KR20150082555A - Abrasive article comprising abrasive particles of a composite composition - Google Patents

Abstract

The abrasive article has a body including a polishing portion having a bonding material, abrasive particles contained in the bonding material, and a reinforcing material contained in the body. The abrasive portion may have a fracture propagation toughness WOF of at least about 5 kJ / m < 2 >. The stiffener is located in the main plane of the stiffener about 100 mm2? Or less. ≪ / RTI >

Description

TECHNICAL FIELD [0001] The present invention relates to abrasive articles comprising abrasive particles of a composite composition. ≪ RTI ID = 0.0 >

The following relates to abrasive articles, and particularly abrasive articles comprising abrasive particles, including composite compositions.

Abrasive wheels are typically used for cutting, polishing, and shaping a variety of materials, such as stone, metal, glass, plastics, among other materials. Generally, the grinding wheels may have various phases of materials including abrasive grains, a bonding agent, and some porosity. Depending on the intended application, the grinding wheel may have a variety of designs and configurations. For example, for applications involving grinding of workpieces, some grinding wheels are made to have a relatively thicker profile for efficient grinding.

However, considering the application of these wheels, the abrasive articles experience fatigue and failure. In fact, the wheels may have limited time usage that is less than a day, depending on the frequency of use. Thus, the industry continues to demand abrasive wheels with improved performance.

Embodiments of the abrasive article may include a body including a polishing portion having a bonding material, abrasive particles contained in the bonding material, and a reinforcement contained in the body. The abrasive portion may have a fracture propagation toughness WOF of at least about 5 kJ / m ² . The stiffener may have apertures having an open area of less than about 100 mm < 2 > in the main plane of the stiffener.

In some embodiments, the abrasive article may include a body including a polishing portion having a bonding material, abrasive particles contained in the bonding material, and a stiffener contained in the body. The body may have an adhesion of at least about 1700 lbf, and an Adhesion Variance Factor (AVF) of about 10% or less.

In other embodiments, the abrasive article comprises a body including a polishing portion having a bonding material, abrasive particles included in the bonding material, iron having an average particle size of about 40 microns or less, 1 filler, and a reinforcement contained in the body. The reinforcing material has a greige weight (or uncoated weight) of less than or equal to about 950 g / m ² ; And / or a thickness of about 2 mm or less; And / or fibers bundles having apertures therebetween, wherein one fiber bundle and one opening have a combined dimension defined as a unit cell (UC) of about 15 mm or less; And / or openings having an open area of less than about 100 mm < 2 >.

The invention may be better understood by those skilled in the art by reference to the accompanying drawings, and many of its features and advantages may become more apparent.
1 shows a schematic side view of a polishing tool according to an embodiment.
Figure 2 is a schematic cross-sectional radial view of a portion of a polishing tool according to an embodiment.
Figure 3 is a schematic, cross-sectional radial view of a portion of a polishing tool according to yet another embodiment.
Figs. 4A and 4B include plan views of embodiments of stiffeners, and Fig. 4C includes a table of various dimensions of embodiments of conventional stiffeners and stiffeners.
Figure 5 includes plots of adhesion performance of abrasive articles and various conventional abrasive articles according to an embodiment.

The abrasive tools may utilize the abrasive portions of the abrasive lips included in the matrix material for grinding, polishing, and finishing the workpieces. Particular embodiments herein relate specifically to abrasive grinding wheels incorporating one or more stiffeners within the body of a tool suitable for grinding and / or shaping metal. The abrasive article may be configured to operate at a speed of at least about 10,000 sfpm, at least about 11,000 sfpm, or even at least about 12,000 sfpm.

Figure 1 includes an illustration of an abrasive tool according to an embodiment. In particular, the polishing tool 100 includes a body 101 having a generally circular shape, as seen in two dimensions. It will be appreciated that in the three dimensions, the tool has a specific thickness such that the body 101 has a disk-like or cylindrical shape. As illustrated, the body may have an outer diameter 103 extending through the center of the tool, which may be particularly large, with dimensions of at least about 20 cm. In other applications, the body 101 may have an outer surface, such as at least about 30 cm, at least about 40 cm, at least about 50 cm, at least about 60 cm, at least about 70 cm, at least about 80 cm, or even at least about 90 cm Diameter < / RTI > Embodiments of outer diameter 103 may be less than about 120 cm, such as less than about 110 cm, less than about 100 cm, less than about 90 cm, or even less than about 80 cm. Certain polishing tools use a body 101 having an outside diameter 103 within the range of any of the previous minimum and maximum values.

As further illustrated, the polishing tool 100 may include a central aperture 105 defined with respect to the center of the body 101 by an inner circular surface 102. The central opening 105 may extend through the entire thickness of the body 101 such that the polishing tool 100 may be mounted on a spindle or other machine for rotation of the polishing tool 100 during operation.

Figure 2 includes a cross-sectional illustration of a portion of a polishing tool according to an embodiment. The abrasive body 201 may be a composite article comprising a combination of parts of different types of materials. In particular, the body 201 may include abrasive portions 204, 206, 208, and 210 and stiffeners 205, 207, and 209. The abrasive tool 200 may be configured such that the stiffeners 205,207 and 209 may be positioned within the body such that they are spaced apart from one another and within which each of the abrasive portions 204,206, Lt; / RTI > That is, the polishing tool 200 is configured such that the stiffeners 205, 207, and 209 are spaced apart from each other in the transverse direction through the thickness 212 of the body 201 and separated by the polishing portions 206 and 208 . As will be appreciated, in this design, the polishing portions 206 and 208 may be disposed between the stiffeners 205, 207, and 209.

As further illustrated, the stiffeners 205, 207, and 209 may be substantially planar members having first planar surfaces and second planar surfaces. For example, the stiffener 205 may be formed such that it is a planar member having a first major surface 215 and a second major surface 216. In addition, the body 201 may have a design that allows the abrasive portions 204, 206, 208, and 210 to rest on the major surfaces of the stiffeners 205, 207, and 209. For example, the abrasive portion 204 may rest on the first major surface 215 of the stiffener 205 and the abrasive portion 206 may rest on the second major surface 216 of the stiffener 205. In certain instances, the body 201 may be formed such that the polishing portions 204 and 206 essentially cover the entire surface area of the first major surface 215 and the second major surface 216, respectively. Thus, the abrasive portions 204 and 206 can directly contact (i.e., adjoin) the stiffener 205 on either side of the first and second major surfaces 215 and 216.

In particular, the abrasive body 201 may be designed such that the stiffeners 205, 207, and 209 may extend through a majority of the diameter 103 of the body 201. [ In certain instances, the stiffeners 205, 207, and 209 may be formed such that they extend through at least about 80%, or even at least about 75%, such as the total diameter 103 of the body 201 .

As shown in the embodiment of Fig. 3, the stiffeners 303 and 305 may vary in length and position throughout the abrading body 301. For example, the abrasive body 301 may include one or more relatively shorter stiffeners 303 (e.g., shown 6) as well as one or more relatively longer stiffeners 305 (e.g., shown 4) . Embodiments of the members 303 may only extend through the outer section 311 of the abrasive body 301 but may not extend through the inner section 313. Embodiments of the members 305 may extend through the entire diameter of the polishing body 301, such as the outer section 311 and the inner section 313. These stiffeners 303 and 305 may also be arranged axially with respect to the center strut 350 in various patterns. For example, as depicted in FIG. 3, two members 303 may be positioned between adjacent members 305. Metal reinforcement rings 355 may also be provided in the inner section 313.

