of the present invention.
- abrasive articles 500 and 550 are made in accordance with an additive manufacturing process as described in detail below with respect to FIG. 6.
- Using an additive manufacturing process allows for internal components, such as acceleration features 520 and 570, to be manufactured at the same time as an active grinding layer.
- at least some internal features are manufactured separately and later added to a grinding wheel structure.
- Grinding wheel 500 is designed to grind a double ball bearing outer ring, and has an active abrasive layer designed accordingly.
- An internal reservoir 510 is configured to collect coolant provided from an external source. Acceleration feature 520 alters a property of the coolant, e.g. the speed and / or pressure, such that it can be delivered through an opening 522 to a contact zone between abrasive wheel 500 and a workpiece (not shown). While only one layer of internal reservoir 510 and acceleration feature 520 are shown in FIGS. 5A and 5B, it is to be understood that a second layer is present below the first, such that two reservoirs 510 are present within grinding wheel 500. Each of reservoirs 510 may extend, for example, along half of the length of grinding wheel 500.
- Reservoirs 510 may be symmetrical or asymmetrical with respect to height and volume. For example, it may be necessary to compensate for the longer distance required for fluid to reach the opposite end of grinding wheel 500 from the feed point. Additionally, while a two-layer double ball bearing outer ring grinding wheel 500 is illustrated, it is to be understood that more layers may also be present based on the needs of an abrasive operation. Additionally, while a double ball bearing outer ring grinding wheel is illustrated, other grinding wheels are also expressly contemplated.
- Grinding wheel 550 is designed for gear grinding. Grinding wheel 550 has an active layer with a plurality of threads. While three threads are shown for simplicity, it is also contemplated that more threads, such as 4, 5, 6, 7, 8 or even more, may be present in other embodiments. Grinding wheel 550 has an internal reservoir 560 and acceleration feature 520 which are configured to receive coolant from an external source and provide it through an opening 520 at a desired speed and pressure.
- FIGS. 5A-5D illustrate two example abrasive articles implementing embodiments of internal coolant delivery structures described herein, these are presented for illustration only. Many other potential abrasive articles are also possible and envisioned by the present disclosure. Additionally, in embodiments where more threads or bearing races are needed, additional internal coolant delivery structures can be combined in sequence. In some embodiments, additional structures are added and rotated at an angle with respect to each other. For example, one internal coolant delivery structure may be rotated 120° with respect to an adjacent internal coolant delivery structure.
- FIG. 6 illustrates a method of manufacturing an abrasive article using additive manufacturing in accordance with an embodiment of the present invention.
- Powder bed jetting process 600 can be used in making a bonded abrasive article.
- the bonded abrasive article may include a vitreous, metal or resin bond.
- Methods of making bonded abrasive articles according to the present disclosure include an additive subprocess.
- the subprocess comprises sequentially, preferably consecutively (although not required) carrying out at least three steps.
- a layer 638 of loose powder particles 610 is deposited in a confined region 640.
- the layer 638 should be of substantially uniform thickness.
- the thickness of the layer may be less than 500 microns, less than 300 microns, less than 200 microns, or less than 100 microns.
- the layers may have any thickness up to about 1 millimeter, as long as the jetted liquid binder precursor material can bind all the loose powder where it is applied.
- the thickness of the layer is from about 10 microns to about 500 microns, 10 microns to about 250 microns, about 50 microns to about 250 microns, or from about 100 microns to about 200 microns.
- the loose powder particles comprise vitreous bond precursor particles and abrasive particles.
- the vitreous bond precursor particles may comprise particles of any material that can be thermally converted into a vitreous material. Examples include glass frit particles, ceramic particles, ceramic precursor particles, and combinations thereof.
- the vitreous bond which binds together the abrasive grain in accordance with this disclosure can be of any suitable composition which is known in the abrasives art, for example.
