TWI541098B - Small diameter cutting tool - Google Patents

Description

Small diameter cutting tool

Priority is claimed on U.S. Provisional Application No. 61/656,444, filed on Jun. 6, 2012, which is hereby incorporated by reference.

The present invention generally relates to abrasive articles and in particular to small diameter cutting tools.

Grinding wheels are typically used for cutting, grinding, and forming of different materials, such as, for example, stone, metal, glass, plastic. Generally, the grinding wheel can have different material phases, including abrasive particles, binder, and some porosity. The grinding wheel can have different designs and configurations depending on the intended application. For example, for finishing and cutting applications for metals, certain grinding wheels are shaped such that they have a particularly thin profile for efficient cutting.

However, in view of the application of such grinding wheels, such abrasive articles are subject to fatigue and failure. In fact, depending on the frequency of use, the wheels may have a limited usage time of less than one day. Therefore, the industry continues to demand grinding wheels that can have improved performance.

The following is directed to a variety of abrasive tools having abrasive particles contained in a binder material for cutting a workpiece. Certain embodiments herein are directed to bonded abrasive wheels (including cutting wheels) that can be used to cut metal workpieces, including titanium or stainless steel. However, certain features of such embodiments herein may be applied to other abrasive techniques including, for example, coated abrasives and the like.

The abrasive article can be made by forming a plurality of components or a mixture of precursor components that can be part of the final abrasive article. For example, the mixture can include various components of the final abrasive article, such as abrasive particles, binder materials, fillers, and combinations thereof. In an embodiment, the mixture can include a first type of abrasive particles. The type of abrasive particles can be defined by at least the composition, mechanical properties (e.g., hardness, brittleness, etc.), particle size, method of manufacture, and combinations thereof.

In some embodiments, the abrasive article can be formed by batch processing of the binder, mixing the abrasive with the binder, filling a mold, extruding the filled mold, baking or curing the extruded The mold, removes the cured article, and then performs finishing, inspection, speed testing, packaging, and shipping the abrasive article.

FIG. 1 includes an illustration of an abrasive tool in accordance with an embodiment. Notably, the abrasive tool 100 includes a body 101 having a substantially circular shape when viewed in a two dimensional space. It will be understood that in a three-dimensional space, the tool has a certain thickness such that the body 101 has a disk or Cylindrical shape. As shown, the body can have an outer diameter 103 extending through the center of the tool, which outer diameter can be relatively small, having a size of at least about 12 cm. Further in some other examples, the outer diameter can be larger, such as at least about 18 cm or even at least about 20 cm. In yet another non-limiting embodiment, the outer diameter can be no greater than about 100 cm, such as no greater than about 75 mm, or even no greater than 50 cm.

As further shown, the abrasive tool 100 can include a central opening 105 defined by an inner circular surface 102 around the center of the body 101. The central opening 105 can extend through the entire thickness of the body 101 such that the abrasive tool 100 can be mounted on a rotating shaft or other machine for rotating the abrasive tool 100 during operation.

2 includes a cross-sectional illustration of a portion of an abrasive tool in accordance with an embodiment. The abrasive body 201 can be a composite article that includes a combination of multiple portions of different types of materials. In particular, the body 201 can include abrasive portions 204, 206, 208, and 210 and reinforcing members 205, 207, and 209. The abrasive tool 200 can be designed such that the reinforcing members 205, 207, and 209 can be placed within their bodies such that they are spaced apart from one another and in which the individual abrasive portions 204, 206, 208, and 210 are separated from one another. That is, the abrasive tool 200 can be formed such that the reinforcing members 205, 207, and 209 are laterally spaced apart from one another by the thickness 212 of the body 201 and are separated by the abrasive portions 206 and 208. As will be appreciated, in such a design, the abrasive portions 206 and 208 can be placed between the reinforcing members 205, 207, and 209.

As further shown, the reinforcing members 205, 207, and 209 can be substantially flat members having a first flat surface and a second flat surface. example For example, the reinforcing member 205 can be formed such that it has a planar member of a first major surface 215 and a second major surface 216. Further, the body 201 may have a design such that the abrasive portions 204, 206, 208, and 210 may cover the major surfaces of the reinforcing members 205, 207, and 209. For example, the abrasive portion 204 can overlie the first major surface 215 of the reinforcing member 205 and the abrasive portion 206 overlies the second major surface 216 of the reinforcing member 205. In particular, the body 201 can be formed such that the abrasive portions 204 and 206 substantially cover the entire surface area of the first major surface 215 and the second major surface 216, respectively. Accordingly, the abrasive portions 204 and 206 can directly contact (ie, abut) the reinforcing member 205 on either side at the first and second major surfaces 215 and 216.

Notably, the abrasive body 201 can be designed such that the reinforcing members 205, 207, and 209 can extend through a majority of the diameter 103 of the body 201. In particular cases, the reinforcing members 205, 207, and 209 can be formed such that they extend through at least about 75%, such as at least about 80%, or even the entire diameter of the diameter 103 of the body 201.

According to an embodiment, the body 201 is formed such that it can have an average thickness 212 measured in a direction parallel to the axial axis 250 extending through the center of the central opening 105. The average thickness 212 of the body 201 can be particularly thin, making it suitable for cutting metal workpieces. For example, the body 201 may have an average thickness of no greater than about 3 centimeters. In other embodiments, the average thickness 212 of the body 201 can be no greater than about 2.5 centimeters, such as no greater than about 2 centimeters, or even no greater than about 1.5 centimeters. However, certain embodiments may utilize between about 0.5 cm and about 3 cm, such as in An average thickness 212 in the range between about 0.5 cm and about 2 cm.

The abrasive articles of the embodiments herein may have a particular aspect ratio that is defined as the ratio of the outer diameter 103 of the body 201 to the average thickness 212. According to some designs, the aspect ratio is at least about 10:1, such as at least about 20:1, at least about 50:1, or even at least about 75:1. Certain embodiments utilize an aspect ratio in the range between about 10:1 and about 125:1, such as between about 20:1 and about 125:1.

Further to the reinforcing members 205, 207, and 209, such members are made of an organic material, an inorganic material, and a combination thereof. For example, the reinforcing members 205, 207, and 209 may be fabricated from an inorganic material such as ceramic, glass, quartz, or a combination thereof. Materials particularly suitable for use as reinforcing members 205, 207, and 209 may include glass materials incorporating fibers of glass materials, which may include oxide-based glass materials.

Particularly suitable organic materials for use in the reinforcing members 205, 207, and 209 may include: phenolic resins, polyimines, polyamines, polyesters, aromatic polyamines, and combinations thereof. For example, in one specific embodiment, the reinforcing members 205, 207, and 209 may include Kevlar ^TM, a special type of aromatic polyamide.

Additionally, the reinforcing members 205, 207, and 209 can include a fibrous material having a coating overlying the outer surface of the fibers and directly bonded thereto. The coating can be an organic material, an inorganic material, or a combination thereof. Some abrasive tools may use reinforcing members 205, 207, and 209 that utilize fibers having a coating of an organic material, which may be a natural organic material or a synthetic organic material, such as polymerization. a material that assists in the bonding between the reinforcing member and the abrasive portion. Some suitable organic coating materials may include resins, which may be thermoset materials, thermoplastic materials, or combinations thereof. Particularly suitable resins may include phenolic resins, epoxies, polyesters, cyanates, shellacs, polyurethanes, and combinations thereof. In a specific case, the abrasive tool incorporates a reinforcing member comprising phenolic resin coated glass fibers.

Reinforcing members 205, 207, and 209 can include a plurality of fibers that are woven together. The fibers can be woven or stitched together in a variety of ways. In some cases, the reinforcing members may be woven together such that a pattern comprising fibers extending primarily in two perpendicular directions is formed.

