JP2021522075A - Abrasive particles with molded abrasive particles with a given rake angle - Google Patents

Abstract

The present disclosure provides a polished article (10). The polished article (10) has a use direction, a y-axis, and a y-axis and a z-axis orthogonal to the use direction. The polished article (10) further includes a backing (12) and molded abrasive particles attached to the backing. About 5% to about 100% of the molded abrasive particles (14) independently have a first side surface (16), a second side surface (18) opposite to the first side surface (16), and a second side surface (18). About 10 degrees to the tip surface (20) connected to the side surface (16) of 1 by the first edge (24) and connected to the second side surface (18) by the second edge (26). A rake angle (30) between the backing (12) and the tip surface (20) in the range of about 110 degrees and a first edge (16) and a second edge (16) in the range of about 10 degrees to about 170 degrees. Includes a z-direction angle of rotation (50) between the line (52) intersecting the edge (18) and the direction of use (22) of the polished article (10).

Description

Abrasive particles, and abrasive articles containing abrasive particles, are useful for polishing, finishing or grinding a wide range of materials and surfaces in the manufacture of goods. Therefore, there is still a need to improve the cost, performance, or life of abrasive particles or articles.

The present disclosure provides a polished article. The polished article has a use direction, a y-axis, and a y-axis and a z-axis orthogonal to the use direction. The abrasive article further includes a backing and molded abrasive particles attached to the technique backing. Approximately 5% to approximately 100% of the molded abrasive particles are independently connected to the first side surface, the second side surface opposite the first side surface, and the first side surface at the first edge. And the rake angle between the backing and the tip surface in the range of about 10 degrees to about 110 degrees with the tip surface connected to the second side surface by the second edge, and about 10 degrees to about 170 degrees. It has a z-direction angle of rotation between the line intersecting the first and second edges of the range and the direction of use of the polished article.

The present disclosure further includes a polished article having a first direction of use. The abrasive article contains abrasive particles attached to the backing. Under the same test conditions, the amount of material removed from the workpiece that comes into contact with the abrasive is the material of the workpiece that is removed when the abrasive is moved in a second direction that is different from the first direction of use. More than the amount of.

The present disclosure further includes a polished article having a first direction of use. The abrasive article contains abrasive particles attached to the backing. Under the same test conditions, the surface roughness of the workpiece in contact with the polished article is greater than the surface roughness of the workpiece when the polished article is moved in a second use direction different from the first use direction.

The present disclosure further provides a method of manufacturing a polished article. The method includes orienting the molded abrasive particles and adhering the molded abrasive particles to the backing. Approximately 5% to approximately 100% of the abrasive particles are molded and independently at the first side surface, the second side surface opposite the first side surface, and the first edge on the first side surface. The rake angle between the backing and the tip surface, which is connected and connected to the second side surface at the second edge, in the range of about 10 degrees to about 110 degrees, and about 10 degrees to about. It has a z-direction rotation angle between the line intersecting the first edge and the second edge and the direction of use of the polished article in the range of 170 degrees.

The present disclosure further includes methods of using the polished article. The method includes bringing the molded abrasive particles into contact with the workpiece, moving the abrasive article in the direction of use with respect to the workpiece, and removing a portion of the workpiece. Approximately 5% to approximately 100% of the abrasive particles are molded and independently at the first side surface, the second side surface opposite the first side surface, and the first edge on the first side surface. The rake angle between the backing and the tip surface, which is connected and connected to the second side surface at the second edge, in the range of about 10 degrees to about 110 degrees, and about 10 degrees to about. It has a z-direction rotation angle between the line intersecting the first edge and the second edge and the direction of use of the polished article in the range of 170 degrees.

Although the drawings are not necessarily drawn in proportion to their actual size, similar symbols in the drawings describe substantially similar components throughout several figures. Similar symbols with different suffixes represent different cases of substantially similar components. The drawings are exemplary, but not limiting, generally showing the various embodiments discussed herein.

It is a side view of the polishing belt according to various embodiments.

It is a front view of the polishing belt according to various embodiments.

It is a bottom view of the polishing belt according to various embodiments.

FIG. 5 is a side view of a polishing belt having molded polishing particles according to various embodiments.

It is a bottom view of a polishing disk according to various embodiments.

It is the schematic of the manufacturing method of the polished article by various embodiments.

It is the schematic which shows the orientation of the molded abrasive particle by the method of FIG. 4 by various embodiments.

It is the schematic which shows the orientation of the molded abrasive particle by the method of FIG. 4 by various embodiments.

It is the schematic which shows the orientation of the molded abrasive particle by the method of FIG. 4 by various embodiments.

It is a plot of the data from the grinding procedure A according to various embodiments.

It is a plot of the data from the grinding procedure B according to various embodiments.

It is a plot of the data from the grinding procedure C according to various embodiments.

2D color contours of the substrate of surface analysis procedure D polished in the reverse direction according to various embodiments.

FIG. 3 is a 2D color contour diagram of the substrate of the surface analysis procedure D polished in the forward direction according to various embodiments.

3D images of the substrate of surface analysis procedure D polished in the reverse direction according to various embodiments.

3D images of the substrate of the surface analysis procedure D polished in the forward direction according to various embodiments.

Next, some embodiments of the disclosed subject matter are referred to in detail. Examples of embodiments are partially shown in the accompanying drawings. The disclosed subjects are described in relation to the listed claims, but it is understood that the illustrated subjects are not intended to limit these claims to the disclosed claims. ..

Throughout this document, the values expressed in the form of a range include not only the numbers explicitly stated as the limits of that range, but also all individual numbers or subranges contained within that range. It should be interpreted flexibly to include each number and subrange as if it were explicitly stated. For example, the range "about 0.1% to about 5%" or "about 0.1% to 5%" is not only about 0.1% to about 5%, but each value within the indicated range ( For example, 1%, 2%, 3%, and 4%) and a partial range (eg, 0.1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%). ) Should also be interpreted. The description "about X to Y" has the same meaning as "about X to about Y" unless otherwise specified. Similarly, the description "about X, Y, or about Z" has the same meaning as "about X, about Y, or about Z" unless otherwise noted.

In this document, the terms "one (a)", "one (an)", or "the" are used to include one or more unless otherwise specified in context. Will be done. The term "or" is used to refer to a nonexclusive "or" unless otherwise noted. The description "at least one of A and B" has the same meaning as "A, B, or A and B". In addition, it should be understood that the expressions or terms not specifically defined as used herein are for illustration purposes only and not for limitation. Any use of section headings is intended to assist in reading this document and should not be construed as limiting, and information related to section headings may be present within or outside that particular section. Can be done.

In the methods described herein, the acts may be performed in any order without departing from the principles of the present disclosure, except where the temporal or operational order is explicitly stated. Furthermore, unless the claims explicitly state that certain acts are to be performed separately, they may be performed at the same time. For example, the claimed act of X and the claimed act of Y can be performed simultaneously in a single operation, and the resulting process is the wording scope of the claimed process. Go inside.

As used herein, the term "about" refers to some volatility of a value or range, eg, within 10%, within 5%, or 1 of the limits of the value or range described. Includes values or ranges that can be tolerated within% and are accurately described.

The term "substantially" as used herein is at least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99. Refers to most or most or 100%, such as 5%, 99.9%, 99.99%, or at least about 99.999% or more.

According to various embodiments of the present disclosure, the polished article is disclosed. The polished article can be selected from many different polished articles such as a polishing belt, a polishing sheet, or a polishing disc. 1A-1C are various views of the polishing belt 10. 1A is a side view of the belt 10, FIG. 1B is a front view of the belt 10, and FIG. 1C is a bottom view of the belt 10. 1A-1C show many of the same features and are described simultaneously. As shown in FIGS. 1A to 1C, the polishing belt 10 has a z-axis and a y-axis orthogonal to the z-axis. The use direction 22 of the polishing belt 10 extends in one direction along the x-axis orthogonal to both the z-axis and the y-axis. For FIG. 1A, the usage direction 22 is from left to right, for FIG. 1B, the usage direction 22 is from the page to the reader, and for FIG. 1C, the usage direction 22 is from the bottom of the page to the top of the page.

The polishing belt 10 includes a backing 12 to which the forming polishing particles 14 are attached. The backing 12 can have any desired degree of flexibility. The backing 12 can include any suitable material. For example, the backing 12 can include polymer films, metal foils, woven fabrics, knitted fabrics, paper, vulcanized fibers, non-woven materials, foams, screens, laminates, or combinations thereof. The backing 12 can further contain various additives. Examples of suitable additives include colorants, processing aids, reinforcing fibers, heat stabilizers, UV stabilizers, and antioxidants. Examples of useful fillers include clay, calcium carbonate, glass beads, talc, clay, mica, wood flour, and carbon black.

As shown, the edges of at least one molded abrasive particle 14 are in substantial contact with the backing 12. In a further embodiment, it may be possible that the edge or edge portion does not come into contact with the backing 12.

The molded abrasive particles 14 are arbitrary abrasive particles in which at least a part of the abrasive particles has a predetermined shape. The predetermined shape can be replicated, for example, from the mold cavity used to form the molding precursor abrasive particles. In embodiments where the shaped abrasive particles 14 are formed within the mold cavity, the given geometry can substantially duplicate the mold cavity used to form the molded abrasive particles 14. The shaped abrasive particles 14 can also duplicate the shape of the die in the example where the molded abrasive particles are formed by extrusion molding. The shaped abrasive particles 14 can also replicate the shape found in a program, such as a computer-aided design (CAD) program, when the shaped abrasive particles 14 or the polished article are formed by a laminated molding process. The molded abrasive particles 14 do not refer to random-sized pulverized abrasive particles formed by, for example, a mechanical pulverization operation.

The molded abrasive particles 14 include many geometric features. For example, as shown in FIGS. 1A-1C, the molded abrasive particles 14 include a first side surface 16, a second side surface 18, a front end surface 20, and a rear surface 28. The surfaces of the molded abrasive particles 14 are joined at the edges. For example, the tip surface 20 is joined to the first side surface 16 at the edge 24 and further joined to the second side surface 18 at the edge 26. During the operation, the front end surface 20 is the front end surface of the molded abrasive particles 14 with reference to the usage direction 22, and the rear surface 28 is arranged on the opposite side to the front end surface 20. In some embodiments, either or both of the front surface 20 and the rear surface 28 may be edges formed at the intersection of the two surfaces.

The first side surface 16, the second side surface 18, the front surface 20, and the rear surface 28 can have any suitable shape. For example, the first side surface 16, the second side surface 18, the front surface 20, and the rear surface 28 can have a polygonal shape that can be a regular polygon or an irregular polygon. In some embodiments, the polygonal shape may substantially match the triangular shape, the quadrangular shape, the pentagonal shape, the hexagonal shape, the heptagonal shape, or the octagonal shape. Other, higher-order polygonal shapes are within the scope of the present disclosure. In embodiments where the shape of the polygon substantially matches the shape of the quadrangle, the shape of the quadrangle can be, for example, a square, a rectangle, or a trapezoid. In embodiments where the shape of the polygon substantially matches the shape of the triangle, the shape of the triangle can be, for example, a right angle triangle, an unequal side triangle, an isosceles triangle, an acute triangle, or an obtuse triangle. In some embodiments, the shape of the triangle is not an equilateral triangle.

The first side surface 16, the second side surface 18, the front surface 20, and the rear surface 28 may have the same shape or different shapes. In addition, the first side surface 16 and the second side surface 18 are substantially the same size or substantially different in at least one of surface area, maximum length dimension, maximum width dimension, or any combination thereof. Can be size. The front surface 20 and the rear surface 28 can each have at least one of a surface area, a maximum length dimension, a maximum width dimension, or any combination thereof smaller than the first side surface 16 and the second side surface 18, respectively. ..

Any of the first side surface 16, the second side surface 18, the front surface 20, and the rear surface 28 may be substantially flat or non-planar. In addition, any of the first side surface 16, the second side surface 18, the front surface 20, and the rear surface 28 can extend substantially parallel or non-parallel to each other. In embodiments where any of the first side surface 16, the second side surface 18, the front end surface 20, and the rear surface 28 is non-planar, their surfaces can have a substantially concave or convex shape. .. In some embodiments, one portion of any one of the first side surface 16, the second side surface 18, the front surface 20, and the rear surface 28 may be substantially planar, and another portion of the same surface may be non-planar. Can be. In some embodiments, one portion of any one of the first side surface 16, the second side surface 18, the front surface 20, and the rear surface 28 may be substantially convex, and another portion of the same surface may be substantially convex. Can be concave.

Any edge, such as edges 24 and 26, may be linear, tapered, or curved, depending on the shape or profile of any one of the first side surface 16, the second side surface 18, the front end surface 20, and the rear surface 28. Can be a profile. The edges that connect one surface to another can be the same length or different lengths. For example, as shown in FIG. 1B, the edge 24 and the edge 26 are parallel and have the same length in the z direction. As a result, the cutting tip 31 of the molded abrasive particles 14 extends parallel to the xy plane. It is understood that the cutting tip 31 refers to an inflection point along the front surface 20 and the rear surface 28. In other embodiments, the edges 24 and 26 have different lengths and the cutting tip 31 is angled so that it is non-parallel to the xy plane. The cutting tip 31 does not have to have a sharp tip with a radius of curvature of at least about 60 microns, at least about 70 microns, at least about 80 microns, at least about 90 microns, or at least about 100 microns.

