US20140137482A1 - Abrasive Article Comprising Abrasive Particles of a Composite Composition - Google Patents

Abrasive Article Comprising Abrasive Particles of a Composite Composition Download PDF

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Publication number
US20140137482A1
US20140137482A1 US14/085,335 US201314085335A US2014137482A1 US 20140137482 A1 US20140137482 A1 US 20140137482A1 US 201314085335 A US201314085335 A US 201314085335A US 2014137482 A1 US2014137482 A1 US 2014137482A1
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United States
Prior art keywords
vol
abrasive
reinforcing member
abrasive article
item
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
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US14/085,335
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English (en)
Inventor
Lingyu Li
Muthu Jeevanantham
Anne M. Bonner
Dean S. Matsumoto
Piotr Miziak
Andre Collin
Alejandro Javier Mantecon Torres
Stefano Francovigh
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Saint Gobain Abrasifs SA
Saint Gobain Abrasives Inc
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Saint Gobain Abrasifs SA
Saint Gobain Abrasives Inc
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Publication date
Application filed by Saint Gobain Abrasifs SA, Saint Gobain Abrasives Inc filed Critical Saint Gobain Abrasifs SA
Priority to US14/085,335 priority Critical patent/US20140137482A1/en
Assigned to SAINT-GOBAIN ABRASIFS, SAINT-GOBAIN ABRASIVES, INC reassignment SAINT-GOBAIN ABRASIFS ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: FRANCOVIGH, STEFANO, COLLIN, ANDRE, LI, LINGYU, MIZIAK, PIOTR, BONNER, ANNE M., JEEVANANTHAM, MUTHU, MANTECON TORRES, ALEJANDRO JAVIER, MATSUMOTO, DEAN S.
Publication of US20140137482A1 publication Critical patent/US20140137482A1/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D5/00—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting only by their periphery; Bushings or mountings therefor
    • B24D5/02—Wheels in one piece
    • B24D5/04—Wheels in one piece with reinforcing means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
    • B24D3/34—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents characterised by additives enhancing special physical properties, e.g. wear resistance, electric conductivity, self-cleaning properties

Definitions

  • the following is directed to abrasive articles, and particularly, bonded abrasive articles comprising abrasive particles comprising a composite composition.
  • Abrasive wheels are typically used for cutting, abrading, and shaping of various materials, such as stone, metal, glass, plastics, among other materials.
  • the abrasive wheels can have various phases of materials including abrasive grains, a bonding agent, and some porosity.
  • the abrasive wheel can have various designs and configurations. For example, for applications directed to the grinding of workpieces, some abrasive wheels are fashioned such that they have a relative thicker profile for efficient grinding.
  • the abrasive articles are subject to fatigue and failure.
  • the wheels may have a limited time of use of less than a day depending upon the frequency of use. Accordingly, the industry continues to demand abrasive wheels capable of improved performance.
  • Embodiments of an abrasive article can include a body including an abrasive portion having a bond material, abrasive particles contained in the bond material, and a reinforcing member contained in the body.
  • the abrasive portion can have a fracture propagation toughness WOF of at least about 5 kJ/m 2 .
  • the reinforcing member can have openings with an open area of not greater than about 100 mm 2 within a major plane of the reinforcing member.
  • an abrasive article can include a body including an abrasive portion having a bond material, abrasive particles contained in the bond material, and a reinforcing member contained in the body.
  • the body can have an adhesion of at least about 1700 lbf, and an Adhesion Variance Factor (AVF) of not greater than about 10%.
  • APF Adhesion Variance Factor
  • an abrasive article can include a body including an abrasive portion having a bond material, abrasive particles contained in the bond material, a first filler contained within the abrasive portion comprising iron and sulfur having an average particle size of not greater than about 40 microns, and a reinforcing member contained in the body.
  • the reinforcing member can include a greige weight (or uncoated weight) of not greater than about 950 g/m 2 ; and/or a thickness of not greater than about 2 mm; and/or fiber bundles with the openings therebetween, and one fiber bundle and one opening have a combined dimension defined as a unit cell (UC) of not greater than about 15 mm; and/or openings with an open area of not greater than about 100 mm 2.
  • a greige weight or uncoated weight
  • UC unit cell
  • FIG. 1 includes a schematic side view of an abrasive tool in accordance with an embodiment.
  • FIG. 2 includes a schematic sectional radial view of a portion of an abrasive tool in accordance with an embodiment.
  • FIG. 3 includes a schematic, sectional radial view of a portion of an abrasive tool in accordance with another embodiment.
  • FIGS. 4A and 4B include plan views of embodiments of a reinforcing member and, FIG. 4C includes a table of various dimensions of conventional reinforcing members and embodiments of a reinforcing member.
  • FIG. 5 includes plots of adhesion performance of abrasive articles in accordance with an embodiment and various conventional abrasive articles.
  • FIG. 1 includes an illustration of an abrasive tool in accordance with an embodiment.
  • the abrasive tool 100 includes a body 101 having a generally circular shape as viewed in two dimensions. It will be appreciated, that in three dimensions the tool has a certain thickness such that the body 101 has a disk-like or a cylindrical shape.