The reinforcing members 205, 207, and 209 can have an average thickness 218 that is defined as the distance between the first major surface 215 and the second major surface 216 of the reinforcing member 205. The average thickness 218 can be less than 0.6 cm, such as less than 0.6 cm, or even less than 0.4 cm.

In terms of relative percentages, depending on the design of the abrasive article, the reinforcing members can be formed to have certain dimensions such that they constitute a certain percentage of the total average thickness of the body. For example, the reinforcing member 205 can have an average thickness 218 that is at least about 3% of the total average thickness 212 of the body 201. In other cases, the reinforcing member 205 can have an average thickness 218 that is at least about 5%, such as at least about 8%, or even at least about 10% of the total average thickness 212 of the body 201. Certain reinforcing members may have an average thickness 218 that is between about 3% and about 15% of the total average thickness 212 of the body 201.

According to embodiments herein, the abrasive tool 200 is formed such that The body 201 includes abrasive portions 204, 206, 208, and 210. The abrasive portion 204 will be referred to in the following paragraphs, but it will be understood that all identified abrasive portions may include the same features. The abrasive portion 204 can be a composite material having abrasive particles contained within a matrix material and further comprising a particular composition and type of porosity.

The abrasive particles can comprise a particularly hard material suitable for grinding and material removal applications. For example, the abrasive particles can have a Vickers hardness of at least about 5 GPa. The hardness of the abrasive particles can be greater in certain tools such that the abrasive particles 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 shown in FIG. 2, the body can be formed such that it incorporates the reinforcing members 202 and 203 that abut the outer surfaces of the abrasive portions 204 and 210 around the central opening 105. In some designs, the reinforcing members 202 and 203 can extend over a portion of the outer diameter 103, such as one-half of the outer diameter 103 of the abrasive body 201. Providing the reinforcing members 202 and 203 around the central opening 105 helps to strengthen the body 201 at a location where it is desired to secure the abrasive tool 200 to the spindle or machine. As will be appreciated, the reinforcing members 202 and 203 can have the same features as the reinforcing members 205, 207, and 209.

3 includes a cross-sectional illustration of a portion of an abrasive tool in accordance with an embodiment. This portion of the illustrated abrasive tool 300 includes the outer circumference of the abrasive tool formed in accordance with an embodiment. In particular, this portion of the abrasive tool 300 can have a body 201 that includes abrasive portions 204, 206, 208, and 210 as previously described. In addition, the abrasive tool 201 includes a reinforcement structure Pieces 205, 207, and 209 are disposed between the abrasive portions 204, 206, 208, and 210 as previously described.

It is to be noted that the body 201 is formed such that it has a flat region 301 adjacent to the center of the grinding wheel and surrounding the central opening 105, and a wedge-shaped region 303 at the outer edge of the body 201. As shown, the wedge shaped region 303 is formed such that it has an average thickness 312 measured at the outer diameter of the body 201 that is substantially greater than the average thickness 311 of the body 201 within the flat region 301. An extension of a tapered edge 305 of the abrasive portion 210 (extending at an angle to the outer surface 308 of the flat region 301 of the abrasive portion 210) facilitates the formation of the tapered region 303. The wedge shaped region 303 is further defined by a tapered surface 306 of the abrasive portion 204 that extends at an angle to the surface 310 of the abrasive portion 204. As shown, the wedge shaped region 303 can form a rim around the outer diameter of the grinding wheel, wherein the tapered surfaces 305 and 306 extend axially outward from the surfaces 308 and 310, respectively, at an angle. The wedge surfaces 305 and 306 can extend at an angle from a radius of the body that extends substantially parallel to the surfaces 308 and 310, and further, the wedge surfaces 305 and 306 can extend with an axial axis extending through the center of the body 201. 250 extends at an angle.

According to some embodiments, the wedge-shaped region 303 may extend circumferentially around a portion of the perimeter of the body 201. Some designs may utilize a wedge-shaped region 303 that extends over the entire circumference of the body 201. Although reference is made herein to abrasive articles incorporating wedge regions 303, it will be appreciated that for certain abrasive articles, wedge regions 303 may not necessarily be present.

As shown, the wedge shaped region 303 can be flat from the body 201 The stan region 301 extends radially. Embodiments herein may form a wedge shaped region 303 having a length 330 that is a specific dimension of the outer diameter 103 of the body 201 as measured parallel to a radius extending from the center of the body 201. percentage. For example, the wedge shaped region 303 can have a length 330 that occupies at least about 5% of the dimensions of the outer diameter 103. In other cases, depending on the intended application, the body 201 can have a wedge-shaped region 303 having a length 330 that is at least about 10%, such as at least about 15%, at least about 20%, at least about the size of the outer diameter 103. 30%, or even at least about 35%. Particular embodiments may utilize a wedge shaped region 303 wherein the length 330 is between about 5% and about 50% of the outer diameter 103, and in particular between about 5% and about 35%, or even more particularly In the range between about 5% and about 20%.

In other aspects, the length 330 of the wedge shaped region can be at least about 10 centimeters. In some embodiments, the length 330 of the wedge shaped region 303 can be larger, such as at least about 13 cm, at least about 15 cm, or even at least about 20 cm. However, a particular embodiment herein may utilize a wedge shaped region 303 having a length 330 between about 10 cm and about 30 cm, such as between about 10 cm and about 20 cm.

In a particular embodiment, a abrasive cutting tool can include a body having the shape of a small diameter disk. The small diameter disc may have an outer diameter of no more than about 100 centimeters. In other various embodiments, the body may have an outer diameter of at least about 12 cm. Moreover, in some other instances, the outer diameter can be larger, such as at least about 18 centimeters, or even at least about 20 centimeters. In yet another non-limiting embodiment, the outer diameter can be no greater than about 75 cm, such as no greater than about 50 cm. The body can have An outer diameter in the range between any of the minimum and maximum values described above.

Additionally, the body of the small diameter disk may have an aspect ratio (D:T) of at least about 10:1, the aspect ratio being defined as the ratio of the outer diameter (D) of the body to the axial thickness (T). . The outer diameter (D) of the wheel is a measure of the radial direction from a peripheral point to an opposite peripheral point on a line extending through the center of the wheel. The axial thickness (T) extends axially through the body, defined as the dimension between the first major surface and the second major surface of the body.

According to a particular embodiment, the body has an aspect ratio (D:T) of at least about 20:1. Additionally, in some other cases, the aspect ratio can be greater, such as at least about 50:1, at least about 75:1, or even at least about 100:1. In yet another non-limiting embodiment, the aspect ratio can be no greater than about 1000:1, such as no greater than about 500:1, or even no greater than about 150:1. The body can have an aspect ratio within a range between any of the minimum and maximum values described above.

The body may also include an abrasive portion having a binder material comprising a resin. The resin can have a standardized heat soak modulus of at least about 1.05 (e.g., at least about 1.10). Alternatively, the resin can have an increasing high temperature flexural modulus.

In some embodiments, the resin used in the binder material may comprise an organic resin. In other various embodiments, the resin may comprise a phenolic resin. In still other embodiments, the phenolic resin can be modified with a curing agent or a crosslinking agent such as hexamethylenetetramine. At temperatures above about 90 ° C, some examples of hexamethylenetetramine can form crosslinks to form methylene and dimethylene amine bridges that help to cure the resin. The six Methylenetetramine can be uniformly dispersed in the resin. More specifically, hexamethylenetetramine can be uniformly dispersed as a crosslinking agent in the resin region. Even more precisely, the phenolic resin may comprise a plurality of resinous regions having crosslinked domains with submicron average size.

In other embodiments, the resin can comprise at least about 40 vol% of the total volume of the bond material. Additionally, in certain other instances, the resin content can be greater, such as at least about 50 vol%, at least about 60 vol%, or even at least about 70 vol%. In yet another non-limiting embodiment, the binder material may have a resin content of no greater than about 90 vol%, no greater than about 80 vol%, no greater than about 70 vol%, no greater than about 60 vol%, Or even no more than 50 vol%. The binder material can have a resin content in the range between any of the minimum and maximum values indicated above. Increasing the total resin content can increase the amount of flow exhibited by the resin.

