US3510994A - Method of manufacturing an electrolytic grinding wheel - Google Patents

Method of manufacturing an electrolytic grinding wheel Download PDF

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Publication number
US3510994A
US3510994A US639326A US3510994DA US3510994A US 3510994 A US3510994 A US 3510994A US 639326 A US639326 A US 639326A US 3510994D A US3510994D A US 3510994DA US 3510994 A US3510994 A US 3510994A
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Prior art keywords
conductive
grinding
wheel
powder
silver
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US639326A
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English (en)
Inventor
John J Amero
Ronald J Gerry
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Saint Gobain Abrasives Inc
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Norton Co
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D18/00—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for

Definitions

  • a method for making conductive grinding wheels for electrochemical grinding comprises abrasive grains bonded by a ceramic material having a maturing temperature below the melting temperature of a conductive metal powder incorporated in the mix used to form the Wheel.
  • a glass bond including lead oxide and boron oxide having a maturing temperature of 600 to 800 C. is disclosed.
  • Silver is disclosed as a conductive metal, and from 4 to 9% silver content is suggested in the finished grinding tool.
  • This invention relates to a grinding wheel for electrochemical grinding and method for making ceramic bonded grinding wheels for use in electrochemical grinding.
  • a vitrified wheel is of ceramic composition, it is fired at relatively high temperatures and is diificult to render conductive.
  • One technique is to impregnate the wheel with a conductive substance. This requires an extensive number of secondary steps, after the initial manufacture of the wheel, such as drying and firing.
  • the impregnation which coats the walls of the pores in the wheel tends to be non-uniform, giving rise to variations in performance from one wheel to another.
  • the impregnation also tends to be non-uniform within an individual wheel with resulting variations throughout the wheel in internal conductivity.
  • resinoid wheels tend to hold their form longer than their vitrified counterparts, but the latter are easier to shape. Special shapes requiring the removal of a significant amount of stock after molding are much easier to prepare as vitrified products.
  • An object of this invention is to achieve a vitrified grinding wheel which is conductive without having been impregnated by conductive substances.
  • a related object is to produce a vitrified, conductive grinding wheel by a unitary manufacturing process which does not require secondary steps after initial manufacture.
  • Another related object is to enhance the uniformity of the characteristics of vitrified conductive grinding wheels from one wheel to another by producing a wheel in which the conductive agent is within the bond rather than coating the pores.
  • Another object of the invention is to increase the efficiency of electrochemical grinding, particularly when using vitrified grinding wheels.
  • the invention provides for the formation of a conductive grinding body from abrasive particles mixed with a ceramic bonding material containing a conductive powder.
  • the ceramic bond is formed below the melting point of the conductive powder, which is distributed as interconnected agglomerates of fine metallic particles within the bond itself.
  • the conductive powder takes the form of finely divided silver particles and the ceramic bonding material is primarily a composition of metallic oxides and clay.
  • the metallic oxides are collectively of a composition that fuses at a temperature belowthe melting point of the silver powder.
  • a grinding unit of suitable conductivity is realized in which the conductive metal is distributed throughout the grinding unit in conductive association.
  • fusion of the bonding material at a temperature above the melting point of the conductive powder would result in the substantial formation of droplets which would be relatively ineffective in producing the desired conductivity within the grinding unit.
  • finely divided conductive powder is mixed with a ceramic bonding material.
  • Abrasive particles are next wetted and combined with a blend of the bonding material and conductive powder in order to form an overall mix.
  • the overall mix is then molded into suitable form, such as a grinding wheel. Once molded, the grinding unit is fired at a temperature below the melting point of the conductive powder.
  • finely divided silver powder is intimately mixed with an inorganic bonding material constituted primarily of clay and glass based on lead oxide.
  • the mix is then molded and fired at a temperature below the melting point of the silver powder.
  • a conductive grinding wheel in accordance with the invention When incorporated into a grinding system, a conductive grinding wheel in accordance with the invention is driven by a motor and employed in conjunction with a source of electrical energy which establishes a partial circuit between the grinding wheel and stock being worked.
  • the circuit is completed by introducing an electrolyte between the face of the grinding wheel and the stock. Surface pores in the grinding wheel are occupied by the electrolyte which acts with conductive powder distributed within the grinding wheel to facilitate electrolyticallyassisted grinding.
  • the porosity of a vitrified wheel promotes better distribution of the electrolyte applied thereto and, acting in conjunction with conductive metal distributed within the wheel, permits greater size control over the stock or workpiece than can be achieved with a comparable grinding wheel of resinoid bond.
  • the bond is vitreous, the bonding material flows during the firing of the wheel to bring about a natural interconnection of the conductive metal particles. As a result, there appears to be a further enhancement in the electrochemical grinding performance of the product.
  • FIG. 1 is a flow chart summarizing the operations employed in fabricating a conductive grinding wheel in accordance with the invention.
  • FIG. 2 is a flow chart detailing the operations summarized by the flow chart of FIG. 1.
  • the mix is formed by combining water wetted abrasive with a blend of an inorganic bonding material and finely divided conductive powder.
  • the resulting mix is deposited in a mold of appropriate dimensions.
  • the finely conductive powder is of silver.
  • the silver powder consisted of individual particles of average size of about one half to one micron and present to the extent of approximately 8 percent by volume of the overall mix for an abrasive size of approximately 80 grit.
