WO2010126934A2 - Abrasive article with improved grain retention and performance - Google Patents
Abrasive article with improved grain retention and performance Download PDFInfo
- Publication number
- WO2010126934A2 WO2010126934A2 PCT/US2010/032659 US2010032659W WO2010126934A2 WO 2010126934 A2 WO2010126934 A2 WO 2010126934A2 US 2010032659 W US2010032659 W US 2010032659W WO 2010126934 A2 WO2010126934 A2 WO 2010126934A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- cutoff wheel
- wheel according
- abrasive
- grain
- cutoff
- Prior art date
Links
- 230000014759 maintenance of location Effects 0.000 title claims abstract description 13
- 239000000463 material Substances 0.000 claims description 85
- 239000006061 abrasive grain Substances 0.000 claims description 77
- 239000000945 filler Substances 0.000 claims description 69
- 229920005989 resin Polymers 0.000 claims description 27
- 239000011347 resin Substances 0.000 claims description 27
- 238000005520 cutting process Methods 0.000 claims description 23
- 238000006243 chemical reaction Methods 0.000 claims description 21
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 14
- 230000015556 catabolic process Effects 0.000 claims description 12
- 238000006731 degradation reaction Methods 0.000 claims description 12
- NIFIFKQPDTWWGU-UHFFFAOYSA-N pyrite Chemical compound [Fe+2].[S-][S-] NIFIFKQPDTWWGU-UHFFFAOYSA-N 0.000 claims description 12
- 229910052683 pyrite Inorganic materials 0.000 claims description 12
- 239000011028 pyrite Substances 0.000 claims description 12
- 238000002844 melting Methods 0.000 claims description 8
- 230000008018 melting Effects 0.000 claims description 8
- MCMNRKCIXSYSNV-UHFFFAOYSA-N ZrO2 Inorganic materials O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims description 5
- 150000004763 sulfides Chemical class 0.000 claims description 5
- FAPWRFPIFSIZLT-UHFFFAOYSA-M Sodium chloride Chemical compound [Na+].[Cl-] FAPWRFPIFSIZLT-UHFFFAOYSA-M 0.000 claims description 4
- 239000005083 Zinc sulfide Substances 0.000 claims description 4
- 229910000416 bismuth oxide Inorganic materials 0.000 claims description 4
- OMZSGWSJDCOLKM-UHFFFAOYSA-N copper(II) sulfide Chemical compound [S-2].[Cu+2] OMZSGWSJDCOLKM-UHFFFAOYSA-N 0.000 claims description 4
- TYIXMATWDRGMPF-UHFFFAOYSA-N dibismuth;oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[Bi+3].[Bi+3] TYIXMATWDRGMPF-UHFFFAOYSA-N 0.000 claims description 4
- 229910000464 lead oxide Inorganic materials 0.000 claims description 4
- 230000007246 mechanism Effects 0.000 claims description 4
- YEXPOXQUZXUXJW-UHFFFAOYSA-N oxolead Chemical compound [Pb]=O YEXPOXQUZXUXJW-UHFFFAOYSA-N 0.000 claims description 4
- XOLBLPGZBRYERU-UHFFFAOYSA-N tin dioxide Chemical compound O=[Sn]=O XOLBLPGZBRYERU-UHFFFAOYSA-N 0.000 claims description 4
- 229910001887 tin oxide Inorganic materials 0.000 claims description 4
- 229910052984 zinc sulfide Inorganic materials 0.000 claims description 4
- DRDVZXDWVBGGMH-UHFFFAOYSA-N zinc;sulfide Chemical compound [S-2].[Zn+2] DRDVZXDWVBGGMH-UHFFFAOYSA-N 0.000 claims description 4
- 239000000919 ceramic Substances 0.000 claims description 3
- 150000001247 metal acetylides Chemical class 0.000 claims description 3
- 150000004767 nitrides Chemical class 0.000 claims description 3
- 229910020261 KBF4 Inorganic materials 0.000 claims description 2
- 229910001610 cryolite Inorganic materials 0.000 claims description 2
- OTYBMLCTZGSZBG-UHFFFAOYSA-L potassium sulfate Chemical compound [K+].[K+].[O-]S([O-])(=O)=O OTYBMLCTZGSZBG-UHFFFAOYSA-L 0.000 claims description 2
- 229910052939 potassium sulfate Inorganic materials 0.000 claims description 2
- 239000011780 sodium chloride Substances 0.000 claims description 2
- AXCZMVOFGPJBDE-UHFFFAOYSA-L calcium dihydroxide Chemical compound [OH-].[OH-].[Ca+2] AXCZMVOFGPJBDE-UHFFFAOYSA-L 0.000 claims 1
- 239000000920 calcium hydroxide Substances 0.000 claims 1
- 229910001861 calcium hydroxide Inorganic materials 0.000 claims 1
- 238000004519 manufacturing process Methods 0.000 abstract description 3
- 235000013339 cereals Nutrition 0.000 description 53
- 239000000203 mixture Substances 0.000 description 43
- 238000009472 formulation Methods 0.000 description 16
- 238000000227 grinding Methods 0.000 description 8
- 239000007788 liquid Substances 0.000 description 8
- 239000000843 powder Substances 0.000 description 8
- 238000000034 method Methods 0.000 description 7
- 239000003082 abrasive agent Substances 0.000 description 6
- 238000002156 mixing Methods 0.000 description 6
- 229910052751 metal Inorganic materials 0.000 description 5
- 239000002184 metal Substances 0.000 description 5