Any one of the first side surface 16, the second side surface 18, the tip surface 20, and the rear surface 28 has an opening, a concave surface, a convex surface, a groove, a ridge, a damaged surface, a low roundness rate, or a sharp tip. It can include additional shape features such as an outer edge having one or more endpoints.

The molded abrasive particles 14 can be positioned relative to the backing 12 to achieve some performance characteristics of the abrasive belt 10. The positioning of the shaped abrasive particles 14 can be characterized by various different angles of the molded abrasive particles 14 with respect to the backing 12.

For example, the rake angle 30 can be characterized by the angle measured between the backing 12 and the tip surface 20 or the cutting tip 31. As shown in FIG. 1A, the rake angle 30 is about 90 degrees. However, in other embodiments, the rake angle 30 can be selected from values in the range of about 10 degrees to about 170 degrees, about 80 degrees to about 100 degrees, about 85 degrees to about 95 degrees, or about 10 degrees, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 105, 110, 115, 120, 125, 130, 135, 140, For values of 145, 150, 155, 160, 165, or about 170 degrees, it may be less than, equal to, or greater than this. The value of the rake angle 30 can be selected according to the intended purpose of the polishing belt 10. For example, if the rake angle 30 is 90 degrees or less, the polished article is sufficient to remove material from the workpiece, achieve a deep cut into the workpiece, or remove large debris from the workpiece. Can be suitable for. Conversely, if the rake angle 30 exceeds 90 degrees, the polishing belt 10 may still have some of the above properties, but may be even better suited for finishing the surface of the workpiece.

In some embodiments of the polishing belt 10, it may be desirable that a certain percentage of the molded polishing particles 14 have substantially the same rake angle 30. For example, in some embodiments, the rake angles 30 of about 50% to about 100% of the molded abrasive particles are substantially the same, or about 90% to about 100%, or about 50%, 55, 60. , 65, 70, 75, 80, 85, 90, 95, or 100%, less than, equal to, or greater than this. It may be desirable for 100% of the abrasive particles 14 or the abrasive belt 10 to share the same rake angle 30 in order to achieve consistent performance in the abrasive belt 10. However, in some embodiments of the polishing belt 10, it may be desirable to have different rake angles. For example, some embodiments of the polishing belt 10 may include a plurality of rows of polishing particles 14. With respect to FIG. 1A, three rows 40, 42, and 44 are shown, but other embodiments of the polishing belt 10 may include fewer or more rows. As shown, each of the columns 40, 42, or 44 extends in the y direction, and adjacent columns (eg, 40 and 42 and 42 and 44) are separated from each other in the x direction. In an embodiment including a plurality of rows, each polishing particle 14 in one row can have the same rake angle 30. For example, each of the shaped abrasive particles 14 in row 44 can have the same rake angle 30. Further, each of the shaped abrasive particles 14 in row 42 can have the same rake angle 30, which rake angle 30 can be different from the rake angle of the shaped abrasive particles 14 in row 42. Further, each of the shaped abrasive particles 14 in row 44 can have the same rake angle 30, which rake angle 30 can be different from the rake angle of the shaped abrasive particles 14 in rows 42 and 40. In this way, a gradient of the rake angle 30 can be created in the polishing belt 10.

The clearance angle 46 is characterized by an angle measured between the backing 12 and the cutting tip 31 at the inflection point of the rear surface 28. As shown in FIG. 1A, the clearance angle 46 is measured along the rear surface 28 between the backing 12 and the cutting tip 30. In various embodiments, the clearance angle 46 may range from about 90 degrees to about 180 degrees, about 120 degrees to about 140 degrees, or about 90 degrees, 95, 100, 105, 110, 115, 120. , 125, 130, 135, 140, 145, 150, 155, 160, 165, 170, 175 degrees, or about 180 degrees, less than, equal to, or greater than. In some embodiments, the difference between the rake angle 30 and the clearance angle 46 may range from about 5 degrees to about 50 degrees, about 10 degrees to about 40 degrees, or about 5 degrees to 10 degrees. , 15, 20, 25, 30, 35, 40, 45, or about 50 degrees may be less than, equal to, or greater than this. The value of the clearance angle 46 can be selected according to the intended purpose of the polishing belt 10. For example, as the clearance angle 46 approaches a higher value, the polishing belt 10 may be able to finish the surface (eg, if the use direction 22 is reversed to the second use direction). Further, if the clearance angle is a higher value, the material removed from the workpiece can be discharged, which may help prevent clogging of the polishing belt 10. However, in some embodiments, having a lower clearance angle 46 helps to strengthen the attachment of the abrasive particles 14 to the backing when a force is applied to the abrasive belt 10 during operation. obtain.

In some embodiments of the polishing belt 10, it may be desirable that a certain percentage of the molded polishing particles 14 have substantially the same clearance angle 46. For example, in some embodiments, about 50% to about 100%, or about 90% to about 100%, or about 50%, 55, 60, 65, 70, 75, 80, 85, 90 of the molded abrasive particles. , 95, or 100%, the clearance angle 46 of less than, equal to, or greater than this is substantially the same. It may be desirable for 100% of the abrasive particles 14 or the abrasive belt 10 to share the same clearance angle 46 in order to achieve consistent performance in the abrasive belt 10. However, in some embodiments of the polishing belt 10, it may be desirable to have different clearance angles 46. For example, each of the molded abrasive particles 14 in row 44 can have the same clearance angle 46. Further, each of the molded abrasive particles 14 in the row 42 can have the same clearance angle 46, but the clearance angle 46 is different from the clearance angle of the molded abrasive particles 14 in the row 42. Further, each of the molded abrasive particles 14 in row 44 can have the same clearance angle 46, which is different from the clearance angle of the molded abrasive particles 14 in rows 42 and 40. In this way, a gradient of the clearance angle 46 can be created in the polishing belt 10.

The draft α48 is characterized by an angle measured between the backing 12 and any one of the first side surface 16 and the second side surface 18. As shown in FIG. 1B, the draft exit α48 is about 90 degrees. However, in other embodiments, the draft exit α48 can range from about 90 degrees to about 130 degrees, about 95 degrees to about 120 degrees, or about 90 degrees, 100, 105, 110, 115, 120, 125. Degrees, or values of about 130 degrees, may be less than, equal to, or greater than this. In some embodiments of the polishing belt 10, it may be desirable that a certain percentage of the molded polishing particles 14 have substantially the same draft loss α48. For example, in some embodiments, the draft α48 of about 50% to about 100% of the molded abrasive particles is substantially the same, or about 90% to about 100%, or about 50%, 55, 60. , 65, 70, 75, 80, 85, 90, 95, or 100%, less than, equal to, or greater than. It may be desirable for 100% of the abrasive particles 14 or the abrasive belt 10 to share a draft α48 to achieve consistent performance in the abrasive belt 10. However, in some embodiments of the polishing belt 10, it may be desirable to have a different draft α48. For example, each of the molded abrasive particles 14 in row 44 can have the same draft α48. Further, each of the shaped abrasive particles 14 in the row 42 can have the same draft α48, but this draft α48 is different from the draft of the formed abrasive particles 14 in the row 42. Further, each of the shaped abrasive particles 14 in row 44 can have the same draft α48, but this draft α48 is different from the draft of the formed abrasive particles 14 in rows 42 and 40. In this way, a gradient of the draft exit gradient α48 can be created in the polishing belt 10. Alternatively, the drafts α48 of adjacent molded abrasive particles in the same row are different and can create a gradient in the y direction.

A further angle that characterizes the shaped abrasive particles 14 can be the z-direction rotation angle 50. As shown in FIG. 1C, the z-direction rotation angle 50 can be defined between the line 52 intersecting the first edge 24 and the second edge 26 and the usage direction 22. The Z-direction rotation angle 50 may range from about 10 degrees to about 170 degrees, about 80 degrees and about 100 degrees, about 85 degrees and about 95 degrees, or about 10, 15, 20, 25, 30. , 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 105, 110, 115, 120, 125, 130, 135, 140, 145, 150, 155. , 160, 165, or about 170 degrees, less than, equal to, or greater than this.

In some embodiments of the polishing belt 10, it may be desirable that a certain percentage of the molded polishing particles 14 have substantially the same z-direction rotation angle 50. For example, in some embodiments, the z-direction rotation angles 50 of about 50% to about 100% of the molded abrasive particles are substantially the same, or about 90% to about 100%, or about 50%, 55. , 60, 65, 70, 75, 80, 85, 90, 95, or 100%, less than, equal to, or greater than. It may be desirable for 100% of the abrasive particles 14 or the abrasive belt 10 to share the same z-direction rotation angle 50 in order to achieve consistent performance in the abrasive belt 10. However, in some embodiments of the polishing belt 10, it may be desirable to have different z-direction angles of rotation 50. For example, each of the molded abrasive particles 14 in row 44 can have the same z-direction rotation angle 50. Further, each of the molded and polished particles 14 in the row 42 can have the same z-direction rotation angle 50, but the z-direction rotation angle 50 is different from the z-direction rotation angle of the molded and polished particles 14 in the row 42. Further, each of the molded and polished particles 14 in the row 44 can have the same z-direction rotation angle 50, but the z-direction rotation angle 50 is the same as the z-direction rotation angle of the molded and polished particles 14 in the rows 42 and 40. different. In this way, a gradient of the z-direction rotation angle 50 can be created in the polishing belt 10. Alternatively, the z-direction rotation angles 50 of adjacent molded abrasive particles in the same row are different, and a gradient can be created in the y-direction.

1A-1C show abrasive particles 14 having a generally triangular shape that matches a right triangle. However, from the above viewpoint, it is possible that any molded abrasive particle 14 of the abrasive belt 10 has one of many other suitable shapes. As an example, FIG. 2 shows a side view of a polishing belt 10A containing molded polishing particles 14A. As shown in the figure, the molded abrasive particles 14A have a substantially triangular shape, but the tip surface 20A has both a convex portion 32 and a concave portion 34. In embodiments such as when the tip surface 20A is non-linear, the rake angle 30 can be determined by measuring the angle between the backing 12 and the line 54. The line 54 is a tangent to the cutting tip 31.

1A-1C and 2 show an embodiment in which the polished article is a polishing belt or a polishing sheet adapted to linear motion. However, in other embodiments, the polished article can be a polishing disc adapted to rotational motion. FIG. 3 is a bottom view of the polishing disc 60. The polishing disc 60 is adapted to rotate about the central axis 62. The rotation use direction 22A can be determined by the tangent line of the outer peripheral portion 64 of the polishing disc 60.

In the polishing disc 60, the molded polishing particles 14 can have the same characteristics as the polishing belt 10. For example, the molded abrasive particles may have the same rake angle 30, draft α48, clearance angle 46, and angle of rotation 50 in the z direction as described herein in connection with FIGS. 1A-1C and 2. can. Each of the rake angle 30, draft α48, and clearance angle 46 can be measured and determined in a manner consistent with the methods described above in relation to FIGS. 1A-1C and 2. In order to measure the z-direction rotation angle 50 of each molded polishing particle 14 in the polishing disk 60, the center of mass 66 of each molded polishing particle 14 is determined. A line 68 is drawn from the central axis 62 through the center of mass 66 to the outer circumference 64. The tangent line of the outer circumference 64 represents the usage direction 22A at the intersection of the line 68 and the outer circumference 64, and this is overlapped on the molded polishing particles 14 so as to pass through the mass center 66 and the tip surface 20. Next, the Z-direction rotation angle 50 is measured between the overlapped tangents 22A and 52.

The molded abrasive particles 14 can occupy 100% by weight of the abrasive particles in any abrasive article. Alternatively, the molded abrasive particles 14 may be part of a blend of abrasive particles distributed on the backing 12. When present as part of the blend, the shaped abrasive particles 14 range from about 5% to about 95% by weight, about 10% to about 80% by weight, and about 30% to about 50% by weight of the blend. May be, or about 5% by weight, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or about 95% by weight. The value may be less than, equal to, or greater than this. In the blend, the remainder of the abrasive particles may include conventional milled abrasive particles. Milled abrasive particles are generally formed by mechanical milling operations and do not have a duplicated shape. The balance of the abrasive particles can also include other molded abrasive particles, such as an equilateral triangular shape (eg, a planar triangular shaped abrasive particle or a tetrahedral abrasive with each face of the tetrahedron being an equilateral triangle). Particles).

Any polishing article, such as the polishing belt 10 or the polishing disc 60, may include a forming polishing particle 14, or a make-up coat for adhering a blend of the forming polishing particle 14 to the pulverized polishing particle to the backing 12. The polished article may further include a size coat for adhering the molded abrasive particles to the make coat. Make coats, size coats, or both are any suitable resins such as phenolic resins, epoxy resins, urea formaldehyde resins, acrylate resins, aminoplast resins, melamine resins, acrylicized epoxy resins, urethane resins, and mixtures thereof. Can be included. In addition, make coats, size coats, or both can include fillers, grinding aids, wetting agents, surfactants, dyes, pigments, coupling agents, adhesion promoters, or mixtures thereof. Examples of fillers include calcium carbonate, silica, talc, clay, calcium metasilicate, dolomite, aluminum sulphate, and mixtures thereof.