  • the body can have an outer diameter 103 extending through the center of the tool, which can be particularly large, having a dimension of at least about 20 cm.
  • the body 101 can have an outer diameter 103 , such as on the order of 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 90 cm.
  • Embodiments of the outer diameter 103 may be not greater than about 120 cm, such as not greater than about 110 cm, not greater than about 100 cm, not greater than about 90 cm, or even not greater than about 80 cm.
  • Particular abrasive tools utilize a body 101 having an outer diameter 103 within a range of any of the previous minimum and maximum values.
  • the abrasive tool 100 can include a central opening 105 defined by an inner circular surface 102 about 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 spindle or other machine for rotation of the abrasive tool 100 during operation.
  • FIG. 2 includes a sectional illustration of a portion of an abrasive tool in accordance with an embodiment.
  • the abrasive body 201 can be a composite article including a combination of portions of different types of material.
  • 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 the body such that they are spaced apart from each other, and therein, separate each of the abrasive portions 204 , 206 , 208 , and 210 from each other.
  • the abrasive tool 200 can be formed such that the reinforcing members 205 , 207 , and 209 are spaced apart from each other laterally through the thickness 212 of the body 201 and separated by abrasive portions 206 and 208 .
  • the abrasive portions 206 and 208 can be disposed between the reinforcing members 205 , 207 , and 209 .
  • the reinforcing members 205 , 207 , and 209 can be substantially planar members having first planar faces and second planar faces.
  • the reinforcing member 205 can be formed such that it is a planar member having a first major surface 215 and a second major surface 216 .
  • the body 201 can have a design such that the abrasive portions 204 , 206 , 208 , and 210 can overlie the major surface of the reinforcing members 205 , 207 , and 209 .
  • 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 .
  • the body 201 can be formed such that the abrasive portions 204 and 206 cover essentially the entire surface area of the first major surface 215 and second major surface 216 , respectively. Accordingly, the abrasive portions 204 and 206 can directly contact (i.e. abut) the reinforcing member 205 on either sides at the first and second major surfaces 215 and 216 .
  • 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 .
  • 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 103 of the body 201 .
  • the reinforcing members 303 , 305 may vary in length and position throughout an abrasive body 301 .
  • the abrasive body 301 may comprise one or more relatively shorter reinforcing members 303 (e.g., six shown), as well as one or more relatively longer reinforcing members 305 (e.g., four shown).
  • Embodiments of members 303 may extend only through an outer section 311 of the abrasive body 301 , but not an inner section 313 .
  • Embodiments of members 305 may extend through the entire diameter of the abrasive body 301 , such as outer section 311 and inner section 313 .
  • These reinforcing members 303 , 305 also may be arranged axially with respect to central axis 350 in a variety of patterns. For example, as depicted in FIG. 3 , two members 303 may be located between adjacent members 305 .
  • Metallic reinforcement rings 355 also may be provided in inner section 313 .
  • the number of reinforcing members may vary depending on the application.
  • the abrasive body may have 1 to 15 reinforcing members in some embodiments.
  • the abrasive body may have at least 2 reinforcing members, such as at least 4 reinforcing members, at least 6 reinforcing members, at least 8 reinforcing members, or even at least 10 reinforcing members.
  • the abrasive body may have not greater than 14 reinforcing members, such as not greater than 12 reinforcing members, not greater than 10 reinforcing members, or even not greater than 8 reinforcing members.
  • the number of reinforcing members may be in a range between any of the foregoing values.
  • the body 201 may be formed such that it can have 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 can 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.
  • the average thickness 212 can be not greater than about 18 cm, such as not greater than about 16 cm, not greater than about 14 cm, not greater than about 12 cm, or even not greater than about 10 cm. Still, certain embodiments may utilize an average thickness 212 within a range between any of the minimum and maximum values described above.
  • the disk also may have an aspect ratio defined as an outer diameter OD to axial thickness AT (OD:AT) of at least about 2, such as at least about 5, at least about 7, at least about 10, or even at least about 20.
  • the aspect ratio may be not greater than about 40, such as not greater than about 30, not greater than about 20, not greater than about 15, or even not greater than about 10. Certain embodiments may utilize an aspect ratio within a range between any of the minimum and maximum values given above.
  • such members can be made of an organic material, inorganic material, and a combination thereof.
  • the reinforcing members 205 , 207 , and 209 can be made of an inorganic material, such as a ceramic, a glass, quartz, or a combination thereof.
  • Particularly suitable materials for use as the reinforcing members 205 , 207 , and 209 can include glass materials, incorporating fibers of glass materials, which may include oxide-based glass materials.
  • suitable organic materials for use in the reinforcing members 205 , 207 , and 209 can include phenolic resin, polyimides, polyamides, polyesters, aramids, and a combination thereof.
  • the reinforcing members 205 , 207 , and 209 can include KevlarTM, a particular type of aramid.
  • embodiments of the reinforcing member may comprise a phenolic resin-based binder.
  • the 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 manners.