The abrasive portion can also include one or more fillers. The filler can include, for example, one or more powders, granules, spheres, fibers, or a combination thereof. The filler may include an inorganic material, an organic material, or a combination thereof. Examples of the filler may include sand, bubble alumina, bauxite, chromite, magnesite, dolomite, bubble mullite, boride, titanium dioxide, carbon product. (eg, carbon black, coke or graphite), tantalum carbide, wood flour, clay, talc, hexagonal boron nitride, molybdenum disulfide, feldspar, nepheline syenite, glass spheres, glass fibers, CaF ₂ , KBF ₄ , ice crystals Stone (Na ₃ AlF ₆ ), potassium cryolite (K ₃ AlF ₆ ), iron sulfide ore, ZnS, copper sulfide, mineral oil, fluoride, carbonate, calcium carbonate or a combination thereof. The filler may comprise a material consisting of an antistatic agent, a lubricant, a pore inducing agent, a colorant or a combination thereof. The filler can also be a particulate material. The filler can be different from the abrasive particles. Alternatively, the average particle size of the filler can be significantly less than any type of abrasive particles.

According to a particular embodiment, the total amount of filler may be at least about 15 vol% of the total volume of the binder material. Further in some examples, the filler content can be greater, such as at least about 20 vol% or even at least about 25 vol%. In yet another non-limiting embodiment, the filler content can be no greater than about 60 vol%, such as no greater than about 50 vol%, or even no greater than about 45 vol%. The binder material can have a filler content in the range between any of the minimum and maximum values noted above.

According to a particular embodiment, the binder material can comprise a specific formulation of filler. For example, the abrasive portion can include a first filler comprising iron and sulfur. In particular, the first filler may comprise pyrite (FeS ₂ ), and more particularly, the first filler may consist essentially of pyrite.

In a particular embodiment, the first filler can be at least about 40 vol% of the total volume of the filler within the abrasive portion. In some examples, the filler content can be greater, such as at least about 45 vol% or even at least about 50 vol%. In yet another non-limiting embodiment, the filler content can be no greater than about 70 vol%, such as no greater than about 65 vol%, or even no greater than about 60 vol, of the total volume of filler within the abrasive portion. %. The abrasive portion can have a filler content within a range between any of the minimum and maximum values noted above.

In some embodiments, the first filler may have an average particle size of no greater than about 30 microns. In some embodiments, the first filler may have an average particle size of no greater than about 20 microns, such as no greater than about 15 microns, no greater than about 10 microns, or even no greater than about 8 microns. In other non-limiting embodiments, the first filler average particle size can be at least about 1 micron, such as at least about 2 microns or at least about 3 microns. The average particle size of the first filler can be in the range between any of the minimum and maximum values indicated above.

In other various embodiments, the abrasive portion can include a second filler that is different from the first filler. The second filler may include potassium. The second filler may further comprise aluminum and/or fluoride. The second filler may further comprise a composite comprising potassium, aluminum and fluoride. The second filler may consist essentially of KAlF ₄ .

In some embodiments, the abrasive portion can include a greater amount of the first filler (vol%) than the second filler content (vol%). The abrasive portion may include a content ratio (V1/V2) of at least about 1, wherein V1 represents the content (vol%) of the first filler in the abrasive portion and V2 represents the content of the second filler in the abrasive portion. (vol%). In other examples, the ratio (V1/V2) can be at least about 1.5, or even at least about 2. In other various non-limiting embodiments, the ratio (V1/V2) can be no greater than about 4, such as no greater than about 3.5, no greater than about 3, no greater than about 2.8, and no greater than about 2.6. This ratio (V1/V2) can be in the range between any of the minimum and maximum values indicated above.

In a specific embodiment, the second filler may be the At least about 5 vol% of the total volume of the filler. For example, the second filler can be at least about 10 vol%, such as at least about 15 vol%, or even at least about 20 vol% of the total volume of the fillers. In certain non-limiting embodiments, the second filler may be no greater than about 40 vol% of the total volume of the fillers, such as no greater than about 35 vol%, no greater than about 30 vol%, or even no More than about 25 vol%. The second filler content can be in the range between any of the minimum and maximum values noted above.

In some cases, the second filler can include an average particle size of no greater than about 75 microns. For example, the second filler may have an average particle size of no greater than 65 microns, such as no greater than 55 microns, or even no greater than about 45 microns. In other various non-limiting embodiments, the second filler may have an average particle size of at least about 5 microns, such as at least about 15 microns, or even at least about 25 microns. The second filler average particle size can be in the range between any of the minimum and maximum values noted above.

In other various embodiments, the abrasive portion can include a third filler that is different from the first filler and the second filler. The third filler may include calcium. The third filler may further comprise oxygen or a complex comprising potassium and oxygen. The third filler may consist essentially of CaO.

Examples of the third filler may include an average particle size of no greater than about 75 microns. In particular instances, the third filler may have an average particle size of no greater than about 65 microns, such as no greater than about 55 microns. A plurality of non-limiting embodiments can include a third filler having an average particle size of at least about 15 microns (e.g., at least about 25 microns or at least about 35 microns). The third filler average particle size can be in the range between any of the minimum and maximum values indicated above. Inside.

The abrasive portion may also include a greater amount of the first filler (vol%) than the content (vol%) of the third filler. The abrasive portion can include a ratio (V1/V3) of at least about 10, wherein V1 represents the content (vol%) of the first filler in the abrasive portion and V3 represents the third filler content in the abrasive portion (vol%) ). In other examples, the ratio (V1/V3) can be at least about 15, such as at least about 20 or even at least about 22. In other various non-limiting embodiments, the ratio (V1/V3) can be no greater than about 40, such as no greater than about 35, no greater than about 30, no greater than about 29, or even no greater than about 28. This ratio (V1/V3) can be in the range between any of the minimum and maximum values indicated above.

In still other various embodiments, the abrasive portion can include a greater amount of second filler (vol%) than the third filler content (vol%). The abrasive portion can include a ratio (V2/V3) of at least about 5, wherein V2 represents the content (vol%) of the second filler in the abrasive portion and V3 represents the content of the third filler in the abrasive portion (vol) %). In some examples, the ratio (V2/V3) can be at least about 7, such as at least about 9. A number of non-limiting examples can include a ratio (V2/V3) of no greater than about 25, such as no greater than about 20, no greater than about 15, no greater than about 14, or even no greater than about 13. This ratio (V2/V3) can be in the range between any of the minimum and maximum values indicated above.

In a particular embodiment, the third filler can be at least about 0.5 vol% of the total volume of the fillers. In some examples, the third filler can be higher, such as at least about 1 vol%, or even at least about 1.5. Vol%. In another non-limiting embodiment, the third filler may be no greater than about 5 vol% of the total volume of the fillers, such as no greater than about 4 vol%, no greater than about 3 vol%, or even no Greater than about 2.5 vol%. The abrasive portion can have a third filler content within a range between any of the minimum and maximum values noted above.

In other various embodiments, the abrasive portion can include a fourth filler that is different from the first filler, the second filler, and the third filler. In other examples, the fourth filler may comprise an aggregate, cement, Portland cement or calcium citrate.

Embodiments of the fourth filler can include an average particle size of no greater than about 40 microns. For example, the fourth filler average particle size can be no greater than about 30 microns, or even no greater than about 20 microns. A non-limiting example of the fourth filler average particle size can be at least about 1 micron, such as at least about 5 microns, or at least about 10 microns. The fourth filler average particle size can be in a range between any of the minimum and maximum values noted above.