The molded abrasive particles 14 can be formed by many suitable methods, for example, the molded abrasive particles 14 can be produced according to a plurality of operational processes. This process can be carried out using any material or precursor dispersion material. Briefly, in the embodiment where the shaped abrasive particles are monolithic ceramic particles, this process can be converted to a corresponding one with a seeded or non-seeded precursor dispersion (eg, alpha alumina). The operation of producing any of the boehmite sol-gel) that can be converted into An operation of drying the dispersion to form precursor-molded abrasive particles, an operation of removing the precursor-formed abrasive particles 14 from the mold cavity, and an operation of calcining the precursor-formed abrasive particles 14 to obtain a calcined precursor. The operation of forming the molded abrasive particles 14 and then the operation of sintering the calcined precursor molded abrasive particles 14 to form the molded abrasive particles 14 may be included. Next, this process will be described in more detail in relation to the alpha alumina-containing molded abrasive particles 14. In other embodiments, the mold cavity may be filled with melamine to form melamine molded abrasive particles.

This process can include the operation of providing either a seed crystal-added or non-seed crystal-free dispersion of the precursor that can be converted to ceramic. In the example in which the precursor is added with a seed crystal, an iron oxide (for example, FeO) can be added with the seed crystal to the precursor. The precursor dispersion can include a liquid that is a volatile component. In one example, the volatile component is water. The dispersion can contain a sufficient amount of liquid to sufficiently reduce the viscosity of the dispersion and allow filling of the mold cavity and replication of the mold surface, but the mold cavity of the liquid that follows. It cannot contain large amounts of liquid that would be very expensive to remove from. In one example, the precursor dispersion is 2% to 90% by weight of particles that can be converted to ceramics such as aluminum oxide monohydrate (boehmite) particles, and at least 10% by weight, or 50% by weight to. Contains 70% by weight, or 50% to 60% by weight, volatile components such as water. Conversely, in some embodiments, the precursor dispersion comprises 30% to 50% by weight or 40% to 50% by weight of solids.

Examples of suitable precursor dispersions include zirconium oxide sol, vanadium oxide sol, cerium oxide sol, aluminum oxide sol, and combinations thereof. Suitable aluminum oxide dispersions include, for example, boehmite dispersions and other aluminum oxide hydrate dispersions. Boehmite can be prepared by a known technique or commercially available. Examples of commercially available boehmite are both Sasol North America, Inc. Examples thereof include products having the trademark names "DISPERAL" and "DISPAL" available from BASF Corporation, or products having the trademark names "HIQ-40" available from BASF Corporation. These aluminum oxide monohydrates are relatively pure, i.e., they have a relatively small amount, even if they contain a hydrate phase other than the monohydrate, and have a high surface area.

The physical properties of the resulting molded abrasive particles 14 may largely depend on the type of material used for the precursor dispersion. As used herein, a "gel" is a three-dimensional network of solids dispersed in a liquid.

The precursor dispersion may contain a modifying additive or a precursor of the modifying additive. The modifying additive can function to enhance some desired properties of the abrasive particles or to enhance the effectiveness of the subsequent sintering steps. The modifying additive or precursor of the modifying additive can be in the form of a soluble salt, such as a water-soluble salt. These can include metal-containing compounds, magnesium, zinc, iron, silicon, cobalt, nickel, zirconium, hafnium, chromium, ytterbium, praseodymium, samarium, ytterbium, neodymium, lanterns, gadolinium, cerium, dysprosium, erbium, titanium. It can be a precursor of an oxide of the above, and a mixture thereof. The specific concentration of these additives that can be present in the precursor dispersion can be varied.

By introducing a modifying additive or a precursor of a modifying additive, the precursor dispersion can become a gel. The precursor dispersion can also be induced in the gel by applying heat over a period of time to reduce the liquid content in the dispersion by evaporation. The precursor dispersion may also contain a nucleating agent. Suitable nucleating agents for the present disclosure include fine particles of alpha alumina, ferric oxide or precursors thereof, titanium oxide and titanate, chromium oxide, or any other material that is the nucleus of the transition. Can be done. If a nucleating agent is used, its amount should be sufficient to result in the transfer of alpha alumina.

A glazing agent can be added to the precursor dispersion to produce a more stable hydrosol or colloidal precursor dispersion. Suitable lytic agents are monobasic acids or acid compounds such as acetic acid, hydrochloric acid, formic acid and nitric acid. Polybasic acids can also be used, but polybasic acids can rapidly gel precursor dispersions, making handling or introduction of additional components difficult. Some commercial sources of boehmite include acid titers (such as absorbed formic acid or nitric acid) that aid in the formation of stable precursor dispersions.

The precursor dispersion can be formed by any suitable means. For example, in the case of the solgel alumina precursor, the aluminum oxide monohydrate is mixed with water containing a thawing agent, or a slurry of aluminum oxide monohydrate is formed, and the thawing agent is added thereto. It can be formed by doing.

Defoamers or other suitable chemicals can be added to reduce the tendency to form bubbles or mix with air during mixing. Additional chemicals such as wetting agents, alcohols, or coupling agents can be added as needed.

Further operations may include providing a mold having at least one mold cavity, or a mold having a plurality of cavities formed on at least one main surface of the mold. In some examples, the mold is formed as a production tool, which is formed with, for example, a coating roll such as a belt, a sheet, a continuous web, a rotating gravure roll, a sleeve mounted on the coating roll, or a die. can do. In one example, the means of production can include polymeric materials. Examples of suitable polymer materials include polyester, polycarbonate, poly (ether sulfone), poly (methyl methacrylate), polyurethane, polyvinyl chloride, polyolefin, polystyrene, polypropylene, polyethylene, or thermoplastic resins such as combinations thereof, or Examples include thermoplastic materials. In one example, the entire tool is made from a polymeric or thermoplastic material. In another example, the tool surface that comes into contact with the ceramic precursor dispersion while the precursor dispersion is drying, eg, the surface of the plurality of cavities, comprises a polymeric or thermoplastic material and the other part of the tool. It can be made from other materials. A suitable polymer coating may be applied to the metal tool to alter surface tension properties, for example.

Polymer tools or thermoplastic production tools can be duplicated from metal master tools. The master tool can have the reverse pattern of what is desirable for the means of production. The master tool can also be made in the same way as the production tool. In one example, the master tool is made of metal (eg nickel) and diamond-turned. In one example, the master tool is formed at least partially using stereolithography. The polymer sheet material can be heated together with the master tool so that the polymer material is embossed with the master tool pattern by pressure forming the two together. Polymers or thermoplastics can also be extruded or cast onto a master tool and then pressure molded. The thermoplastic material is cooled and solidified to produce the means of production. When using a thermoplastic production tool, care must be taken not to distort the thermoplastic production tool and generate excessive heat that may limit its life.

The cavity can be accessed through an opening on the top or bottom of the mold. In some examples, the cavity can extend over the entire thickness of the mold. Alternatively, the cavity can extend only over a portion of the mold thickness. In one example, the top surface is substantially parallel to the bottom surface of the mold with a cavity having a substantially uniform depth. At least one side of the mold, the side on which the cavity is formed, can remain exposed to the surrounding open air during the step of removing volatile components.

The cavity has a specific three-dimensional shape for making the molded abrasive particles 14. The depth dimension is equal to the vertical distance from the top to the bottom of the bottom. The depth of a given cavity can be uniform or can vary along its length and / or width. The cavities of a given mold can have the same shape or different shapes.

A further operation involves filling the cavity in the mold with a precursor dispersion (eg, by conventional techniques). In some examples, a knife roll coater or a vacuum slot die coater can be used. If desired, a mold release agent can be used to assist in removing the particles from the mold. Examples of the release agent include oils such as peanut oil or mineral oil, fish oil, silicone, polytetrafluoroethylene, zinc stearate, and graphite. Generally, if a mold release agent is desired, about 0.1 mg / in ² (0.6 mg / cm ² ) to about 3.0 mg / in ² (20 mg / cm ² ), or about 0, per unit area of the mold. Separation of peanut oil, etc. in a liquid such as water or alcohol so that there is a mold release agent of 1 mg / in ² (0.6 mg / cm ² ) to about 5.0 mg / in ² (30 mg / cm ^2). The mold is applied to the surface of the production tool that the precursor dispersion comes into contact with. In some embodiments, the top surface of the mold is coated with a precursor dispersion. The precursor dispersion can be pumped onto the top surface.

In a further operation, a scraper or break-in rod can be used to push the precursor dispersion completely into the mold cavity. The rest of the precursor dispersion that does not enter the cavity can be removed from the top of the mold and reused. In some examples, a small portion of the precursor dispersion may remain on the top surface, in other cases there is virtually no dispersion on the top surface. The pressure applied by the scraper or break-in bar can be less than 100 psi (0.6 MPa), less than 50 psi (0.3 MPa), or even less than 10 psi (60 kPa). In some examples, the exposed surface of the precursor dispersion does not extend substantially beyond the top surface.

In these examples, the exposed surface of the cavity is desired to be a flat surface of the molded abrasive particles, overfilling the cavity (eg, using a micronozzle array) and slowly drying the precursor dispersion. May be desirable.

Further operations involve removing volatile components and drying the dispersion. Volatile components can be removed by high evaporation rates. In some examples, the removal of volatile components by evaporation occurs at temperatures above the boiling point of these volatile components. The upper limit of the drying temperature is often determined by the material from which the mold is made. For polypropylene tools, the temperature should be below the melting point of the plastic. In one example, for an aqueous dispersion of about 40-50% solids and a polypropylene mold, the drying temperature is about 90 ° C to about 165 ° C, or about 105 ° C to about 150 ° C, or about 105 ° C to about. It can be 120 ° C. Higher temperatures can improve production rates, but can also degrade polypropylene tools and limit their useful life as a mold.

During drying, the precursor dispersion shrinks, often causing retraction from the cavity wall. For example, if the cavity has a flat wall, the resulting molded abrasive particles 14 may tend to have at least three concave main surfaces. In the present invention, it has been found that by making the cavity wall concave (increasing the cavity volume), it is possible to obtain molded abrasive particles 14 having at least three substantially flat main surfaces. The degree of recessing generally depends on the solid content of the precursor dispersion.

A further operation involves removing the resulting precursor-molded abrasive particles 14 from the mold cavity. The precursor-formed abrasive particles 14 are removed from the cavity by using the processes of gravity, vibration, ultrasonic vibration, vacuum, or pressurized air in the mold alone or in combination and removing the particles from the mold cavity. be able to.

The precursor-molded abrasive particles 14 can be further dried outside the mold. This additional drying step is not necessary if the precursor dispersion is dried to the desired level in the mold. However, in some cases it may be economical to employ this additional drying step to minimize the time that the precursor dispersion stays in the mold. The precursor-molded abrasive particles 14 are dried for 10 to 480 minutes or 120 to 400 minutes at a temperature of 50 ° C. to 160 ° C. or 120 ° C. to 150 ° C.

A further operation involves calcination of the precursor forming abrasive particles 14. During calcination, essentially all volatile materials are removed and the various components present in the precursor dispersion are converted to metal oxides. The precursor-molded abrasive particles 14 are generally heated to a temperature of 400 ° C. to 800 ° C. and maintained within this temperature range until free water and any bound volatile material in excess of 90% by weight are removed. .. In the optional step, it may be desirable to introduce a modifying additive by the impregnation process. The water-soluble salt can be introduced by impregnating the pores of the calcinated precursor-molded abrasive particles 14. Next, the precursor-molded abrasive particles 14 are pre-baked again.

A further operation may involve sintering the calcined precursor-molded abrasive particles 14 to form the particles. However, in some cases where the precursor contains rare earth metals, sintering may not be required. Prior to sintering, the calcined precursor molded abrasive particles 14 are not perfectly compact and therefore lack the desired hardness for use as the molded abrasive particles 14. Sintering is performed by heating the calcined precursor-molded abrasive particles 14 to a temperature of 1000 ° C to 1650 ° C. The length of time it takes to expose the calcined precursor-formed abrasive particles 14 to the sintering temperature to obtain this level of conversion depends on a variety of factors, but can be from 5 seconds to 48 hours. ..

In other embodiments, the duration of the sintering step ranges from 1 minute to 90 minutes. After sintering, the molded abrasive particles 14 can have a Vickers hardness of 10 GPa (gigapascal), 16 GPa, 18 GPa, 20 GPa, or more.

Described using additional operations, such as rapidly heating the material from calcination temperature to sintering temperature, and centrifuging the precursor dispersion to remove sludge and / or waste. You can change the process. In addition, this process can be modified by combining two or more process steps, if desired.

The molded abrasive particles 14 can be individually sized according to a defined nominal grade recognized in the abrasive industry. The grade standards recognized in the polishing industry are promulgated by ANSI (American National Standards Institute), FEPA (Federation of European Producers of Abrasives) and JIS (Japanese Industrial Standards). Some are listed. ANSI grade notation (ie, defined nominal grade) includes, for example, ANSI4, ANSI6, ANSI8, ANSI16, ANSI24, ANSI36, ANSI46, ANSI54, ANSI60, ANSI70, ANSI80, ANSI90, ANSI100, ANSI120, ANSI150, ANSI180, ANSI220, ANSI240, ANSI280. , ANSI320, ANSI360, ANSI400 and ANSI600. FEPA grade notation includes F4, F5, F6, F7, F8, F10, F12, F14, F16, F18, F20, F22, F24, F30, F36, F40, F46, F54, F60, F70, F80, F90, Examples thereof include F100, F120, F150, F180, F220, F230, F240, F280, F320, F360, F400, F500, F600, F800, F1000, F1200, F1500 and F2000. JIS grade notation is JIS8, JIS12, JIS16, JIS24, JIS36, JIS46, JIS54, JIS60, JIS80, JIS100, JIS150, JIS180, JIS220, JIS240, JIS280, JIS320, JIS360, JIS400, JIS600, JIS800, JIS1000, JIS1. , JIS2500, JIS4000, JIS6000, JIS8000, and JIS10,000.