  • the reinforcing members can be woven together such that a pattern is formed, including fibers extending primarily in two perpendicular directions.
  • the reinforcing members 205 , 207 , and 209 can have a maximum 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 maximum thickness 218 of each reinforcing member can 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 can be not greater than about 2 mm, such as not greater than about 1.8 mm, not greater than about 1.5 mm, or even not greater than about 1.4 mm. Certain embodiments may utilize a thickness within a range between any of the minimum and maximum values given above.
  • the reinforcing members can be formed to have certain dimensions such that they compose a certain percentage of the total average thickness of the body.
  • the reinforcing members can be at least about 3 vol % of the total volume of the body 201 .
  • the reinforcing member 205 can 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 .
  • the reinforcing members can be not greater than about 17 vol % of the total volume of the body, such as not greater than about 15 vol %.
  • Certain embodiments of the abrasive article can have reinforcing members within a range between the minimum and maximum values given above.
  • a volumetric ratio of the abrasive portion to the reinforcing members is at least about 5, such as at least about 10, or even at least about 15.
  • Other embodiments have a volumetric ratio of not greater than about 20, such as not greater than about 15, or even not greater than about 10.
  • Certain embodiments of the abrasive article can have reinforcing members within a range between the minimum and maximum values given above.
  • the abrasive tool 200 is formed such that the body 201 includes abrasive portions 204 , 206 , 208 , and 210 .
  • the abrasive portion 204 can be a composite material having abrasive grains contained within a matrix material and further comprising a particular composition and type of porosity.
  • the abrasive grains can include a particularly hard material suitable for abrading and material removal applications.
  • the abrasive grains can have a Vickers hardness of at least about 5 GPa.
  • the hardness of the abrasive grains can be greater in some tools, such that the abrasive grains 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.
  • Embodiments of the body of the abrasive article may comprise a reinforcing member, such as a first reinforcing member.
  • the first reinforcing member may abut the abrasive portion.
  • the first reinforcing member may be disposed within the abrasive portion.
  • the first reinforcing member may define an external surface of the body.
  • the first reinforcing member may be disposed internally within the body.
  • the first reinforcing member may comprise an organic material.
  • the first reinforcing member may comprise a polyimide, polyamide, polyester, aramid, and a combination thereof.
  • the first reinforcing member may comprise an inorganic material.
  • the inorganic material may comprise ceramic materials, glass materials, glass-ceramic materials, or a combination thereof.
  • the first reinforcing member may comprise glass fibers
  • the first reinforcing member may extend through an entire diameter of the body.
  • the first reinforcing member may comprise a planar member comprising a first major surface and a second major surface.
  • the abrasive portion may overlie the first major surface.
  • the abrasive portion can be in direct contact with the first major surface of the first reinforcing member.
  • the body of the abrasive article may comprise a first reinforcing member and a second reinforcing member.
  • the first reinforcing member and the second reinforcing member can be spaced apart from each other within the body.
  • at least a portion of the abrasive portion may be disposed between the first reinforcing member and the second reinforcing member.
  • the first reinforcing member can be at least about 0.5% of an average thickness of the body.
  • the first reinforcing member can 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%.
  • the first reinforcing member can be not greater than about 5% of the average thickness of the body, such as not greater than about 2%, or even not greater than about 1.5%.
  • the average thickness of the body can have a first reinforcing member content within a range between any of the minimum and maximum values noted above.
  • the abrasive article can be formed by forming a mixture of components or precursor components that may be part of the final abrasive article.
  • the mixture can include abrasive particles.
  • the abrasive particles can have composite composition including alumina (Al 2 O 3 ), iron oxide (Fe 2 O 3 ), silica (SiO 2 ), calcia (CaO), titania (TiO 2 ) and the like.
  • the composite composition can include a majority content of alumina.
  • the composite composition can have at least about 82% alumina for the total content of compounds (or elements) within the composite composition.
  • the content of alumina can 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%.
  • the composite composition can contain not greater than about 95% alumina, such as not greater than about 92% alumina, not greater than about 91% alumina, not greater than about 90% alumina, or even not greater than about 89% alumina. It will be appreciated that the composite composition can have a content of alumina within a range between any of the above noted minimum and maximum percentages.
  • the composite composition can have a minority content of silica.
  • the composite composition can have a lesser content of silica as compared to the content of alumina.
  • the composite composition can have not greater than about 6.6% silica, such as not greater than about 6.5% silica, not greater than about 6% silica, not greater than about 5% silica, not greater than about 4% silica, or even not greater than about 3% silica.
  • the composite composition can 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 can have a content of silica within a range between any of the above noted minimum and maximum percentages.
  • the composite composition can include a minority content of iron oxide.
  • the composite composition may include a lesser content of iron oxide as compared to the content of alumina.
  • the composite composition may have a lesser content of iron oxide as compared to the content of silica.
  • the composite composition can have a greater content of iron oxide as compared to the content of silica.
  • the composite composition of the abrasive particles can have not greater than about 7% iron oxide, such as not greater than about 6% iron oxide, not greater than about 5% iron oxide, not greater than about 4.5% iron oxide, or even not greater than about 4% iron oxide.
