TH22114B - Abrasive wheel with flexible bond. - Google Patents

Abstract

The DC60 abrasive wheel is a thin, straight wheel formed with hard, non-flexible abrasive grains and a caustic bond, including metallic and reactive metal components, exhibiting excellent strength. Metallic components can be selected from a wide range of caustic metal compositions. Reactive metals are those that react to form bonds with the abrasive grains under caustic conditions and are present in effective quantities. Combining copper/tin/titanium grains and caustic bonds, diamond abrasives are preferred. Such wheels are beneficial for abrasive operations in the electronics industry, such as cutting thin and light silicon and alumina-titanium carbide spherical grains. The strength of these new abrasive wheels is higher than conventional straight abrasive wheels, and therefore cutting accuracy is improved, and less chipping can be achieved without the increased wheel thickness and associated increased cutting loss. The thin, straight abrasive wheel formed with hard, non-flexible abrasive grains and a caustic bond, including metallic and reactive metal components, exhibits excellent strength. Metallic components can be selected from a wide range of caustic metal compositions. Many reactive metals are those that can react to form abrasive grains under the cauterizing condition and are present in sufficient quantities to incorporate abrasive grains and cauterized binders of copper/tin/titanium, with diamond abrasives being desirable. Such wheels are useful for abrasive operations in the electronics industry, such as cutting thin and light silicon and alumina-titanium carbide spherical grains. The strength of these new abrasive wheels is higher than that of conventional abrasive wheels, and therefore cutting accuracy is improved, and less chipping can be achieved without the increase in wheel thickness and the associated increased loss of the cutting edge.

Claims (18)

1. Abrasive wheels consisting of a reinforced, straight abrasive disc with a uniform width ranging from 20-2,500 µm, composed primarily of 2.5-50 vol% abrasive grains and a reinforcing amount of a binder. This binder consists of reactive metal and abrasive components chemically bonded to the abrasive grains by sintering. The reactive metal and abrasive grains are present in quantities effective enough to produce a reinforced abrasive disc with an elastic modulus at least 10% higher than that of identical abrasive discs without reactive metal. 2. The abrasive wheel of claim 1, where the abrasive grain size is approximately 0.5-100 µm and the abrasive disc is reinforced with grains, has an elastic modulus of at least 100 GPa. 3. The polishing wheel of claim 2 in which the value of the elastic modulus is at least twice as high as the value of the elastic modulus of the same polished composite material without abrasive grains. 4. The polishing wheel of claim 3 in which the polishing disc consists mainly of 15-30 vol% of abrasive grains. 5. The polishing wheel of claim 4 states that a reactive metal shall be selected from a group consisting of titanium, zirconium, hafnium, chromium, tantalum, and a mixture of at least two of those. 6. The polishing wheel of claim 5 where the abrasive grains are free from a coating of reactive metal. 7. The polishing wheel of claim 5 in which the abrasive grains are coated with a layer of macromolecular thickness of metal. 8. The inclusion of a compound in the claim under paragraph 1 is that the metal components shall consist of a metal alloy or a metal compound consisting of materials chosen from a group of materials which include boron, silicon and compounds and their combinations. 9. The wheel of claim 1, which is a stone. 10. The polishing wheel of claim 1, in which the metallic components shall be selected from a group comprising copper, tin, cobalt, iron, nickel, silver, zinc, antimony, manganese, metal carbides, and alloys of at least two of those. 11. The polishing wheel of claim 10 in which the calcined binder consists of (a) 45–75 wt% copper, (b) 20–35 wt% tin, and (c) 5–20 wt% reactive metal, in which all of (a), (b), and (c) are 100 wt%. 12. The wheel of claim 11 shall be polished in which a reactive metal shall be selected from a group which shall consist of titanium, zirconium, hafnium, chromium, tantalum and a mixture of at least two of those. 13. The wheel of claim 12, where the reactive metal is titanium. 14. The polishing wheel of claim 1 in which the abrasive grains are an abrasive material selected from a group consisting of diamond, cubic boron nitride, silicon carbide, fused aluminum oxide, microcrystalline alumina, silicon nitride, boron carbide, tungsten carbide and a mixture of at least two of those. 15. The polishing wheel of claim 14, where the polishing bead is a diamond. 16. The polishing wheel of claim 1, consisting mainly of a polishing disc with an outer diameter of 40-120 mm, with a bore of 12-90 mm, having a uniform width in the range of 100-500 µm, and consisting mainly of diamond grains and a composite material consisting of 59.5 wt% copper, 24 wt% tin, and 16.5 wt% titanium. 17. The polishing wheel of claim 16, where the uniform width is in the range of 100-200 µm. 18. Abrasive wheels consisting of a reinforced, straight abrasive disc of uniform width and a grit ratio of 20-6000:1, composed primarily of 2.5-50 vol% abrasive grains and an additional amount of binder consisting of reactive metal and metal components. This binder forms chemical metal-abrasive bonds with the abrasive grains during machining. The reactive metal and abrasive grains are present in sufficient quantities to produce a reinforced abrasive wheel with an elastic modulus at least 10% higher than that of a similar abrasive wheel without reactive metal.