As described herein, the number of stiffeners may vary depending on the application. For example, the abrasive body may have from 1 to 15 stiffeners in some embodiments. In other embodiments, the abrasive body may have at least two stiffeners, such as at least four stiffeners, at least six stiffeners, at least eight stiffeners, or even at least ten stiffeners. In other examples, the abrasive body may have no more than 14 stiffeners, such as no more than twelve stiffeners, no more than ten stiffeners, or even no more than eight stiffeners. The number of stiffeners may be in the range between any of the aforementioned values.

According to the embodiment of Figure 2, the body 201 may be formed such that it has an average thickness 212 measured in a direction parallel to the axis 250 extending through the center of the central opening 105. The average thickness 212 of the body 201 may be at least about 3 cm, such as at least about 5 cm, at least about 7 cm, at least about 9 cm, or even at least about 11 cm. In other embodiments, the average thickness 212 may be less than or equal to about 18 cm, such as less than about 16 cm, less than about 14 cm, less than about 12 cm, or even less than about 10 cm. Subsequently, certain embodiments may utilize an average thickness 212 within a range between any of the minimum and maximum values described above.

The disk also has an outer diameter (OD) of at least about 2, such as an axial thickness (AT), such as at least about 5, at least about 7, at least about 10, or even at least about 20 You can have defined aspect ratios. In other embodiments, the aspect ratio may be less than or equal to about 40, such as less than about 30, less than about 20, less than about 15, or even less than about 10. Certain embodiments may utilize an aspect ratio within a range between any of the given minimum and maximum values.

In further references to stiffeners 205, 207, and 209, such members may be constructed of organic materials, inorganic materials, and combinations thereof. For example, the stiffeners 205, 207, and 209 may be constructed of inorganic materials, such as ceramic, glass, quartz, or a combination thereof. Particularly suitable materials for use as stiffeners 205, 207, and 209 may include glass materials incorporating fibers of glass materials, which may include oxide-based glass materials.

Some suitable organic materials for use in the stiffeners 205, 207, and 209 may include phenolic resins, polyimides, polyamides, polyesters, aramids, and combinations thereof. For example, in one particular embodiment, the stiffeners 205, 207, and 209 may include Kevlar ™, a particular type of aramid. In addition, embodiments of the reinforcement may include a poly resin-based binder.

The stiffeners 205, 207, and 209 may comprise a plurality of fibers woven together. The fibers can be interlaced or stitched together in a variety of ways. In certain instances, the stiffeners may include fibers extending in two vertical directions, and may be interlaced together to form a pattern.

The stiffeners 205,207 and 209 may have a maximum thickness 218 defined as the distance between the first major surface 215 and the second major surface 216 of the stiffener 205. [ The maximum thickness 218 of each stiffener may be at least about 1 mm, such as at least about 1.1 mm, at least about 1.2 mm, or even at least about 1.3 mm. In other embodiments, the maximum thickness 218 may be less than or equal to about 2 mm, such as less than or equal to about 1.8 mm, less than or equal to about 1.5 mm, or even less than or equal to about 1.4 mm. Certain embodiments may utilize thicknesses within a range between any of the given minimum and maximum values.

In relative proportions, depending on the design of the abrasive article, the stiffeners may be formed to have specific dimensions so that they constitute a specific percentage of the total average thickness of the body. For example, the stiffeners may be at least about 3 vol% of the total volume of the body 201. In other instances, the stiffener 205 may be at least about 5 vol%, such as at least about 7 vol%, or even at least about 9 vol%, of the total volume of the body 201. In other embodiments, the stiffeners may be about 17 vol% or less of the total volume of the body, such as about 15 vol% or less. Certain embodiments of the abrasive article may have stiffeners within a range between the given minimum and maximum values.

In some embodiments, the volume ratio of abrasive portion to stiffeners is at least about 5, such as at least about 10, or even at least about 15. Other embodiments have a volume ratio of about 20 or less, such as about 15 or less, or even about 10 or less. Certain embodiments of the abrasive article may have stiffeners within a range between the given minimum and maximum values.

According to the embodiments herein, the polishing tool 200 is formed such that the body 201 includes the polishing portions 204, 206, 208, and 210. It will be appreciated that while reference will be made to the polishing portion 204 in the following paragraphs, it is to be understood that all of the identified polishing portions may contain the same features. The abrasive portion 204 may be a composite material having abrasive grains contained within the matrix material and further comprising a porosity of a specific composition and type.

The abrasive lips may include hard materials, particularly suitable for abrasive and material removal applications. For example, the abrasive lips may have a Vickers hardness of at least about 5 GPa. The hardness of the abrasive particles may be greater in some tools, so that the abrasive lips have a Vickers hardness of at least about 10 GPa, at least about 20 GPa, at least about 30 GPa, or even at least about 50 GPa.

As further illustrated in Figure 2, the body may be formed such that it incorporates stiffeners 202 and 203 adjacent the outer surfaces of the abrasive portions 204 and 210 with respect to the central aperture 105 . In certain designs, the stiffeners 202 and 203 may extend about a portion of the outer diameter 103, such as half of the outer diameter 103 of the abrasive body 201. The provision of stiffeners 202 and 203 to the central opening 105 facilitates the reinforcement of the body 201 in a position where the abrasive tool 200 is intended to be attached to the spindle or machine. As will be appreciated, the stiffeners 202 and 203 may have the same characteristics as the stiffeners 205, 207, and 209.

Embodiments of the body of the abrasive article may include a stiffener, such as a first stiffener. The first stiffener may be adjacent to the polishing portion. The first stiffener may be disposed within the polishing portion. Alternatively, the first stiffener may define an outer surface of the body. Also, the first stiffener may be disposed internally within the body.

Some embodiments of the first stiffener may comprise an organic material. In certain embodiments, the first stiffener may comprise a polyimide, a polyamide, a polyester, an aramid, and combinations thereof. Alternatively, the first stiffener may comprise an inorganic material. For example, the inorganic material may comprise ceramic materials, glass materials, glass-ceramic materials, or a combination thereof. Alternatively, the first stiffener may comprise glass fibers.

In other versions, the first stiffener may extend through the entire diameter of the body. The first stiffener may include a planar member including a first major surface and a second major surface. The abrasive portion may rest on the first major surface. Alternatively, the abrasive portion may be in direct contact with the first major surface of the first stiffener.

Alternative embodiments of the body of the abrasive article may include a first stiffener and a second stiffener. The first stiffener and the second stiffener may be spaced apart from each other in the body. Alternatively, at least a portion of the abrasive portion may be disposed between the first stiffener and the second stiffener.

In certain embodiments of the abrasive article, the first stiffener may be at least about 0.5% of the average thickness of the body. For example, the first stiffener may be at least about 1% of the average thickness of the body, such as at least about 1.1%, or even at least about 1.2%. In other non-limiting embodiments, the first stiffener may be less than about 5% of the average thickness of the body, such as about 2% or less, or even about 1.5% or less. The average thickness of the body may have a first stiffener content within a range between any of the noted minimum and maximum values.