- the vitreous bond phase also variously known in the art as a “ceramic bond”, “vitreous phase”, vitreous matrix”, or “glass bond” (e.g., depending on the composition) may be produced from one or more oxide (e.g., a metal oxide and/or boria) and/or at least one silicate as frit (i.e., small particles), which upon being heated to a high temperature react to form an integral vitreous bond phase.
- oxide e.g., a metal oxide and/or boria
- silicate as frit i.e., small particles
- glass particles e.g., recycled glass frit, water glass frit
- silica frit e.g., sol-gel silica frit
- alumina trihydrate particles alumina particles, zirconia particles, and combinations thereof.
- Suitable frits, their sources and compositions are well known in the art.
- Abrasive articles are typically prepared by forming a green structure comprised of abrasive grain, the vitreous bond precursor, an optional pore former, and a temporary binder. The green structure is then fired.
- the vitreous bond phase is usually produced in the firing step of the process for producing the abrasive article of this disclosure. Typical firing temperatures are in the range of from 540°C to 1700°C (1000°F to 3100°F). It should be understood that the temperature selected for the firing step and the composition of the vitreous bond phase must be chosen so as to not have a detrimental effect on the physical properties and/or composition of abrasive particles contained in the vitreous bond abrasive article.
- Useful glass frit particles may include any glass frit material known for use in vitreous bond abrasive articles. Examples include glass frit selected from the group consisting of silica glass frit, silicate glass frit, borosilicate glass frit, and combinations thereof.
- a typical vitreous binding material contains about 70 - 90% SiO 2 + B 2 O 3 , 1-20% alkali oxides, 1-20% alkaline earth oxides, and 1-20% transition metal oxides.
- the vitreous binding material has a composition of about 82 wt% SiO 2 + B 2 O 3 , 5% alkali metal oxide, 5% transition series metal oxide, 4% Al 2 O 3 , and 4% alkaline earth oxide.
- a frit having about 20% B 2 O 3 , 60% silica, 2% soda, and 4% magnesia may be utilized as the vitreous binding material.
- the size of the glass frit can vary. For example, it may be the same size as the abrasive particles, or different. Typically, the average particle size of the glass frit ranges from about 0.01 micrometer to about 100 micrometers, preferably about 0.05 micrometer to about 50 micrometers, and most preferably about 0.1 micrometer to about 25 micrometers.
- the average particle size of the glass frit in relation to the average particle size of the abrasive particles having a Mohs hardness of at least about 5 can vary.
- the average particle size of the glass frit is about 1 to about 200 percent of the average particle size of the abrasive, preferably about 10 to about 100 percent, and most preferably about 15 to about 50 percent.
- the weight ratio of vitreous bond precursor particles to abrasive particles in the loose powder particles ranges from about 10:90 to about 90: 10.
- the shape of the vitreous bond precursor particles can also vary. Typically, they are irregular in shape (e.g., crushed and optionally graded), although this is not a requirement. For example, they may be spheroidal, cubic, or some other predetermined shape.
- the coefficient of thermal expansion of the vitreous bond precursor particles is the same or substantially the same as that of the abrasive particles.
- Glassy inorganic binders may be made from a mixture of different metal oxides.
- these metal oxide vitreous binders include silica, alumina, calcia, iron oxide, titania, magnesia, sodium oxide, potassium oxide, lithium oxide, manganese oxide, boron oxide, phosphorous oxide, and the like.
- Specific examples of vitreous hinders based upon weight include, for example, 47.61 percent SiO 2 , 16 65 percent AI 2 O 3 , 0.38 percent Fe 2 O 3 .
- 0.35 percent TiO 2 1.58 percent CaO, 0.10 percent MgO, 9.63 percent Na 2 O, 2.86 percent K 2 O, 1 .77 percent Li 2 O, 19.03 percent B 2 O 3 , 0.02 percent MnO 2 , and 0.22 percent P 2 O 5 ; and 63 percent SiO 2 , 12 percent AI 2 O 3 , 1.2 percent CaO, 6.3 percent Na 2 O, 7.5 percent K 2 O, and 10 percent B 2 O 3 .