In addition to the materials already described, at least one magnetic material may be included or coated in the individual molded abrasive particles 14. Examples of magnetic materials include iron; cobalt; nickel; various alloys of nickel and iron commercially available as Permalloally in various grades; iron, nickel, commercially available as Fernico, Kovar, FerNiCo I, or FerNiCo II. And various alloys of cobalt; various alloys of iron, aluminum, nickel, cobalt, and possibly copper and / or titanium commercially available as Alnico in various grades; iron, silicon, commercially available as Sendust alloys. And iron alloys (weight ratio about 85: 9: 6); Heusler alloys (eg Cu ₂ MnSn); manganese bismuthized (also known as Bismanol); rare earth magnetizable materials such as gadolinium, dysprosium, formium, Europium oxide, neodymium-iron-boron alloys (eg Nd ₂ Fe ₁₄ B), and samarium-cobalt alloys (eg SmCo ₅ ); MnSb; MnOFe ₂ O ₃ ; Y ₃ Fe ₅ O ₁₂ ; CrO ₂ MnAs; ferrites such as ferrite, magnetite _; zinc ferrite; nickel ferrite; cobalt ferrite, magnesium ferrite, barium ferrite, and strontium ferrite; yttrium iron garnet; and combinations thereof. In some embodiments, the magnetizable material is 8-12% by weight (wt%) aluminum, 15-26% by weight nickel, 5-24% by weight cobalt, up to 6% by weight copper, up to 6% by weight. It is an alloy containing 1% titanium, and the balance for making 100% by weight is iron. In some other embodiments, a magnetizable coating can be deposited on the abrasive particles 14 using, for example, a vapor deposition technique such as physical vapor deposition (PVD) involving magnetron sputtering.

The inclusion of these magnetizable materials allows the molded abrasive particles 14 to respond to a magnetic field. All of the molded abrasive particles 14 may contain the same material or may contain different materials. In addition, the molded abrasive particles 14 and the ground abrasive particles, if present, may contain the same material or may contain different materials.

The polished articles described herein can be produced according to many suitable methods. The method described herein can allow accurate placement of at least a portion of the molded abrasive particles 14 on the backing 12. This allows accurate and predetermined alignment of the small surfaces 20. This makes it possible to form various predetermined patterns of the molded abrasive particles 14. For example, in the polishing belt 10, the z-direction rotation angle 50 of the molded polishing particles 14 can be positioned so that the pattern formed by the molding polishing particles 14 includes a plurality of parallel lines. As a further example, in the polishing disc 60, the z-direction rotation angle 50 of the molding polishing particles 14 can be positioned so that the pattern formed by the molding polishing particles 14 includes a plurality of circles.

The polished articles described herein can be produced according to any suitable method. Generally speaking, the polished article has a rake angle of 30, a z-direction rotation angle of 50, a clearance angle of 46, a draft of α48, or at least one of these combinations of molded abrasive particles 14 on the backing 12. It can be formed by orienting at least a part. The method may further include adhering the molded abrasive particles 14 to the backing 12.

Orientation of the abrasive particles 14 can be achieved, for example, by including one or more cavities within the backing 12. The cavity has individual shaped abrasive particles 14 on the backing 12 such that at least one of a rake angle 30, a z-direction rotation angle 50, a clearance angle 46, a draft α48, or a combination thereof achieves a predetermined value. It can be molded in such a way that it is positioned in.

The inclusion of cavities in the backing 12 allows the abrasive particles 14 to be drop-coated or electrostatically coated on the backing 12 while achieving the intended orientation. As is generally understood, in drop coating technology, the bulk feed of abrasive particles 14 is fed through a hopper, falls onto the backing 12 under gravity and lands in the cavity. Without the cavity, the spatial orientation of the abrasive particles 14 upon contact with the backing 12 would be totally random in all directions. However, the cavity eliminates the random spatial orientation.

In other embodiments, the exact orientation of the shaped abrasive particles 14 can be achieved using a distribution tool or screen. The distribution tool or screen can include one or more slots defined by multiple walls. Slots can be opened on two ends. One end can be configured to receive the shaped abrasive particles 14, and the other end can contact the backing 12. The backing 12 can optionally have a make-up coat distributed on it. The slot is where the individual abrasive particles 14 are positioned on the backing 12, resulting in a rake angle of 30, a z-direction rotation angle of 50, a clearance angle of 46, a draft α48, or at least one of a combination thereof. Designed to achieve the value. Particles that do not fit properly into the cavity can be removed from the distribution tool, and additional particles can be brought into contact with the distribution tool into empty slots.

The distribution tool containing the molded abrasive particles 14 can be kept in contact with the backing 12 for any suitable time as the molded abrasive particles 14 adhere to the make coat. After sufficient time has elapsed for good adhesion between the shaped abrasive particles 14 and the make coat, the means of production are removed and the size coat is optionally placed on the shaped abrasive particles 14.

In another embodiment, the exact orientation of the shaped abrasive particles 14 can be achieved using a rotary means of production tool. Rotating tools are circular and contain multiple cavities on the outer surface. Each of the cavities is designed to receive the shaped abrasive particles 14 in a particular orientation. Excess molded abrasive particles 14 are brought into contact with the means of production to increase the probability that each cavity will be filled. The molded abrasive particles 14 that do not enter the cavity are recovered for later use. Once fixed in the cavity, the molded abrasive particles 14 come into contact with the backing 12 which can be supplied as a web. The backing 12 can have a pre-arranged make-up coat on it, so that the molded abrasive particles 14 adhere to the backing 12 when in contact and are removed from the production tool.

In other embodiments, the exact orientation of the molded abrasive particles 14 can be achieved using the molded abrasive particles containing at least some magnetic material. Molded abrasive particles containing the magnetic material can be randomly arranged on the backing 12. The shaped abrasive particles 14 are then placed in a magnetic field in such a way that the formed abrasive particles 14 are rotated and aligned so as to achieve at least one of a rake angle 30, a z-direction rotation angle 50, a clearance angle 46, and a draft α48. Can be exposed. When properly oriented, the molded abrasive particles 14 can be adhered to the backing 12 using a make coat and optionally a size coat. As a result of this process, the individual abrasive particles 14 are backed so that at least one of a rake angle 30, a z-direction rotation angle 50, a clearance angle 46, a draft α48, or a combination thereof achieves a predetermined value. Positioned on 12. An example of this process is described in more detail below in connection with FIGS. 4-7.

FIG. 4 shows a web 110 containing a backing 115 on which the make layer precursor 120 is placed, the web moving in the downweb direction 114 (eg, mechanical direction) along the web path 112. The web 110 has a cross-web direction (not shown) perpendicular to the down web direction 114. The make-up layer precursor 120 contains a first curable binder precursor (not shown). The magnetizable particles 132 (having a structure corresponding to the molded abrasive particles 14) fall onto the make-up layer precursor 120 through a portion of the applied magnetic field 140. At least a portion of the magnetizable particles 132 are abrasive particles. The magnetizable particles 132 are fed from the hopper 175, move downward on the dispensing surface 185, and then deposit predominantly on the web 110. The longest side of the magnetizable abrasive particles tends to align with the applied magnetic field 140 while moving down the downwardly inclined distribution surface 185. Various web handling components 180 (eg, rollers, conveyor belts, feed rolls, and take-up rolls) handle the web 110.

Throughout the method, the magnetizable particles are continuously oriented by the applied magnetic field, at least until the magnetizable abrasive particles move to the make precursor layer, the longest axis of which is substantially parallel to the magnetic field lines 165. Or antiparallel). After migration, the applied magnetic field may continue to have an orientation effect on the magnetizable abrasive particles, but this is not required.

In general, the applied magnetic fields used in the practice of the present disclosure have a magnetic field strength in the region of magnetizable particles affected (eg, attraction and / or orientation) of at least about 10 gauss (1 mT) and at least about 100 gauss (10 mT). ), Or at least about 1000 gauss (0.1T), but this is not required.

The applied magnetic field may be provided, for example, by one or more permanent magnets and / or electromagnets, or a combination of magnets and ferromagnetic members. Rare earth magnets, including magnetizable materials, are described herein as suitable permanent magnets. The applied magnetic field can be a static magnetic field or a fluctuating (eg, vibration) magnetic field. The upper and / or lower magnetic members (152, 154) may be monolithic, each having an north pole and an south pole, or may be magnetized with multiple component magnets (154a, 154b) and / or magnetized. It may consist of a body. When composed of a plurality of magnets, the plurality of magnets in a given magnetic member are continuous and / or co-aligned (eg, at least substantially parallel) with respect to the magnetic field lines of which the constituent magnets are closest to each other. ) Can be. Stainless steel retainers 156, 158a, and 158b hold the magnet in place. Stainless steel 304 or equivalent is suitable due to its non-magnetic properties, but magnetizable materials can also be used. Mild steel mounts 162 and 164 support stainless steel retainers 156, 158a and 158b, respectively. Although steel mounts are shown in FIG. 4, the mounts may be made of any dimensionally stable material, whether magnetizable or not.

The downwardly inclined distribution surface may be inclined at any suitable angle, provided that the magnetizable particles can move downward on the surface and be distributed on the web. Suitable angles may be in the range of 15-60 degrees, but other angles may also be used. In some cases, it may be desirable to vibrate the downwardly inclined distribution surface, for example, to facilitate the movement of the particles.

The downwardly inclined distribution surface may be made of any dimensionally stable material or may be non-magnetizable. Examples include metals such as aluminum, wood, and plastics.

5 to 7 show the general process of FIG. 4, where the downwardly inclined distribution surface 185 moves onto the web 110 depending on the position of the downwardly inclined distribution surface 185 within the applied magnetic field 140. Shows the alignment of the magnetizable particles 132 in.

For example, in the configuration shown in FIG. 5, the magnetizable shaped abrasive particles 132 are distributed on the web 110, where the magnetic field lines 165 form a downweb angle α of less than 90 degrees with the web 100, whereby the particles are: When navigating to the web, the long edges achieve an orientation that slopes upward from right to left. As shown, the magnetizable molded abrasive particles 132 slide down the downwardly inclined distribution surface 185 and begin to orient their longest edges aligned with the magnetic field lines 165. The magnetizable molded abrasive particles 132 are tilted down web upon contact with the make layer precursor 120 of the web 110. The gravity and / or downward magnetic member allows the magnetically molded abrasive particles to rest on the make layer precursor 120, and after curing, the particles substantially adhere to the backing 115. Most of the magnetizable shaped abrasive particles 132 are between the backing of the magnetizable shaped abrasive particles and the tip edge in the nominal rake angle (eg, upweb or downweb). Angle) is glued at about 90 degrees in the upweb direction.

Referring here to the configuration shown in FIG. 6, the magnetizable molded abrasive particles 132 are oriented so that their longest edges tilt upward either from right to left or left to right when moved to the web 110. Align to achieve. The magnetizable molded abrasive particles 132 slide down the downwardly inclined dispensing surface 185 and begin to orient their longest edges aligned with the magnetic field lines 165. The magnetizable molded abrasive particles 132 are distributed on the web 110, where the lines of magnetic force 165 are approximately perpendicular to the web 110. The magnetizable molded abrasive particles 132 are placed on the web 110 with their longest edges approximately perpendicular to the backing. This allows the particles to rotate around their longest edges. The lower magnetic member and / or gravity causes the magnetizable molded abrasive particles 132 to rest on the make layer precursor 120, and after curing, the particles are adhered to the backing 115. Approximately equal proportions of magnetizable molded abrasive particles have a nominal 90 degree rake angle facing downweb as facing upweb.

In the configuration shown in FIG. 7, the magnetizable molded abrasive particles 132 are aligned so that when moved to the web, their long edges achieve an orientation that slopes upward from left to right. As the magnetizable molded abrasive particles 132 slide down the downwardly inclined dispensing surface 185, the particles begin to orient their longest edges aligned with the magnetic field lines 165. The magnetizable molded abrasive particles 132 are distributed on the backing, where the down web angle β of the magnetic field lines 165 with the web 100 exceeds 90 degrees. When the particles come into contact with the web, they tilt forward in the down web direction. The lower magnetic member and / or gravity causes the magnetizable molded abrasive particles 132 to rest on the make layer precursor 120, and after curing, the particles are adhered to the backing 115. Most of the magnetizable molded abrasive particles 132 are adhered to the web 110 at a rake angle of about 90 degrees in the downweb direction.

When the magnetizable particles are coated on the curable binder precursor, they are at least partially cured at a first curing station (not shown) to hold the magnetizable particles firmly in place. In some embodiments, additional magnetizable and / or non-magnetizable particles (eg, filler abrasive particles and / or abrasive particles) can be applied to the make-up layer precursor prior to curing. ..

In the case of coated abrasive articles, the curable binder precursor comprises a make-up layer precursor and the magnetizable particles include magnetizable abrasive particles. The size layer precursor may be applied at least on the partially cured make layer precursor and magnetizable abrasive particles, but this is not essential. If present, the size layer precursor is then at least partially cured at the second curing station and optionally further cured at least partially cured make layer precursor. In some embodiments, the supersize layer is placed on a size layer precursor that is at least partially cured.