The abrasive article may be formed by forming a mixture of components or precursor components that may be part of the final abrasive article. In one embodiment, the mixture may comprise abrasive particles. In certain instances, the abrasive particles may have a composite composition comprising alumina (Al ₂ O ₃ ), iron oxide (Fe ₂ O ₃ ), silica (SiO ₂ ), calcia (CaO), titania (TiO ₂ ), and the like. In certain situations, the composite composition may comprise a majority of alumina. For example, the composite composition may have at least about 82% alumina to the total content of the compounds (or elements) in the composite composition. In other instances, the alumina content may be greater, such as at least about 83%, at least about 84%, at least about 85%, at least about 86%, or even at least about 87%, at least about 88%. Subsequently, at least in a non-limiting embodiment, the composite composition comprises less than or equal to about 95% alumina, such as less than or equal to about 92% alumina, less than or equal to about 91% alumina, less than or equal to about 90% alumina, or even less than or equal to about 89% . It will be appreciated that the composite composition may have an alumina content within a range between any of the above noted minimum and maximum percentages.

According to one embodiment, the composite composition may have a small amount of silica. For example, in one instance, the composite composition may have a lower content of silica compared to the alumina content. In certain embodiments, the composite composition may have up to about 6.6% silica, such as up to about 6.5% silica, up to about 6% silica, up to about 5% silica, up to about 4% silica, or even up to about 3% have. Subsequently, in at least one non-limiting embodiment, the composite composition may have at least about 1% silica, such as at least about 2% silica, or even at least about 3% silica. It will be appreciated that the composite composition may have a content of silica within a range between any of the above-noted minimum and maximum percentages.

According to another embodiment, the composite composition may comprise a minority of iron oxide. For example, the composite composition may contain a lesser amount of iron oxide compared to the alumina content. Moreover, in other instances, the composite composition may have a lower content of iron oxide compared to the content of silica. Subsequently, in another alternative embodiment, the composite composition may have a higher content of iron oxide compared to the content of silica. In one particular embodiment, the composite composition of abrasive particles may have up to about 7% iron oxide, such as less than about 6% iron oxide, less than about 5% iron oxide, less than about 4.5% iron oxide, or even less than about 4% iron oxide . Subsequently, in other non-limiting examples, the composite composition may have at least about 1% iron oxide, such as at least about 2% iron oxide, or at least about 3% iron oxide. It will be appreciated that the composite composition may have a content of silica within a range between any of the above-noted minimum and maximum percentages.

Specific exemplary hybrid composition of the abrasive particles may further include a titania (TiO ₂₎ of some amount. For example, one composite composition may contain a small amount of titania. In other specific instances, the composite composition may have a lower content of titania as compared to the alumina content. In another embodiment, the composite composition may have a lower content of titania compared to the content of silica. In another embodiment, the composite composition may have a lower content of titania compared to the content of iron oxide. For at least one non-limiting example, the composite composition may have less than about 5% titania, such as less than about 4% titania. Subsequently, for one non-limiting example, the composite composition may comprise at least about 3.8% titania, such as at least about 3.9% titania. It will be appreciated that the composite composition may have an amount of titania in the range between any of the above-noted minimum and maximum percentages.

The composite composition may, in certain instances, comprise a content of calcia (CaO). For example, the composite composition may comprise a minority of calcia. More specifically, in one particular embodiment, the composite composition may have a lesser amount of calcia compared to the alumina content. In addition, certain composite compositions can have a lesser amount of calcia compared to the amount of silica. In another embodiment, the composite composition may comprise lesser amounts of calcia compared to the iron oxide content. For one particular composite composition, the content of calcia may be less than the content of titania. According to one particular embodiment, the composite composition has less than about 5% calcia, such as less than about 4% calcia, less than about 3% calcia, less than about 2% calcia, or even less than about 1% . In at least one non-limiting embodiment, the composite composition comprises at least about 0.4% calcia, at least about 0.5% calcia, at least about 0.6% calcia, or even at least about 0.7% calcia, at least about 0.8% , Such as at least about 0.3% calcia. It will be appreciated that the composite composition may have a content of calcia within a range between any of the above noted minimum and maximum percentages.

Certain composite compositions of abrasive articles may also contain some amount of magnesia (MgO). According to one embodiment, the composite composition may comprise a minority of magnesia. In certain instances, the composite composition may have a lesser content of magnesia compared to the content of alumina. For another embodiment, the composite composition may have a lower content of magnesia compared to the content of silica. According to another embodiment, the composite composition may have a smaller content of magnesia compared to the content of iron oxide. In certain other instances, the composite composition may have a lower content of magnesia compared to the content of titania. Moreover, the composite composition may have a lower content of magnesia compared to the content of calcia. Subsequently, in at least one non-limiting embodiment, the composite composition may have a greater content of magnesia compared to the content of calcia. According to one particular embodiment, the composite composition comprises less than about 30% magnesia, less than about 20% magnesia, less than about 15% magnesia, less than about 10% magnesia, less than about 8% magnesia, less than about 5% magnesia, Or less, about 40% or less of magnesia, such as less than 10% of magnesia. Nonetheless, in at least one non-limiting embodiment, the composite composition may comprise at least about 0.05% magnesia, such as at least about 0.1% magnesia. It will be appreciated that the composite composition may have a content of magnesia within a range between any of the above noted minimum and maximum percentages.

According to one embodiment, the composite composition may comprise a combination of alumina, silica, iron oxide, magnesia, calcia, and titania. In one aspect, the composition may be mined and generally unrefined ores. According to one embodiment, the abrasive particles can be made of a crystalline material, and more specifically, can be composed essentially of a crystalline material. In one particular embodiment, the composite composition may be bauxite, and more particularly the abrasive particles may be essentially composed of bauxite.

The abrasive particles may have other specific characteristics. For example, the abrasive particles may have an elongated shape. In certain instances, the abrasive particles may have an aspect ratio defined as a ratio of length to width of at least about 1: 1, wherein the length is the longest dimension of the particle and the width is the width of the particle, 2 The longest dimension (or diameter). In other embodiments, the aspect ratio of abrasive particles is at least about 2: 1 such as at least about 2.5: 1, at least about 3: 1, at least about 4: 1, at least about 5: 1, or even at least about 10: Lt; / RTI > In one non-limiting embodiment, the abrasive particles may have an aspect ratio of about 5000: 1 or less.

In at least one embodiment, the abrasive particles can be extruded, and thus the composite composition is extruded and divided to produce abrasive particles of the desired size and shape. The abrasive particles can be sintered and sintered in a particular manner to ensure certain properties and compositions described in the embodiments herein. According to one embodiment, the abrasive particles may be formed to have an ellipsoidal cross-sectional shape. The ellipsoidal shape may include shapes of circles, ellipses, and any other curve. Alternatively, in other instances, the abrasive particles may have a polygonal cross-sectional shape. Some suitable, non-limiting examples of polygonal cross-sectional shapes include triangular, square, pentagonal, hexagonal, hexagonal, octagonal, and the like.

Embodiments of abrasive particles can be characterized with respect to grain toughness (K1C) and hardness. For example, the hardness of the abrasive particles may be less than about 12 GPa. In some embodiments, the hardness of the abrasive particles may be less than about 11.5 GPa, such as less than about 11 GPa, less than about 10.5 GPa, less than about 10 GPa, or even less than about 9.5 GPa. In other embodiments, the hardness of the abrasive particles may be at least about 8.75 GPa, such as at least about 9 GPa, at least about 9.5 GPa, at least about 10 GPa, at least about 10.5 GPa, or even at least about 11 GPa. It will be appreciated that abrasive particles may have a hardness in the range between any of the above noted minimum and maximum values.

