US3481723A - Abrasive grinding wheel - Google Patents

Abrasive grinding wheel Download PDF

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Publication number
US3481723A
US3481723A US436543A US3481723DA US3481723A US 3481723 A US3481723 A US 3481723A US 436543 A US436543 A US 436543A US 3481723D A US3481723D A US 3481723DA US 3481723 A US3481723 A US 3481723A
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abrasive
grains
cross
grinding
abrasive grains
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US436543A
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Samuel S Kistler
Charles V Rue
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STERLING ABRASIVE PRODUCTS Co A CORP OF
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Deutsche ITT Industries GmbH
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Assigned to STERLING ABRASIVE PRODUCTS COMPANY A CORP OF DE reassignment STERLING ABRASIVE PRODUCTS COMPANY A CORP OF DE ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: ITT CORPORATION
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    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K3/00—Materials not provided for elsewhere
    • C09K3/14—Anti-slip materials; Abrasives
    • C09K3/1409—Abrasive particles per se
    • C09K3/1418—Abrasive particles per se obtained by division of a mass agglomerated by sintering
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K3/00—Materials not provided for elsewhere
    • C09K3/14—Anti-slip materials; Abrasives
    • C09K3/1409—Abrasive particles per se

Definitions

  • An abrasive grinding wheel comprising an abrasive matrix containing from about 40% to about 64% by volume of a plurality of dense, hard abrasive grains bonded in a bonding matrix of which the predominant proportion of the abrasive grains have a preshaped cylindrical configuration and a cross section of a controlled cross sectional area ranging from 500 to about 20,000 square mils and wherein the ratio of the peripheral length squared to the cross sectional area is within the range of from 13:1 to about 100:1.
  • the present invention broadly pertains to abrasive articles, and more particularly to improved grinding wheels of a type employed for snagging steel, incorporating therein abrasive grains of a preshaped cylindrical configuration.
  • snagging-type grinding wheels comprise an abrasive mass which consists of a suitable bonding agent in which a plurality of abrasive grains are tenaciously bonded.
  • Snagging wheels may additionally include suitable reinforcing elements for strengthening the wheel, as well as various filler materials serving as extenders and also as modifying agents, to achieve optimum grinding characteristics. It has been conventional in the past to derive the abrasive grains for use in such snagging wheels from naturally occurring minerals or ores, such as natural corundum or emery, by crushing and screening the material to provide granules of the appropriate mesh size.
  • abrasive grains have 4been derived from a crushing or grinding of fused bricks or pigs derived from an electric furnace such as fused alumina or silicon carbide pigs which subsequently are screened, providing a wide range in nominal sizes of abrasive grains.
  • abrasive grains produced are characterized as being of a generally uncontrolled configuration and nonuniform in shape, as well as incorporating residual in- Mice ternal stresses and incipient cracks or fissures therein, resulting in a substantial reduction in their physical properties.
  • Another object of the present invention is to provide an improved abrasive grinding ⁇ wheel incorporating preshaped cylindrical abrasive grains that provides for a significant improvement in the efficiency of grinding expressed in terms of speed of metal removal, as well as the amount of metal removed per pound of abrasive material consumed.
  • Still another object of the present invention is to provide abrasive grinding wheels incorporating therein abrasive grains of a preshaped cylindrical configuration which enables the adaptation of Specific abrasive compositions to an increased variety of grinding operations, substantially enhancing the flexibility and versatility of the abrasive material.
  • a further object of the present invention is to provide an improved abrasive grinding wheel which, through careful and controlled modifications in the shape and size of the preshaped cylindrical abrasive grains and the composition thereof, provides for optimum grinding efiiciency for any one specific grinding operation, providing substantial improvements in the economy and simplicity of metal removal.
  • Yet still a further object of the present invention is to provide an improved grinding wheel which, through careful control of the size and configuration of the preshaped cylindrical abrasive grains, permits controlled changes in the cutting speed of the grinding wheel, enabling the attainment of optimum economy of any one specific abrasive finishing operation.