According to various embodiments, the method of using a polished article such as a polishing belt 10 or a polishing disc 60 comprises bringing the molded abrasive particles 14 into contact with a workpiece or substrate. The workpiece or substrate can include many different materials such as steel, steel alloys, aluminum, plastics, wood, or combinations thereof. Upon contact, one of the polished article and the workpiece is moved relative to each other in the direction of use 22 and a portion of the workpiece is removed.

According to various embodiments, the depth of cut into the substrate or workpiece can be at least about 10 μm, at least about 20 μm, at least about 30 μm, at least about 40 μm, at least about 50 μm, or at least about 60 μm. A portion of the substrate or workpiece is removed as chips by the abrasive article. The maximum average size or length of chips taken from chip recovery after a grinding cycle is at least about 1200 μm millimeters, at least about 1250 μm, at least about 1300 μm, at least about 1350 μm, at least about 1400 μm, at least about 1450 μm, at least about 1500 μm, at least. It can be about 1500 μm, at least about 1550 μm, at least about 1600 μm, or at least about 1650 μm.

According to various embodiments, the cutting speed of the polished article is at least about 100 m / min, at least about 110 m / min, at least about 120 m / min, at least about 130 m / min, at least about 140 m / min, at least about 150 m / min. , At least about 160 m / min, at least about 170 m / min, at least about 180 m / min, at least about 190 m / min, at least about 200 m / min, at least about 300 m / min, at least about 400 m / min, at least about 500 m / min, at least about 500 m / min. It can be about 1000 m / min, at least about 1500 m / min, at least about 2000 m / min, at least about 2500 m / min, at least about 3000 m / min, or at least about 4000 m / min.

The usage direction 22 is the first direction to be displayed, as shown in FIGS. 1A-1C, 2 and 3. The polished article can be moved in a second direction different from the direction of use 22. The second direction is about 1 degree to 360 degrees, about 160 degrees to about 200 degrees, about 1 degree, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50 with respect to the usage direction 22. , 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 105, 110, 115, 120, 125, 130, 135, 140, 145, 150, 155, 160, 165, 170, 175 , 180, 185, 190, 195, 200, 205, 210, 215, 220, 230, 240, 250, 260, 265, 270, 275, 280, 285, 290, 295, 300, 305, 310, 315, 320. For values of 325, 330, 335, 340, 350, 355 or about 360 degrees, the direction may be less than, equal to, or greater than this.

According to various embodiments, the polished article described herein can have some advantages when moved in the direction of use 22, as opposed to any other direction of use. For example, at the same applied force, cutting speed, or a combination thereof, the amount of material removed from the workpiece, the length of chips removed from the workpiece, the depth of cut of the workpiece, the surface roughness of the workpiece. , Or a combination thereof, is greater in the first direction than in any other second direction.

For example, in the first use direction, at least about 10% more, or at least about 15%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60. %, At least about 65%, at least about 70%, at least 75%, at least about 80%, at least about 85%, at least 90%, at least about 95%, at least about 100%, at least about 120%, at least about 130%, At least about 140% and at least about 150% more material is removed from the substrate or workpiece. In some embodiments, in the first use direction, about 15% to about 500% more, or about 30% to about 70%, or about 40% to about 60%, or about 15%, 20%, 25. %, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 100%, 105%, 110%, 115%, 120%, 125%, 130%, 135%, 140%, 145%, 150%, 155%, 160%, 165%, 170%, 175%, 180%, 185%, 190% 195%, 200%, 205%, 210%, 215%, 220%, 225%, 230%, 235%, 240%, 245%, 250%, 255%, 260%, 265%, 270%, 275 % 280%, 285%, 290%, 295%, 300%, 305%, 310%, 315%, 320%, 325%, 330%, 335%, 340%, 345%, 350%, 355%, 360%, 365%, 370%, 375%, 380%, 385%, 390%, 395%, 400%, 405%, 410%, 415%, 420%, 425%, 430%, 435%, 440% Less than, equal to, or about 500% for values of 445%, 450%, 455%, 460%, 465%, 470%, 475%, 480%, 485%, 490%, 495%, or about 500%. More material is removed. The amount of material removed can be referred to as initial cutting (eg, the first cut of the cutting cycle) or total cutting (eg, total amount of material removed over a set number of cutting cycles).

Procedures for grinding workpieces are described in grinding procedures A and B in the examples herein. The initial cutting of the workpiece measured according to grinding procedure A (when the polished article travels in the direction of use) is at least about 9 grams, at least about 9.5 grams, at least about 10 grams, at least about 10.5 grams, at least about. 11 grams, at least about 11.5 grams, at least about 12 grams, at least about 12.5 grams, at least about 13 grams, at least about 13.5 grams, at least about 14 grams, at least about 14.5 grams, at least about 15 grams , At least about 15.5 grams, at least about 16 grams, at least about 16.5 grams, at least about 17 grams, at least about 17.5 grams, at least about 17.8 grams, at least about 18 grams, at least about 18.5 grams At least about 19 grams, at least about 19.5 grams, at least about 20 grams, at least about 20.5 grams, at least about 21 grams, at least about 21.5 grams, at least about 22 grams, at least about 22.5 grams, at least It can be about 23 grams, at least about 23.5 grams, at least about 24 grams, at least about 25.5 grams, or at least about 25 grams. The total cutting in the workpiece measurement by grinding procedure A (when the polished article travels in the direction of use) is at least about 65 grams, at least about 70 grams, at least about 75 grams, at least about 80 grams, at least about 85 grams, at least about. It can be 90 grams, at least about 95 grams, at least about 100 grams, at least about 105 grams, at least about 110 grams, at least about 115 grams, at least about 118.37 grams, at least about 120 grams, or at least about 125 grams. The initial cutting of the workpiece measured according to grinding procedure B (when the polished article travels in the direction of use) is at least about 9 mm, at least about 9.5 mm, at least about 10 mm, at least about 10.5 mm, at least about 11 mm, at least about about. 11.5 mm, at least about 12 mm, at least about 12.5 mm, at least about 13 mm, at least about 13.5 mm, at least about 14 mm, at least about 14.5 mm, at least about 15 mm, at least about 15.5 mm, at least about 16 mm, at least about 16.5 mm, at least about 17 mm, at least about 17.5 mm, at least about 18 mm, at least about 18.47 mm, at least about 19 mm, at least about 19.5 mm, at least about 20 mm, at least about 20.5 mm, at least about 21 mm, at least about It can be 21.5 mm, at least about 22 mm, at least about 22.5 mm, at least about 23 mm, at least about 23.5 mm, at least about 24 mm, at least about 25.5 mm, or at least about 25 mm. The total cutting in the workpiece measurement by grinding procedure B (when the polished article travels in the direction of use) is at least about 172 mm, at least about 180 mm, at least about 190 mm, at least about 200 mm, at least about 210 mm, at least about 220 mm, at least about 230 mm. At least about 240 mm, at least about 250 mm, at least about 260 mm, at least about 270 mm, at least about 280 mm, at least about 290 mm, at least about 300 mm, at least about 310 mm, at least about 320 mm, at least about 330 mm, at least about 340 mm, at least about 350 mm, at least About 360 mm, at least about 370 mm, at least about 380 mm, at least about 390 mm, at least about 400 mm, at least about 410 mm, at least about 420 mm, at least about 430 mm, at least about 440 mm, at least about 450 mm, at least about 460 mm, at least about 470 mm, at least about 480 mm At least about 485.29 mm, at least about 490 mm, at least about 500 mm, at least about 510 mm, at least about 520 mm, at least about 530 mm, at least about 540 mm, at least about 550 mm, at least about 560 mm, at least about 570 mm, at least about 580 mm, at least about 590 mm , Or at least about 600 mm.

As a further example, the depth of cut into the substrate or workpiece can be at least about 10% deeper in the first use direction, or at least about 30%, at least about 35%, at least about 40%, at least about. 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least 75%, at least about 80%, at least about 85%, at least 90%, at least about 95% Can be at least about 100%, at least about 120%, at least about 130%, at least about 140%, at least about 150% deeper. In some embodiments, it is about 10% to about 500% deeper, or about 30% to about 70%, or about 40% to about 60% deeper, or about 15%, 20%, 25 in the first use direction. %, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 100%, 105%, 110%, 115%, 120%, 125%, 130%, 135%, 140%, 145%, 150%, 155%, 160%, 165%, 170%, 175%, 180%, 185%, 190% 195%, 200%, 205%, 210%, 215%, 220%, 225%, 230%, 235%, 240%, 245%, 250%, 255%, 260%, 265%, 270%, 275 % 280%, 285%, 290%, 295%, 300%, 305%, 310%, 315%, 320%, 325%, 330%, 335%, 340%, 345%, 350%, 355%, 360%, 365%, 370%, 375%, 380%, 385%, 390%, 395%, 400%, 405%, 410%, 415%, 420%, 425%, 430%, 435%, 440% Less than, equal to, or about 500% for values of 445%, 450%, 455%, 460%, 465%, 470%, 475%, 480%, 485%, 490%, 495%, or about 500%. Deeper than this.

As a further example, the arithmetic mean roughness value (Sa) of the workpiece or substrate cut by moving the polished article in the first direction of use 22 is in exactly the same conditions but in the second direction of movement. Can be higher than the corresponding substrate or workpiece cut. For example, the surface roughness can be about 30% greater, or about 40% greater, about 50% greater, about 60% greater, about 70% when the workpiece or substrate is cut in the first direction. Large, about 80% larger, about 90% larger, about 100% larger, about 110% larger, about 120% larger, about 130% larger, about 140% larger, about 150% larger, about 160% larger, about 170% Large, about 180% larger, about 190% larger, about 200% larger, about 210% larger, about 220% larger, about 230% larger, about 240% about 250% larger, about 260% larger, about 270% larger, About 280% larger, about 290% larger, about 300% larger, about 310% larger, about 320% larger, about 330% larger, about 340% larger, about 350% larger, about 360% larger, about 370% larger, About 380% larger, about 390% larger, about 400% larger, about 410% larger, about 420% larger, about 430% larger, about 440% larger, about 450% larger, about 460% larger, about 470% larger, It can be about 480% larger, about 490% larger, or about 500% larger. Arithmetic mean roughness values range from about 1000 to about 2000, about 1000 to about 1100, or about 1000, 1050, 1100, 1150, 1200, 1250, 1300, 1350, 1400, 1450, 1500, 1550, 1600, 1650. For values of 1,700, 1750, 1800, 1850, 1900, 1950, or about 2000, it can be less than, equal to, or greater than this.

It may be desirable to move the polished article in the first use direction 22, but there are several reasons to move the polished article in a second direction of movement other than the first use direction 22. For example, bringing the substrate or workpiece into contact with the abrasive article and moving the abrasive article in a second direction can be beneficial in finishing the substrate or workpiece. Without being bound by any particular theory, the inventors may expose the substrate or workpiece to clearance angle 46 due to movement in the second direction, and clearance angle is rake angle. It is assumed that it has a value different from 30 that is more suitable for the finishing application.
(Example)

Assembly of Magnet Device (MA1) Upper magnet assembly UM1 each with a width of 10.16 cm x depth of 7.62 cm x thickness of 5.08 cm in the thickness direction of grade N52 magnetic material (from SM Magnetics (Pelham, AL)). It was formed from three identical rectangular magnets that were magnetized. These three magnets are arranged to form a magnet assembly of width 15.08 cm x depth 7.62 cm x thickness 5.08 cm so that the magnetic poles of each magnet point in the same direction and have the same poles in the same plane. bottom. This magnet arrangement was adhered to a 1018 steel plate (width 110.16 cm x depth 12.7 cm x thickness 7.62 cm) using an epoxy resin (DP460, 3M Company (St. Paul, MN)) to make it thicker. It was covered with a sheet of 304 stainless steel measuring 0.476 cm.

The first lower magnet assembly LM1 was formed in the same fashion as the UM, except that the opposite poles pointed away from the steel plate.

The second lower magnet assembly LM2 was magnetized in the thickness direction of a grade N52 magnetic material (from SM Magnetics (Pelham, AL)), each measuring 10.16 cm wide x 15.24 cm deep x 5.08 cm thick. Formed from three identical rectangular magnets. These three magnets form a magnet assembly of width 15.08 cm x depth 15.24 cm x thickness 5.08 cm so that the magnetic poles of each magnet point in the same direction as LM1 and have the same poles in the same plane. Arranged in. This magnet arrangement was adhered to a 1018 steel plate (width 110.16 cm x depth 20.32 cm x thickness 7.62 cm) using an epoxy resin (DP460, 3M Company (St. Paul, MN)) to make it thicker. It was covered with a sheet of 304 stainless steel measuring 0.47625 m.

The composite downward magnetic assembly LM3 was formed by combining LM1 and LM2. LM1 and LM2 form a magnet assembly with a width of 15.08 cm, a depth of 22.86 cm, and a thickness of 5.08 cm. , Arranged so as to have the same pole in the same plane. Both LM1 and LM2 were bolted to a 1018 steel plate (width 110.16 cm x depth 27.94 cm x thickness 2.54 cm) to make LM3.

The LM3 was positioned parallel to the upper magnet UM with a gap of 15.24 cm with both rear edges aligned. UM1 and LM3 have both poles facing each other to make a magnet device MA1.