- 230000006872 improvement Effects 0.000 description 4
- 238000001000 micrograph Methods 0.000 description 4
- 238000005979 thermal decomposition reaction Methods 0.000 description 4
- 230000009471 action Effects 0.000 description 3
- 230000002411 adverse Effects 0.000 description 3
- 230000000593 degrading effect Effects 0.000 description 3
- 230000008569 process Effects 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 2
- 230000004913 activation Effects 0.000 description 2
- 230000000052 comparative effect Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 239000013312 porous aromatic framework Substances 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 2
- 229910010271 silicon carbide Inorganic materials 0.000 description 2
- 239000004575 stone Substances 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 239000005995 Aluminium silicate Substances 0.000 description 1
- 235000013162 Cocos nucifera Nutrition 0.000 description 1
- 244000060011 Cocos nucifera Species 0.000 description 1
- 229920003261 Durez Polymers 0.000 description 1
- 241000196324 Embryophyta Species 0.000 description 1
- 239000004593 Epoxy Substances 0.000 description 1
- 229910020239 KAlF4 Inorganic materials 0.000 description 1
- 229920001328 Polyvinylidene chloride Polymers 0.000 description 1
- -1 S13N4 Chemical class 0.000 description 1
- UCKMPCXJQFINFW-UHFFFAOYSA-N Sulphide Chemical compound [S-2] UCKMPCXJQFINFW-UHFFFAOYSA-N 0.000 description 1
- 238000002679 ablation Methods 0.000 description 1
- 235000012211 aluminium silicate Nutrition 0.000 description 1
- INJRKJPEYSAMPD-UHFFFAOYSA-N aluminum;silicic acid;hydrate Chemical compound O.[Al].[Al].O[Si](O)(O)O INJRKJPEYSAMPD-UHFFFAOYSA-N 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 239000010425 asbestos Substances 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000013590 bulk material Substances 0.000 description 1
- 229910000019 calcium carbonate Inorganic materials 0.000 description 1
- 239000002826 coolant Substances 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 239000007799 cork Substances 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 239000010431 corundum Substances 0.000 description 1
- 229910052593 corundum Inorganic materials 0.000 description 1
- 239000004643 cyanate ester Substances 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000003628 erosive effect Effects 0.000 description 1
- 239000010433 feldspar Substances 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 235000013312 flour Nutrition 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 230000017525 heat dissipation Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 230000002401 inhibitory effect Effects 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 1
- 239000010443 kyanite Substances 0.000 description 1
- 229910052850 kyanite Inorganic materials 0.000 description 1
- 230000000670 limiting effect Effects 0.000 description 1
- 238000005461 lubrication Methods 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000002923 metal particle Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 239000005033 polyvinylidene chloride Substances 0.000 description 1
- 230000002265 prevention Effects 0.000 description 1
- 239000008262 pumice Substances 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 150000003254 radicals Chemical class 0.000 description 1
- 230000002829 reductive effect Effects 0.000 description 1
- 230000008439 repair process Effects 0.000 description 1
- 229910052895 riebeckite Inorganic materials 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- 230000003746 surface roughness Effects 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Classifications
-
- 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
- B24D5/12—Cut-off wheels
-
- 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
-
- 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
- B24D3/02—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent
- B24D3/20—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially organic
-
- 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
- B24D3/02—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent
- B24D3/20—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially organic
- B24D3/28—Resins or natural or synthetic macromolecular compounds
-
- 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
- B24D3/342—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 incorporated in the bonding agent
Definitions
- the present invention relates generally to abrasive articles and more particularly to an abrasive article with improved grain retention and performance.