Other examples of the abrasive portion may include a greater amount of the first filler (vol%) than the content of the fourth filler (vol%). The abrasive portion can include a ratio (V1/V4) of at least about 5, wherein V1 represents the content (vol%) of the first filler in the abrasive portion and V4 represents the content of the fourth filler in the abrasive portion (vol) %). Alternatively, the ratio (V1/V4) can be at least about 10, such as at least about 15. Other non-limiting embodiments of the ratio (V1/V4) can be no greater than about 30, such as no greater than about 25, no greater than about 20, or even no greater than about 19. This ratio (V1/V4) can be in the range between any of the minimum and maximum values indicated above.

A plurality of examples of the abrasive portion may include a greater amount of the second filler (vol%) than the content of the fourth filler (vol%). The abrasive portion can include a ratio (V2/V4) of at least about 1, wherein V2 represents the content (vol%) of the second filler in the abrasive portion and V4 represents the content of the fourth filler in the abrasive portion (vol) %). In a particular embodiment, the ratio (V2/V4) can be at least about 3, such as at least about 5. According to one non-limiting example, the ratio (V2/V4) can be no greater than about 15, such as no greater than about 12, no greater than about 10, no greater than about 9, or even no greater than about 8. This ratio (V2/V4) can be in the range between any of the minimum and maximum values indicated above.

In yet another embodiment, the abrasive portion can include a greater amount of fourth filler (vol%) than the third filler content (vol%). The abrasive portion may include a content ratio (V3/V4) of at least about 0.1, wherein V3 represents the content (vol%) of the third filler in the abrasive portion and V4 represents the content of the fourth filler in the abrasive portion ( Vol%). Other examples of ratios (V3/V4) may be at least about 0.3, such as at least about 0.5, or even at least about 0.6. Other non-limiting embodiments of the ratio (V3/V4) can be no greater than about 3, such as no greater than about 2.5, no greater than about 2, or even no greater than about 1. This ratio (V3/V4) can be in the range between any of the minimum and maximum values indicated above.

An example of the fourth filler can be at least about 1 vol% of the total volume of the fillers. Alternatively, the fourth filler may be at least about 1.5 vol%, such as at least about 2 vol%, of the total volume of the fillers. According to a non-limiting embodiment, the fourth filler may be no more than the fillers About 5 vol% of the total volume, such as no more than about 4.5 vol%, no more than about 4 vol%, or even no more than about 3.5 vol%. The content of the fourth filler in the total volume of the fillers may be in a range between any of the minimum and maximum values indicated above.

Other embodiments herein may employ an abrasive portion that includes a fifth filler that is different from the first filler, the second filler, the third filler, and the fourth filler. The fifth filler may comprise sodium. The fifth filler may further comprise aluminum, fluoride, sodium, and combinations thereof. In a particular example, the fifth filler can consist essentially of Na ₃ AlF ₆ .

In a particular embodiment, the abrasive portion can include a greater amount of first filler (vol%) than the fifth filler content (vol%). The abrasive portion can include a ratio (V1/V5) of at least about 1, wherein V1 represents the content (vol%) of the first filler in the abrasive portion and V5 represents the content of the fifth filler in the abrasive portion (vol) %).

Embodiments of the ratio (V1/V5) can be at least about 1.5, such as at least about 2.

In yet another non-limiting example, the ratio (V1/V5) can be no greater than about 10, such as no greater than about 7, no greater than about 5, or even no greater than about 3. This ratio (V1/V5) can be in the range between any of the minimum and maximum values indicated above.

Another specific embodiment of the abrasive portion can include a greater amount of second filler (vol%) than the fifth filler content (vol%). The abrasive portion may include a content (vol%) with the fifth filler Approximately the same amount of second filler (vol%). The abrasive portion may comprise a ratio (V2/V5) of at least about 0.1, wherein V2 represents the content (vol%) of the second filler in the abrasive portion and V5 represents the content of the fifth filler in the abrasive portion (vol%) ). In other various embodiments, the ratio (V2/V5) can be at least about 0.3, such as at least about 0.5, or even at least about 0.8. According to a non-limiting embodiment, the ratio (V2/V5) may be no greater than about 5, such as no greater than about 4, no greater than about 3, no greater than about 2, or even no greater than about 1.5. This ratio (V2/V5) can be in the range between any of the minimum and maximum values indicated above.

Further, in another embodiment, the abrasive portion may include a greater amount of the fifth filler (vol%) than the content (vol%) of the third filler. The abrasive portion can include a ratio (V3/V5) of at least about 0.01, wherein V3 represents the content (vol%) of the third filler in the abrasive portion and V5 represents the content of the fifth filler in the abrasive portion (vol) %). Other examples of ratios (V3/V5) can be at least about 0.05, such as at least about 0.06 or even at least about 0.07. According to a non-limiting embodiment, the ratio (V3/V5) may be no greater than about 1, such as no greater than about 0.5, or even no greater than about 0.1. This ratio (V3/V5) can be in the range between any of the minimum and maximum values indicated above.

Still other various embodiments of the abrasive portion can include a greater amount of fifth filler (vol%) than the fourth filler content (vol%). The abrasive portion can include a ratio (V4/V5) of at least about 0.01, wherein V4 represents the fourth filler content (vol%) in the abrasive portion and V5 represents the fifth filler content in the abrasive portion (vol) %). ratio Other examples of (V4/V5) may be at least about 0.05, such as at least about 0.10 or even at least about 0.12. In yet another embodiment, the ratio (V4/V5) can be no greater than about 1, such as no greater than about 0.5, or even no greater than about 0.2. This ratio (V4/V5) can be in the range between any of the minimum and maximum values indicated above.

In a particular embodiment, the fifth filler can be at least about 5 vol% of the total volume of the fillers. In other cases, the first filler can be at least about 10 vol%, such as at least about 15 vol% or even at least about 20 vol% of the total volume of the fillers. Other non-limiting embodiments of the fifth filler may be no more than about 40 vol%, such as no more than about 35 vol%, no more than about 30 vol%, or even no more than about 25, of the total volume of the fillers. Vol%. The fifth filler content can be in the range between any of the minimum and maximum values indicated above.

In an embodiment, the abrasive portion may include a combination of the first filler, the second filler, the third filler, the fourth filler, and the fifth filler. The abrasive portion can include at least about 10 vol% of the total filler, second filler, third filler, fourth filler, and fifth filler total content of the total volume of the abrasive portion. In other examples, the total content of the first filler, the second filler, the third filler, the fourth filler, and the fifth filler may be at least about 15 vol% of the total volume of the abrasive portion, such as at least about 20 vol%, at least about 22 vol%, or even at least about 25 vol%. A non-limiting embodiment of the total content of the first filler, the second filler, the third filler, the fourth filler, and the fifth filler may be no more than about 60 vol% of the total volume of the abrasive portion, such as Not more than about 55 vol%, no more than About 50 vol%, or even no more than about 45 vol%. The total content of the first filler, the second filler, the third filler, the fourth filler, and the fifth filler may be between any of the minimum and maximum values indicated above with respect to the total volume of the abrasive portion. Within the scope.

In other various embodiments, the abrasive portion can include a wettable liquid residue. The wettable liquid residue may comprise an aliphatic chain, such as an aliphatic chain from trilauryl alcohol (TDA). Alternatively, the abrasive portion can include a wettable liquid residue comprising a plurality of cyclic organic molecules, such as waxes from high chlorination, furfural or chlorine 40 (Chloro 40).

According to a particular embodiment, the binder portion of the abrasive portion can comprise at least about 20 vol% of the total volume of the abrasive portion. Additionally, in some other instances, the binder material content can be greater, such as at least about 30 vol%, at least about 40 vol%, or even at least about 42 vol%. In yet another non-limiting embodiment, the binder material may be present in the abrasive portion in an amount of no greater than about 70 vol%, no greater than about 65 vol%, no greater than about 60 vol%, and no greater than about 56 vol%. No more than about 52 vol%, or even no more than 50 vol%. The abrasive portion can have a binder material content in a range between any of the minimum and maximum values noted above.