  • the composite composition may have at least about 1% iron oxide, such as at least about 2% iron oxide, or even at least about 3% iron oxide. It will be appreciated that the composite composition can have a content of silica within a range between any of the above noted minimum and maximum percentages.
  • Certain exemplary composite compositions of the abrasive particles may further include some content of titania (TiO 2 ).
  • one composite composition may include a minority content of titania.
  • the composite composition can have a lesser content of titania as compared to the content of alumina.
  • the composite composition can have a lesser content of titania as compared to the content of silica.
  • the composite composition may have a lesser content of titania as compared to the content of iron oxide.
  • the composite composition can have not greater than about 5% titania, such as not greater than about 4% titania.
  • the composite composition can include at least about 3.8% titania, such as at least about 3.9% titania. It will be appreciated that the composite composition can have a content of titania within a range between any of the above noted minimum and maximum percentages.
  • the composite composition may, in certain instances, include a content of calcia (CaO).
  • the composite composition may include a minority content of calcia.
  • the composite composition can have a lesser content of calcia as compared to the content of alumina.
  • certain composite compositions can have a lesser content of calcia as compared to the content of silica.
  • the composite composition can include a lesser content of calcia as compared to the content of iron oxide.
  • the content of calcia can be less than the content of titania.
  • the composite composition can have not greater than about 5% calcia, such as not greater than about 4% calcia, not greater than about 3% calcia, not greater than about 2% calcia, or even not greater than about 1% calcia.
  • the composite composition can have at least about 0.3% calcia, such as 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% calcia. It will be appreciated that the composite composition can have a content of calcia within a range between any of the above noted minimum and maximum percentages.
  • Certain composite compositions of the abrasive particles may also include some content of magnesia (MgO).
  • the composite composition can include a minority content of magnesia.
  • the composite composition can have a lesser content of magnesia as compared to the content of alumina.
  • the composite composition may have a lesser content of magnesia as compared to the content of silica.
  • the composite composition may have a lesser content of magnesia as compared to the content of iron oxide.
  • the composite composition may have a lesser content of magnesia as compared to the content of titania.
  • the composite composition may have a lesser content of magnesia as compared to the content of calcia. Still, in at least one non-limiting embodiment, the composite composition can have a greater content of magnesia as compared to a content of calcia. According to one particular embodiment, the composite composition may have not greater than about 40% magnesia, such as not greater than about 30% magnesia, not greater than about 20% magnesia, not greater than about 15% magnesia, not greater than about 10% magnesia, not greater than about 8% magnesia, not greater than about 5% magnesia, or even not greater than about 2% magnesia.
  • the composite composition may include at least about 0.05% magnesia, such as at least about 0.1% magnesia. It will be appreciated that the composite composition can have a content of magnesia within a range between any of the above noted minimum and maximum percentages.
  • the composite composition can include a combination of alumina, silica, iron oxide, magnesia, calcia, and titania.
  • the composition can be an ore, which has been mined and generally unrefined.
  • the abrasive particles can be made of a crystalline material, and more particularly, can consist essentially of a crystalline material.
  • the composite composition can be bauxite, and more particularly, the abrasive particles may consist essentially of bauxite.
  • the abrasive particles can be extruded, such that the composite composition is extruded and segmented to make abrasive particles of a desired size and shape.
  • the abrasive particles may be sintered, and may be sintered in a particular manner to ensure certain properties and compositions described in the embodiments herein.
  • the abrasive particles can be formed to have an ellipsoidal cross-sectional shape.
  • An ellipsoidal shape can include circles, ellipses, and any other curvilinear shapes.
  • the abrasive particles can have a polygonal cross-sectional shape.
  • Some suitable, non-limiting, examples of polygonal cross-sectional shapes include triangular, rectangular, pentagonal, hexagonal, septagonal, octagonal, and the like.
  • Embodiments of the abrasive particles may be characterized in terms of grain toughness (K1C) and hardness.
  • the hardness of the abrasive particles may be less than about 12 GPa.
  • 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.
  • 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 the abrasive particles can have a hardness within a range between any of the above noted minimum and maximum values.
  • Embodiments of the abrasive particles also can have a toughness of at least about 4.6 MPa-m 0.5 .
  • 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 .
  • the abrasive particles can have a toughness of not greater than about 5.4 MPa-m 0.5 , such as not greater than about 5.3 MPa-m 0.5 , not greater than about 5.2 MPa-m 0.5 , not greater than about 5.1 MPa-m 0.5 , or even not greater than about 5 MPa-m 0.5 . It will be appreciated that the abrasive particles can have a toughness within a range between any of the above noted minimum and maximum values.
  • the abrasive particles can have an average particle size of not greater than about 10 mm, such as not greater than about 5 mm, not greater than about 4 mm, not greater than about 3 mm, not greater than about 2 mm, or even not greater than about 1 mm. It will be appreciated, that the average particle size may be determined by measuring and averaging the longest dimension (i.e., the length) of the particles. The abrasive particles can have an average particle size within a range between any of the minimum and maximum values noted above.