- One preferred vitreous bond has an oxide-based mole percent (%) composition of SiO 2 63.28; TiO 2 0.32; AI 2 O 3 10.99; B 2 O 3 5.11; Fe 2 O 3 0.13; K 2 O 3.81; Na 2 O 4.20; Li 2 O
- the vitreous bond precursor particles may comprise ceramic particles. In such cases sintering and/or fusing of the ceramic particles forms the vitreous matrix. Any sinterable and/or fusible ceramic material may be used. Preferred ceramic materials include alumina, zirconia, and combinations thereof.
- the vitreous bond precursor particles may be present in an amount from 10 to 40 volume percent of the combined volume of the vitreous bond precursor particles and abrasive particles, preferably from 15 to 35 volume percent of the abrasive composition.
- suitable metal binders include tin, copper, aluminum, nickel, and combinations thereof.
- Suitable resin binders include formaldehyde-containing resins, such as phenol formaldehyde, novolac phenolics and especially those with added crosslinking agent (e.g., hexamethylenetetramine), phenopiasts, and aminoplasts; un saturated polyester resins; vinyl ester resins; alkyd resins, allyl resins; furan resins; epoxies; polyurethanes; cyanate esters; and polyimides.
- the amount of resin should be sufficient to fully wet the surfaces of ail the individual particles during manufacturing such that a continuous resin structure is formed with the inorganic components discretely bonded throughout.
- alpha-alumina ceramic particles may be modified with oxides of metals such as magnesium, nickel, zinc, yttria, rare earth oxides, zirconia, hafnium, chromium, or the like.
- Alumina and zirconia abrasive particles may be made by a sol-gel process, for example, as disclosed in U.S. Pat. Nos. 4,314,827 (Leitheiser et al.); 4,518,397 (Leitheiser et al.); 4,574,003 (Gerk); 4,623,364 (Cottringer et al.); 4,744,802 (Schwabel); and 5,551,963 (Larmie).
- additives in the making of bonded abrasive articles both to assist in the making of the abrasive article and/or improve the performance of such articles.
- Such conventional additives which may also be used in the practice of this disclosure include but are not limited to lubricants, fillers, pore inducers, and processing aids.
- lubricants include, graphite, sulfur, polytetrafluoroethylene and molybdenum disulfide.
- pore inducers include glass bubbles and organic particles. Concentrations of the additives as are known in the art may be employed for the intended purpose of the additive, for example. Preferably, the additives have little or no adverse effect on abrasive particles employed in the practice of this disclosure.
- the loose powder particles may optionally be modified to improve their flowability and the uniformity of the layer spread.
- Methods of improving the powders include agglomeration, spray drying, gas or water atomization, flame forming, granulation, milling, and sieving. Additionally, flow agents such as, for example, fumed silica, nanosilica, stearates, and starch may optionally be added.
- the bond precursor particles may comprise a ceramic precursor (e.g., a precursor of alumina or zirconia) such as, for example, bauxite, boehmite, calcined alumina, or calcined zirconia that when fired converts to the corresponding ceramic form.
- a ceramic precursor e.g., a precursor of alumina or zirconia
- bauxite, boehmite calcined alumina, or calcined zirconia that when fired converts to the corresponding ceramic form.
- Procedures and conditions known in the art for producing bonded abrasive articles e.g., grinding wheels
- procedures and conditions for producing bond abrasive articles may be used to make the abrasive articles of this disclosure. These procedures may employ conventional and well-known equipment in the art.
- the abrasive particles may comprise any abrasive particle used in the abrasives industry.
- the abrasive particles have a Mohs hardness of at least 4, preferably at least 5, more preferably at least 6, more preferably at least 7, more preferably at least 8, more preferably at least 8.5, and more preferably at least 9.
- the abrasive particles comprise superabrasive particles.
- the term "superabrasive” refers to any abrasive particle having a hardness greater than or equal to that of silicon carbide (e.g., silicon carbide, boron carbide, cubic boron nitride, and diamond).