Embodiments of abrasive particles may also have toughness of at least about 4.6 MPa-m < ^0.5 >. For example, the abrasive particles may have a toughness of at least about 4.7 MPa-m ^0.5 , such as at least about 4.8 MPa-m ^0.5 , at least about 4.9 MPa-m ^0.5 , or even at least about 5 MPa-m ^0.5 . In other versions, the abrasive particles are from about 5.3 MPa-m ^0.5 or less, about 5.2 MPa-m ^0.5 or less, about 5.1 MPa-m ^0.5 or less, or even such as from about 5 MPa-m ^0.5 or less, about 5.4 MPa-m ^0.5 Or less toughness. It will be appreciated that abrasive particles may have toughness within a range between any of the above noted minimum and maximum values.

For absolute values for the stiff impact strength, the force (in Newton) required to break the grains can be provided for the percentage of grains destroyed when subjected to destructive forces. For example, in one embodiment, from about 500 N to about 800 N may be required to destroy 50% of one or more types of abrasive particles. In one embodiment, at least about 500 N, such as at least about 600 N, or even at least about 700 N, is required to break 50% of the abrasive particles. In another non-limiting embodiment, less than about 1000 N is required to break the abrasive particles, such as less than about 900 N, or even about 800 N or less is required. It will be appreciated that each type of abrasive particle may have an absolute impact strength within a range between the noted minimum and maximum values.

In another embodiment, a force of about 850 N to about 1350 N may be required to destroy 90% of each type of abrasive grain. In one embodiment, at least about 800 N, such as at least about 850 N, or even at least about 900 N, is required to break 50% of the abrasive particles. In another non-limiting embodiment, less than about 1500 N is required to break the abrasive particles, such as about 1400 N or even about 1300 N being required. It will be appreciated that each type of abrasive grain may have an absolute impact strength within a range between the noted minimum and maximum values.

According to one particular embodiment, the abrasive particles are at least about 50 microns, at least about 80 microns, at least about 100 microns, at least about 150 microns, at least about 200 microns, at least about 300 microns, at least about 400 microns, At least about 20 microns, such as at least about 600 microns, at least about 800 microns, at least about 1000 microns, at least about 1200 microns, at least about 1500 microns, at least about 1600 microns, at least about 1700 microns, or even at least about 1800 microns Particle size. Subsequently, in yet another non-limiting embodiment, the abrasive particles have an abrasive particle size of less than about 10 mm, such as less than about 5 mm, less than about 4 mm, less than about 3 mm, less than about 2 mm, or even less than about 1 mm And may have an average particle size. It will be appreciated that the average particle size can be determined by measuring and averaging the longest dimension (i.e., length) of the particles. The abrasive particles may have an average particle size within a range between any of the noted minimum and maximum values.

According to one embodiment, the abrasive particles may have a specific porosity, which may enable improved performance. For example, the average porosity of the abrasive particles may be at least about 0 vol% relative to the total volume of abrasive particles. In one embodiment, the average porosity of the abrasive particles is at least about 2.5 vol%, at least about 3 vol%, at least about 3.5 vol%, at least about 4 vol%, at least about 5 vol%, at least about 7 vol% vol%, at least about 11 vol, or even at least about 13 vol%, such as at least about 2 vol%. Subsequently, in one non-limiting embodiment, the average porosity of the abrasive particles is less than or equal to about 14 vol%, less than about 12 vol%, less than about 10 vol%, less than about 8 vol% About 6 vol% or less, about 4 vol% or less, about 2 vol% or less, or even about 1 vol% or less, such as about 15 vol% or less. It will be appreciated that the average porosity of the abrasive particles can be in the range between any of the above noted minimum and maximum percentages.

Moreover, abrasive particles may have a certain average pore size. For example, the average pore size of the abrasive particles may be less than about 6 microns, such as less than about 5 microns, less than about 4 microns, less than about 3 microns, less than about 2 microns, or even less than about 1.5 microns. According to another non-limiting embodiment, the average pore size of the abrasive particles may be at least about 0.01 microns, such as at least about 0.1 microns. It will be appreciated that the average pore size of the abrasive particles may be in the range between any of the above noted minimum and maximum percentages.

The abrasive grains can be made of crystalline grains. In certain instances, the abrasive particles may include crystalline grains having a central grain size of about 1.2 microns or less. In other instances, the central grain size may be less than about 1 micron, such as less than about 0.9 microns, less than about 0.8 microns, and even less than about 0.7 microns. According to one non-limiting embodiment, the central grain size of the abrasive particles may be at least about 0.01 microns, such as at least about 0.05 microns, at least about 0.1 microns, at least about 0.2 microns, or even at least about 0.4 microns. It will be appreciated that the central grain size of the abrasive grains may be in the range between any of the above noted minimum and maximum percentages.

Crystalline grain size was measured from SEM micrographs. The grains are embedded in the epoxy blocks and then polished to obtain a flat cross-section. The sections are then etched by HF acid for 2 minutes to reveal the fine microstructure and measure the central grain size.

As described herein, in addition to abrasive particles, the mixture may also include other components or precursors to facilitate the formation of the abrasive article. For example, the mixture may comprise abrasive particles and a bonding material. According to one embodiment, the bonding material may comprise a material selected from the group consisting of an organic material, an organic precursor material, an inorganic material, an inorganic precursor material, a natural material, and combinations thereof. In certain instances, the bonding material may comprise a metal or metal alloy, such as a powder metal material, or a precursor to a metal material, suitable for forming a metal bond matrix material during further processing.

According to another embodiment, the mixture may comprise a glassy material, or a precursor of a glassy material, suitable for the formation of a glassy bonding material during further processing. For example, the mixture may comprise a glassy material in the form of a powder, including, for example, an oxygen-containing material, an oxide compound, or aggregate, frit, and any combination thereof.

In yet another embodiment, the mixture may comprise a ceramic material, or a precursor of a ceramic material, suitable for forming a ceramic bonding material during further processing. For example, the mixture may include a ceramic material in the form of a powder, including, for example, an oxygen-containing material, an oxide compound or aggregate, and any combination thereof.

According to another embodiment, the mixture may comprise an organic material, or a precursor of an organic material, suitable for the formation of an organic bonding material during further processing. Such organic materials may include one or more natural organic materials, synthetic organic materials, and combinations thereof. In certain instances, the organic material may be comprised of a resin, which may include thermosetting, thermoplastic, and combinations thereof. For example, some suitable resins may include phenols, epoxies, polyesters, cyanate esters, shellac, polyurethanes, rubber, and combinations thereof. In one particular embodiment, the mixture comprises an uncured resin material configured to form a phenolic resin bond material through further processing.

In some embodiments, the resin may have a high temperature flexural modulus of at least 1.05. Alternatively, the resin may have an increasing high temperature flexural modulus. The phenolic resin may be modified with a curing or crosslinking agent, such as hexamethylenetetramine. At temperatures above about < RTI ID = 0.0 > 90 C, < / RTI > some examples of hexamethylenetetramine can form crosslinks to form methylene and dimethylene amide bridges to help cure the resin. Hexamethylenetetramine can be uniformly dispersed in the resin. More specifically, hexamethylenetetramine can be uniformly dispersed in the resin regions as a crosslinking agent. More specifically, the phenolic resin may comprise resin regions having cross-linked domains with a submicron-average size.