  • the abrasive particles can have a particular porosity, which may facilitate improved performance.
  • the average porosity of the abrasive particles can be at least about 0 vol % for the total volume of an abrasive particle.
  • the average porosity of the abrasive particles can be at least about 2 vol %, such as 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 %, at least about 9 vol %, at least about 11 vol, or even at least about 13 vol %.
  • the average porosity of the abrasive particles may be not greater than about 15 vol %, such as not greater than about 14 vol %, not greater than about 12 vol %, not greater than about 10 vol %, not greater than about 8 vol %, not greater than about 6 vol %, not greater than about 4 vol %, not greater than about 2 vol %, or even not greater than about 1 vol % for the total volume of the abrasive particle. It will be appreciated that the average porosity of the abrasive particles can be within a range between any of the minimum and maximum percentages noted above.
  • the abrasive particles may have a particular average pore size.
  • the average pore size of the abrasive particles can be not greater than about 6 microns, such as not greater than about 5 microns, not greater than about 4 microns, not greater than about 3 microns, not greater than about 2 microns, or even not greater than about 1.5 microns.
  • the average pore size of the abrasive particles can 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 can be within a range between any of the minimum and maximum percentages noted above.
  • the mixture may include a vitreous material, or a precursor of a vitreous material, suitable for formation of a vitreous bond material during further processing.
  • the mixture may include a vitreous material in the form of a powder, including for example, an oxygen-containing material, an oxide compound or complex, a frit, and any combination thereof.
  • the mixture may include a ceramic material, or a precursor of a ceramic material, suitable for formation of a ceramic bond material during further processing.
  • the mixture may include a ceramic material in the form of a powder, including for example, an oxygen-containing material, an oxide compound or complex, and any combination thereof.
  • the mixture may include an organic material, or a precursor of an organic material, suitable for formation of an organic bond material during further processing.
  • an organic material may include one or more natural organic materials, synthetic organic materials, and a combination thereof.
  • the organic material can be made of a resin, which may include a thermoset, a thermoplastic, and a combination thereof.
  • some suitable resins can include phenolics, epoxies, polyesters, cyanate esters, shellacs, polyurethanes, rubber, and a combination thereof.
  • the mixture includes an uncured resin material configured to form a phenolic resin bond material through further processing.
  • the resin may have a high temperature flexure 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 cross-linking agent, such as hexamethylene tetramine. At temperatures in excess of about 90° C., some examples of the hexamethylene tetramine may form crosslinks to form methylene and dimethylene amino bridges that help cure the resin.
  • the hexamethylene tetramine may be uniformly dispersed within the resin. More particularly, hexamethylene tetramine may be uniformly dispersed within resin regions as a cross-linking agent. Even more particularly, the phenolic resin may contain resin regions with cross-linked domains having a sub-micron average size.
  • the process can continue by treating the green body to form a finally-formed abrasive article comprising a body.
  • treating can include curing, heating, sintering, crystallizing, polymerization, pressing, and a combination thereof.
  • the process may include bond batching, mixing abrasive with bond, filling a mold, pressing, wheel baking or curing, finishing, inspection, speed testing, and packing and shipping.
  • the body can have at least about 30 vol % bond material for the total volume of the body.
  • the content of bond material in the body can be greater, such as 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 %.
  • the content of bond material in the body can be not greater than about 70 vol %, such as not greater than about 65 vol %, not greater than about 60 vol %, not greater than about 55 vol %, not greater than about 50 vol %, not greater than about 45 vol %, not greater than about 40 vol %, or even not greater than about 35 vol %. It will be appreciated that the content of bond material in the body can be within a range between any of the minimum and maximum percentages noted above.
  • the body can have a content of abrasive particles of not greater than about 70 vol %, such as not greater than about 65 vol %, not greater than about 60 vol %, not greater than about 55 vol %, not greater than about 50 vol %, not greater than about 45 vol %, not greater than about 40 vol %, or even not greater than about 35 vol %. It will be appreciated that the content of abrasive particles in the body can be within a range between any of the minimum and maximum percentages noted above.
  • the abrasive articles of the embodiments herein can have a body that may be in the form of a bonded abrasive having a shape such as a hone, a cone, a cup, flanged shapes, a cylinder, a wheel, a ring, and a combination thereof.
  • the body can be a bonded abrasive snagging wheel.
  • the abrasive article may be particularly suited for grinding and conditioning of workpieces.
  • Certain suitable workpieces can include inorganic materials, and more particularly workpieces made of a metal or metal alloy.
  • the abrasive article may be particularly suited to grind materials such as stainless steel or titanium.
  • Embodiments of the reinforcing member can have openings with an open area of not greater than about 100 mm 2 within a major plane of the reinforcing member.
  • the open area can be not greater than about 80 mm 2 within the major plane of the reinforcing member, not greater than about 60 mm 2 , not greater than about 40 mm 2 , not greater than about 35 mm 2 , or even not greater than about 30 mm 2 .
  • the open area also can 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 can be within a range between any of the minimum and maximum values noted above.