Preparation of Magnetizable Abrasive Particles (MAP1) AP1 was coated with 304 stainless steel using physical deposition by magnetron sputtering. The 304 stainless steel sputter targets described in Barbee et al. (Thin Solid Films, 1979, vol. 63, pp. 143-150) were deposited as ferrite magnetic core cubics. The equipment used to prepare 304 stainless steel film coated abrasive particles (eg, magnetizable abrasive particles) was disclosed in US Pat. No. 8,698,394 (McCutcheon et al.). Physical deposition was performed on 51.94 grams of AP1 at 10 milittle (1.33 pascals) argon sputtering gas pressure at 1.0 kilowatt for 4 hours. The weight percent of the metal coating in the coated AP1 is about 0.65% and the coating thickness is about 1 micron.

Preparation of Magnetizable Abrasive Particles (MAP2) AP2 was coated with 304 stainless steel using physical deposition by magnetron sputtering. The 304 stainless steel sputter targets described in Barbee et al. (Thin Solid Films, 1979, vol. 63, pp. 143-150) were deposited as ferrite magnetic core cubics. 304 The equipment used to prepare stainless steel film coated abrasive particles (ie, magnetizable abrasive particles) was disclosed in US Pat. No. 8,698,394 (McCutcheon et al.). Physical deposition was performed on 51.94 grams of AP2 at 10 milittle (1.33 pascals) argon sputtering gas pressure at 1.0 kilowatt for 4 hours. The weight percent of the metal coating in the coated AP2 is about 0.65% and the coating thickness is about 1 micron.

Example 1
75 parts of epoxy resin (bisphenol A diglycidyl ether, trade name) of untreated polyester cloth with a basis weight of ^{300 to 400 g / m 2} obtained from Milliken & Company (Spartanburg, South Carolina) under the trade name "POWERSTRAIT". 10 parts of trimethylolpropane triacrylate (obtained from Resin Performance Products, Houseton, Texas in "EPON 828") 10 parts of trimethylolpropane triacrylate (obtained from Cytec Industrial Inc. (trade name "TMPTA") from Cytec Industrial Inc. (Ownedland Park, New)) Hardener (obtained from Air Products and Chemicals (Allentown, Pennsylvania) under the trade name "DICYANEX 1400B"), 5 parts of novolak resin (obtained from Momentive Special, Special Chemicals (trade name "RUTAPHEN 8656") 1 part 2,2-dimethoxy-2-phenylacetophenone (obtained from BASF Corporation (Florham Park, New Jersey) with brand name "IRGACURE 651" photoinitiator), and 0.75 part 2-propylimidazole (brand name) A composition having Synthron (obtained from Morganton, North Carolina) in "ACTIRON NXJ-60 LIQUID" was used and presized at a basis weight of ^{113 g / m 2.}

52 parts 75% by weight aqueous solution of resolphenol formaldehyde resin (1.5: 1 to 2.1: 1 (formaldehyde: phenol) condensate catalyzed by 1 to 5% metal hydroxide, Georgia-Pacific (Georgia-Pacific) 209 g / m of phenolic make-up resin containing 45 parts of calcium metasilicate (obtained from NYCO Company (Willsboro, NY) under the brand name "M400 WOLLASTOCOAT"), and 2.5 parts of water. ^{In 2} , the cloth backing was coated.

As shown in FIG. 4, the abrasive particles MAP1 were distributed to the make resin-coated backing through the inclined distribution path when the backing passed through the magnet device MA1. As shown in FIG. 4, the end of the inclined distribution path was 1.27 cm from the surface of the backing and 15.87 cm from the rear corner of the bottom of the upper magnet. The coating weight of MAP1 was 480 g / m ² . Immediately after coating the abrasive particles MAP1 on the backing, the abrasive particles AP3 were coated on the backing with a coating weight of ^{376 g / m 2.}

The abrasive-coated backing was placed in an oven at 90 ° C. for 1.5 hours to partially cure the make-up resin. 45.76 parts of a 75 wt% aqueous solution of resolphenol formaldehyde resin (1.5: 1-2.1: 1 (formaldehyde: phenol) condensate catalyzed by 1-5% metal hydroxide, Georgia- Obtained from Phenol formaldehyde (Atlanta, Metal)), 4.24 parts of water, 24.13 parts of formaldehyde (Solvay Formaldehyde, LLC (Houston, Texas)), 24.13 parts of calcium metasilicate (trade name "M400"). A size resin consisting of NYCO Company (Willsboro, NY) at "WORKLASTOCOAT" and 1.75 parts of red iron oxide was applied to each strip of backing material with a basis weight of ^{712 g / m 2 and this coated strip.} Was placed in an oven at 90 ° C. for 1 hour, and then at 102 ° C. for 8 hours. After curing, the coated strips of abrasive were converted to belts, as is known in the art.

Comparative Example A
75 parts of epoxy resin (bisphenol A diglycidyl ether, trade name ^{) is obtained from untreated polyester cloth having a basis weight of 300 to 400 g / m 2} obtained from Milliken & Company (Spartanburg, South Carolina) under the trade name "POWERSTRAIT". 10 parts of trimethylolpropane triacrylate (obtained from Resin Performance Products (Houston, Texas) in "EPON 828") 10 parts of trimethylolpropane triacrylate (obtained from Cytec Industrial Inc. (trade name "SR351") from Cytec Industrial Inc. (Woodland Park, New) Diglycidyl amide curing agent (obtained from Air Products and Chemicals (Allentown, Pennsylvania) under the trade name "DICYANEX 1400B"), 5 parts of novolak resin (obtained from Momentive Optical (trade name "RUTAPHEN 8656") , 1 part of 2,2-dimethoxy-2-phenylacetophenone (trade name "IRGACURE 651" photoinitiator obtained from BASF Corporation (Florham Park, New Jersey)), and 0.75 part of 2-propylimidazole (trademark). A composition consisting of Synthron (obtained from Morganton, North Carolina) under the name "ACTIRON NXJ-60 LIQUID" was used and presized at a basis weight of ^{113 g / m 2.}

52 parts 75% by weight aqueous solution of resolphenol formaldehyde resin (1.5: 1 to 2.1: 1 (formaldehyde: phenol) condensate catalyzed by 1 to 5% metal hydroxide, Georgia-Pacific (Georgia-Pacific) (Obtained from Atlantica, Georgia)), 45 parts of calcium metasilicate (obtained from NYCO Company (Willsboro, NY) under the brand name "M400 WOLLASTOCOAT"), and 2.5 parts of water, a phenol formaldehyde resin 209 g / m ² So, I coated the cloth backing.

The abrasive particles MAP2 were distributed to the make resin coated backing as the backing passed through the magnet device MA1, as shown in FIG. As shown in FIG. 4, the end of the inclined distribution path was 1.27 cm from the surface of the backing and 15.87 cm from the rear corner of the bottom of the upper magnet. The coating weight of MAP1 was 480 g / m ² . Immediately after coating the abrasive particles MAP1 on the backing, the abrasive particles AP3 were coated on the backing with a coating weight of ^{376 g / m 2.}

The abrasive-coated backing was placed in an oven at 90 ° C. for 1.5 hours to partially cure the make-up resin. 45.76 parts of a 75 wt% aqueous solution of resolphenol formaldehyde resin (1.5: 1-2.1: 1 (formaldehyde: phenol) condensate catalyzed by 1-5% metal hydroxide, Georgia- Obtained from Phenol formaldehyde (Atlanta, Metal)), 4.24 parts of water, 24.13 parts of formaldehyde (Solvay Formaldehyde, LLC (Houston, Texas)), 24.13 parts of calcium metasilicate (trade name "M400"). A size resin having 1.75 parts of red iron oxide (obtained from NYCO Company (Willsboro, NY) at "WORKLASTOCOAT") was applied to each strip of backing material with a basis weight of ^{712 g / m 2 and this coated strip.} Was placed in an oven at 90 ° C. for 1 hour, and then at 102 ° C. for 8 hours. After curing, the coated strips of abrasive were converted to belts, as is known in the art.

Comparative Example B
Comparative Example B is a polishing and grinding belt obtained under the brand name Cubitron II Cross Belt 991FZ, Grade 36+, 3M Company (St. Paul, MN).

Comparative Example C
Comparative Example B is a polishing and grinding belt obtained under the brand name Cubitron II Cross Belt 984F, Grade 36+, 3M Company (St. Paul, MN).

Grinding test procedure A
Using the grinding test procedure A, the effectiveness of the polishing belt of Example 1, the polishing belt of Comparative Example A, and the polishing belt of Comparative Example C was evaluated. The workpiece was aluminum 6061 bar, which was applied to the polishing belt along 5.08 cm x 91.44 cm. A durometer shore A, serrated (land-to-groove ratio 1: 1) rubber contact disc with a diameter of 20.3 cm and 70 was used. The belt was run at 5500 surface feet (SFM) per minute. A mixture of 10 to 15 pounds (4.53 to 6.8 kg) of normal force was used to urge the workpiece against the central portion of the belt. This test included measuring the weight loss of the workpiece after 15 seconds of grinding (1 cycle). The workpiece was then cooled and tested again. The test was completed after 15 test cycles. Cycle 1 is called the initial cutting of each embodiment. In Example 1 and Comparative Example C, the test was carried out in the forward direction of the first usage direction and in the opposite direction of the second usage direction opposite. Cuttings were recorded in grams after each cycle.

The results of grinding procedure A (aluminum) are shown in Table 1 of the present specification. A plot of the data is also provided in FIG.

Grinding test procedure B (wood)
Example A is a particle board workpiece having a length of 40.6 cm × 30.48 cm × thickness of 1.6 cm obtained from the brand name COLLINS PINE PARTICLE BOARD (Collins Co. (Portland Oregon)), the edge of which is 30.48 cm. And it was fixed to the test jig at the position where it was polished by the polishing belt of Comparative Example B. The polishing belts were endless polishing belts having dimensions of 5.08 cm × 91.44 cm, respectively. In each test, the polishing belt was backed up by a graphite coated platen. In each test, the board was pushed into the polishing belt as the belt was moving at a feed rate of 5500 surface feet per minute. A total force of 15 lbs was applied to the board and the board was brought into contact with the polishing belt for a grinding time of 10 seconds. The board was removed from the belt and the amount of material removed from the board was measured. This process was repeated for a total of 25 cycles. Cycle 1 is called the initial cutting of each embodiment. In Example 1 and Comparative Example B, the test was carried out in the forward direction of the first usage direction and in the opposite direction of the second usage direction opposite. The amount of particle board material removed was recorded in mm after each cycle. The results of grinding procedure B (particle board) are shown in Table 2 in the present specification. A plot of the data is also provided in FIG.

Belt force data procedure C
The polishing belt of Example, the polishing belt of Comparative Example A, and the polishing belt of Comparative Example B. The test belts were endless belts each having dimensions of 5.08 cm x 91.44 cm. The polishing belt was attached to a belt sander fitted with a 20.6 cm steel contact wheel. A particle board workpiece (COLLINS PINE PARTICLE BOARD, Collins Co. (Portland Oregon)) measuring 40.6 cm in length x 30.48 cm in thickness x 1.6 cm in thickness was tested at a position where its edge was polished by an endless polishing belt. Fixed to the jig. The test jig was adjusted to provide 10 mm of interference between the adjacent surface of the edge of the workpiece and the surface of the polishing belt. The belt sander was activated at a surface speed of 1753 m / min and the workpiece was advanced at a speed of 150 mm / sec along a dimension of 40.6 cm. In Example 1 and Comparative Example B, the test was carried out in the forward direction of the first usage direction and in the opposite direction of the second usage direction opposite. For Comparative Example B, the test was carried out in the direction opposite to the second usage direction. Cuttings were recorded in grams after each cycle.

The normal force at the polishing belt / workpiece contact surface was measured when the specified volume of wood was removed by polishing. After this first stroke, the edge of the particle board was taken from the polishing belt and returned to its starting position, adjusted to provide an additional 10 mm of interference, and further polished. This process was repeated for a total of 25 steps. The results of grinding procedure C are shown in Table 3 of the present specification. A plot of the data is also provided in FIG.

Workpiece surface analysis procedure D
From the grinding procedure A, a part of the workpiece of the first embodiment traveled in the forward direction and the workpiece of the first embodiment traveled in the reverse direction are subjected to the brand name KEYENCE VK available from Keyence Corporation of America (Itasca Illinois). Analysis was performed using a microscope obtained with a -X250 confocal laser scanning microscope. A 10x objective lens was used. The 10x objective lens has a field of view of 1 mm x 1.43 mm. Images were created by stitching individual images in a 3x3 array to analyze larger regions. As a result, a field of view of 2.9 mm × 3.9 mm of the final image was obtained.

The stitched images were then analyzed using the Keyence Multi-file Analyzer. 2D color contour diagrams are shown in FIGS. 11 and 12. FIG. 11 shows the base material of Example 1 running in the reverse direction, and FIG. 12 shows the base material of Example 1 running in the forward direction. 3D images of each surface were also created to show the differences between the samples. FIG. 13 shows a 3D image of the base material of Example 1 running in the opposite direction, and FIG. 14 shows the base material of Example 1 running in the forward direction. Further, the measured values of the surface finish of each surface are recorded and shown in Table 4.

The parameters referred to include the arithmetic mean height (Sa). Sa is an extension to the surface of Ra (arithmetic mean height of the line). This expresses the difference in height of each point compared to the arithmetic mean of the surface as an absolute value. This parameter is generally used to assess surface roughness.

Skewness (Ssk) was also a measured Ssk value representing the degree of bias of the roughness shape. A Ssk greater than 0 means that the height distribution is biased above the average plane (mountains), and an Ssk equal to 0 means that the height distribution (peaks and valleys) is symmetrical around the average plane. When Ssk is less than 0, it means that the height distribution is biased downward (valley) of the average plane.