Additionally, the abrasive portion can further include a plurality of abrasive particles contained in the bond material. In some embodiments, the abrasive particles can comprise an inorganic material. For example, the abrasive particles can include one or more oxides, carbides, borides, nitrides, oxycarbides, oxynitrides, or combinations thereof. In other various embodiments, the abrasive particles It can consist mainly of oxides. In a particular case, the abrasive particles can comprise an oxide material such as alumina, zirconia, yttria, or a combination thereof. In yet another example, the abrasive particles can be comprised of a superabrasive material. Such superabrasive particles can include diamond, cubic boron nitride, or a combination thereof. For example, the abrasive particles can consist essentially of diamond.

In some embodiments, the abrasive particles can be at least about 30 vol% of the total volume of the abrasive portion. Additionally, in some other instances, the abrasive particles can be at least about 35 vol% of the total volume of the abrasive portion, such as at least about 40 vol%, at least about 41 vol%, or even at least about 42 vol%. In yet another non-limiting embodiment, the abrasive particles can be no greater than about 70 vol% of the total volume of the abrasive portion, such as no greater than about 60 vol%, no greater than about 55 vol%, and no greater than about 52 vol. %, or even no more than about 50 vol%.

The total volume of the abrasive portion can have an abrasive particle content in a range between any of the minimum and maximum values noted above.

In other various embodiments, the abrasive portion can include a plurality of apertures. For example, the pores can be at least about 0.5 vol% of the total volume of the abrasive portion. Additionally, in some other instances, the pores can be at least about 1 vol%, such as at least about 2 vol%, of the total volume of the abrasive portion. In yet another non-limiting embodiment, the pores can be no greater than about 30 vol% of the total volume of the abrasive portion, such as no greater than about 25 vol%, or even no greater than about 22 vol%. The total volume of the abrasive portion can have a void content in the range between any of the minimum and maximum values noted above.

In some embodiments, the first type of abrasive particles comprise brown corundum (BFA) or may consist essentially of BFA. The abrasive particles can Contains a coating. The coating may comprise, for example, a ceramic, a metal, a transition metal element, an iron, an oxide, a metal oxide or an oxide of iron.

For example, the first type of particles can include a Treibacher BFA. The BFA can include a variety of oxides such as BaO, CaO, Na ₂ O, P ₂ O ₅ , and combinations thereof. For example, the BFA can comprise from about 1360 to about 1560 PPM of BaO. The BFA may also comprise CaO from about 4940 to about 5140 PPM. The BFA may also comprise from about 820 to about 1020 PPM of Na ₂ O. The BFA can also include less than about 50 PPM of P ₂ O ₅ .

In some examples of the abrasive cutting tool, the BFA can comprise no more than about 99 vol% Al ₂ O ₃ . In other examples, the BFA may include not greater than about 98 vol% of Al ₂ O _3, such as not greater than about 97 vol% of Al ₂ O _3. In other non-limiting examples, the BFA can be at least about 80 vol% Al ₂ O ₃ , such as at least about 85 vol% Al ₂ O ₃ , or even at least about 90 vol% Al ₂ O _{3 .} . The BFA of the abrasive cutting tool can have an Al ₂ O ₃ content in the range between any of the minimum and maximum values noted above.

In an alternative example of the abrasive cutting tool, the BFA may include not greater than about 20 vol% of ZrO _2. For example, the BFA may be not greater than about 15 vol% of ZrO _2, for example, not greater than about 10 vol% of ZrO _2, no more than about 5 vol% of ZrO _2, or even not greater than about 1 vol% of ZrO _2. Other non-limiting examples of the BFA may have at least about 0.01 vol% of ZrO _2, such as at least _2, or even at least about 0.10 vol% to about 0.05 vol% of ZrO ZrO _2. The BFA of the abrasive cutting tool can have a ZrO ₂ content in the range between any of the minimum and maximum values noted above.

In another specific case, the BFA can have no more than about 20 GPa hardness. For example, the BFA can have a hardness of no greater than about 19 GPa, such as no greater than about 18 GPa, or even no greater than about 17 GPa. Alternative non-limiting embodiments can include the BFA having a hardness of at least about 15.5 GPa, such as at least about 15.8 GPa, or even at least about 16 GPa. The BFA of the abrasive cutting tool can have a hardness in the range between any of the minimum and maximum values noted above.

In one example of the hardness test, the sample particles are mounted in an epoxy resin and then polished. Once the particles are installed and polished, the desired load is selected on the hardness tester for the indentation. The load typically selected is 500 g, but a load of 1 kg can also be selected depending on the strength of the particles. Once the indentation is completed, a diamond indentation appears and measurements are taken to determine the hardness.

Brittleness can be defined by the relative rupture of the sample compared to the standard. Typically, brittleness can be measured by ball milling the particles for a given period of time, which is the same time as ball milling a standard particle. After ball milling, the residual granules/powder are sieved and the amount of granules that have been broken is weighed. These measurements are compared to the initial amount of particles and then compared to the rupture of the standard. This allows a relative comparison of the durability of the particles to be obtained.

For example, ball brittleness can be measured by placing a given amount of granules into a ball mill vessel containing a medium (e.g., tungsten carbide) and ball milling for a set period of time. Typically, this time depends on when the standard or reference particle reaches at least about 50% cracking. This means that 50% of the initial weight of the granules can pass through a small sieve.

The standard for brittleness can be based on the particles tested And choose. For example, if a very brittle particle is considered (i.e., it is more susceptible to cracking), a standard having similar brittleness should be selected. For BFA samples, a more durable alumina standard can be selected. The choice of standard of choice also depends on its application to determine the relevance of the standard.

Embodiments of the BFA can also have a brittleness of no more than about 70% of the standard. For example, the BFA can have a brittleness of no greater than about 65% (eg, no greater than about 60%). Non-limiting embodiments of the BFA can have a friability of at least about 20%, such as at least about 30%, at least about 40%, or even at least about 50%. The BFA of the abrasive cutting tool can have a brittleness in the range between any of the minimum and maximum values noted above. Classiced alumina particles can be 70% brittle than blue fired alumina.

The abrasive particles of the mixture and the finally formed abrasive article may comprise more than one type of abrasive particles. For example, the mixture can include a second type of abrasive particles different from the first type of abrasive particles. The second type of abrasive particles can differ from the first type of abrasive particles by any of the following: composition, mechanical properties (eg, hardness, brittleness, etc.), particle size, fabrication method, or a combination thereof.

For example, the second type of abrasive particles can include alumina, zirconia or alumina, and zirconia. The second type of abrasive particles can comprise primarily alumina and zirconia.

The second type of abrasive particles can include blue fired alumina (BLFA). For example, the second type of particles can include Treibacher Blue Fired Alumina.

In some examples of the abrasive cutting tool, the BLFA can include no more than about 95.3 vol% Al ₂ O ₃ . In other examples, the BLFA can include Al ₂ O ₃ that is no greater than about 95.2 vol%, such as no more than about 95.1 vol% Al ₂ O ₃ . In other non-limiting examples, which may be BLFA least about 80 vol% of Al ₂ O _3, such as at least about 85 vol% of Al ₂ O _3, or even at least about 90 vol% of Al ₂ O _3. The BLFA of the abrasive cutting tool can have an Al ₂ O ₃ content in the range between any of the minimum and maximum values noted above.

In an alternative embodiment of the abrasive cutting tool, the BLFA may include not greater than about 20 vol% of ZrO _2. For example, the BLFA may be not greater than about 15 vol% of ZrO _2, for example, not greater than about 10 vol% of ZrO _2, no more than about 5 vol% of ZrO _2, or even not greater than about 1 vol% of ZrO _2. Other non-limiting examples of such BLFA may have at least about 0.16 vol% of ZrO _2, such as at least _2, or even at least about 0.18 vol% to about 0.17 vol% of ZrO ZrO _2. The BLFA of the abrasive cutting tool can have a ZrO ₂ content in the range between any of the minimum and maximum values noted above.