- suitable abrasive materials include aluminum oxide (e.g., alpha alumina) materials (e.g., fused, heat-treated, ceramic, and/or sintered aluminum oxide materials), silicon carbide, titanium diboride, titanium nitride, boron carbide, tungsten carbide, titanium carbide, aluminum nitride, diamond, cubic boron nitride (CBN), garnet, fused alumina-zirconia, sol-gel derived abrasive particles, cerium oxide, zirconium oxide, titanium oxide, and combinations thereof. Examples of sol-gel derived abrasive particles can be found in U.S. Pat. No. 4,314,827 (Leitheiser et al.), U.S.
- sol-gel derived abrasive particles can be found in U.S. Pat. No. 4,314,827 (Leitheiser et al.), U.S.
- the loose powder particles are preferably sized (e.g., by screening) to have a maximum size of less than or equal to 400 microns, preferably less than or equal to 250 microns, more preferably less than or equal to 200 microns, more preferably less than or equal to 150 microns, less than or equal to 100 microns, or even less than or equal to 80 microns, although larger sizes may also be used.
- the size of the powder particles may relate to the size of the abrasive particle used.
- the vitreous bond precursor particles, abrasive particles, and any optional additional particulate components may have the same or different maximum particle sizes, D 90 , D 50 , and/or D 1 0 particle size distribution parameters.
- the loose powder particles may optionally further comprise other components such as, for example, pore inducers, and/or filler particles.
- pore inducers include glass bubbles and organic particles.
- a liquid binder precursor material 670 is jetted by printer 650 onto predetermined region(s) 680 of layer 638.
- the liquid binder precursor material thus coats the loose powder particles in region 680, and is subsequently converted to a binder material that binds the loose powder particles in region 680 to each other.
- the liquid binder precursor material may be any composition that can be converted (e.g., by evaporation, or thermal, chemical, and/or radiation curing (e.g., using UV or visible light)) into a binder material that bonds the loose powder particles together according to the jetted pattern (and ultimate 3-D shape upon multiple repetitions).
- the liquid binder precursor material comprises a liquid vehicle having a polymer dissolved therein.
- the liquid may include one or more of organic solvent and water.
- organic solvents include alcohols (e.g., butanol, ethylene glycol monomethyl ether), ketones, and ethers, preferably having a flash point above 100°C.
- a suitable solvent or solvents will typically depend upon requirements of the specific application, such as desired surface tension and viscosity, the selected particulate solid, for example.
- the liquid vehicle can be entirely water, or can contain water in combination with one or more organic solvents.
- the aqueous vehicle contains, on a total weight basis, at least 20 percent water, at least 30 percent water, at least 40 percent water, at least 50 percent water, or even at least 75 percent water.
- one or more organic solvents may be included in the liquid vehicle, for instance, to control drying speed of the liquid vehicle, to control surface tension of the liquid vehicle, to allow dissolution of an ingredient (e.g., of a surfactant), or, as a minor component of any of the ingredients; e.g., an organic co-solvent may be present in a surfactant added as an ingredient to the liquid vehicle.
- Exemplary organic solvents include: alcohols such as methyl alcohol, ethyl alcohol, n-propyl alcohol, isopropyl alcohol, n-butyl alcohol, sec-butyl alcohol, t-butyl alcohol, and isobutyl alcohol; ketones or ketoalcohols such as acetone, methyl ethyl ketone, and diacetone alcohol; esters such as ethyl acetate and ethyl lactate; polyhydric alcohols such as ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol, butylene glycol, 1,4-butanediol, 1,2,4-butanetriol, 1,5- pentanediol, 1,2,6-hexanetriol, hexylene glycol, glycerol, glycerol ethoxylate, trimethylolpropane ethoxylate; lower alkyl ethers such as ethylene glycol methyl or ethyl
- the amounts of organic solvent and/or water within the liquid vehicle can depend on a number of factors, such as the particularly desired properties of the liquid binder precursor material such as the viscosity, surface tension, and/or drying rate, which can in turn depend on factors such as the type of ink jet printing technology intended to be used with the liquid vehicle ink, such as piezo-type or thermal-type printheads, for example.