  • Yet still another object of the present invention is to provide an improved abrasive grinding wheel and method of making the grinding wheel and abrasive grains thereof, providing for simplification and increased economy and versatility over the techniques and grinding wheels heretofore known.
  • an abrasive grinding wheel from about 40% up to about 64%, by volume, of a plurality of dense, hard abrasive grains tenaciously bonded by a suitable bonding agent.
  • the predominant portion of the abrasive grains in the abrasive matrix are of a preshaped cylindrical shape having a controlled geometrical configuration and having a cross-sectional area preferably of from about 500 to about 20,000 square mils.
  • the cross-sectional configuration of the abrasive grains is controlled so as to provide a ratio of the square of the peripheral length of the cross section to the area of the cross section within a range from about 13:1 up to about :1.
  • the length of each of the abrasive grains exceeds the maximum width of its cross section, and preferably does not exceed a length greater than about 5 times its width, with a length-to-width ratio of about 3 :1 being preferred in most instances.
  • FIGURE 1 is a perspective view of a typical abrasive grinding wheel to which the present invention is applicable;
  • FIGS. 2-16 are perspective views of a variety of typical abrasive-grain configurations which can be satisfactorily employed in accordance with the practice of the present invention.
  • FIG. 17 is a graphical portrayal of the effect of variations in the perimeter squared to area ratio of the crosssectional configuration of abrasive grains on the rate of metal removal and on the efficiency of the grinding operation.
  • FIG. 1 a typical grinding wheel is illustrated in FIG. 1 consisting of a cylindrically shaped body 20 containing a plurality of the preshaped cylindrical abrasive grains tenaciously bonded by a suitable bonding agent.
  • the wheel is suitably supported for rotation by means of a pair of clamping plates 22 which are secured to a drive shaft 24 for rotatably supporting and driving the grinding ⁇ wheel in a manner well known in the art.
  • the lbond may be of the vitrified, resinoid, shellac, rubber, silicate, magnesium, oxychloride type or metallic type.
  • the bonding agent employed in manufacturing heavy-duty grinding wheels such as snagging wheels consists of suitable thermosetting resins including urea formaldehyde and phenol-aldehyde, of which the condensation product of phenol and formaldehyde is the most common and preferred material.
  • the bonding agent and abrasive grains are conventionally employed in proportions such that the resultant abrasive matrix comprises from about 40% up to about 64% by volume of the abrasive grains, with the 4balance thereof consisting of the bonding agent, reinforcing elements, filler materials, pores and plasticizers, and the like.
  • Filler materials suitable for inclusion in the abrasive matrix include powdered cryolite, metallic sulphides, and other filler materials of the types well known in the art which are either inert or which improve the cutting efficiency of the resultant abrasive grinding wheel.
  • thermosetting-type bonding materials When thermosetting-type bonding materials are employed, modifications can ⁇ be achieved by adding small quantities of other resinous materials such as epoxy resins, vinyl resins, and the like, as well as cross-linking aids such as hexamethylene tetramine, or paraformaldehyde, as well as suitable plasticizers including furfuraldehyde and propylene sulfite.
  • resinous materials such as epoxy resins, vinyl resins, and the like, as well as cross-linking aids such as hexamethylene tetramine, or paraformaldehyde, as well as suitable plasticizers including furfuraldehyde and propylene sulfite.
  • cross-linking aids such as hexamethylene tetramine, or paraformaldehyde
  • suitable plasticizers including furfuraldehyde and propylene sulfite.
  • each of the abrasive grains is of a preshaped cylindrical shape wherein the term cylindrical as herein employed is defined as a volume encompassed within an enclosed surface generated by the movement of a straight line parallel to a fixed straight line.
  • the preshaped abrasive grains are all of a generally prismatic configuration, wherein the length thereof as measured along the longitudinal axis of the abrasive grain is greater than the maximum width of the abrasive grain as measured across a cross section of the grain taken in a plane perpendicular to the longitudinal axis thereof. It has been found that, to provide cutting rates and grinding efficiency within a range applicable to most grinding operations, it is important that the crosssectional area of the abrasive grains be controlled within a range from about 500 square mils up to about 20,000 square mils.