Other materials, such as fillers, may be included in the mixture. The filler may or may not be present in the final-formed abrasive article. The filler may comprise a material selected from the group consisting of powders, granules, spheres, fibers, chopped strand fibers (CSF), and combinations thereof wherein the filler is an inorganic material, an organic material , And combinations thereof, wherein the filler is selected from the group consisting of sand, bubble alumina, chromium iron, magnesite, dolomites, bubble wrightite, borides, titanium dioxide, carbon products, silicon carbide CaF ₂ , KBF ₄ , cyanide (Na ₃ AlF ₆ ), potassium cryolite (K ₃ AlF ₆ ), and calcium carbonate were used as the raw materials for the production of cryolite, wood flour, clay, talc, hexagonal boron nitride, molybdenum disulfide, feldspar, from pyrite, ZnS, copper sulfide, a mineral oil, the fluoride, the carbonate, calcium carbonate, Saran, phenoxy resin, CaO, K ₂ SO _4, mineral wool, MnCl _2, KCl, and the group consisting of a combination thereof Including a selected material, where the filler comprises a material selected from an antistatic agent, a lubricant, a porous inductors, coloring agents, and the group consisting of a combination thereof. The filler may include iron and sulfur having an average particle size of about 40 microns or less. The filler may comprise pyrite (FeS ₂ ) or may consist essentially of pyrite. The filler can include materials selected from the group consisting of antistatic agents, lubricants, porous inductors, colorants, and combinations thereof. In certain instances, the filler may be a particulate material, which may be quite different from abrasive particles, where the average particle size is much smaller than the abrasive particles.

After forming the mixture, the process of forming the abrasive article may further comprise forming a green body containing abrasive particles contained in the bonding material. The unfolded body is an unfinished body and may undergo further processing before the final-formed abrasive article is formed. For example, the formation of the green body may include techniques such as pressing, hot pressing, molding, casting, printing, spraying, and combinations thereof. In one particular embodiment, the formation of the green body may comprise pressing the mixture in a particular form.

After forming the green body, the process may continue by treating the green body to form the final-formed polishing article containing the body. Some suitable examples of processing may include curing, heating, sintering, crystallization, polymerization, pressing, and combinations thereof. In one example, the process may include bonding batching, mixing the abrasive and abrasive, filling the mold, pressing, wheel baking, or curing, finishing, inspection, speed testing, and packing and transport.

After processing, the abrasive article is formed to have a body that contains a specific amount of the bonding material. For example, the body may have at least about 30 vol% bonding material for the total volume of the body. In other instances, the content of bonding material in the body is at least about 35 vol%, at least about 40 vol%, at least about 45 vol%, at least about 50 vol%, at least about 55 vol%, at least about 60 vol% Or even at least about 65 vol%. Subsequently, in at least one non-limiting embodiment, the amount of bonding material in the body is less than about 65 vol%, less than about 60 vol%, less than about 55 vol%, less than about 50 vol%, less than about 45 vol% About 70 vol% or less, such as about 40 vol% or less, or even about 35 vol% or less. It will be appreciated that the content of bonding material in the body may be in the range between any of the above noted minimum and maximum percentages.

According to a particular embodiment, the body may have a specific content of porosity. For example, the body may have a porosity of about 40 vol% or less relative to the total volume of the body. In certain instances, the body may comprise less than about 30 vol%, less than about 25 vol%, less than about 20 vol%, less than about 15 vol%, less than about 10 vol% porosity, less than about 5 vol% About 4 vol%, about 3 vol%, about 2 vol%, about 1.5 vol%, about 1 vol%, about 0.8 vol%, about 0.5 vol%, about 0.3 vol% 0.1 vol% or less, and about 35 vol% or less. The body may also have a porosity of at least about 0.001 vol%, such as at least about 0.01 vol% porosity. It will be appreciated that the porosity of the body may be in the range between any of the above noted minimum and maximum percentages.

For certain abrasive articles of the embodiments herein, the body may have a certain amount of abrasive particles. For example, in one embodiment, the body may comprise at least about 30 vol% abrasive particles relative to the total volume of the body. In yet another embodiment, the body comprises at least about 35 vol%, at least about 40 vol%, at least about 45 vol%, at least about 50 vol%, at least about 55 vol%, at least about 60 vol%, or even at least about 65 vol % Abrasive grains. In at least a non-limiting embodiment, the body may comprise up to about 65 vol%, up to about 60 vol%, up to about 55 vol%, up to about 50 vol%, up to about 45 vol%, up to about 40 vol% About 70 vol% or less of abrasive particles, such as about 35 vol% or less. It will be appreciated that the content of abrasive particles in the body may be in the range between any of the above noted minimum and maximum percentages.

The abrasive articles of the embodiments herein may have a body that may be in the form of a bonded abrasive having the shape of a horn, a cone, a cup, flange shapes, a cylinder, a wheel, a ring, and combinations thereof. In one particular embodiment, the body may be a bonded abrasive snagging wheel.

According to one embodiment, the abrasive article may be particularly suitable for grinding and conditioning the workpieces. Particular suitable workpieces may include inorganic materials, and more particularly workpieces comprised of metal or metal alloys. According to one embodiment, the abrasive article may be particularly suitable for grinding materials such as stainless steel or titanium.

Embodiments of the abrasive portion may have a fracture propagation toughness or work of fracture (WOF) of at least about 5 kJ / m ² . The fracture propagation toughness WOF may also be at least about 6 kJ / m ² , at least about 7 kJ / m ² , at least about 8 kJ / m ² , at least about 9 kJ / m ² , or even at least about 10 kJ / m ² . In other versions, the fracture propagation toughness WOF may be less than or equal to about 13 kJ / m ^2, less than or equal to about 12 kJ / m ^2, less than or equal to about 11 kJ / m ² , or even less than or equal to about 10 kJ / m ² . It will be appreciated that the polishing portion may have a fracture propagation toughness WOF within a range between any of the above noted minimum and maximum values.

Embodiments of the stiffener may have openings with an open area of less than about 100 mm < 2 > in the major plane of the stiffener. In other embodiments, the open area may be less than about 80 mm 2, less than about 60 mm 2, less than about 40 mm 2, less than about 35 mm 2, or even less than about 30 mm 2 in the main plane of the stiffener. The open area may also be at least about 5 mm 2, at least about 8 mm 2, at least about 10 mm 2, or even at least about 12 mm 2. It will be appreciated that the open area may be in the range between any of the above noted minimum and maximum values.

Embodiments of the apertures may extend axially through at least a portion of its thickness. The apertures may extend entirely through the thickness of the stiffener. The openings can also have peripheries and define polygonal two-dimensional shapes.

Other embodiments of the stiffener may have a graze weight (or uncoated weight) of about 950 g / m ² or less. For example, the graze weight may be less than or equal to about 800 g / m ^2, less than or equal to about 600 g / m ² , or even less than or equal to about 500 g / m ² . Alternatively, the graze weight may be greater than about 400 g / m ^2, greater than about 450 g / m ² , or even greater than about 490 g / m ² . The graze weight may also be within a range between any of the above noted minimum and maximum values.