  • Grit size refers to selecting the size of the grain as specified in Simplified Practice Recommendation 118-50 of the US. Department of Commerce.
  • the appropriate amount of silver depends upon grit size; as the grit size is reduced, the silver content is increased, since there is a greater total area of abrasive tobe coated by the powder. With relatively fine abrasive of 120 grit, 9 volume percent silver was found satisfactory. For 100 grit wheels, 4.8% of silver by volume produced an essentially non-conductive wheel unsuitable for electrochemical grinding, while 6% produced a highly conductive wheel suitable for electrochemical grinding. With 46 grit abrasive, only 4% silver was required, while with only 2% silver, the 46 grit wheel was non-conductive. The volume percent is based on the total volume of abrasive, bond (including the silver) and pores.
  • Silver is the preferred metal to use because it is not subject to deleterious oxidation in the firing of the wheels.
  • Other metals such as platinum are useful but expensive. Copper, unless the particles are protected against oxidation by a silver or other coating, is not desirable. Reducing or nitrogen atmospheres may be deleterious to the ceramic bond, and thus not recommended in most cases even though their use would avoid the oxidation problem in the firing of the wheel.
  • the percentage of silver content can be made higher than 9%, there is little to be gained after the necessary level of conductivity has been reached, except for special applications where very high conductivity may be desirable. In such cases, the upper limit of the silver content is restricted only by the physical properties of the fired wheel.
  • the abrasive may be any of the materials commonly used in the manufacture of grinding wheels, such as silicon carbide. In a tested model of the invention the abrasive was fused alumina and amounted to 48 percent by volume of the overall mix.
  • the bonding material is of glass-like composition which fuses at a temperature below the melting point of the conductive metal powder.
  • Useful bonds are those that mature at from 600 to 800 C.
  • Such a composition is principally of clay and glass.
  • the glass is desirably in a form known as frit, which is so called because it is produced by the melting and rapid quenching of oxide materials to produce small particles.
  • the principal ingredients of the clay are hydrous aluminous materials, including aluminum silicate.
  • the bonding material may include such substances as sodium carbonate, i.e. soda ash, and boric acid.
  • the bonding material was 50 percent by weight glass frit; 35 percent by weight plastic clay, commonly designated as Imperial ball clay; 7 percent by weight soda ash and 8 percent by weight boric acid.
  • the glass frit the major ingredient of the bonding material, was in turn formed by mixing a number of oxides, the controlling consideration being that the melting point of the resulting composition be below that of silver powder.
  • the process of preparing conductive grinding media in accordance with the invention is summarized by the flow chart of FIG. 1. Initially, finely divided conductive powder is intimately blended with an inorganic bonding material of composition and characteristics similar to those described previously. Next, wetted" abrasive" particles are combined with the blend of the conductive ppw; der and bonding material to form an overall mix. The overall mix is poured into atmold and pressed, following which firing takes place at a temperature below the melting point of the conductive powder.
  • finely divided silver powder is obtained.
  • Such metal powder is obtainable commerciallydown to an average particle size of approximately one half to one micron and was used in a tested model of the invention.
  • suitably finely divided conductive metal powder may be obtained in standard fashionby precipitation.
  • the conductive powder is coarse-mixed with an inorganic bonding material having the characteristics described previously.
  • the conductive powder and bonding material are then intimately blended.
  • silver powder was intimately blended with a bonding material, primarily of ball clay and lead based glass, by being passed twice through a mesh screen.
  • the abrasive is mixed with Water until uniformly wet.
  • a test model of the invention added abrasive in the form ofv fused alumina to a mixer to which water was added until the alumina was uniformly wet.
  • the bond-conductive-power blend is added slowly to the wetted abrasive and. mixed until the abrasive appears to be uniformly coated.
  • the mix amounted to 48 percent by volume abrasive, 10 percent by volume bonding material, 8 percent by volume silver and the remainder water.
  • the actual quantities were 600 grams abrasive, 113 grams bonding material with a base of lead oxide, 268.2 grams of fine silver powder, and 19.5 cubic centimeters of water.
  • the mold consisted of conventional constituents, including a mold band, arbor, top plate and bottom plate.
  • the mold pressure was approximately 3 tons per square inch.
  • the wheel is dried and fired in air in order to properly fuse the bonding material.
  • the molded wheel was raised from room temperature to a firing temperature of 800 C. at a rate of 100 C. per hour and, once the firing temperature of 800 C. was attained, it was maintained for two hours.
  • the firing temperature of 800 C. is below the melting point of conductive silver powder and, at the same time, well below the typical firing temperature of 1200 C. for vitrified bonded wheels.
  • the latter temperature being above the melting point of silver, would result inthe formation of a large number of droplets of metalic silver, breaking up the network of conductive paths, and thus materially reducing the suitability of the wheel for electro-chemical grinding.
  • test "grinding wheels, manufactured in accordance with the invention, were sided, faced and reamed in conventional fashion to cylindrical disks A2 inch in thickness and 7 inches in diameter. Each disk was provided with a hole 1% inches in diameter for mounting on a spindle of a conventional electrolytic grinding apparatus. The test wheels were'inspected and speed tested to verify their suitabilityi for use in commercial grinding operations.
  • the depth of cut was 0.010 inch for a traverse rate of 1.5 inches per minute, resulting in a spindle power of 75 watts for a current draw of 200 amperes. Similar high performance results were obtained for all test grinding wheels manufactured in accordance with the invention.
  • vitrified grinding wheels in accordance with the invention are more efficient than the impregnated wheels.
  • bonding material comprises glass frit, clay, boric acid, and sodium carbonate.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Polishing Bodies And Polishing Tools (AREA)
US639326A 1967-05-18 1967-05-18 Method of manufacturing an electrolytic grinding wheel Expired - Lifetime US3510994A (en)