- Abrasive articles are typically used in various industries to machine workpieces by cutting, lapping, grinding, or polishing.
- the use of abrasive articles for machining spans a wide industrial scope from optics industries, automotive plant repair industries to metal fabrication industries.
- manufacturing facilities use abrasives to remove bulk material to reach designed dimensions, geometry, and surface characteristics of products (e.g., planarity, surface roughness).
- thermal degradation is even more apparent when using an abrasive grain that exhibits good resistance to mechanical fractures. Eventually, the thermal degradation weakens the rough grinding abrasive articles, impairing performance and ultimately leading to a shorter life. Thermal degradation can be especially problematic relative to ultra-thin, dry cut-off wheels, which tend to reach thermal degrading temperatures very quickly at the grain/bond interface.
- an ultra-thin, small diameter cutoff wheel comprising: a plurality of abrasive grains, an organic bond material and an active filler material.
- the active filler material comprises an effective amount of an active endothermic filler material that provides an endothermic reaction at normal dry cutting conditions.
- an ultra-thin, small diameter cutoff wheel that comprises a plurality of abrasive grains and an organic bond material comprising an active endothermic filler material providing an endothermic reaction added thereto.
- the amount of active endothermic filler material is in a range of about 12 to about 50 percent by volume of the bond.
- an ultra-thin, small diameter cutoff wheel that comprises a plurality of abrasive grains and an organic bond material with an active endothermic filler material added thereto to provide an endothermic reaction that improves grain retention.
- the plurality of abrasive grains are selected from the group consisting of seeded or unseeded sol gel alumina grain, Al 2 (VZrO 2 grain and combinations thereof.
- the active endothermic filler material is selected from the group consisting of sulfides, low melting point oxides and combinations thereof.
- FIG. 1 is an image of an abrasive article according to one embodiment of the present invention
- FIG. 2 is a micrograph image of a conventional abrasive article showing a large- number of grain pull-out according to the prior art.
- FIG. 3 is a micrograph image of an abrasive article formed according to one embodiment of the present invention.
- FIG. 1 is an image of an abrasive article 100 according to one embodiment of the present invention.
- abrasive article 100 is an abrasive wheel product.
- abrasive wheel products come in a variety of sizes such as for example, large diameter cutoff abrasive wheel products, medium diameter cutoff abrasive wheel products and small diameter cutoff abrasive wheel products.
- large diameter cutoff abrasive wheel products have a diameter that is greater than about 1000 mm
- medium diameter cutoff abrasive wheel products have a diameter that is greater than about 400 mm and less than about 1000 mm
- small diameter cutoff abrasive wheel products have a diameter that is less than about 400 mm.
- abrasive mix used to form abrasive article 100 is preferably suitable for small diameter cutoff abrasive wheel products and more particularly to ultra-thin, small diameter cutoff abrasive wheel products that have diameters less than about 250 mm, those skilled in the art will recognize that the abrasive mix used to form abrasive article 100 may have applicability for large diameter cutoff abrasive wheel products and medium diameter cutoff abrasive wheel products as well.
- abrasive article 100 is an ultra-thin, small diameter bonded abrasive article formed from an abrasive mix that comprises abrasive grains and an organic bond material with active filler materials added thereto such as active endothermic filler material(s).
- active endothermic filler material(s) provide an endothermic reaction at "normal dry cutting conditions" to reduce the temperature at the interface of grains and their surrounding organic bond.
- active fillers can be used in bonded abrasives to enhance grinding performance.
- Active fillers also known as reactive fillers, are designed to be physically and/or chemically active. They generally provide extended, increased cutting rates and coolness of cut.
- active fillers can do one or more of the following:
- the abrasive article 100 contains at least one type of primary abrasive grain selected from the group of abrasive families consisting of seeded or unseeded sol gel alumina and Al 2 Os-ZrO 2 .