  • Embodiments of the openings may extend axially through at least a portion of a thickness thereof.
  • the openings may extend entirely through the thickness of the reinforcing member.
  • the openings also may have perimeters and define polygonal two-dimensional shapes.
  • the reinforcing member can have a greige weight (or uncoated weight) of not greater than about 950 g/m 2 .
  • the greige weight can be not greater than about 800 g/m 2 , not greater than about 600 g/m 2 , or even not greater than about 500 g/m 2 .
  • the greige weight can be not less than about 400 g/m 2 , not less than about 450 g/m 2 , or even not less than about 490 g/m 2 .
  • the greige weight also can be within a range between any of the minimum and maximum values noted above.
  • the theoretical distance between the centers of the threads or “s” may be about 5 mm to about 17 mm, in some embodiments.
  • Examples of the grid dimension or “h” i.e., the distance between two threads
  • the grid dimension also may be not greater than about 8 mm, such as not greater than about 6 mm, or even not greater than about 5 mm.
  • the grid dimension also can at least about 2 mm, at least about 2.5 mm, or even at least about 3 mm.
  • Each of the construction parameters can be within a range between any of the approximate minimum and maximum values noted above.
  • Some embodiments of the threads can have a width “y” of not less than about 1 mm, such as not less than about 1.2 mm, not less than about 1.4 mm, not less than about 1.6 mm, not less than about 1.8 mm, not less than about 2 mm, not less than about 2.2 mm, not less than about 2.4 mm, not less than about 2.6 mm, or even not less than about 2.8 mm.
  • the width of the fiber bundles can be not greater than about 4.5 mm, such as not greater than about 4 mm, not greater than about 3.5 mm, not greater than about 3 mm, not greater than about 2.5 mm, or even not greater than about 2 mm.
  • the construction also can be within a range between any of the minimum and maximum values noted above.
  • embodiments of the body can have has an adhesion of at least about 1700 lbf, e.g., for a 1-inch bar.
  • Embodiments of the adhesion of the body can be at least about 1800 lbf, such as at least about 1900 lbf.
  • the adhesion can be not greater at least about 2200 lbf, such as not greater than about 2100 lbf, or even not greater than about 2000 lbf.
  • the adhesion also can be within a range between any of the minimum and maximum values noted above.
  • Embodiments of the reinforcing member can have a fracture initiation toughness (G 1C ) of at least about 3.3 kJ/m 2 , such as 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 .
  • G 1C fracture initiation toughness
  • Other embodiments can have a G 1C of not greater than about 5 kJ/m 2 , such as not greater than about 4.8 kJ/m 2 , or even not greater than about 4.6 kJ/m 2 .
  • the G 1C also can be within a range between any of the minimum and maximum values noted above.
  • G 1C fracture initiation toughness
  • WOF fracture propagation toughness
  • Both G 1C and WOF can be determined from a single sample, such as a rectangular bar.
  • the test employs 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 on edge of the bar with a 0.005′′ thick diamond wheel.
  • the specimen thickness is 0.5-inch, leaving a 0.36-inch uncracked ligament.
  • the notched sample is placed in a 3-point bend fixture with a 2-inch load span. The load is applied at 0.02 in/min.
  • the G 1C is calculated using a technique developed by J G Williams ( Fracture Mechanics of Polymers, Ellis Horwood Ltd, chapter 4 (1984)). After the initiation, the loading continues until the entire bar is fractured. The total integrated energy divided by the area of the original uncracked ligament is the WOF. In addition, WOF also changes with the web spacing (e.g., about 0.2 to about 1 inch between webs), which is in turn determined by the width of the sample.
  • the conventional samples CS11, CS12 and CS13 were formed with IPAC fiberglass webs 103, 24 and 717, respectively, each of which is commercially available.
  • the sample S11 was formed with web T700LL, commercially available from Adfors.
  • Sample S11 comprises a lock leno weave, which is a standard leno weave plus an additional yarn in the warp direction to lock the leno interlacement and provide an even greater stability of the fabric. Every other variable of the samples was identical. The results of this example appear in Table 1.
  • samples S11, CS11 and CS12 were measured for various parameters such as thread width and opening width.
  • the various dimensions of the samples S11, CS11 and CS12 are shown in the table of FIG. 4C . Both theoretical dimensions and the actual measurements from sample S11 are included.
  • an Adhesion Variance Factor may be calculated for the various samples.
  • AVF is defined as the relative ‘spread’ of the data points (vertically in FIG. 5 ) for each sample.
  • Samples CS11, CS12, CS13 and S11 are the same as described previously herein.
  • Sample CS14 is a conventional sample commercially available from Adfors as model T350L. For this testing, 1-inch wide specimens are notched. The root of the notch is at the edge of the glass web. A wedge is driven into the notch and specimen is split. This is a type of delamination test called the “wedge-driven delamination test.”
  • An abrasive article comprising:
  • a body including an abrasive portion having:
  • the abrasive portion has a fracture propagation toughness WOF of at least about 5 kJ/m 2
  • the reinforcing member has openings with an open area of not greater than about 100 mm 2 within a major plane of the reinforcing member.