Also, and as depicted in FIGS. 4A and 4B, the stiffener may include fiber bundles having apertures therebetween. The various dimensions of the stiffener (Fig. 4c) depend on many factors, such as the radii, the thickness of the coating, and the style of the weave. For example, some embodiments of the stiffener may have a selected number of threads per set distance. In the warp and weft directions, the selected number of yarns may, in some embodiments, be from about 10 to about 15 yarns per 100 mm, either or both of the warp and weft directions. The theoretical distance between the centers of the threads or "s " (both in the warp and weft directions) may, in some embodiments, be between about 5 mm and about 17 mm. Examples of grid dimensions or "h" (i.e., distance between two chambers) may be from about 2 mm to about 9 mm. The grid dimension may also be about 8 mm or less, such as about 6 mm or less, or even about 5 mm or less. The grid dimension may also be at least about 2 mm, at least about 2.5 mm, or even at least about 3 mm. Each of the configuration parameters may be in a range between any of the known approximate minimum and maximum values.

In some embodiments, the thickness of yarn "y" is from about 2 mm to about 4 mm in the weft direction and from about 1 mm to about 3 mm in the warp direction. The yarn thickness may also be less than about 6 mm, such as less than about 5 mm, or even less than about 4 mm. Again, each of the configuration parameters may be within a range between any of the known approximate minimum and maximum values.

Some embodiments of the threads may have a diameter of at least about 1.2 mm, at least about 1.4 mm, at least about 1.6 mm, at least about 1.8 mm, at least about 2 mm, at least about 2.2 mm, at least about 2.4 mm, at least about 2.6 mm, lt; RTI ID = 0.0 > mm, < / RTI > In other embodiments, the width of the fiber bundles may be less than about 4.5 mm, such as less than about 4 mm, less than about 3.5 mm, less than about 3 mm, less than about 2.5 mm, or even less than about 2 mm. The configuration may also be within a range between any of the above noted minimum and maximum values.

Embodiments of the reinforcement may include at least about 2.5 mm, at least about 3 mm, at least about 3.5 mm, at least about 4 mm, at least about 4.2 mm, at least about 4.4 mm, or even at least about 4.4 mm And a grid distance "h" to an adjacent fiber bundle of about 2 mm. In other embodiments, the distance between the fiber bundles is about 10 mm or less, such as about 8 mm or less, about 6 mm or less, or even about 5 mm or less. The distance between the fiber bundles may also be within a range between any of the above noted minimum and maximum values.

Referring to Fig. 5, embodiments of the body may have an adhesive force of at least about 1700 lbf, for example, for a 1-inch bar. Embodiments of the attachment force of the body may be at least about 1800 lbf, such as at least about 1900 lbf. In other embodiments, the adhesive force may be at least about 2200 lbf, such as not greater than about 2100 lbf, or even not greater than about 2000 lbf. Adhesion may also be in the range between any of the above noted minimum and maximum values.

Figure 5 also shows abrasive cutting tools with bodies having an adhesion force balancing factor (AVF). The AVF can be defined as the relative ' spread ' of data points (vertically in FIG. 5) for each sample. Embodiments disclosed herein can have an AVF of about 10% or less, such as about 8% or less, about 6% or less, or even about 4% or less. Other embodiments have an AVF that is at least 1%, such as at least 2%. The AVF may also be within a range between any of the above noted minimum and maximum values.

Embodiment of a reinforcing material for example, are at least about 3.4 kJ / m ^2, at least about 3.6 kJ / m ^2, at least about 3.8 kJ / m ^2, at least about 4 kJ / m ^2, or even at least about 4.2 kJ / m ^2, such as at least And can have a fracture toughness (G _1C ) of about 3.3 kJ / m ² . Other embodiments may have about 4.8 kJ / m ² or less, and even, G _1C of about 5 kJ / m ² or less, such as about 4.6kJ / m ² or less. G _1C may also be within a range between any of the above noted minimum and maximum values.

Examples

A comparison of both fracture toughness (G _1C ) and fracture propagation toughness WOF was made for the three conventional samples and the samples according to the embodiments herein. The G 1 _C and WOF tests measure crack initiation-energy and crack-propagation stability, respectively. The G _1C value is determined by measuring the point at which cracking begins in a sample with an existing defect. WOF is calculated by measuring the total energy to propagate the crack through the entire sample. If the crack grows steadily, G 1 _C will be the same as WOF. When there is unstable failure, the initial crack propagates farther than stable growth. As a result, unstable WOF is smaller than G _1C . With materials such as fiber-reinforced composites, it becomes more difficult to propagate the crack as the crack grows, and hence WOF is then larger than G _1C .

Both G _1C and WOF can be determined from a single sample, such as a rectangular bar. The test uses a single-edge-notch (SEN) geometry. The width of the sample (e.g., 0.5 to 1.5 inches) depends on the number and spacing of the webs. A 0.14-inch notch is cut along the edge of the bar with a 0.005 "thick diamond wheel. The sample thickness is 0.5-inch, leaving a 0.36-inch unbroken ligament. _G1C is measured by JG Williams (Ellis Horwood Ltd, chapter 4 (1984)), which is the fracture mechanics of polymers, The total integrated energy divided by the area of the original undistorted ligament is WOF, and WOF is the web spacing, (E.g., about 0.2 to about 1 inch between webs), which is ultimately determined by the width of the sample.

Conventional samples CS11, CS12, and CS13 are formed with IPAC fiberglass webs 103, 24, and 717, respectively, each of which is commercially available. Sample S11 was formed with a web T700LL commercially available from Adfors. Sample S11 includes additional radiation plus a standard linoleus lock leno weave in the warp direction to fix the leno entanglement and provides much greater stability of the fabric. All other variables of the samples were the same. The results of these examples are shown in Table 1.

Table 1

Also, and as depicted in FIGS. 4A and 4B, samples S11, CS11, and CS12 were measured for various parameters such as the actual width and aperture width. The various dimensions of the samples S11, CS11, and CS12 are shown in the table of FIG. 4C. Both the actual measurements from the sample S11 and the theoretical dimensions are included.

Referring again to Figure 5, the Adhesion Force Dispersion Factor (AVF) can be calculated for various samples. The AVF is defined as the relative ' spread ' of the data points (vertically in FIG. 5) for each sample. The samples CS11, CS12, CS13, and S11 are the same as those previously described herein. The sample (CS14) is a conventional sample commercially available from Adfors as a model (T350L). For this testing, 1-inch wide specimens are notated. The notch route is at the edge of the glass web. The wedge is led to the notch and the specimen is separated. This is the type of exfoliation test called "wedge-driven exfoliation test ".

All of the adhesion force (lbf) data points for S11 have an average of about 1892 lbf and are between about 1835 and 1950 lbf. Thus, for a total of about 6%, the AVF for S11 at the upper end is (1950-1892) / 1892 = 3% and the lower end is (1892-1835) / 1892 = 3%.

Conversely, the AVFs at the upper and lower ends of CS11 are (1981-1900) / 1900 = 4%, and (1900-1613) / 1900 = 15%, respectively, or the total AVF for CS11 is 19%.

AVF at the upper and lower ends of CS12 are (2037-1875) / 1875 = 9%, and (1875-1346) / 1875 = 28%, respectively, or the total AVF for CS12 is 37%.

The AVFs at the upper and lower ends of CS13 are (2035-1625) / 1625 = 25%, and (1625-817) / 1625 = 50%, respectively, or the total AVF for CS13 is 75%.

The AVFs at the top and bottom of CS14 are (1749-1450) / 1450 = 21%, and (1450-1028) / 1450 = 29%, respectively, or the total AVF for CS14 is 50%.