- a non-exhaustive list of abrasive grains from the seeded or unseeded sol gel alumina family that may be used in embodiments of this invention include SG grain and NQ grain, commercially available from Saint-Gobain Abrasives, Inc. of Worcester, MA; 3M321 Cubitron grain and 3M324 Cubitron grain, both commercially available from 3M Corporation of St. Paul, MN; and combinations thereof.
- a non-exhaustive list of abrasive grains from the Al 2 Os-ZrO 2 family that may be used in embodiments of this invention include NZ Plus grain, commercially available from Saint-Gobain Abrasives, Inc. of Worcester, MA; ZF grain and ZS grain, both commercially available from Saint-Gobain Abrasives, Inc. of Worcester, MA; ZK40 grain, commercially available from Schwarzacher Industry, Inc. of Toronto, Ontario CA; and ZR25B grain and ZR25R grain, both commercially available from Alcan, Inc. of Montreal, Quebec CA.
- the amount of the primary abrasive grain comprises between about 20 to about 100 percent of the total amount of abrasive grain by volume.
- At least one type of secondary abrasive grain can be blended with the primary abrasive grain to achieve either cost or performance requirements.
- the secondary abrasive grain may be selected from the group consisting of ceramic oxides (e.g., coated or non-coated fused AI 2 O3, monocrystal AI 2 O3), nitrides (e.g., S13N 4 , AlN) and carbides (e.g., SiC).
- the amount of the secondary abrasive grain may range from about 80 to about 0 percent of the total amount of abrasive grain by volume or balance.
- the organic bond material is comprised essentially of art- recognized organic bond material, such as one or more organic resins - e.g. epoxy, polyester, phenolic, and cyanate ester resins, or other suitable thermosetting or thermoplastic resins.
- organic resins e.g. epoxy, polyester, phenolic, and cyanate ester resins, or other suitable thermosetting or thermoplastic resins.
- resins that can be used include the following: resins sold by Dynea Oy, Finland, under the trade name Prefere and available under the catalog/product numbers 8522G, 8528G, 8680G, and 8723G; resins sold by Hexion Specialty Chemicals, OH, under the trade name Rutaphen.RTM.
- the bond material comprises a dry resin material.
- types and amounts of active endothermic fillers are chosen in order to provide an endothermic reaction at "normal dry cutting conditions.”
- normal dry cutting conditions refers generally to those conditions encountered at the grain/bond interface of a small diameter, ultra-thin cutoff wheel during dry cutting of common materials for which the wheel is designed to cut/grind.
- An "effective amount" of active endothermic filler provides an endothermic reaction at normal dry cutting conditions. These conditions typically include very quick ramping to thermal degrading temperatures in excess of 450 0 C. Thermal degradation can be especially problematic relative to ultra-thin, dry cutoff wheels, which tend to transfer heat very quickly and to reach thermal degrading temperatures very quickly at the grain/bond interface.
- the active endothermic fillers produce an endothermic reaction at the conditions typically encountered during dry cutting and, therefore, reduce the temperature at the grain/bond interface, resulting in much improved grain retention and longer life.
- the active endothermic fillers provide an endothermic reaction when temperature at the grain/bond interface is at least about 450 0 C, or at least about 500 0 C, or at least about 527°C, or at a temperature which provides an amount of thermal energy greater than the activation energy necessary to decompose the active endothermic filler. It is noted that when the heating rate is slow or if the grain/bond interface temperature is too low, exothermic reactions may occur; therefore, the thickness of the abrasive article can play a roll in obtaining the desired endothermic reaction.
- At least one type of active endothermic filler material that provides an endothermic reaction is selected from the group of filler types consisting of sulfides and low melting point oxides.
- a non-exhaustive list of active endothermic fillers from the sulfide types that may be used in embodiments of the present invention include pyrite, zinc sulfide, copper sulfide, and combinations thereof.
- a non-exhaustive list of active endothermic fillers from the low melting point oxides types that may be used in embodiments of the present invention include bismuth oxide, lead oxide, tin oxide and combinations thereof. Note that in one embodiment, it is preferable that the active fillers of the low melting point oxides have a melting point below about 1000 degrees Celsius.
- fillers may be added to the organic bond material in order to enhance the ability of abrasive article 100 to cut, lap, grind, or polish.