Applications Claiming Priority (1)

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US63932667A 1967-05-18 1967-05-18

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US (1) US3510994A (de)
CS (1) CS150579B2 (de)
DE (1) DE1765433A1 (de)
ES (1) ES353699A1 (de)
FR (1) FR1569906A (de)
GB (1) GB1190534A (de)

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3909991A (en) * 1970-09-22 1975-10-07 Norton Co Process for making sintered abrasive grains
JPS59182065A (ja) * 1983-03-31 1984-10-16 Inoue Japax Res Inc 砥粒から成る砥石
US4490158A (en) * 1981-05-21 1984-12-25 Ohyo Jiki Lab. Co. Grinding wheel for electrolytic and mechanical grinding
US20120066982A1 (en) * 2010-09-03 2012-03-22 Saint-Gobain Abrasifs Bonded abrasive articles, method of forming such articles, and grinding performance of such articles
US8715381B2 (en) 2010-09-03 2014-05-06 Saint-Gobain Abrasives, Inc. Bonded abrasive article and method of forming
US9102039B2 (en) 2012-12-31 2015-08-11 Saint-Gobain Abrasives, Inc. Bonded abrasive article and method of grinding
US9266219B2 (en) 2012-12-31 2016-02-23 Saint-Gobain Abrasives, Inc. Bonded abrasive article and method of grinding
US9278431B2 (en) 2012-12-31 2016-03-08 Saint-Gobain Abrasives, Inc. Bonded abrasive article and method of grinding
US9833877B2 (en) 2013-03-31 2017-12-05 Saint-Gobain Abrasives, Inc. Bonded abrasive article and method of grinding

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
SU1135625A1 (ru) * 1978-05-04 1985-01-23 Всесоюзный научно-исследовательский и конструкторско-технологический институт природных алмазов и инструмента Масса дл изготовлени абразивных инструментов