Thus, the AVF is much more consistent with the embodiments disclosed herein than it is for conventional samples.

Other embodiments may include the following items:

Item 1. For abrasive articles:

Bonding material;

Abrasive particles contained in the bonding material;

The body including a grinding portion including a stiffener contained in the body, the grinding portion having a fracture propagation toughness WOF of at least about 5 kJ / m < ² >, wherein the stiffener has an opening area Wherein the body has an opening with an opening.

Item 2. The article of item 1, wherein the fracture propagation toughness WOF is at least about 6 kJ / m ² , at least about 7 kJ / m ² , at least about 8 kJ / m ² , at least about 9 kJ / m ² , m ² , about 13 kJ / m ² or less, about 12 kJ / m ² or less, about 11 kJ / m ² or less, about 10 kJ / m ² or less.

The method according to item 3. Item 1, wherein the reinforcing material is from about 950 g / m ² or less, about 800 g / m ² or less, about 600 g / m ² or less, about 500 g / m ² or less, and about 400 g / m ² Or greater, greater than or equal to about 450 g / m ^{2, and} greater than or equal to about 490 g / m ² .

Item 4. The article of item 1, wherein the stiffener is at least about 1.1 mm, at least about 1.2 mm, at least about 1.3 mm, at least about 2 mm, at least about 1.8 mm, at least about 1.5 mm, 0.0 > 1 mm. ≪ / RTI >

Item 5. The article of item 1, wherein the stiffener comprises threads having apertures therebetween, wherein the threads are at least about 1 mm, at least about 1.2 mm, at least about 1.4 mm, at least about 1.6 mm, Less than or equal to about 3.5 mm and less than or equal to about 3 mm.

Item 6. The method of item 1, wherein said open area is less than about 80 mm2, less than about 60 mm2, less than about 40 mm2, less than about 35 mm2, less than about 30 mm2 in the primary plane of said reinforcement, About 5 mm < 2 >, at least about 8 mm < 2 >, at least about 10 mm < 2 >, and at least about 12 mm &

Item 7. The item of item 1, wherein the stiffener comprises fiber bundles having the apertures therebetween, the distance from one fiber bundle to an adjacent fiber bundle being at least about 2 mm, at least about 3 mm, at least about 3.5 mm, And up to about 10 mm, up to about 8 mm, up to about 6 mm.

Item 8. The method of item 1, wherein said opening extends axially through at least a portion of its thickness, said openings extending entirely through the thickness of said stiffener, said openings having peripheries and having a polygonal two- A polishing cutting tool.

Item 9. The article of item 1, wherein the stiffener comprises at least about 0.5 percent, at least about 1 percent, at least about 1.1 percent, at least about 1.2 percent, at least about 5 percent, at least about 2 percent, at least about 1.5 percent, A polishing cutting tool, comprising:

Item 10. The abrasive cutting tool according to item 1, wherein the volume ratio of the abrasive portion to the stiffener is at least about 5, at least about 10, at least about 15, no more than about 20, no more than about 15,

Item 11. The abrasive cutting tool of item 1, wherein the body has an adhesive force of at least about 1700 lbf.

Item 12. The article of item 11, wherein the adhesive force of the body is at least about 1800 lbf, at least about 1900 lbf, and not greater than about 2200 lbf, not greater than about 2100 lbf, not greater than about 2000 lbf.

Item 13. The abrasive cutting tool of item 1, wherein the body has an Adhesive Dispersion Factor (AVF) of about 10% or less.

Item 14. The article of item 13, wherein the AVF of the body is less than about 8%, less than about 6%, less than about 4%; At least 1%, at least 2%.

The method according to item 15. Item 1, wherein the reinforcing material is at least about 3.3 kJ / m ^2, at least about 3.4 kJ / m ^2, at least about 3.6 kJ / m ^2, at least about 3.8 kJ / m ^2, at least about 4 kJ / m ² (G _1C ) of at least about 4.2 kJ / m ² , less than about 5 kJ / m ^2, less than about 4.8 kJ / m ^{2, and} less than about 4.6 kJ / m ² .

Item 16. The article of item 1, wherein the abrasive article is at least about 50 cm, at least about 60 cm, at least about 70 cm, at least about 80 cm, at least about 90 cm, and up to about 120 cm, cm or less, about 90 cm or less, and about 80 cm or less in outer diameter.

Item 17. The article of item 1, wherein the abrasive article has a thickness of at least about 3 cm, at least about 5 cm, at least about 7 cm, at least about 9 cm, at least about 11 cm, and up to about 18 cm, cm or less, about 12 cm or less, or about 10 cm or less.

Item 18. The article of item 1, wherein the abrasive article comprises at least about 2, at least about 5, at least about 7, at least about 10, at least about 20, and up to about 40, up to about 30, up to about 20, up to about 15, And an aspect ratio (OD) of an outer diameter (OD) to an axial thickness (AT) of 10 or less.

Item 19. The method of item 1, wherein the body is less than or equal to about 10 vol%, less than about 5 vol%, less than about 4 vol%, less than about 3 vol%, less than about 2 vol% at least about 0.001 vol.%, at least about 0.01 vol.% porosity, of at least about 1 vol.%, less than about 1 vol.%, less than about 0.8 vol.%, less than about 0.5 vol.%, less than about 0.3 vol. Abrasive article.

Item 20. The article of item 1, wherein the abrasive article is configured to operate at a speed of at least about 10,000 sfpm, at least about 11,000 sfpm, and at least about 12,000 sfpm.

Item 21. The article of item 1, wherein the article to be polished is hot-pressed.

Item 22. The method of item 1, wherein the stiffener comprises a first stiffener, the first stiffener is adjacent to the grinding portion, the first stiffener is disposed within the grinding portion, Wherein the first stiffener is disposed internally within the body.

Item 23. The method of item 22, wherein the first stiffener extends through the entire diameter of the body, the first stiffener is a planar member including a first major surface and a second major surface, Wherein the abrasive portion is in direct contact with the first major surface of the first stiffener.

Item 24. The method of item 22, further comprising a second stiffener, wherein the first stiffener and the second stiffener are spaced from each other in the body, and at least a portion of the grinding portion is spaced apart from the first stiffener and the second stiffener, 2 < / RTI > stiffeners.

Item 25. The article of item 22 wherein said first stiffener comprises at least about 0.5%, at least about 1%, at least about 1.1%, at least about 1.2%, at least about 5%, at least about 2% 1.5% or less.

Item 26. The method of item 1, wherein the bonding material comprises a material selected from the group consisting of an organic material, an inorganic material, and combinations thereof, the bonding material being selected from the group consisting of metals, glass materials, ceramics, resins, Wherein the bonding material comprises a phenolic resin.

Item 27. The method of item 1, wherein the body further comprises a filler, wherein the bonding material further comprises a filler, wherein the filler is selected from the group consisting of powders, granules, spheres, fibers, cut strand fibers (CSF) Wherein the filler comprises a material selected from the group consisting of an inorganic material, an organic material, and combinations thereof, wherein the filler is selected from the group consisting of sand, bubble alumina, chromium iron, magnesite, the dolomite s, bubble mullite, borides of titanium dioxide, carbon products of silicon carbide, wood flour, clay, talc, hexagonal boron nitride, molybdenum disulfide, feldspar, nepheline syenite, glass spheres, glass fibers, CaF _2, KBF ₄ , Na ₃ AlF ₆ , K ₃ AlF ₆ , pyrite, ZnS, copper sulfide, mineral oil, fluorides, carbonates, ₂ SO ₄ , mineral wool, MnCl ₂ , KCl, and combinations thereof, wherein the filler comprises a material selected from the group consisting of an antistatic agent, a lubricant, a porous inductor, a colorant, and combinations thereof The abrasive article.