The BLFA can include a variety of oxides such as BaO, CaO, Na ₂ O, P ₂ O ₅ , and combinations thereof. For example, the BLFA can include no more than about 1200 PPM of BaO, such as no more than about 800 PPM of BaO, no more than about 400 PPM of BaO, or even no more than about 200 PPM of BaO.

Various embodiments of the BLFA can also include CaO no greater than about 4000 PPM. For example, the BLFA can be CaO no greater than about 3000 PPM, such as CaO no greater than about 2000 PPM.

Other embodiments may further include BLFA no greater than about 800 PPM of Na ₂ O. For example, the BLFA can be no more than about 400 PPM of Na ₂ O, such as no more than about 200 PPM of Na ₂ O.

Still other embodiments of BLFA can include P ₂ O ₅ greater than about 50 PPM. For example, BLFA may be greater than about 100 PPM of P ₂ O _5, for example, greater than about 500 PPM of P ₂ O _5, or even greater than about 1000 PPM of P ₂ O _5.

Unlike BLFA, embodiments of BFA can include amounts of oxides that are very different from those described above for BLFA. For example, the BFA can include at least about 200 PPM of BaO, such as at least about 500 PPM of BaO, or even greater than about 1000 PPM of BaO.

Embodiments of the BFA can also include CaO greater than about 2000 PPM. For example, the BFA can be CaO greater than about 3000 PPM, such as CaO greater than about 4000 PPM.

Other embodiments of the BFA can also include greater than about 200 PPM of Na ₂ O. For example, the BFA can be greater than about 400 PPM of Na ₂ O, such as greater than about 800 PPM of Na ₂ O.

BFA further other embodiments may include no more than about 50 PPM of P ₂ O _5. For example, BFA may be not greater than about 40 PPM of P ₂ O _5, for example not greater than about 30 PPM of P ₂ O _5, or even not greater than about 20 PPM of P ₂ O _5.

In other embodiments, the second type of abrasive particles may include not greater than about 90 vol% of Al ₂ O _3. For example, the second type of abrasive particles may be not greater than about 85 vol% of Al ₂ O _3, such as not greater than about 80 vol% of Al ₂ O _3. A non-limiting embodiment of the second type of abrasive particles can be at least about 70 vol% Al ₂ O ₃ , such as at least about 65 vol% Al ₂ O ₃ or even at least about 60 vol% Al ₂ O ₃ . The second type of abrasive particles can have an Al ₂ O ₃ content within a range between any of the minimum and maximum values noted above.

In another embodiment, the second type of abrasive particles may include not greater than about 40 vol% of ZrO _2. Other examples of the second type of abrasive particles may include not greater than about 35 vol% of ZrO _2, for example, not greater than about 30 vol% of ZrO _2, or even not greater than about 25 vol% of ZrO _2. Non-limiting examples of the second type of abrasive particle may be at least about 10 vol% of ZrO _2, for example at least ₂ or even at least about 20 vol% to about 15 vol% of ZrO ZrO _2. The second type of abrasive particles can have a ZrO ₂ content in the range between any of the minimum and maximum values noted above.

Other embodiments of the second type of abrasive particles can have a hardness of no greater than about 20 GPa. For example, the second type of abrasive particles can have a hardness of no greater than about 18 GPa, such as no greater than about 17 GPa, or even no greater than about 16 GPa. A non-limiting embodiment of the second type of abrasive particles can have a hardness of at least about 14 GPa, such as at least about 14.5 GPa, or even at least about 15 GPa. The second type of abrasive particles can have a hardness within a range between any of the minimum and maximum values noted above.

In another example, the second type of abrasive particles can have a brittleness of no more than about 20% of the standard. In a particular case, the second type of abrasive particles can have a brittleness of no greater than about 15% (e.g., no greater than about 10%). Non-limiting embodiments of the second type of abrasive particles can have a brittleness of at least about 2%, such as at least about 4%, at least about 5%, or even at least about 6%. The second type of abrasive particles can have a brittleness in the range between any of the minimum and maximum values noted above.

The abrasive cutting tool can further include a reinforcing member in the body. The reinforcing member can be at least about 1 vol% of the total volume of the body. In an embodiment, the reinforcing member can be at least about 2 vol% of the total volume of the body, such as at least about 3 vol%, at least about 4 vol%, at least about 5 vol%, or even at least about 6 vol%. Non-limiting embodiments of the abrasive cutting tool can include no more than about 15 vol%, such as no more than about 14 vol%, no more than about 13 vol%, or even no more than about 12 vol% of reinforcing members of the total volume of the body. . The body may include a reinforcing member content in a range between any of the minimum and maximum values indicated above.

Various embodiments of the body of the abrasive cutting tool can include a first reinforcing member. The first reinforcing member can abut the abrasive portion. The first reinforcement member can be disposed within the abrasive portion. The first reinforcing member can define an outer surface of the body. Alternatively, the first reinforcing member may be disposed inside the abrasive portion.

A plurality of examples of the first reinforcing member may comprise an organic material. For example, the first reinforcing member may further comprise: polyimine, polyamine, polyester, aromatic polyamine, and combinations thereof. Other embodiments of the first reinforcing member may comprise an inorganic material. The first reinforcing member may comprise an inorganic material such as a ceramic material, a glass material, a glass-ceramic material, or a combination thereof. The first reinforcing member may comprise glass fibers, such as phenolic resin coated glass fibers.

In still other embodiments, the first reinforcing member can extend through the entire diameter of the body. The first reinforcing member can include a planar member including a first major surface and a second major surface. The abrasive portion can overlie the first major surface. The abrasive portion can be in direct contact with the first major surface of the first reinforcing member.

In a particular embodiment, the body can include a first reinforcement member and a second reinforcement member. The first reinforcing member and the second reinforcing member may be spaced apart from each other within the body. At least a portion of the abrasive portion can be disposed between the first reinforcement member and the second reinforcement member.

In some embodiments, the first reinforcing member can be at least about 3% of the average thickness of the body. In other examples, the first reinforcing member can be at least about 5%, such as at least about 8%, or even at least about 10% of the average thickness of the body. A non-limiting embodiment of the first reinforcing member can be no greater than about 18% of the average thickness of the body, such as no greater than about 15%, or even no greater than about 12%. The first reinforcing member may have a thickness in a range between any of the minimum and maximum values described above.

Any type of abrasive particles can have an elongated shape. In a particular case, the abrasive particles can have an aspect ratio of at least about 2:1, the aspect ratio being defined as a ratio of length to width, wherein the length is the longest dimension of the particle and the width is The second long dimension (or diameter) of the particle perpendicular to the length dimension when viewed in a two dimensional space. In other various embodiments, the abrasive particles can have an aspect ratio of at least about 2.5:1, such as at least about 3:1, at least about 4:1, at least about 5:1, or even at least about 10: 1. In a non-limiting embodiment, the abrasive particles can have an aspect ratio of no greater than about 5000:1. Again, it will be appreciated that in other embodiments, any type of abrasive particles can be generally equiaxed with a substantially 1:1 aspect ratio. In yet another embodiment, any type of abrasive particles can have There are irregular shapes.

In at least one embodiment, the (any type of) abrasive particles can have a particular cross-sectional shape when viewed in a two dimensional space. For example, the abrasive particles can have an ellipsoidal cross-sectional shape. The ellipsoidal shape can include a circle, an ellipse, and any other curved shape. Alternatively, in other cases, the abrasive particles may have a polygonal cross-sectional shape. Some suitable, non-limiting examples of polygonal cross-sectional shapes include triangles, rectangles, pentagons, hexagons, heptagons, octagons, and the like.