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2233176A (en) * 1940-03-28 1941-02-25 Carborundum Co Manufacture of bonded abrasive articles
US2555174A (en) * 1948-06-15 1951-05-29 J K Smit & Sons Inc Vitreous bonded diamond abrasive product and method of making same
US2578167A (en) * 1945-09-21 1951-12-11 Dentatus Ab Grinding wheel and method of producing same
US3062633A (en) * 1958-12-30 1962-11-06 Norton Co Electrically conductive organic bonded grinding wheel
US3203775A (en) * 1960-11-30 1965-08-31 Carborundum Co Inorganically bonded abrasive articles
US3216854A (en) * 1960-06-06 1965-11-09 Gen Electric Method for making an electrolytic grinding wheel
US3283448A (en) * 1964-08-14 1966-11-08 Bay State Abrasive Products Co Organic bonded abrasive article
US3433730A (en) * 1965-04-28 1969-03-18 Gen Electric Electrically conductive tool and method for making

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2233176A (en) * 1940-03-28 1941-02-25 Carborundum Co Manufacture of bonded abrasive articles
US2578167A (en) * 1945-09-21 1951-12-11 Dentatus Ab Grinding wheel and method of producing same
US2555174A (en) * 1948-06-15 1951-05-29 J K Smit & Sons Inc Vitreous bonded diamond abrasive product and method of making same
US3062633A (en) * 1958-12-30 1962-11-06 Norton Co Electrically conductive organic bonded grinding wheel
US3216854A (en) * 1960-06-06 1965-11-09 Gen Electric Method for making an electrolytic grinding wheel
US3203775A (en) * 1960-11-30 1965-08-31 Carborundum Co Inorganically bonded abrasive articles
US3283448A (en) * 1964-08-14 1966-11-08 Bay State Abrasive Products Co Organic bonded abrasive article
US3433730A (en) * 1965-04-28 1969-03-18 Gen Electric Electrically conductive tool and method for making

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3909991A (en) * 1970-09-22 1975-10-07 Norton Co Process for making sintered abrasive grains
US4490158A (en) * 1981-05-21 1984-12-25 Ohyo Jiki Lab. Co. Grinding wheel for electrolytic and mechanical grinding
JPS59182065A (ja) * 1983-03-31 1984-10-16 Inoue Japax Res Inc 砥粒から成る砥石
JPH0327346B2 (de) * 1983-03-31 1991-04-15 Inoue Japax Res
US9676077B2 (en) 2010-09-03 2017-06-13 Saint-Gobain Abrasives, Inc. Bonded abrasive article and method of forming
US20120066982A1 (en) * 2010-09-03 2012-03-22 Saint-Gobain Abrasifs Bonded abrasive articles, method of forming such articles, and grinding performance of such articles
US8715381B2 (en) 2010-09-03 2014-05-06 Saint-Gobain Abrasives, Inc. Bonded abrasive article and method of forming
US9254553B2 (en) 2010-09-03 2016-02-09 Saint-Gobain Abrasives, Inc. Bonded abrasive article and method of forming
US10377017B2 (en) 2010-09-03 2019-08-13 Saint-Gobain Abrasives, Inc. Bonded abrasive article and method of forming
US9102039B2 (en) 2012-12-31 2015-08-11 Saint-Gobain Abrasives, Inc. Bonded abrasive article and method of grinding
US9278431B2 (en) 2012-12-31 2016-03-08 Saint-Gobain Abrasives, Inc. Bonded abrasive article and method of grinding
US9266219B2 (en) 2012-12-31 2016-02-23 Saint-Gobain Abrasives, Inc. Bonded abrasive article and method of grinding
US10377016B2 (en) 2012-12-31 2019-08-13 Saint-Gobain Abrasives, Inc. Bonded abrasive article and method of grinding
US9833877B2 (en) 2013-03-31 2017-12-05 Saint-Gobain Abrasives, Inc. Bonded abrasive article and method of grinding
US10946499B2 (en) 2013-03-31 2021-03-16 Saint-Gobain Abrasives, Inc. Bonded abrasive article and method of grinding

Also Published As

Publication number Publication date
CS150579B2 (de) 1973-09-04
ES353699A1 (es) 1970-02-16
GB1190534A (en) 1970-05-06
DE1765433A1 (de) 1971-07-29
FR1569906A (de) 1969-06-06

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