- the liquid binder precursor material may include a polymer that is soluble or dispersible in the liquid vehicle.
- suitable polymers may include polyvinyl pyrrolidones, polyvinyl caprolactams, polyvinyl alcohols, polyacrylamides, poly(2-ethyl-2- oxazoline) (PEOX), polyvinyl butyrate, copolymers of methyl vinyl ether and maleic anhydride, certain copolymers of acrylic acid and/or hydroxyethyl acrylate, methyl cellulose, natural polymers (e.g., dextrin, guar gum, xanthan gum).
- PEOX poly(2-ethyl-2- oxazoline)
- polyvinyl butyrate copolymers of methyl vinyl ether and maleic anhydride
- acrylic acid and/or hydroxyethyl acrylate methyl cellulose
- natural polymers e.g., dextrin, guar gum, xanthan gum.
- the liquid binder precursor material may include one or more free-radically polymerizable or otherwise radiation-curable materials; for example, acrylic monomers and/or oligomers and/or epoxy resins.
- An effective amount of photoinitiator and/or photocatalysts for curing the free-radically polymerizable or otherwise radiation-curable materials may also be included.
- suitable (meth)acrylate monomers and oligomers and otherwise radiation-curable materials e.g., epoxy resins
- suitable (meth)acrylate monomers and oligomers and otherwise radiation-curable materials can be found in, for example, U.S. Pat. No. 5,766,277 (DeVoe et al.).
- the liquid binder precursor material is essentially free of (e.g., contains less than 1 percent, less than 0.1 percent, less than 0.01 percent, or is even free of) metal nanoparticles and/or metal oxide nanoparticles.
- nanoparticles refers to particles having an average particle diameter of less than or equal to one micron; for example less than or equal to 500 nanometers (nm), or even less than or equal to 150 nm.
- the liquid binder precursor may be an aqueous sol including a ceramic precursor for alumina and/or zirconia.
- aqueous boehmite sols and zirconia sols examples include aqueous boehmite sols and zirconia sols.
- the liquid binder precursor may have the same or different composition as the abrasive particles. Details concerning zirconia sols can be found, for example, in U. S. Pat. No. 6,376,590 (Kolb et al.). Details concerning boehmite sols can be found, for example, in U.S. Pat. Nos.
- the jetted liquid binder precursor material is converted into a binder material that bonds together the loose powder particles in predetermined regions of the loose powder particles to form a layer of bonded powder particles; for example, by evaporation of a liquid vehicle in the liquid binder precursor material.
- heating the binder material to sufficiently high temperature causes it to volatilize and/or decompose (e.g., "bum out") during a subsequent firing step. Cooling may be accomplished by any means known to the art (e.g., cold quenching or air cooling to room temperature).
- the jetted liquid binder precursor material 670 is converted (step 690) into a binder material that bonds together the loose powder particles in at least one predetermined region of the loose powder particles to form a layer of bonded powder particles; for example, by evaporation of a liquid vehicle in the liquid binder precursor material.
- heating the binder material to sufficiently high temperature causes it to volatilize and/or decompose (e.g., "bum out") during subsequent sintering or infusion steps.
- step 685 The above steps are then repeated (step 685) with changes to the region where jetting is carried out according to a predetermined design resulting through repetition, layer on layer, in a three-dimensional (3-D) abrasive article preform.
- the loose powder particles and the liquid binder precursor material may be independently selected; that is, either or both or the loose powder particles and the liquid binder precursor material may be the same as, or different from those in adjacent deposited layers.
- the abrasive article preform comprises the bonded powder particles and remaining loose powder particles. Once sufficient repetitions have been carried out to form the abrasive article preform, it is preferably separated from substantially all (e.g., at least 85 percent, at least 90 percent, preferably at least 95 percent, and more preferably at least 99 percent) of the remaining loose powder particles, although this is not a requirement.
- multiple particle reservoirs each containing a different powder may be used.