The maximum mountain height (Sp) was also measured. Sp is the highest peak height in the defined area. The maximum valley depth (Sv) was also measured. Sv indicates the absolute value of the maximum valley depth within the defined region. Each of Sa, Sk, Sp, and Sv was measured according to a standard known as ISO 25178.

Workpiece chip analysis procedure E
A portion of chips was collected from the workpiece of Example 1 that ran in the forward direction. A part of chips was also collected from the workpiece of Comparative Example C that ran in the forward direction.

Each chip portion was analyzed using a scanning electron microscope (SEM). Images of chips were taken using a field emission scanning electron microscope available from JEOL Ltd. (Tokyo) under the brand name JSM-7600F field emission scanning electron microscope. An image using Jeol JSM-7600F was photographed at an inclination of 45 degrees and 33 times, and a 2 × 2 composite image was obtained by stitching.

The average length of chips collected from Example 1 and Comparative Example C was measured using a microscope available from the Keyence Corporation of America (Itasca Illinois) under the brand name KEYENCE 5000 Digital Microscope. The average length was measured using binary image analysis to calculate the maximum diagonal length.

The analysis showed that the average length of the 78 chips collected from Example 1 was 1772 μm. Further analysis showed that the average length of 89 chips collected from Comparative Example C was 1109 μm.

Additional Embodiments The following exemplary embodiments are shown, but their numbering is not construed as indicating importance.

The first embodiment is a polished article having a usage direction, a y-axis, and a y-axis and a z-axis orthogonal to the usage direction.
Backing and
Approximately 5% to approximately 100% of the molded abrasive particles, including the molded abrasive particles attached to the backing, are independent.
The first aspect and
The second side opposite to the first side,
With the tip surface connected to the first side surface at the first edge and connected to the second side surface at the second edge,
The rake angle between the backing and the tip surface in the range of about 10 degrees to about 110 degrees,
The z-direction rotation angle between the line intersecting the first edge and the second edge and the direction of use of the polished article in the range of about 10 degrees to about 170 degrees.
To provide a polished article having.

The second embodiment is a polished article having the first direction of use, and the polished article is a polished article.
Under the same test conditions, the amount of material removed from the workpiece that contains the abrasive particles attached to the backing and comes into contact with the abrasive article is such that the abrasive article is moved in a second direction that is different from the first use direction. Provided is an abrasive article that is greater than the amount of workpiece material removed when it is removed.

The third embodiment provides the polished article according to the second embodiment, in which at least 15% more material is removed in the first direction of use.

Embodiment 4 provides the polished article according to embodiment 2 or 3, in which at least 50% more material is removed in the first direction of use.

The fifth embodiment provides the polished article according to the second embodiment, in which about 10% to about 500% more material is removed in the first direction of use.

Embodiment 6 provides the polished article according to embodiment 1 or 5, from which about 30% to about 70% more material is removed in the first direction of use.

Embodiment 7 provides the polished article according to any one of Embodiments 1 or 5-6, from which about 40% to about 60% more material is removed in the first direction of use.

In the eighth embodiment, about 5 to about 100% of the abrasive particles are molded abrasive particles, and independently.
The first aspect and
The second side opposite to the first side,
With the tip surface connected to the first side surface at the first edge and connected to the second side surface at the second edge,
The rake angle between the backing and the tip surface in the range of about 10 degrees to about 110 degrees,
The z-direction rotation angle between the line intersecting the first edge and the second edge and the direction of use of the polished article in the range of about 10 degrees to about 170 degrees.
The polished article according to any one of Embodiments 2 to 7, which is a molded abrasive particle having the above.

Embodiment 9 provides the polished article according to any one of embodiments 2-8, wherein the material is removed according to at least one of grinding procedure A and grinding procedure B.

The tenth embodiment provides the polished article of embodiment 9, wherein the initial cutting of the workpiece when the polished article is run in the direction of use according to the grinding procedure A is at least 9 grams.

The eleventh embodiment provides the polished article according to embodiment 9 or 10, wherein the initial cutting of the workpiece when the polished article is run in the direction of use according to the grinding procedure A is at least 11 grams.

The twelfth embodiment is the polished article according to any one of embodiments 9 to 11, wherein the initial cutting of the workpiece when the polished article is run in the direction of use according to the grinding procedure A is at least 17.8 grams. offer.

13. The polishing according to any one of embodiments 9-12, wherein the total cutting of the workpiece after 15 cycles is at least 65 grams when the polished article is run in the direction of use according to the grinding procedure A. Providing goods.

Embodiment 14 according to any one of embodiments 9-13, wherein the total cutting of the workpiece after 15 cycles is at least 118.37 grams when the polished article is run in the direction of use according to grinding procedure A. Provides polished articles.

15. The polishing according to any one of embodiments 9-14, wherein the total cutting of the workpiece after 15 cycles is at least 120 grams when the polished article is run in the direction of use according to the grinding procedure A. Providing goods.

The 16th embodiment provides the polished article according to the 9th embodiment, wherein the initial cutting of the workpiece is at least 9 mm when the polished article is run in the direction of use according to the grinding procedure B.

Embodiment 17 provides the polished article according to embodiment 9 or 16, wherein the initial cutting of the workpiece is at least 11 mm when the polished article is run in the direction of use according to grinding procedure B.

The polished article according to any one of embodiments 9, 16 or 17, wherein the embodiment 18 has an initial cutting of the workpiece of at least 18.47 mm when the polished article is run in the direction of use according to the grinding procedure B. I will provide a.

19 is described in any one of embodiments 9 or 16-19, wherein the total cutting of the workpiece after 25 cycles is at least 180 mm when the polished article is run in the direction of use according to grinding procedure B. Provide polished articles.

20. Provide polished articles.

The 21st embodiment is made into any one of the 9th or 16th to 20th embodiments, wherein the total cutting of the workpiece after 25 cycles is at least 485.29 mm when the polished article is run in the direction of use according to the grinding procedure B. The described polished article is provided.

Embodiment 22 is a polished article having a first direction of use.
Under the same test conditions, the average surface roughness of the abrasive particles attached to the backing and polished by the polished article moves the polished article to a second use direction different from the first use direction. Provided is a polished article containing abrasive particles, which are greater than the average surface roughness of the workpiece when polished.

The 23rd embodiment provides the polished article according to the 22nd embodiment, wherein the average surface roughness is at least 90% larger in the first use direction.

Embodiment 24 provides the polished article according to embodiment 22 or 23, wherein the average surface roughness is at least 105% greater in the first direction of use.

The 25th embodiment provides the polished article according to the 22nd embodiment, wherein the average surface roughness is about 10% to about 500% larger in the first use direction.

In the 26th embodiment, about 5 to about 10% of the abrasive particles are molded abrasive particles, and independently.
The first aspect and
The second side opposite to the first side,
With the tip surface connected to the first side surface at the first edge and connected to the second side surface at the second edge,
The rake angle between the backing and the tip surface in the range of about 10 degrees to about 110 degrees,
The z-direction rotation angle between the line intersecting the first edge and the second edge and the direction of use of the polished article in the range of about 10 degrees to about 170 degrees.
The polished article according to any one of embodiments 22 to 25, which is a molded abrasive particle having the above.

Embodiment 27 provides the polished article according to any one of embodiments 9-26, wherein the workpiece is polished according to at least one of grinding procedure A and grinding procedure B.

Embodiment 28 is any one of embodiments 1 to 27, wherein about 25% to about 100% has a first side surface, a second side surface, a tip surface, a rake angle, and a rotation angle in the z direction. The polished article according to one of the above is provided.

Embodiment 29 is any of embodiments 1 to 28, wherein about 50% to about 100% has a first side surface, a second side surface, a tip surface, a rake angle, and a rotation angle in the z direction. The polished article according to one of the above is provided.

Embodiment 30 is a flexible backing in which the backing comprises a polymer film, a metal foil, a woven fabric, a knitted fabric, a paper, a vulcanized fiber, a non-woven material, a foam, a screen, a laminate, or a combination thereof. , The polished article according to any one of embodiments 1 to 29.

Embodiment 31 provides the polished article according to any one of embodiments 1 to 30, wherein at least one of the molded abrasive particles is a ceramic molded abrasive particle.

Embodiment 32 provides the polished article according to any one of Embodiments 1-31, wherein the molded abrasive particles independently contain α-alumina, sol-gel-derived α-alumina, or a mixture thereof.

In the 33rd embodiment, the molded abrasive particles are independently molten aluminum oxide, heat-treated aluminum oxide, ceramic aluminum oxide, sintered aluminum oxide, silicon carbide material, titanium diboride, boron carbide, tungsten carbide, titanium carbide, and diamond. The polished article according to any one of embodiments 1-32, comprising, cubic boron nitride, garnet, molten alumina-zirconia, cerium oxide, zirconium oxide, titanium oxide, or a combination thereof.

Embodiment 34 provides the polished article according to any one of embodiments 1-33, wherein at least one first side surface and second side surface of the molded abrasive particles form a polygonal shape. ..

The 35th embodiment provides the polished article according to the 34th embodiment, wherein the polygonal shapes of the first side surface and the second side surface are independently regular polygons or irregular polygons.

The 36th embodiment provides the polished article according to the 33rd or 34th embodiment, wherein the polygonal shapes of the first side surface and the second side surface are independently triangular or quadrangular shapes.

The 37th embodiment provides the polished article according to the 36th embodiment, in which the polygonal shape is a quadrangular shape.

Embodiment 38 provides the polished article of embodiment 37, wherein the quadrangular shape comprises a trapezoid, a square, or a rectangle.

The 39th embodiment provides the polished article according to the 36th embodiment, wherein the polygonal shape is a triangular shape.

Embodiment 40 provides the polished article of embodiment 39, wherein the shape of the triangle comprises a right angle triangle, an isosceles triangle, an isosceles triangle, an acute triangle, or an obtuse triangle.

Embodiment 41 provides the polished article according to embodiment 39 or 40, wherein the shape of the triangle does not include an equilateral triangle.

In the 42nd embodiment, at least one of the molded abrasive particles further includes a third side surface having a triangular shape.
The tip surface has a triangular shape and
The molded polished particles provide the polished article according to any one of embodiments 39 to 41, which is a tetrahedron.

Embodiment 43 is any of Embodiments 1-42, wherein the clearance angle between the backing and the rear surface or the edge is in the range of about 90 degrees to about 180 degrees in at least one cutting tip of the molded abrasive particles. The polished article according to one of the above is provided.

80. The polished article according to one of the above is provided.

In embodiment 45, at least one first side surface and second side surface of the molded abrasive particles are substantially the same size for at least one of the surface area, maximum length dimension, and maximum width dimension. , The polished article according to any one of Embodiments 1-44.

In the 46th embodiment, at least one first side surface and a second side surface of the molded abrasive particles are different sizes for at least one of the surface area, the maximum length dimension, and the maximum width dimension. The polished article according to any one of 1 to 45 is provided.

The polished article according to any one of Embodiments 1 to 46, wherein the polished article 47 has at least one first side surface, a second side surface, and a tip surface of the molded abrasive particles that are substantially flat. I will provide a.

Embodiment 48 is any one of embodiments 1-46, wherein at least one of the first side surface, the second side surface, and the tip surface of the molded abrasive particles is substantially non-planar. The polished article according to one is provided.

The 49 according to any one of embodiments 1 to 46, wherein at least one first side surface, a second side surface, and a tip surface of the molded abrasive particles are substantially parallel to each other. Provide polished articles.

50 is described in any one of embodiments 1-46, wherein at least one first side surface, second side surface, and tip surface of the molded abrasive particles are substantially non-parallel to each other. Provide polished articles.

51 is described in any one of embodiments 1-46, wherein at least one of the first side surface, the second side surface, and the tip surface of the molded abrasive particles has a concave shape. Provides polished articles.

Embodiment 52 relates to at least one of the molded abrasive particles.
The first side surface has a concave shape and the second side surface is substantially flat.
Embodiments where the first side surface has a convex shape and the second side surface has a concave shape, or the first side surface is molded inward and the second side surface is molded inward. The polished article according to 46 is provided.

In embodiment 53, at least one of the molded abrasive particles comprises an outer edge having an opening, a concave surface, a convex surface, a groove, a ridge, a broken surface, a low roundness, or one or more endpoints having a sharp tip. The polished article according to any one of embodiments 1 to 28, comprising one shape feature.

Embodiment 54 provides the polished article according to any one of embodiments 1-53, wherein at least one of the molded abrasive particles comprises an opening.

Embodiment 55 provides the polished article according to any one of embodiments 1-54, wherein the first edge and the second edge of at least one of the molded abrasive particles are substantially parallel. ..

Embodiment 56 provides the polished article according to any one of embodiments 1-55, wherein at least one first edge and a second edge of the molded abrasive particles are tapered.

Embodiment 57 provides the polished article according to any one of embodiments 1-55, wherein at least one first edge and a second edge of the molded abrasive particles are curved.

Embodiment 58 is any one of embodiments 1 to 55, wherein the draft angle α between at least one second side surface and the tip surface of the molded abrasive particles is in the range of about 95 degrees to about 130 degrees. The polished article described in one is provided.

Embodiment 59 provides the polished article according to any one of embodiments 1-58, wherein at least one cutting tip of the molded abrasive particles is substantially aligned with the y direction.