As described herein, in addition to the abrasive particles, the mixture may include other components or precursors to facilitate the formation of the abrasive article. For example, the mixture can include a binder material. According to an embodiment, the binder material may comprise a material selected from the group consisting of organic materials, organic precursor materials, inorganic materials, inorganic precursor materials, natural materials, and combinations thereof.

According to another embodiment, the mixture may comprise a precursor of an organic or organic material suitable for forming an organic binder material during further processing. Such organic materials can include one or more natural organic materials, synthetic organic materials, and combinations thereof. In a specific example, the organic material may be made of a resin, which may include a thermosetting resin, a thermoplastic resin, and a combination thereof. For example, some suitable resins may include phenolic resins, epoxies, polyesters, cyanate esters, shellac, polyurethanes, rubbers, and combinations thereof. In a specific embodiment, the mixture includes an uncured resin material configured to form a phenolic resin binder material by further processing.

Multiple embodiments of the body may include an integral body At least about 5 vol% of binder material. In other various embodiments, the body can comprise at least about 10 vol%, such as at least about 15 vol%, at least about 20 vol%, at least about 25 vol%, at least about 30 vol%, at least, of the total volume of the body. About 35 vol%, at least about 40 vol%, at least about 45 vol%, at least about 50 vol%, or even at least about 55 vol% of the binder material of the total volume of the body. In other examples, the body can comprise no more than about 90 vol% binder material of the total volume of the body. Still other examples of the body can include no more than about 85 vol%, no more than about 80 vol%, no more than about 75 vol%, no more than about 70 vol%, no more than about 65 vol%, and no more than the total volume of the body. More than about 60 vol%, no more than about 55 vol%, no more than about 50 vol%, at least about 45 vol%, or even no more than about 40 vol% binder material of the total volume of the body. It will be appreciated that the body can have a binder material within a range between any of the minimum and maximum values described above.

Various embodiments of the body can include a porosity of no more than about 10 vol% of the total volume of the body. In other examples, the body can comprise no more than about 5 vol%, no more than about 3 vol%, no more than about 2.5 vol%, no more than about 2 vol%, no more than about 1.5 vol%, of the total volume of the body, No more than about 1 vol%, no more than about 0.8 vol%, no more than about 0.5 vol%, no more than about 0.4 vol% porosity, or even no more than about 0.3 vol% porosity of the total bulk of the body. In still other embodiments, the body can include a porosity of at least about 0.01 vol% of the total volume of the body, or even at least about 0.05 vol% of the total volume of the body. It will be appreciated that the body can have between any of the minimum and maximum values described above. The porosity within the range.

100, 200, 300‧‧‧ grinding tools

101, 201‧‧‧ ontology

102‧‧‧Internal round surface

103‧‧‧outer diameter

105‧‧‧Central opening

202, 203, 205, 207, 209‧‧‧ reinforcement components

204, 206, 208, 210‧‧‧ abrasive parts

212‧‧‧ thickness

215, 216‧‧‧ main surface

218, 312, 311‧‧ ‧ average thickness

250‧‧‧Axial axis

301‧‧‧flat area

303‧‧‧Wedge area

305‧‧‧Wedge edge

306‧‧‧Wedge surface

308, 310‧‧‧ surface

330‧‧‧ Length

The manner in which the features and advantages of the embodiments are obtained in a more detailed manner can be more specifically described by referring to the embodiments shown in the drawings. However, the figures are merely illustrative of certain embodiments and are therefore not considered to be limiting of their scope, as other equally effective embodiments may be present.

FIG. 1 includes an illustration of an abrasive tool in accordance with an embodiment.

2 includes a cross-sectional illustration of a portion of an abrasive tool in accordance with an embodiment.

3 includes a cross-sectional illustration of a portion of an abrasive tool in accordance with an embodiment.

Figure 4 includes a comparison of normalized abrasive and hot soak modulus performance for a conventional abrasive article versus an abrasive article embodiment.

The use of the same reference symbols in different drawings indicates similar or identical items.

Instance

Two samples were prepared and tested for hot soak modulus and grinding performance. The samples are identical except for the resin used to form their abrasive binder. The first sample was a conventional abrasive article with standard resin 29-722 supplied by Durez-North America. The second sample is one described here. Embodiments include HAP resin (34-279) also supplied by Durez-North America. Each sample was rectangular in size 4 x 1 x 0.235 inches and contained two internally symmetrically positioned fiberglass meshes called #57 glass and supplied by IPAC. Each sample has 46 vol% abrasive (standard brown fused alumina with iron oxide coating), 40 vol% binder, 30 vol% resin, 4.9 vol% pyrite, 3.5 vol% fluoroaluminate Potassium, 1.1 vol% lime, 0.5 vol% polymer microspheres, and 14 vol% pores.

The samples were heated at 400 ° C for 30 minutes, cooled to room temperature, and then ruptured in a three point bend test (according to ASTM D790) spanning 2 inches to check the strength and modulus due to exposure to 400 ° C. Effective downgrade. As shown in Figure 4, the thermal immersion modulus of this conventional sample was normalized to 1.0. The hot soak modulus of the HAP sample was 1.13. Thus, with regard to the thermal immersion modulus, the HAP sample outperformed the conventional sample by 13%, which means that the HAP sample has a standardized thermal immersion modulus of 1.13. Likewise, with regard to the abrasive performance, the HAP sample outperformed the conventional sample by 9%.

According to an embodiment, the abrasive article may be particularly suitable for cutting a workpiece.

Some suitable workpieces may include inorganic materials, and more particularly, the workpieces are made of a metal-containing or metal alloy. According to an embodiment, the abrasive article may be particularly suitable for cutting materials such as metal alloys or titanium.

According to another embodiment, the abrasive particles may be shaped abrasive particles. The shaped abrasive particles can have a well-defined and regular arrangement of edges and sides (ie, non-random), thus defining an identifiable Other shapes. For example, the shaped abrasive particles can have a polygonal shape when viewed in a plane defined by any two of length, width, and height. Some exemplary polygonal shapes may be triangular, quadrilateral (eg, rectangular, square, trapezoidal, parallelogram), pentagon, hexagonal, heptagonal, octagonal, octagonal, decagon, and the like. Additionally, the shaped abrasive particles can have a three-dimensional shape defined by a polyhedral shape (e.g., prismatic, etc.). Further, the shaped abrasive particles can have curved edges and/or surfaces such that the shaped abrasive particles can have a convex, concave, ellipsoidal shape. In addition, it is possible to provide abrasive particles in the shape of rods and cylinders as well as particles having a rugged shape, such as a rod-shaped pretzel shape having a salt-like projection.

The shaped abrasive particles can be in the form of any alphanumeric character, such as 1, 2, 3, etc., A, B, C, and the like. Further, the shaped abrasive particles may be in the form of a character selected from the group consisting of: Greek alphabet, modern Latin alphabet, ancient Latin alphabet, Russian alphabet, any other alphabet (eg, Chinese) Character), and any combination thereof.

The shaped abrasive particles can have a body defining a length (1), a height (h), and a width (w), wherein the length is greater than or equal to the height and the height is greater than or equal to the width. Additionally, in a particular aspect, the body can include a major aspect ratio defined by a length:height ratio of at least about 1:1. The body can also include an upright orientation probability of at least about 50%.

In another aspect, the shaped abrasive particles can have a body having a length (1), a width (w), and a height (h), wherein The length, width, and height may correspond to a longitudinal axis, a horizontal axis, and a vertical axis, respectively, and the vertical axis, the horizontal axis, and the vertical axis may define three perpendicular planes. In this aspect, the body can include an asymmetrical geometry with respect to any of the three perpendicular planes.

In yet another aspect, the shaped abrasive particles can comprise a body having a complex three-dimensional geometry comprising three perpendicular planes defined by a longitudinal axis, a horizontal axis, and a vertical axis. 3 heavy symmetry. Additionally, the body can include an opening that extends through the entire interior of the body along one of a longitudinal axis, a horizontal axis, or a vertical axis.