- multiple different liquid binder precursor materials may be used, either through a common printhead or, preferably, through separate printheads. This results in different powders/binders distributed in different and discrete regions of the bonded abrasive article.
- relatively inexpensive, but lower performing abrasive particles and or vitreous bond precursor particles may be relegated to regions of the bonded abrasive article where it is not particularly important to have high performance properties (e.g., in the interior away from the abrading surface).
- bonded abrasive articles made in such ways have considerable porosity throughout their volumes. Accordingly, the abrasive article preform may then be infused with a solution or dispersion of additional bond precursor material, or grain growth modifiers.
- Powder bed jetting equipment suitable for practicing the present disclosure is commercially available, for example, from ExOne, North Huntington, Pennsylvania. Further details concerning powder bed jetting techniques suitable for practicing the present disclosure can be found, for example, in U.S. Pat. Nos. 5,340,656 (Sachs et al.) and 6,403,002 B 1 (van der Geest).
- abrasive articles made according to embodiments described herein are configured to receive a coolant fluid from an external source and provide the coolant to an active grinding area.
- Abrasive articles described herein have an internal reservoir that receives coolant from an external source. Within the internal reservoir is a feature that changes a property of the coolant. For example, the coolant pressure and / or flow speed may increase. The coolant is then delivered to an active grinding area, for example through one or more openings extending through a grinding layer of the abrasive article. Additionally, one or more fluid channels may be present along the surface of the grinding area. Using abrasive articles with such systems may reduce or even prevent surface burning and / or damage to a workpiece subsurface during an abrading operation.
- FIGS. 7-9 illustrate abrasive articles with internal coolant delivery systems made using additive manufacturing in accordance with embodiments herein.
- FIGS. 7A-7C illustrate views of an abrasive article 700, formed by additive manufacturing, with a channel region 710 and a grinding region 720.
- Channel region 710 includes a plurality of internal channels 712 that allow flow of coolant from an exterior edge 714 to an interior space 716.
- the size and length of channels 712 can be adapted to fit the input fluid or air flow and the desired wheel size.
- internal features 718 can be used to adjust conductance of the fluid or air along the channel. For instance, residence time and pressure drop can provide guidance for the design of internal features 718 and channels 712 for a given operation. Exit openings of channels 712 be used to concentrate or spread the flow along and across a grinding area. Channels 712 can direct the flow radially outward, or through the wheel 700 to the side opposite of its incidence.
- FIGS. 7 A and 7B illustrates a perspective view and a diameter cross-section along the shaft axis 705 where a fluid for instance would enter the top size and exit out the radius.
- FIG. 7C illustrates channels 712 using a cross-section plane made at the middle of the channel region 710.
- FIG. 8 illustrate an embodiment of an abrasive article with larger channels 812 in channel region 810.
- FIG. 8A illustrates a perspective view of article 800 with a channel region 810 that extends from a center region of the abrasive article around a shaft region 805 as illustrated in FIGS. 8A and 8B.
- FIG. 8B illustrates a cutaway view along a shaft axis
- FIG. 8C illustrates a cutaway view of region 810.
- Embodiment 37 includes the features of Embodiment 36, however the second internal reservoir is separated from the internal reservoir, and wherein the second contact area is a different surface portion of the active grinding surface than the first contact area.
- Embodiment 45 includes the features of any of Embodiment 40-44, however adjusting a property of the received coolant comprises the coolant flowing through a feature within an internal reservoir of the bonded abrasive article.
- Embodiment 49 includes the features of any of Embodiments 40-48, however moving the abrasive article comprises rotating the abrasive article about a shaft.
- a 3D model was created into Solidworks 2017 CAD software.
- the saved file represents a rotating grinding wheel having features as grooves, openings, coolant collector and accelerating system.
- the file was saved as STL file format which is readable by the printer.
- the file was loaded into a print job of the printer. Printing was made of successive steps to spread powder layers, to jet binder in 2D patterns made from cross sections of the 3D objects, and to at least partially dry that binder between jetting and spreading steps.