- the fillers may include active and/or inactive fillers.
- active fillers may include Cryolite, PAF, KBF 4 , K 2 SO 4 , NaCl/KCl, and combinations thereof.
- inactive fillers may include CaO, CaCO 3 , Ca(OFTh, CaSi ⁇ 3, Kyanite (a mixture of Al 2 ⁇ 3-Si ⁇ 2 ), Saran (Polyvinylidene chloride), Nephenline (Na, K) AlSiO 4 , wood powder, coconut shell flour, stone dust, feldspar, kaolin, quartz, short glass fibers, asbestos fibers, balotini, surface-treated fine grain (silicon carbide, corundum etc.), pumice stone, cork powder and combinations thereof.
- an active filler material such as PAF, which is a mixture of K 3 AlF 6 and KAlF 4 , can be added to the organic bond material in order to corrode metals and reduce the friction between the wheel and workpiece.
- the formulation of the abrasive mix used to form abrasive article 100 may be as follows.
- the abrasive grains present in this mix may range from about 35 to about 55 percent by volume of the total mix (i.e., excluding porosity).
- the abrasive grains present in this mix may range from about 40 to about 54 percent by volume of the total mix (i.e., excluding porosity).
- the organic bond material (e.g., resin) in this mix may range from about 25 to about 45 percent by volume of the total mix.
- the organic bond material (e.g., resin) in this mix may range from about 30 to about 40 percent by volume of the total mix.
- the active endothermic filler material in this mix may be in an amount that ranges from about 5 to about 30 percent by volume (amount in the total mix). In another embodiment, the active endothermic filler material in this mix may be in an amount that ranges from about 5 to about 24 percent by volume (amount in the total mix). In other embodiments, the active endothermic filler material in this mix may be in an amount that ranges from about 12 to about 50 percent by volume (amount in the total bond). While in other embodiments, the active endothermic filler material in this mix may be in an amount that ranges from about 12 to about 35 percent by volume (amount in the total bond). The balance will be other fillers that include active or inactive fillers.
- the volume ratio of the active filler material providing endothermic reaction to the organic bond material is in the range of about 0.136 to about 1 (e.g., resin). In another embodiment, the volume ratio of the active filler material providing endothermic reaction to the organic bond material is in the range of about 0.136 to about 0.67 (e.g., resin).
- abrasive article 100 is an ultra-thin, small diameter cutoff abrasive wheel product.
- abrasive article 100 has a diameter that ranges from about 75 mm to about 250 mm and, a thickness of less than about 2.5 mm.
- the thickness of the wheel is between about 0.8 mm and about 2.2 mm.
- the wheel can have an aspect ratio that ranges from about 40 to about 160.
- the abrasive article formed from the above-described formulation does not suffer from large amounts of grain pull-out like conventional abrasive articles.
- Abrasive articles formed from conventional formulations are adversely affected by large amounts of grain pull-out because the bond between the abrasive grains and bond material in these mixes is unable to withstand the thermal degradation that arises from the heat input associated with the cutting action of the abrasive article.
- the temperature at the interfaces of the grains and their surrounding organic bond at the surface level of the abrasive article is at the highest and can range from about 600 degrees Celsius to about 1000 degrees Celsius.
- the organic bond material can act as an insulation layer due to its low thermal conductivity (i.e., less than 2 W/(m-K)) and thus the heat input from the cutting action does not substantially penetrate the depth of the abrasive article, where other layers of abrasives reside. Therefore, the temperature at the interfaces of the grains and their surrounding organic bond at these lower levels, which can be from 250 degrees Celsius to 350 degrees Celsius, is substantially less than the temperatures at the interfaces of the top surface.
- the bond becomes weaker (a typical thermal decomposition temperature of an organic bond material such as a resin is 500 degrees Celsius) and eventually the grains at this level pull-out and fall from the surface instead of being steadily worn out through the typical attrition process.
- the abrasive article formed from the above-described formulation suffers from less grain pull-out because it is less adversely affected by thermal degradation at the interfaces of the grains and their surrounding bond material due to the endothermic reaction occurring to reduce the interfacial temperature.
- the abrasive articles according to embodiments of the present invention are not adversely affected by thermal degradation at the interface of the grains and their surrounding organic bond material because of the dimensioning of the wheel and the formulation of the specific types of abrasive grains and active endothermic fillers.