In yet another aspect, the shaped abrasive particles can have a body having a complex three-dimensional geometry defined by length (1), width (w), and height (h). The body can also include a center of mass and a geometric midpoint. The centroid may be displaced from the geometric midpoint along a defined vertical axis of the body by a distance (Dh) of at least about 0.05 (h).

In another aspect, the shaped abrasive particles can have a body defining a length (1), a width (w), and a height (h). The body can include a base surface and an upper surface. Additionally, the surface of the substrate includes a cross-sectional shape that is different from the cross-sectional shape of the upper surface.

In yet another aspect, the shaped abrasive particles can have a body having a generally flat bottom and a rounded top extending from the generally flat bottom.

In another aspect, the shaped abrasive particles can comprise a body comprising a length (1), a width (w), and a height (h). The length, width, and height may correspond to the vertical axis, the horizontal axis, and the vertical axis, respectively. Additionally, the body can include a twist along a longitudinal axis defining the length of the body such that the surface of the substrate is rotated relative to the upper surface to establish a twist angle.

In still another aspect, the shaped abrasive particles can include a body having a first end surface and a second end surface, at least three adjacent sides extending between the first end surface and the second end surface, and An edge structure established between each pair of adjacent sides.

In another aspect, the shaped abrasive particles can include a body having a central portion and at least three radial arms extending outwardly from the central portion along an overall length of the central portion.

The abrasive articles and methods disclosed herein represent deviations from the prior art. The abrasive article herein can utilize a combination of features, such as abrasive particles having certain characteristics including, but not limited to, composition, average porosity, average particle size, particle ratio, and combinations thereof. Additionally, the abrasive articles may utilize additional features such as binder material, binder material content, abrasive particle content, fillers, and the like. Although not fully understood, the combination of features promotes the formation of abrasive articles that have exhibited unexpected and significantly improved performance.

This written description uses a number of examples to disclose the embodiments, including the best mode thereof, and to enable those skilled in the art to make and use the invention. The patentable scope is defined by the scope of the patent application and may include other examples that would be apparent to those skilled in the art. If such other examples have structural elements that do not differ from the language of the scope of the present application, or include equivalent structural elements that are not substantially different from the literal language of the scope of the present application, it is intended to be Within the scope of the range.

It should be noted that not all of the activities described above throughout the description or examples are required, a portion of a particular activity may not be required, and one or more additional activities may be performed in addition to those described. Still further, the order in which the activities are listed does not have to be the order in which they are performed.

In the above description, the concepts have been described in relation to a number of specific embodiments. However, it will be understood by those skilled in the art that various modifications and changes can be made without departing from the scope of the invention as set forth in the appended claims. The specification and drawings are, accordingly, to be construed in the

As used herein, the terms "comprises", "comprising", "includes", "including", "has", "having" Or any other variation thereof is intended to cover non-exclusive inclusions. For example, a process, method, article, or instrument that comprises a list of features is not necessarily limited to those features, but may include other features not specifically listed or inherent to such a process, method, article, or instrument. In addition, "or" means inclusive - or not exclusive - or, unless explicitly stated to the contrary. For example, Condition A or B meets any of the following: A is true (or exists) and B is false (or non-existent), A is false (or non-existent) and B is true (or exists), and A and B Both are true (or exist).

In addition, use "one / one / one (a / an)" to describe this The components and components described herein. This is done for convenience only and gives a general meaning of the scope of the invention. This description is to be construed as inclusive or inclusive, and the singular

Benefits, other advantages, and solution to problems have been described above with respect to specific embodiments. However, the benefits, advantages, solutions to problems, and any one or more features that may result in any or all of the benefits, advantages, or solutions may not be construed as critical to any or all of the scope of the claims. , required, or necessary features.

Upon reading this specification, the skilled artisan will appreciate that some of the features described herein in the context of a plurality of separate embodiments may also be provided in combination in a single embodiment. In contrast, for the sake of brevity, the different features described in the context of a single embodiment may also be provided separately or in any sub-combination. Further, the recited numerical values are intended to include each value within the range.

The Abstract of the Disclosure is provided to comply with the Patent Law and the Abstract is submitted to the extent that it is not intended to be interpreted or limited. In addition, in the above Detailed Description, various features may be grouped together or described in a single embodiment for the purpose of a simplified disclosure. This disclosure is not to be interpreted as reflecting an intent that the claimed embodiments require more features than are specifically described in the scope of each application. Rather, as the following claims reflect, the subject matter of the present invention may be related to less than all features of any of the disclosed embodiments. Therefore, the scope of the following patent application is incorporated into the detailed description, each of which is individually The subject of the request.

Claims (15)

An abrasive cutting tool comprising: a body having a small diameter disk shape, the body having: an outer diameter of no more than 100 cm, at least a 10:1 aspect ratio, the aspect ratio being defined as the outer diameter and the body axis To thickness ratio (D:T), the abrasive portion, the abrasive portion having: a binder material comprising a resin having a normalized thermal soak modulus of at least about 1.05; and included in the binder material Abrasive particles, wherein the abrasive portion comprises a wettable liquid residue comprising at least one of an aliphatic chain and a cyclic organic molecule. The abrasive cutting tool of claim 1, wherein the standardized thermal soak modulus is at least about 1.10. The abrasive cutting tool of claim 1, wherein the wettable liquid residue comprises a chlorinated wax. The abrasive cutting tool of claim 1, wherein the abrasive particles comprise a first type of abrasive particles and a second type of abrasive particles different from the first type, and the second type of abrasive particles comprises alumina and oxidation zirconium. An abrasive cutting tool comprising: a body having a small diameter disk shape, the body having: an outer diameter of no more than 100 cm, at least a 10:1 aspect ratio, the aspect ratio being defined as the outer diameter and the body axis To the thickness ratio (D:T), the abrasive portion, the abrasive portion having a normalized thermal immersion modulus of at least about 1.05 a resin; a binder material comprising a resin; and abrasive particles contained in the binder material, wherein the abrasive particles comprise a first type of abrasive particles and a second type of abrasive particles different from the first type, the first One type of abrasive particles includes brown fused alumina (BFA), and the abrasive particles include a coating comprising iron oxide. The abrasive cutting tool of claim 1 or 5, wherein the abrasive portion comprises a filler comprising pyrite (FeS ₂ ). The abrasive cutting tool of claim 1 or 5, wherein the abrasive portion comprises a filler comprising KAlF ₄ . The abrasive cutting tool of claim 1 or 5, wherein the abrasive portion comprises a filler comprising CaO. The abrasive cutting tool of claim 1 or 5, wherein the abrasive portion comprises a filler comprising calcium silicate. The abrasive cutting tool of claim 1 or 5, wherein the abrasive portion comprises a filler comprising Na ₃ AlF ₆ . The abrasive cutting tool of claim 1 or 5, wherein the abrasive portion comprises a combination of fillers, the total filler content being at least 10 vol% of the total volume of the abrasive portion, and not greater than the abrasive portion 60 vol% of the total volume. The abrasive cutting tool of claim 1 or 5, wherein the abrasive portion comprises at least 30 vol% and no more than 65 vol of abrasive particles of the total volume of the abrasive portion. The application of the abrasive cutting tool according to item 5 patentable scope, the BFA which comprises not more than 99vol% of Al ₂ O _3, and at least 80vol% of Al ₂ O _3. The abrasive cutting tool of claim 5, wherein the BFA comprises no more than 20 vol% ZrO ₂ and at least 0.01 vol% ZrO ₂ . The abrasive cutting tool of claim 5, wherein the second type of abrasive particles comprises no more than 90 vol% Al ₂ O ₃ , at least 60 vol% Al ₂ O ₃ , no more than 40 vol% ZrO ₂ , and At least 10 vol% of ZrO ₂ .