Embodiment 60 provides the polished article according to any one of embodiments 1-59, wherein the rake angle of at least one of the molded abrasive particles is in the range of about 80 degrees to about 100 degrees.

Embodiment 61 provides the polished article according to any one of embodiments 1-60, wherein the rake angle of at least one of the molded abrasive particles is in the range of about 85 degrees to about 95 degrees.

Embodiment 62 provides the polished article according to any one of embodiments 1 to 61, wherein at least one of the molded abrasive particles has an angle of rotation in the z direction in the range of about 80 degrees to about 100 degrees. ..

Embodiment 63 provides the polished article according to any one of embodiments 1 to 62, wherein at least one of the molded abrasive particles has an angle of rotation in the z direction in the range of about 85 degrees to about 95 degrees. ..

Embodiment 64 relates to at least one of the molded abrasive particles.
The first side surface and the second side surface have a triangular shape that does not include an equilateral triangular shape.
The first edge and the second edge are substantially parallel and
The rake angle ranges from about 80 degrees to about 110 degrees.
The angle of rotation in the z direction ranges from about 80 degrees to about 110 degrees.
The polished article according to any one of embodiments 1 to 63 is provided.

Embodiment 65 provides the polished article of embodiment 64, wherein the shape of the triangle is a right triangle.

Embodiment 66 provides the polished article according to any one of embodiments 1-65, wherein at least one edge of the molded abrasive particles is substantially aligned with the backing in the xy plane. do.

Embodiment 67 provides the polished article according to any one of embodiments 1-36, wherein at least one of the molded abrasive particles responds to a magnetic field.

Embodiment 68 provides the polished article according to any one of embodiments 1-67, wherein at least one of the molded abrasive particles has a magnetic field.

Embodiment 69 provides the polished article of embodiment 68, wherein the magnetic material coats the surface of the molded abrasive particles at least partially.

Embodiment 70 provides the polished article according to embodiment 69, wherein at least one of the molded abrasive particles is a monolithic abrasive particle.

Embodiment 71 provides the polished article according to any one of embodiments 1 to 70, wherein the rake angle of about 50% to about 100% of the molded abrasive particles is substantially the same.

Embodiment 72 provides the polished article according to any one of embodiments 1-71, wherein the rake angle of about 90% to about 100% of the molded abrasive particles is substantially the same.

Embodiment 73 provides the polished article according to any one of embodiments 1-72, wherein the z-direction rotation angles of about 50% to about 100% of the molded abrasive particles are substantially the same.

Embodiment 74 provides the polished article according to any one of embodiments 1-73, wherein the z-direction rotation angles of about 90% to about 100% of the molded polished particles are substantially the same.

Embodiment 75 provides the polished article according to any one of embodiments 1-74, further comprising pulverized abrasive particles.

The 76th embodiment provides the polished article according to the 75th embodiment, which comprises a material in which the pulverized polishing particles and the molding polishing particles are different from each other.

Embodiment 77 provides the polished article according to embodiment 75 or 76, wherein the molded abrasive particles contain from about 5% to about 95% by weight a blend of the molded abrasive particles and the ground abrasive particles.

Embodiment 78 provides the polished article according to any one of embodiments 1-77, including a belt, disc, or sheet.

Embodiment 79 provides the polished article according to any one of embodiments 1-78, further comprising a make-up coat that adheres the molded abrasive particles to the backing.

Embodiment 80 provides the polished article of embodiment 79, further comprising a size coat that adheres the molded abrasive particles to the make coat.

In the 81st embodiment, at least one of the make coat and the size coat is a phenol resin, an epoxy resin, a urea formaldehyde resin, an acrylate resin, an aminoplast resin, a melamine resin, an acrylic epoxy resin, a urethane resin, and a mixture thereof. Provided are the polished articles according to embodiment 79 or 80, including.

In embodiment 82, at least one of the make coat and size coat comprises a filler, a grinding aid, a wetting agent, a surfactant, a dye, a pigment, a coupling agent, an adhesion promoter, or a mixture thereof. The polished article according to any one of embodiments 78 to 81 is provided.

Embodiment 83 provides the polished article of embodiment 82, wherein the filler comprises calcium carbonate, silica, talc, clay, calcium metasilicate, dolomite, aluminum sulphate, or a mixture thereof.

Embodiment 84 is any one of embodiments 1 to 83, wherein the polished article comprises a disc, the z-direction rotation angle positions the tip surface in the circumferential direction, and the pattern created by the molded abrasive particles comprises a plurality of circles. The polished article described in one is provided.

Embodiment 85 positions a substantially flat surface at an angle of rotation in the z direction such that the abrasive article comprises a sheet or belt and the pattern produced by the shaped abrasive particles comprises a plurality of parallel lines. The polished article according to any one of embodiments 1 to 84 is provided.

Embodiment 86
Orienting the molded abrasive particles and
Adhering the molded abrasive particles to the backing and
The method for producing the polished article according to any one of Embodiments 1 to 85, which comprises.

In embodiment 87, at least one of the molded abrasive particles is deposited in a backing cavity shaped such that orienting the molded abrasive particles results in at least one molded abrasive particle having a z-direction rotational orientation. The method according to embodiment 87, which comprises.

88. The method described is provided.

In the 89th embodiment, at least one molding polishing particle is oriented, the at least one molding polishing particle is placed in the individual cavity of the transfer tool, and the at least one molding polishing particle is brought into contact with the backing. The method of embodiment 88, comprising providing at least one molded abrasive particle having a z-direction rotational orientation.

Embodiment 90 provides the method of embodiment 89, comprising orienting at least one molded abrasive particle exposing the at least one molded abrasive particle to a magnetic field.

Embodiment 91 further provides the method of embodiment 90, further comprising rotating at least one molded abrasive particle in a magnetic field.

92. The method described in is provided.

93. Providing a method.

The 94th embodiment is a method of using the polished article according to any one of embodiments 1 to 85 or the polished article produced by the method according to any one of embodiments 86 to 93.
Making the molded abrasive particles into contact with the workpiece
Moving at least one of the polished article and workpiece with respect to each other in the direction of use.
Provided are methods, including removing a portion of the workpiece.

Embodiment 95 provides the method of embodiment 94, wherein at least one cutting tip of the molded abrasive particles comes into contact with the workpiece.

Embodiment 96 provides the method of embodiment 95, wherein the cutting tip does not include a sharp tip with a radius of curvature of at least 60 microns.

Embodiment 97 provides the method according to any one of embodiments 94-96, wherein the depth of cut into the workpiece is at least 10 μm.

Embodiment 98 provides the method according to any one of embodiments 94-97, wherein the depth of cut into the workpiece is at least 30 μm.

Embodiment 99 provides the method according to any one of embodiments 94-98, wherein the cutting speed of the polished article is at least 100 m / min.

Embodiment 100 provides the method according to any one of embodiments 94-99, wherein the cutting speed of the polished article is at least 300 m / min.

Embodiment 101 provides the method of any one of embodiments 94-100, wherein at least a portion of the workpiece is removed as chips by an abrasive article.

Embodiment 102 provides the method of embodiment 101, wherein the longest average dimension of the individual chips produced in one grinding cycle is at least 1200 μm millimeters.

Embodiment 103 provides the method of embodiment 101 or 102, wherein the longest average dimension of the individual chips produced in one grinding cycle is at least 1772 μm.

Embodiment 104 provides the method of embodiment 102 or 103, wherein the chips comprise low carbon steel.

In the 105th embodiment, the usage direction is the first direction, and under the same test conditions, the amount of the material removed from the workpiece is in the first direction and in the second direction different from the first direction. The method according to any one of embodiments 94 to 104, which is larger than the above.

In the 106th embodiment, the use direction is the first direction, and the magnitude of the force required to remove the same amount of material from the workpiece under the same test conditions is different from the use direction in the first direction. The method according to any one of embodiments 94-105, wherein the force is less than the magnitude of the force required to remove the same amount of material at the same feed rate in different second directions.

Embodiment 107 provides the method of embodiment 106, wherein the workpiece feed rate is from about 110 mm / sec to about 200 mm / sec.

Embodiment 108 provides the method of embodiment 106 or 107, wherein the workpiece feed rate is from about 140 mm / s to about 160 mm / s.

Embodiment 109 provides the method of embodiment 105, wherein the article is moved in a second direction to finish the workpiece.

Embodiment 110 provides the method according to any one of embodiments 98-109, wherein the direction of use is a linear direction or a rotational direction.

The 111th embodiment is described in the 110th embodiment, wherein the direction of use is the rotation direction, and the rotation angle in the z direction is between a line intersecting the first edge and the second edge and a tangent line in the rotation direction. Provide a method.

Embodiment 112 provides the method of embodiment 111, wherein the polished article is a belt or sheet and the direction of use is along the x-axis orthogonal to the y-axis and z-axis.

Embodiment 113 provides the method of any one of claims 94-112, wherein the workpiece comprises steel, aluminum, alloys thereof, wood, or mixtures thereof.

Embodiment 114 is any one of embodiments 94-113, wherein the amount of work piece material removed by the force applied to the polished article is greater than the corresponding polished article containing molded abrasive particles with equilateral triangles. The method described in is provided.

Embodiment 115 relates to any one of embodiments 94 to 114, wherein the arithmetic mean roughness value of the workpiece material is in the range of about 1000 to about 2000 when the polished article is moved in the first direction of use. The method described is provided.

The 116th embodiment is adapted to any one of the 94th to 115th embodiments, wherein the arithmetic mean roughness value of the workpiece material is in the range of about 1000 to about 1100 when the polished article is moved in the first direction of use. The method described is provided.

In the 117th embodiment, the arithmetic mean roughness value of the workpiece material is higher when the polished article is moved in the first use direction than when the polished article is moved in the second use direction. The method according to any one of 94 to 116 is provided.

The terms and expressions used are used as descriptive terms, not limitations, and the use of such terms and expressions is not intended to exclude features illustrated and described or equivalents thereof. It is understood that various modifications are possible within the scope of the disclosed embodiments. Accordingly, although the present disclosure has been specifically disclosed according to specific embodiments and optional features, modified and modified forms of the concepts disclosed herein can be used by those skilled in the art. It should be understood that the modified and modified forms are considered to be within the scope of the embodiments of the present disclosure.

Claims (20)

A polished article having a first direction of use, wherein the polished article has a first direction of use.
A second direction in which the abrasive particles are attached to the backing and are removed from the workpiece in contact with the abrasive article under the same test conditions in a second direction in which the abrasive article is different from the first use direction. Abrasive article, greater than the amount of material of the workpiece removed when moved to. The polished article according to claim 2, wherein at least 15% more material is removed in the first use direction. The polished article according to claim 2 or 3, wherein at least 50% more material is removed in the first use direction. The polished article according to any one of claims 1 to 3, wherein the material is removed according to at least one of grinding procedure A and grinding procedure B. A polished article having a usage direction, a y-axis, the y-axis, and a z-axis orthogonal to the usage direction, and the polished article is a polished article.
Backing and
Including molded abrasive particles attached to the backing, about 5% to about 100% of the molded abrasive particles independently.
The first aspect and
A second side surface opposite to the first side surface,
A tip surface connected to the first side surface at the first edge and connected to the second side surface at the second edge.
The rake angle between the backing and the tip surface in the range of about 10 degrees to about 110 degrees.
The z-direction rotation angle between the line intersecting the first edge and the second edge and the direction of use of the polished article in the range of about 10 degrees to about 170 degrees.
A polished article. The polished article according to claim 5, wherein at least one of the molded abrasive particles is a ceramic molded abrasive particle. The polished article according to claim 5 or 6, wherein the rake angle of at least one of the molded polished particles is in the range of about 80 degrees to about 100 degrees. The polished article according to any one of claims 5 to 7, wherein the rake angle of at least one of the molded polished particles is in the range of about 85 degrees to about 95 degrees. The polished article according to any one of claims 5 to 8, wherein at least one of the molded polished particles has an angle of rotation in the z direction in the range of about 80 degrees to about 100 degrees. The polished article according to any one of claims 5 to 9, wherein at least one of the molded polished particles has an angle of rotation in the z direction in the range of about 85 degrees to about 95 degrees. Any one of claims 5 to 10, wherein in at least one cutting tip of the molded abrasive particles, the clearance angle between the backing and the rear surface or edge is in the range of about 90 degrees to about 180 degrees. Polished article described in. The polished article according to any one of claims 5 to 11, wherein at least one edge of the molded polished particles is substantially aligned with the backing in the xy plane. The polished article according to any one of claims 5 to 12, wherein the rake angle of about 50% to about 100% of the molded polished particles is substantially the same. The polished article according to any one of claims 5 to 13, wherein the z-direction rotation angles of about 90% to about 100% of the molded polished particles are substantially the same. The polished article according to any one of claims 5 to 14, further comprising pulverized abrasive particles. The method for using a polished article according to any one of claims 5 to 15.
When the molded abrasive particles are brought into contact with the workpiece,
To move at least one of the polished article and the workpiece with respect to each other in the direction of use.
Removing a portion of the material of the workpiece
Including methods. The use direction is the first direction, and a part of the material removed from the workpiece under the same test conditions is twisted in the first direction in a second direction different from the first direction. The method according to claim 16, which is also large. 16. The method of claim 16 or 17, wherein the article is moved in the second direction to finish the workpiece. The method according to any one of claims 16 to 18, wherein the direction of use is a linear direction or a rotational direction. The method of any one of claims 16-19, wherein the workpiece comprises steel, aluminum, alloys thereof, wood, or mixtures thereof.

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