- the use of the active fillers in the formulations noted above act to provide thermal decomposition of the active fillers that result in a cooling effect that lowers the temperature at the interface of the abrasive grains and the bond. This counteracts the propensity for rampant thermal degradation to occur.
- FIG. 2 is a micrograph image 200 of a conventional abrasive article showing a large-number of grain pull-out holes 210. Note that for ease of illustration only a few grain pull-out holes 210 are highlighted. A closer look at image 200 shows that this abrasive article formed according to the prior art has a very large number of grain pull-out holes 210. An abrasive article with this many grain pull-out holes will not perform well and consequently will have a shorter life-span.
- FIG. 3 shows a micrograph image 300 of an abrasive article formed according to embodiments of the present invention.
- the abrasive article formed according to embodiments of the present invention has significantly fewer grain pull-out holes than the conventional abrasive article shown in FIG. 2. Although not all of the grain pull-out holes are highlighted in FIG. 3, it is clear that there are significantly fewer grain pull-out holes in this figure than in FIG. 2.
- the abrasive article in FIG. 3 has significantly fewer grain pull-out holes, this article as described herein performs cutting operations better and lasts longer than conventional abrasive articles.
- the Absolute G-Ratio is attained by mounting the abrasive article on a portable machine for a dry cutting application that may have a maximum operation speed of about 80 m/s.
- a workpiece material with typical dimensions e.g., 600 mm (length) x 100 (width) x 6 (thickness) mm
- the number of pieces of cuts from the workpiece material is then counted and recorded into a computer system along with the diameter of the abrasive article.
- An experienced operator then manually conducts testing by using the grinder to perform cutting operations on the workpiece material.
- a data acquisition system connected with the grinder monitors the power and current of the grinder, and cutting time during the testing. The testing lasts until the abrasive article is fully consumed. The diameter of the tested article is then measured and recorded. The weight of the remaining workpiece material is weighed and recorded as well.
- the computer system using a commercially available software application determines material removal rate (MRR) and wheel wear rate (WWR). The application calculates the Absolute G-Ratio by dividing MRR by WWR. A higher Absolute G-Ratio indicates that the performance of the abrasive article is better.
- the Relative G-Ratio which is the ratio of the Absolute G-Ratio of abrasive article B divided by the Absolute G-Ratio of abrasive article A (reference), is used herein to compare the performance of abrasive articles.
- the Relative G-Ratio of abrasive article A is 1.
- a higher Relative G-Ratio indicates that better performance improvement has been obtained.
- the abrasive article formed herein using the above -noted formulations has Relative G-Ratios that are greater than 1.00. Examples below show that it is possible to obtain Relative G-Ratio values that range from about 1.4 to about 2.4. Examples
- Example 1 provides particular examples of abrasive articles formed according to embodiments described herein.
- Example 1 an abrasive article is formed with the above -noted formulation. About 44 lbs of Al 2 (VZrO 2 abrasive grain blended with about 25 lbs of monocrystal AI 2 O3 abrasive grains was added into a mixing container. At least one processing liquid was introduced to the grains. Herein, about 5 lbs of liquid resin was added into the abrasive grains. About 11 lbs of powder resin, about 6 lbs of PAF and about 9 lbs of pyrite were prepared in a separate mixing container.
- the mixture of the abrasive grains with the liquid resin was poured into that separate container to mix with the powder resin, PAF, and pyrite mixture. Then the abrasive article was formed in the same method as a conventional abrasive article, such as, for example, the forming methods described in U.S. Patent Number 6,866,691 Bl - which is incorporated by reference in its entirety.
- the dimension of the abrasive article was 125 mm in diameter with 1 mm thickness.
- the performance of the abrasive article with the above formulation was tested and its Relative G-Ratio (compared with a conventional abrasive article at the same dimension) was 2.2.
- an abrasive article was formed with the above noted formulation.
- About 68 lbs of seeded or unseeded sol gel alumina AI 2 O3 abrasive grain was added into a mixing container.
- At least one processing liquid was introduced to the grain.
- about 5 lbs of liquid resin was added into the abrasive grain.
- about 11 lbs of powder resin, about 6 lbs of PAF and about 10 lbs of pyrite were prepared in a separate mixing container. The mixture of the abrasive grain with the liquid resin was poured into the separate container to mix with the powder resin, PAF, and pyrite mixture.