  • Item 2 The abrasive 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 , at least about 10 kJ/m 2 , not greater than about 13 kJ/m 2 , not greater than about 12 kJ/m 2 , not greater than about 11 kJ/m 2 , not greater than about 10 kJ/m 2 .
  • 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 , at least about 10 kJ/m 2 , not greater than about 13 kJ/m 2 , not greater than about 12 kJ/m 2 , not greater than about 11 kJ/m 2 , not greater than about 10
  • Item 3 The abrasive article of Item 1, wherein the reinforcing member comprises a greige weight of not greater than about 950 g/m 2 , not greater than about 800 g/m 2 , not greater than about 600 g/m 2 , not greater than about 500 g/m 2 , and not less than about 400 g/m 2 , not less than about 450 g/m 2 , not less than about 490 g/m 2 .
  • Item 4 The abrasive cutting tool of Item 1, wherein the reinforcing member comprises a maximum thickness of at least about 1 mm, such as at least about 1.1 mm, at least about 1.2 mm, at least about 1.3 mm, not greater than about 2 mm, not greater than about 1.8 mm, not greater than about 1.5 mm, not greater than about 1.4 mm.
  • Item 5 The abrasive article of Item 1, wherein the reinforcing member comprises threads with the openings therebetween, and the threads have a width of not less than about 1 mm, not less than about 1.2 mm, not less than about 1.4 mm, not less than about 1.6 mm, and not greater than about 4 mm, not greater than about 3.5 mm, not greater than about 3 mm.
  • Item 6 The abrasive cutting tool of Item 1, wherein the open area is not greater than about 80 mm 2 within the major plane of the reinforcing member, not greater than about 60 mm 2 , not greater than about 40 mm 2 , not greater than about 35 mm 2 , not greater than about 30 mm 2 , wherein the open area is at least about 5 mm 2 , at least about 8 mm 2 , at least about 10 mm 2 , at least about 12 mm 2 .
  • Item 8 The abrasive cutting tool of Item 1, wherein the openings extend axially through at least a portion of a thickness thereof, the openings extend entirely through the thickness of the reinforcing member, wherein the openings have perimeters and define polygonal two-dimensional shapes.
  • Item 9 The abrasive cutting tool of Item 1, wherein the reinforcing member comprises not greater than about 0.5% of an average thickness of the body, at least about 1%, at least about 1.1%, at least about 1.2%, not greater than about 5%, not greater than about 2%, not greater than about 1.5%.
  • Item 10 The abrasive cutting tool of Item 1, wherein a volumetric ratio of the abrasive portion to the reinforcing member is at least about 5, at least about 10, at least about 15, not greater than about 20, not greater than about 15, not greater than about 10.
  • Item 11 The abrasive cutting tool of Item 1, wherein the body has an adhesion of at least about 1700 lbf.
  • Item 12 The abrasive article of Item 11, wherein the adhesion of the body is at least about 1800 lbf, at least about 1900 lbf, and not greater at least 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 Adhesion Variance Factor (AVF) of not greater than about 10%.
  • APF Adhesion Variance Factor
  • Item 15 The abrasive article of Item 1, wherein the reinforcing member has a fracture initiation toughness (G 1C ) of 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 , at least about 4.2 kJ/m 2 , not greater than about 5 kJ/m 2 , not greater than about 4.8 kJ/m 2 , not greater than about 4.6 kJ/m 2 .
  • G 1C fracture initiation toughness
  • Item 16 The abrasive article of Item 1, wherein the abrasive article has an outer diameter of 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 not greater than about 120 cm, not greater than about 110 cm, not greater than about 100 cm, not greater than about 90 cm, not greater than about 80 cm.
  • Item 17 The abrasive article of Item 1, wherein the abrasive article has an axial 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 not greater than about 18 cm, not greater than about 16 cm, not greater than about 14 cm, not greater than about 12 cm, not greater than about 10 cm.
  • Item 19 The abrasive article of Item 1, wherein the body comprises not greater than about 10 vol % porosity for the total volume of the body, not greater than about 5 vol %, not greater than about 4 vol %, not greater than about 3 vol %, not greater than about 2 vol %, not greater than about 1.5 vol %, not greater than about 1 vol %, not greater than about 0.8 vol %, not greater than about 0.5 vol %, not greater than about 0.3 vol %, not greater than about 0.1 vol %, at least about 0.001 vol %, at least about 0.01 vol %.
  • Item 21 The abrasive article of Item 1, wherein the abrasive article is hot pressed.
  • Item 23 The abrasive article of Item 22, wherein the first reinforcing member extends through an entire diameter of the body, wherein the first reinforcing member is a planar member comprising a first major surface and a second major surface, and wherein the abrasive portion overlies the first major surface, wherein the abrasive portion is in direct contact with the first major surface of the first reinforcing member.
  • Item 24 The abrasive article of Item 22, further comprising a second reinforcing member, wherein the first reinforcing member and the second reinforcing member are spaced apart from each other within the body, wherein at least a portion of the abrasive portion is disposed between the first reinforcing member and the second reinforcing member.