- the printed object and the powder bed were extracted from the printer and placed into an ambient atmosphere oven to cure for 6 hours at 195°C. After cooling down to 23°C, the printed object was removed from the powder bed and loose powder was removed using a soft bristle brush. The object was then placed into a furnace and burned out at 400°C for 2 hours, followed by sintering at 900°C for 4 hours, resulting in an abrasive tool having specific feature to collect fluid and distribute it at the contact grinding zone.
- AME cBN size B91 grit from World Wide Superabrasives was dry mixed with glass frit SP2436 from Specialty Glass, respectively 74% and 26% by weight until homogeneously distributed. This mixture was placed in the hopper of the Innovent machine by ExOne.
- the CAD files for the first and second 3D objects shown in FIGS. 8 and 9 were converted into *.stl files and loaded into the ExOne software for controlling the Innovent machine.
- FIGS. 8D, 9D After cooling to room temperature, those“green” parts of powder and binder illustrated in FIGS. 8D, 9D, were removed from the loose powder and de-powdered with a combination of mechanical means and pressurized air from the nozzle of an air gun. Those “green” parts were placed into a sintering furnace to build final strength with a furnace profile, detailed as: ramp to 420 C at 2 deg/minute, hold at 420 C for 2 hours, ramp to 845 C at 2 deg/minute and then hold at 845 C for 2 hours, then ramp down to room temperature at 3 deg/minutes (or whatever slower rate is actually achieved for cooling). This produced sintered parts 8D, 9D. After sintering, the parts were mounted onto metal shafts for use in grinding equipment with epoxy DP460 3M Soctch-weld epoxy adhesive.
- FIGS. 8D and 9D illustrate the“green” part while FIGS. 8E and 9E illustrate the sintered part.
- the green body dimensions were approximately 27 mm diameter and 16.2 mm height.
- the sintered parts were approximately 24.3 mm diameter and 14.3 mm height.
- ANSYS CFX part of ANSYS CFD Premium from ANSYS, Inc. software was use.
- the features and assumptions of the model include: single phase numerical model assuming the grinding wheel is immersed in fluids, i.e., the grinding wheel is flooded; Fluid selected: water (in laminar and turbulent behavior); The model is transient, i.e., the motion of rotation is explicit captured; No cavitation considered; Ambient temperature (25°C) and pressure (1 atm) were selected; and Adiabatic walls without roughness effect.
- the model was used to investigate fundamental parameters on the fluid flow (flow rate, velocity, pressure), specifically: (1) Gap between the wheel and the work piece; (2) Effect of boundary condition at the end of work piece; (3) RPM of the wheel; and (4) Rotational direction of the wheel.
- FIG. 10 illustrates an image of the simulated grinding wheel.
- the model includes the wheel in a fluid domain as illustrated in FIG. 10.
- the side boundary of the domain is set as wall (surface of the work piece)
- the gap between the wheel and the work piece is labeled as L1.
- the value L1 has significate effects on the results.
- When the value L1 is set 0 means contact with the workpiece; when L1 is set 2mm means the grinding wheel side which is opposite to the workpiece.
- BC2 is set as the inlet for fresh coolant.
- BC1 has two different settings, one is wall, one is opening, depends on the settings, the results are different. Both cases are existing in real grinding process at customers.
- the prepared mixture was placed in the hopper of the Exone Innovent lab printer.
- a 3D model was prepared into file to make a rotating grinding wheel having features as in the FEM flow simulation study.
- the CAD file was created into Soliworks CAD system and saved as STL file format which is readable by the Exone Innovent lab printer.
- the file was prepared into print job for the ExOne Innovent lab printer with the help of Netfabb software from Autodesk. Printing was made of successive steps to spread powder layers, to jet binder in 2D patterns made from cross sections of the 3D objects and to at least partially dry that binder between jetting and spreading steps.
- the main used parameters were: Recoat speed (mm/s): 25 - Oscillator speed (rpm): 2800 - Roller Speed (rpm): 200 - Roller Traverse speed (mm/s): 15.