- the abrasive article was formed and tested in the same methods as a conventional abrasive article which has been mentioned above.
- the dimension of the abrasive article in this example was 125 mm in diameter with 1 mm thickness. Its Relative G-Ratio was 1.6.
- the resulting performance improvement was due to the fact that the thermal decomposition of the pyrite reduces the temperature at the interface of the abrasive grain and their surrounding organic bond, resulting in improved grain retention and a longer life.
- Comparative Example 1 provides a comparative example of an abrasive article not formed according to embodiments described herein. Comparative Example 1 :
- an abrasive article was formed with the above-noted abrasive grain, but with different active fillers.
- about 44 lbs of Al 2 Os-ZrO 2 abrasive grain blended with about 25 lbs of monocrystal Al 2 Cb abrasive grain was added into a mixing container.
- about 5 lbs of liquid resin was added into the abrasive grain.
- PAF active filler
- the mixture of the abrasive grain with the liquid resin was poured into that separate container to mix with powder resin and PAF mixture. Then the abrasive article was formed and tested in the same method as described in Example 1.
- the dimension of the abrasive article in this example was 125 mm in diameter with 1 mm thickness.
- the resulting Relative G-Ratio (compared with a conventional abrasive article at the same dimension) was 1.1.
- the life of the abrasive article or grain retention did not improve in the same scale as in Example 1 because the endothermic reaction did not occur during the cutting operation.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Polishing Bodies And Polishing Tools (AREA)
Abstract
Description
Claims
Priority Applications (13)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
SG2011078896A SG175807A1 (en) | 2009-04-30 | 2010-04-28 | Abrasive article with improved grain retention and performance |
NZ596311A NZ596311A (en) | 2009-04-30 | 2010-04-28 | Abrasive article with improved grain retention and performance |
KR1020117027918A KR101326032B1 (en) | 2009-04-30 | 2010-04-28 | Abrasive article with improved grain retention and performance |
JP2012508616A JP2012525273A (en) | 2009-04-30 | 2010-04-28 | Abrasive article having improved abrasive retention and performance |
CN2010800245066A CN102470513A (en) | 2009-04-30 | 2010-04-28 | Abrasive article with improved grain retention and performance |
MX2011011383A MX2011011383A (en) | 2009-04-30 | 2010-04-28 | Abrasive article with improved grain retention and performance. |
UAA201114187A UA100639C2 (en) | 2009-04-30 | 2010-04-28 | Abrasive article with improved grain retention and performance |
RU2011147732/02A RU2498892C2 (en) | 2009-04-30 | 2010-04-28 | Cutting wheel |
AU2010241762A AU2010241762B2 (en) | 2009-04-30 | 2010-04-28 | Abrasive article with improved grain retention and performance |
BRPI1014834A BRPI1014834A2 (en) | 2009-04-30 | 2010-04-28 | abrasive article with improved grain retention and performance |
CA2760208A CA2760208A1 (en) | 2009-04-30 | 2010-04-28 | Abrasive article with improved grain retention and performance |
IL215958A IL215958A0 (en) | 2009-04-30 | 2011-10-26 | Abrasive article with improved grain retention and performance |
ZA2011/08220A ZA201108220B (en) | 2009-04-30 | 2011-11-09 | Abrasive article with improved grain retention and perfomance |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US17424009P | 2009-04-30 | 2009-04-30 | |
US61/174,240 | 2009-04-30 | ||
US12/768,107 | 2010-04-27 | ||
US12/768,107 US20110111678A1 (en) | 2009-04-30 | 2010-04-27 | Abrasive article with improved grain retention and performance |
Publications (2)