  • the particular configuration of the cross section of the abrasive grains is controlled so as to provide a ratio of perimeter squared to the area of the cross section taken in a plane perpendicular to the longitudinal axis of the grain greater than about 13:1 up to about 100:1.
  • FIGS. 2-16 Typical examples of preshaped cylindrical abrasive grains, within the definition as hereinabove set forth, are illustrated in FIGS. 2-16.
  • An abrasive grain 216 is illustrated in FIG. 2 which is of a right-triangular configuration.
  • an abrasive grain 28 is illustrated in FIG. 3 which also is of a right-triangular configuration, but wherein the hypotenuse thereof is concave, lfurther increasing the ratio of perimeter squared to area, as may be desired.
  • An elliptical cross-sectional shaped abrasive grain 30 is illustrated in FIG. 4, while a generally rectangular abrasive grain 32 having rounded side edges is illustrated in FIG. 5.
  • An abrasive ⁇ grain 34 is illustrated in FIG.
  • FIG. 6 which is of a general dumbbell cross-sectional configuration
  • FIGURE 7 which has a thin rectangular cross-sectional shape
  • suitable abrasive grains typical of those satisfactory for use in accordance with the practice of the present invention include the L-shaped abrasive grain 38 shown in FIG. 8, the kidney-shaped abrasive grain 40 shown in FIG. 9, the abrasive grain 42 having a cross-sectional configuration in the form of a cross shown in FIG. 10, an abrasive grain 44 of a generally rectangular cross-sectional configuration formed with a V-shaped surface along one side thereof illustrated in FIG. ll, and FIG.
  • FIG. 12 is illustrative of an abrasive grain having a plurality of longitudinally extending edges as defined 'by a cross-sectional configuration in the form of an X.
  • a generally rectangular-shaped abrasive grain 48 is shown in FIG. 13 wherein one side thereof is of a convex configuration and the opposite side thereof is of a concave configuration.
  • a cross-sectional shape generally of a keyhole configuration is illustrated by an abrasive grain S0 illustrated in FIG. 14, while a U-shaped and H-shaped cross-sectional configuration is illustrated by the abrasive grains 52 and 54 as illustrated in FIGS. 15 and 16, respectively.
  • the various cross-sectional configurations as typified by the abrasive grains illustrated in FIGS. 2-16 are intended to be illustrative of the various congurations feasible, and are in no way to be construed as limiting of other suitable shapes which can be satisfactorily employed, provided that the crosssectional configuration is one providing a perimeter squared to cross-sectional area ratio Within a range of from about 13:1 up to about 100:1.
  • the abrasive grain 32 as illustrated in FIG. 5, which is of a generally rectangular configuration having roundedside edges, can be made having a total Width of 0.120 and a thickness of 0.020" providing a cross-sectional area of 2,314 square mils.
  • the specific cross-sectional shape has a perimeter of 263 mils providing a perimeter squared per area ratio of 29.9.
  • the L-shaped abrasive grain 38 illustrated in FIG. 8 when shaped so as to provide a cross section such that the long side edge of the L is 0.080" long and with a thickness of each leg of 0.040, provides a cross section of 4,800 square mils.
  • the perimeter squared to area relationship of this L- shaped configuration is about 21.3.
  • the ends of the abrasive grains may be cut in a plane perpendicular to the longitudinal axis of the grains. Accordingly, the end edges of the abrasive grains may be cut on a bias, or may be chamfered as desired, without materially affecting the grinding characteristics thereof in comparison to grains the ends of which are precut in a plane perpendicular to the longitudinal axis.
  • the abrasive grains are of substantially uniform cross section throughout their length.
  • the length of the abrasive grain should exceed the maximum width of its cross section as measured along a plane perpendicular to the longitudinal axis of the grain, and may range upwards therefrom to any convenient length.
  • abrasive grains having a length-to-Width ratio of greater than 1 up to about 5:1 are preferred, while ratios of about 3:1 have been found particularly effective in providing an efficient abrasive.