  • Item 25 The abrasive article of Item 22, wherein the first reinforcing member is at least about 0.5% of an average thickness of the body, at least about 1%, at least about 1.1%, at least about 1.2%, not greater than about 5%, not greater than about 2%, not greater than about 1.5%.
  • Item 26 The abrasive article of Item 1, wherein the bond material comprises a material selected from the group consisting of an organic material, an inorganic material, and a combination thereof, wherein the bond material comprises a material selected from the group consisting of a metal, a vitreous material, a ceramic, a resin, and a combination thereof, wherein the bond material comprises a phenolic resin.
  • Item 27 The abrasive article of Item 1, wherein the body further comprises a filler, wherein the bond material further comprises a filler, wherein the filler comprises a material selected from the group consisting of powders, granules, spheres, fibers, chopped strand fibers (CSF) and a combination thereof, wherein the filler comprises a material selected from the group consisting of an inorganic material, an organic material, and a combination thereof, wherein the filler comprises a material selected from the group consisting of sand, bubble alumina, chromites, magnesite, dolomites, bubble mullite, borides, titanium dioxide, carbon products, silicon carbide, wood flour, clay, talc, hexagonal boron nitride, molybdenum disulfide, feldspar, nepheline syenite, glass spheres, glass fibers, CaF 2 , KBF 4 , Cryolite (Na 3 AlF 6 ), potassium
  • Item 28 The abrasive article of Item 1, further comprising a first filler contained within the abrasive portion comprising iron and sulfur having an average particle size of not greater than about 40 microns, wherein the first filler comprises pyrite (FeS 2 ), wherein the first filler consists essentially of pyrite.
  • a first filler contained within the abrasive portion comprising iron and sulfur having an average particle size of not greater than about 40 microns, wherein the first filler comprises pyrite (FeS 2 ), wherein the first filler consists essentially of pyrite.
  • Item 29 The abrasive article of Item 1, wherein the body comprises at least about 30 vol % bond material for the total volume of the body, 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 not greater than about 70 vol %, not greater than about 65 vol %, not greater than about 60 vol %, not greater than about 55 vol %, not greater than about 50 vol %, not greater than about 45 vol %, not greater than about 40 vol %, not greater than about 35 vol %.
  • Item 30 The abrasive article of Item 1, wherein the body comprises at least about 30 vol % abrasive particles for the total volume of the body, 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 not greater than about 70 vol %, not greater than about 65 vol %, not greater than about 60 vol %, not greater than about 55 vol %, not greater than about 50 vol %, not greater than about 45 vol %, not greater than about 40 vol %, not greater than about 35 vol %.
  • Item 31 The abrasive article of Item 1, wherein the body is in the form of a bonded abrasive body having a shape selected from the group consisting of hones, cones, cups, flanged shapes, cylinders, wheels, rings, and a combination thereof, wherein the body is a bonded abrasive snagging wheel.
  • Item 32 The abrasive article of Item 1, wherein the reinforcing member comprises an organic material, a polyimide, polyamide, polyester, aramid, or a combination thereof.
  • Item 33 The abrasive article of Item 1, wherein the reinforcing member comprises an inorganic material, ceramic, glass, glass-ceramic, or a combination thereof, wherein the reinforcing member comprises a phenolic resin-based binder.
  • An abrasive article comprising:
  • a body including an abrasive portion having:
  • Item 35 The abrasive article of Item 34, wherein the adhesion of the body is at least about 1800 lbf, at least about 1900 lbf, and not greater at least about 2200 lbf, not greater than about 2100 lbf, not greater than about 2000 lbf.
  • An abrasive article comprising:
  • a body including an abrasive portion having:
  • a first filler contained within the abrasive portion comprising iron and sulfur having an average particle size of not greater than about 40 microns;
  • the reinforcing member comprising:
  • Item 38 The abrasive article of Item 1, wherein the reinforcing member comprises a lock leno weave.
  • abrasive articles herein can utilize a combination of features, such as abrasive particle having certain features, including but limited to, composition, average pore size, average porosity, average crystal size, crystal shape, and a combination thereof.
  • the abrasive articles may utilize additional features such as bond material, content of bond material, content of abrasive particles, fillers, and the like. While not entirely understood, the combination of features facilitates the formation of abrasive articles that have demonstrated unexpected and remarkable improved performance.

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US20140073230A1 (en) * 2012-08-28 2014-03-13 Kelley McNeal Large Diameter Cutting Tool
WO2018236705A1 (en) * 2017-06-19 2018-12-27 Saint-Gobain Abrasives, Inc. ABRASIVE ARTICLES AND METHODS OF FORMING THE SAME
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RU2015121784A (ru) 2017-01-10
TW201420277A (zh) 2014-06-01
KR20150082555A (ko) 2015-07-15
TWI491471B (zh) 2015-07-11
CN104781047A (zh) 2015-07-15
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AR093483A1 (es) 2015-06-10
WO2014081828A1 (en) 2014-05-30

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