Item 28. The method of item 1, further comprising a first filler contained within the abrasive portion including iron and sulfur having an average particle size of about 40 microns or less, wherein the first filler comprises pyrite (FeS ₂ ) And the first filler is essentially composed of pyrite.

Item 29. The method of item 1, wherein the body is at least about 30 vol%, at least about 35 vol%, at least about 40 vol%, at least about 45 vol%, at least about 50 vol% At least about 55 vol%, at least about 60 vol%, at least about 65 vol%, and at least about 70 vol%, at least about 65 vol%, at least about 60 vol%, at least about 55 vol%, at least about 50 vol% Or less, about 40 vol% or less, about 35 vol% or less of a bonding material.

Item 30. The method of item 1, wherein the body is at least about 30 vol%, at least about 35 vol%, at least about 40 vol%, at least about 45 vol%, at least about 50 vol% At least about 55 vol%, at least about 60 vol%, at least about 65 vol%, and at least about 70 vol%, at least about 65 vol%, at least about 60 vol%, at least about 55 vol%, at least about 50 vol% Or less, about 40 vol% or less, about 35 vol% or less of abrasive particles.

Item 31. The method of item 1, wherein the body is in the form of a bonded abrasive body having a shape selected from the group consisting of horns, cones, cups, flange shapes, cylinders, wheels, rings, and combinations thereof, The body is a bonded abrasive swaging wheel.

Item 32. The article of item 1, wherein the stiffener comprises an organic material, a polyimide, a polyamide, a polyester, an aramid, or a combination thereof.

Item 33. The article of item 1, wherein the stiffener comprises an inorganic material, ceramic, glass, glass-ceramic, or a combination thereof, wherein the stiffener comprises a phenolic resin-based binder.

Item 34. In a polishing article,

Bonding material;

Abrasive particles contained in the bonding material;

A body including a grinding portion including a stiffener included in the body, wherein the body has an adherence of at least about 1700 lbf and an adherence force dispersion factor (AVF) of about 10% or less.

Item 35. The article of item 34, wherein the adhesion of the body is at least about 1800 lbf, at least about 1900 lbf, and at least about 2200 lbf, and up to about 2100 lbf, and not greater than about 2000 lbf.

Item 36. The article of item 34, wherein the adhesive force dispersion factor (AVF) of the body is about 8% or less, about 6% or less, about 4% or less; At least 1%, at least 2%.

Item 37. In a polishing article,

Bonding material;

Abrasive particles contained in the bonding material;

A first filler contained within said polishing portion including iron and sulfur having an average particle size of about 40 microns or less; And

As a reinforcing material contained in the body,

(a) a graze weight of about 950 g / m ² or less; or

(b) a thickness of about 2 mm or less; or

(c) fiber bundles having apertures therebetween, wherein one fiber bundle and one opening have a combined dimension of about 15 mm or less; or

(d) said body including an abrasive portion having said stiffener, including openings having an open area of less than about 100 mm < 2 >.

Item 38. The article of item 1, wherein the stiffener comprises a locolino.

The processes and abrasive articles disclosed herein exhibit departures from advanced technology. The abrasive articles herein may utilize a combination of features, such as, but not limited to, abrasive particles having specific characteristics, including composition, mean pore size, average porosity, average crystal size, crystal morphology, and combinations thereof . In addition, the abrasive articles may utilize additional features such as the bonding material, the content of bonding material, the content of abrasive particles, fillers, and the like. Although not entirely understood, the combination of features is not expected and facilitates the formation of abrasive articles that demonstrate remarkable improved performance.

The subject matter disclosed above is considered to be illustrative and not restrictive, and the appended claims are intended to cover all such modifications, enhancements, and other embodiments that fall within the true scope of the invention. Thus, to the maximum extent permitted by law, the scope of the present invention is determined by the broadest permissible interpretation of the following claims and their equivalents, and shall not be limited or limited by the foregoing detailed description.

The summary is provided to comply with patent law and is submitted including the fact that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the foregoing detailed description, various features may be grouped together or may be described in a single embodiment for purposes of streamlining the disclosure. This disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are explicitly recited in each claim. Rather, as the following claims reflect, the subject matter of the invention may be of less than all features of any of the disclosed embodiments. Accordingly, the following claims are incorporated into the detailed description, and each claim is independent as it defines the claimed subject matter separately.

Claims (15)

Bonding material;
Abrasive particles included in the bonding material;
The body comprising a grinding portion having a stiffener contained in the body, wherein the grinding portion has a fracture propagation toughness WOF of at least about 5 kJ / m < ² >, wherein the stiffener is at least about 100 mm & An abrasive article comprising a body having openings with an open area. Bonding material;
Abrasive particles included in the bonding material;
The body comprising a polishing portion having a stiffener included in the body and having apertures, the body having an adherence of at least about 1700 lbf and an Adhesion Variance Factor (AVF) of about 10% or less, ≪ / RTI > The method according to claim 1 or 2,
Wherein the fracture propagation toughness WOF is at least about 6 kJ / m ² , and no more than about 13 kJ / m ² . The method according to any one of claims 1 to 3,
Wherein the stiffener comprises a greige weight of at least about 950 g / m ² , and a greige weight of at least about 400 g / m ² . The method according to any one of claims 1 to 4,
Wherein the stiffener comprises a maximum thickness of at least about 1 mm, and up to about 2 mm. The method according to any one of claims 1 to 5,
The stiffener comprising threads having apertures therebetween, wherein the threads have a width of at least about 1 mm, and a width of at least about 4 mm. The method according to any one of claims 1 to 6,
Wherein the open area is less than or equal to about 80 mm < 2 > and at least about 5 mm < 2 > in the main plane of the stiffener. The method according to any one of claims 1 to 7,
Wherein the stiffener comprises fiber bundles having the apertures therebetween, wherein the distance from one fiber bundle to an adjacent fiber bundle is at least about 2 mm, and no more than about 10 mm. The method according to any one of claims 1 to 8,
Wherein the volume ratio of the abrasive portion to the stiffener is at least about 5 and not more than about 20. The method according to any one of claims 1 to 9,
Wherein the stiffener has a fracture toughness ( _G1C ) of at least about 3.3 kJ / m < ² >, and no greater than about 5 kJ / m < ² >. The method according to any one of claims 1 to 10,
Wherein the body comprises less than about 10 vol%, and at least about 0.001 vol% porosity, relative to the total volume of the body. The method according to any one of claims 1 to 11,
Further comprising a first filler comprised within said polishing portion comprising iron and sulfur having an average particle size of about 40 microns or less, said first filler comprising pyrite (FeS ₂ ). The method according to any one of claims 1 to 12,
Wherein the adhesive force of the body is at least about 1800 lbf, and at least about 2200 lbf. The method according to any one of claims 1 to 13,
Wherein the tensile strength factor (AVF) of the body is less than or equal to about 8%, and at least about 1%. The method according to any one of claims 1 to 14,
Wherein the stiffener comprises a lock leno weave.

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