  • Lengths substantially above about 5 times the maximum Width of the a-brasive grains result in difiiculty in some instances in a packing of the abrasive grains to form an abrasive matrix incorporating the requisite quantity of abrasive material. Nevertheless, in some instances unique grindin-g action is achieved when the abrasive grains are of a length substantially in excess of a lengthto-width ratio of about 5:1.
  • the wheel wear W was almost twice as high for the shorter abrasive grains as for the longer grains.
  • the shorter grains effected a higher rate of steel removal S, expressed in terms of pounds of steel removed per hour, providing a ratio of steel removed to wheel wear S/ W of 2.27 for the short grains in comparison to 3.31 for the longer grains.
  • the longer grains provided an efiiciency of 268 in comparison to 222 for the shorter grains.
  • the formation of the abrasive grains can be achieved by any one of a variety of techniques, including extrusion, pelletizing, casting, 'California-type pellet milling, molding, etc., of which the extrusion technique constitutes the preferred method.
  • the composition of the abrasive grains can be varied, consistent with the specific material to be ground, to provide the desired abrasive characteristics and abrasive finishing action to achieve optimum ef'liciency.
  • the following examples are provided. It will be understood that the compositions as disclosed in the following examples are provided for illustrative purposes and are not intended to be limiting of the scope of the invention as herein disclosed and as defined in the subjoined claims.
  • EXAMPLE 1 Composition: Percent by wt. A1203
  • EXAMPLE 2 Composition: Percent by wt.
  • TiOz 5 The alumina and titanium dioxide constituents are milled and extruded in the Same manner as described in Example l, and the resultant green abrasive pellets are fired to a pyrometric cone #30, forming dense hard abrasive pellets.
  • EXAMPLE 3 Composition: Percent by wt. A1203 96 M1102 2 TiO3 2
  • the alumina, manganese dioxide and titanium dioxide constituents are milled to a particle size of less than about 2 microns and are subsequently mixed with an organic binding agent and extruded in accordance wtih the procedure as set forth in Example l.
  • the resultant green abrasive grains are thereafter fired to a pyrometric cone #121/2, forming dense, hard, abrasive grains of a controlled cylindrical configuration.
  • Example 3 The constituents are milled, extruded and fired under the same conditions as set forth in Example 3, forming dense, hard, abrasive grains of a preshaped cylindrical configuration halving a controlled cross-sectional shape and a controlled length.
  • EXAMPLE Composition Percent by wt. A1203 49 ZrSiO., 47 Mn02 2 TiO2 2
  • the several constituents comprising the abrasive mixture are prepared, employing the same procedure as set forth in Example 3, with the exception that the green extruded abrasive pellets formed are fired to a pyrometric cone #14.
  • EXAMPLE 6 Composition: Percent by wt. ZrSiO4 93 Bentonite 3 MnOz 2 Ti02 2 The several constituents are milled and extruded in accordance with the same procedure as set forth in Example 3, except that the resultant green abrasive pellets are fired to a pyrometric cone 16.
  • EXAMPLE 7 Composition: Percent by wt. SiC 90 Silicon 10
  • the silicon carbide and silicon constituents are milled to a particle size preferably less than about 5 microns and are thereafter extruded and subsequently fired to a pyrometric cone in a nitrogen atmosphere, forming dense, hard, abrasive pellets comprising about 87% silicon carbide and 13% silicon nitride which are of the requisite size and configuration.
  • EXAMPLE 8 Composition: Percent by Wt. A1203 60 SiC Bentonite 10 The constituents are milled and extruded in accordance with the procedure as set forth in Example 7, except that the resultant green abrasive pellets are fired to a pyrometric cone #15 in either a neutral or a reducing atmosphere.
  • the specific composition of the abrasive grains may include any of those well known in the art, and in each case substantial improvements are obtained in their abrasive finishing characteristics over grains of the same composition of an irregular, uncontrolled, slivery configuration derived from a crushing of either the crude product or fused CTI bricks or pigs.
  • the specific composition of the abrasive grain employed, as Well as the specific cross-sectional configuration and length of the abrasive grain, and the cross sectional area thereof, are controlled consistent with the intended end use to which the abrasive grinding wheel is to be employed.