- the produced grinding wheels were glued on a 6 mm steel shaft and mounted on a rotating spindle of a milling machine.
- a specifically designed transparent container is fixed on the milling machine table.
- the wheel was mounted in the spindle, run-out was checked and wheel was centered into the transparent container, as illustrated in FIG. 15.
- the coolant nozzle was placed to infeed the inner part of the grinding wheel and not the outside surface.
- a high-speed camera was used to record the fluid flow behavior and validate what was predicted by the FEM Flow simulation model.
- a video of fluid behavior made with the high-speed camera confirms the predicted flow behavior means that with a hole in the middle height of the grinding wheel, the upper part of the groove is mainly used by the fluid.
- FIG. 16 illustrates an image taken by the high speed camera. It is clear on the picture that the fluid movement (including air bubbles) is much intense above the hole than below it.
- FIG. 18 illustrates the 2 wheels after the experiment - one as more iron particles (1802) remaining than the other one (1801).
- FIGS. 19A-C illustrate a multi -phase simulation and transient model of the flow behavior, with a mixture air-coolant which contains at minimum 20% of coolant in volume at the considered location.
- FIG. 19A illustrates a multi-phase model of a middle hole, open bottom construction at 10k rpm. The model shows that the top part of the grooves are already filled by the coolant before fluid is touching the workpiece surface coming from the holes.
- FIG. 19B illustrates a multi -phase model of a bottom hole, open bottom construction at 10k rpm. In case of hole at the bottom of the grinding wheel then the complete groove is filled before fluid is touching the workpiece surface coming from the holes
- FIGS. 20A and 20B illustrate multiphase model results for the groove-only model and the groove+middle hole model.
- the FEM flow simulation surprisingly demonstrates that nearly no fluid is captured by the grooves when designed with grooves only.
- FIG. 21A Compared with the designs of previous examples, the number of blades of the internal impeller was reduced keeping the same number of holes. It was discovered that the flow movement inside of the grinding wheel has also a vertical component which is not negligible. Therefore, a special design to keep the coolant longer in the wheel and have less coolant coming out of the wheel is presented in FIG. 21A. The holes in the center of the grinding wheel were kept. Using the same material and the same printing process as described in Example 10, just modifying the CAD file, another grinding wheel was produced having the new design. This resulted in the printed parts of FIG. 21B.
- FIGS. 22A-D shows the modeling results for a comparison of the design of FIG. 20 (FIGs. 22 A and B) and FIG. 21 (22C and D), indicating the amount of air or coolant in the system at a given time.
- the model shows about 15% increase in the coolant amount inside the grooves near the grinding surface for the design of FIG. 21.
- reducing the number of ribs increases the amount of coolant gets inside the wheel.
- the baffle extended from the inner wall also increased the pressure to push coolant through the holes on the groove.
Abstract
Description
Claims
Applications Claiming Priority (2)
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US201962874140P | 2019-07-15 | 2019-07-15 | |
PCT/IB2020/056599 WO2021009673A1 (en) | 2019-07-15 | 2020-07-14 | Abrasive articles having internal coolant features and methods of manufacturing the same |
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EP3999280A1 true EP3999280A1 (en) | 2022-05-25 |
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EP20743355.8A Pending EP3999280A1 (en) | 2019-07-15 | 2020-07-14 | Abrasive articles having internal coolant features and methods of manufacturing the same |
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US (1) | US20220266421A1 (en) |
EP (1) | EP3999280A1 (en) |
CN (1) | CN114144282A (en) |
WO (1) | WO2021009673A1 (en) |
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-
2020
- 2020-07-14 CN CN202080051573.0A patent/CN114144282A/en active Pending
- 2020-07-14 WO PCT/IB2020/056599 patent/WO2021009673A1/en unknown
- 2020-07-14 US US17/597,578 patent/US20220266421A1/en active Pending
- 2020-07-14 EP EP20743355.8A patent/EP3999280A1/en active Pending
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WO2021009673A1 (en) | 2021-01-21 |
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