Publication Number | Publication Date |
---|---|
WO2010126934A2 true WO2010126934A2 (en) | 2010-11-04 |
WO2010126934A3 WO2010126934A3 (en) | 2011-03-03 |
Family
ID=43032754
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2010/032659 WO2010126934A2 (en) | 2009-04-30 | 2010-04-28 | Abrasive article with improved grain retention and performance |
Country Status (16)
Country | Link |
---|---|
US (1) | US20110111678A1 (en) |
EP (1) | EP2177318B1 (en) |
JP (1) | JP2012525273A (en) |
KR (1) | KR101326032B1 (en) |
CN (1) | CN102470513A (en) |
AU (1) | AU2010241762B2 (en) |
BR (1) | BRPI1014834A2 (en) |
CA (1) | CA2760208A1 (en) |
CO (1) | CO6470829A2 (en) |
IL (1) | IL215958A0 (en) |
MX (1) | MX2011011383A (en) |
NZ (1) | NZ596311A (en) |
RU (1) | RU2498892C2 (en) |
SG (1) | SG175807A1 (en) |
WO (1) | WO2010126934A2 (en) |
ZA (1) | ZA201108220B (en) |
Families Citing this family (9)
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US20130337730A1 (en) * | 2012-06-06 | 2013-12-19 | Siddharth Srinivasan | Large diameter cutting tool |
TWI541098B (en) * | 2012-06-06 | 2016-07-11 | 聖高拜磨料有限公司 | Small diameter cutting tool |
WO2014036097A1 (en) * | 2012-08-28 | 2014-03-06 | Saint-Gobain Abrasives, Inc. | Large diameter cutting tool |
US20140378036A1 (en) * | 2013-06-25 | 2014-12-25 | Saint-Gobain Abrasives, Inc. | Abrasive article and method of making same |
CN104742029B (en) * | 2013-12-31 | 2018-11-16 | 圣戈班磨料磨具有限公司 | A kind of grinding materials and grinding tool and manufacturing method |
CN104669134A (en) * | 2015-01-30 | 2015-06-03 | 洛阳希微磨料磨具有限公司 | Production method of abrasive grinding wheel |
CN106799685B (en) * | 2017-01-25 | 2020-01-17 | 蓝思科技(长沙)有限公司 | Diamond abrasive grinding tool |
CN109231970B (en) * | 2018-10-25 | 2021-06-08 | 河南东风新研材科技有限公司 | Nanocrystalline ceramic corundum abrasive and preparation method thereof |
CN110328623B (en) * | 2019-07-23 | 2021-06-01 | 广州奥拓夫精密智能制造有限公司 | Precision cutting grinding wheel |
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- 2010-04-28 NZ NZ596311A patent/NZ596311A/en not_active IP Right Cessation
- 2010-04-28 JP JP2012508616A patent/JP2012525273A/en active Pending
- 2010-04-28 KR KR1020117027918A patent/KR101326032B1/en not_active IP Right Cessation
- 2010-04-28 CN CN2010800245066A patent/CN102470513A/en active Pending
- 2010-04-28 BR BRPI1014834A patent/BRPI1014834A2/en not_active IP Right Cessation
- 2010-04-28 AU AU2010241762A patent/AU2010241762B2/en not_active Expired - Fee Related
- 2010-04-28 MX MX2011011383A patent/MX2011011383A/en not_active Application Discontinuation
- 2010-04-28 SG SG2011078896A patent/SG175807A1/en unknown
- 2010-04-28 CA CA2760208A patent/CA2760208A1/en not_active Abandoned
- 2010-04-28 WO PCT/US2010/032659 patent/WO2010126934A2/en active Application Filing
- 2010-04-28 RU RU2011147732/02A patent/RU2498892C2/en not_active IP Right Cessation
-
2011
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Also Published As
Publication number | Publication date |
---|---|
BRPI1014834A2 (en) | 2016-04-12 |
IL215958A0 (en) | 2012-01-31 |
US20110111678A1 (en) | 2011-05-12 |
RU2011147732A (en) | 2013-06-10 |
ZA201108220B (en) | 2012-09-26 |
JP2012525273A (en) | 2012-10-22 |
AU2010241762A1 (en) | 2011-11-24 |
CA2760208A1 (en) | 2010-11-04 |
RU2498892C2 (en) | 2013-11-20 |
AU2010241762B2 (en) | 2014-07-10 |
KR101326032B1 (en) | 2013-11-05 |
CN102470513A (en) | 2012-05-23 |
WO2010126934A3 (en) | 2011-03-03 |
CO6470829A2 (en) | 2012-06-29 |
KR20120012476A (en) | 2012-02-10 |
MX2011011383A (en) | 2012-01-20 |
EP2177318A1 (en) | 2010-04-21 |
EP2177318B1 (en) | 2014-03-26 |
SG175807A1 (en) | 2011-12-29 |
NZ596311A (en) | 2014-02-28 |
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