  • FIG. 17 The tailoring of a grinding wheel to a specific grinding ⁇ operation for any specic abrasive composition is facilitated by the general relationship, as graphically portrayed in FIG. 17.
  • the rate of metal removal S increases as the perimeter squared to area ratio of the grain increases.
  • This relationship is indicated by the upper curve in the graph illustrated in FIG. 17, which is based on the grinding of a type 302 stainless steel billet.
  • Corresponding relationships can be derived for alternative metals at the same or different grinding wheel surface speeds.
  • the efficiency of the grinding wheel as indicated by the lower curve of the graph, also increases, but at a lesser rate as the ratio of perimeter squared to cross-sectional area increases.
  • grinding wheels incorporating abrasive grains having a ratio of their perimeter squared to cross-sectional area less than 14:1 can be classified as slow-cutting grains which provide for a relatively low wheel Wear rate and a moderate rate of metal removal in a grinding operation.
  • Abrasive grains within the aforementioned classification accordingly are best adapted in those situations Iwherein rate of metal removal per unit time is not critical in comparison to providing a wheel of a substantially greater useful operating life.
  • abrasive grains having a perimeter squared per crosssectional area ratio ranging from about 14:1 up to about 20:1 are classified as being of an intermediate cutting rate, providing thereby a relatively rapid rate of metal removal which is accompanied by an increasing greater wear rate of the grinding wheel.
  • Abrasive grains having a ratio of perimeter squared per cross-sectional area ratio of greater than 10:1 and up to ⁇ about 100:1 are classified as fast-cutting abrasive grains, providing the most rapid rate of metal removal, which is accompanied also by a high rate of wheel wear.
  • the efficiency of the abrasive grains of the intermediate and fast-cutting classification increases slightly from a perimeter squared to cross-sectional area ratio 14:1 to the upper ratio of 100:1. Accordingly, the importance andeconomics of rate of metal removal for a given grinding operation can be optimized by forming an abrasive grinding wheel wherein the individual ⁇ abrasive grains, or at least the predominant portion of abrasive grains employed, are of a controlled cross-sectional c011- fguration providing a perimeter squared to cross-sectional area ratio consistent with the cutting speed desired.
  • An abrasive grinding wheel comprising an abrasive mass containing from about 40% to about v64% by volume of a plurality of dense, hard, abrasive grains tenaciously bonded in 4a bonding matrix; said abrasive grains consisting essentially of an abrasive material selected from the group consisting of aluminum oxide, zirconium oxide, zirconium silicate, silicon carbide, titanium oxide, manganese oxide, bentonite, silicon and mixtures thereof; the predominant portion of said grains having -a preshaped cylindrical shape with a cross section of a controlled geometrical configuration and an area of from about 500 to about 20,000 square mils, said grains having a length greater than the maximum width of said cross section, said configuration of said cross section controlled to provide a ratio of peripheral length square to cross-sectional area of from 20:1 to about 100:1.
  • abrasive grinding wheel as defined in claim 1, wherein said grains consist essentially of about 96% alumina, :about 2% manganese dioxide, and about 2% titanium dioxide.

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Cited By (65)

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US4162900A (en) * 1976-09-13 1979-07-31 The Hutson Corporation Composition having improved wear resistant and compression resilient properties
US4253850A (en) * 1979-08-17 1981-03-03 Norton Company Resin bonded abrasive bodies for snagging metal containing low abrasive and high filler content
US4481016A (en) * 1978-08-18 1984-11-06 Campbell Nicoll A D Method of making tool inserts and drill bits
US4960441A (en) * 1987-05-11 1990-10-02 Norton Company Sintered alumina-zirconia ceramic bodies
US5009676A (en) * 1989-04-28 1991-04-23 Norton Company Sintered sol gel alumina abrasive filaments
US5035723A (en) * 1989-04-28 1991-07-30 Norton Company Bonded abrasive products containing sintered sol gel alumina abrasive filaments
US5035724A (en) * 1990-05-09 1991-07-30 Norton Company Sol-gel alumina shaped bodies
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