WO2017112906A1

WO2017112906A1 - Abrasive wheels and methods for making and using same

Info

Publication number: WO2017112906A1
Application number: PCT/US2016/068439
Authority: WO
Inventors: Dashi NIE; Kuo GAO; Xu Chen
Original assignee: Saint-Gobain Abrasives, Inc.; Saint-Gobain Abrasifs
Priority date: 2015-12-25
Filing date: 2016-12-22
Publication date: 2017-06-29
Also published as: CN106914831A

Abstract

An abrasive article can includes a body having an abrasive portion. The abrasive portion can include a filler composition including pyrite, in particular, pyrite having a sulfur content of at least at least 43 wt% for a total weight of the pyrite. The abrasive portion can include abrasive particles including brown alumina. In a particular embodiment, the abrasive particle can consist essentially of brown alumina. In another particular embodiment, the filler composition can include pyrite, sodium aluminum fluoride, potassium aluminum fluoride, and calcium carbonate. In some instances the abrasive article can include a chop saw, while in other situations, the cutting wheel can include a cut-off wheel.

Description

ABRASIVE WHEELS AND METHODS FOR MAKING AND USING SAME

BACKGROUND ART

Typically, bonded abrasive articles are prepared by blending abrasive particles with a bond and optional additives and shaping the resulting mixture by using, for instance, a suitable mold. The mixture can be shaped to form a green body which is thermally processed, for example, by curing or sintering, to produce an article in which the abrasive particles are held in a three dimensional bond matrix. In some cases, the green body can be cold processed or warm pressed (mold temperature 20 ^°C to 60 ^°C) to form the bonded abrasive article. Among bonded abrasive tools, abrasive wheels often are prepared for grinding, cutting, polishing, and the like. Such wheels can be reinforced using, for example, discs cut out of nylon, carbon, glass or cotton cloth, or they may not be reinforced. A need for improved abrasive articles continues to exist.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings, reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale.

FIG. 1 includes a flow diagram of a method to make a cutting wheel according to an embodiment.

FIG. 2 includes a side view of a cutting wheel in accordance with an embodiment. FIG. 3 includes cross-sectional view of the cutting wheel of FIG. 2 according to an embodiment.

FIG. 4 includes a cross-sectional view of the cutting wheel of FIG. 2 in accordance with another embodiment.

FIG. 5 includes a cross-sectional view of the cutting wheel of FIG. 2 in accordance with an additional embodiment.

FIG. 6 includes a cross-sectional view of the cutting wheel of FIG. 2 having a depressed center configuration in accordance with an embodiment.

FIG. 7 includes a cross-sectional view of the cutting wheel of FIG. 2 having a depressed center configuration in accordance with another embodiment.

FIG. 8 includes a cross-sectional view of the cutting wheel of FIG. 2 having a depressed center configuration in accordance with an additional embodiment.

FIG. 9 includes a cross-sectional view of the cutting wheel of FIG. 2 having a depressed center configuration in accordance with a further embodiment. FIG. 10 includes a graph indicating a si/e distribution of a conventional filler and a filler in accordance with an embodiment herein.

FIG. 1 1 includes a histogram indicating performance for cutting wheels having different filler compositions.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

The following description in combination with the figures is provided to assist in understanding the teachings disclosed herein. The following discussion will focus on specific implementations and embodiments of the teachings. This focus is provided to assist, in describing the teachings and should not be interpreted as a limitation on the scope or applicability of the teachings. However, other teachings can certainly be used in this application.

As used herein, the terms "comprises," "comprising," "includes," "including," "has," "having" or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such method, article, or apparatus. Further, unless expressly stated to the contrary, "or" refers to an inelusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

Also, the use of "a" or "an" is employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be read to include one or at least one and the singular also includes the plural, or vice versa, unless it is clear that it is meant otherwise. For example, when a single item is described herein, more than one item may be used in place of a single item. Similarly, where more than one item is described herein, a single item may be substituted for that more than one item.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The materials, methods, and examples are illustrative only and not intended to be limiting. To the extent, that certain details regarding specific materials and processing acts are not described, such details may include conventional approaches, which may be found in reference books and other sources within the manufacturing arts.

The disclosure generally relates to abrasive articles, and in particular, to bonded abrasive articles, which may be in the form of wheels suitable for use as cut-off wheels or chop saws and to methods tor producing the same. FIG. 1 includes a flow diagram of a method 100 to make an abrasive article according to an embodiment. In particular, at 102, the method 100 includes providing a mixture including abrasive particles and a bond material. The mixture can also include additional components, such as a filler composition, processing aids, lubricants (e.g., wetting agents), curing agents, cross! inking agents, antistatic agents, a porosity inducer, coloring agents, and the like.

In an embodiment, the mixture may include at least 53 wt% abrasive particles for a total weight of the mixture, at least 59 wt% abrasive particles for a total weight of the mixture, or at least 64 wt% abrasive particles for a total weight of the mixture. In another embodiment, the mixture includes not greater than 85 wt% abrasive particles for a total weight of the mixture, such as not greater than 79 wt%, not greater than 73 wt%, or not greater than 68 wt% abrasive particles for a total weight of the mixture. It will be appreciated that the content of abrasive particles in the mixture can be within a range including any of the minimum and maximum percentages noted above. For example, the mixture can include 53 wt% to 85 wt% abrasive particles. In a particular embodiment, the mixture can include abrasive particles within a range of at least 64 wt% to not greater than 79 wt% abrasive particles for a total weight of the mixture.

In an embodiment, the abrasive particles can include an oxide, such as alumina, and particularly, brown alumina. In a particular embodiment, the abrasive particles can consist, essentially of brown alumina. According to an aspect, brown alumina can include at least 88 wt% alumina for a total weight of the abrasive particles, such as at least 90 wt%, or at least 92 wt%, or at least 95 wt% alumina for a total weight of the abrasive particles. According to another aspect, brown alumina may not include greater than 99 wt% alumina for a total weight of the abrasive particles. It is to be understood that brown alumina can include alumina within a range including any of the minimum and maximum percentages disclosed herein. For instance, brown alumina can include alumina within a range of at least 88 wt% to not greater than 99 wt% for a total weight of the abrasive particles, such as within a range of at least 92 wt% to not greater than 99 wt% for a total weight of the abrasive particles.

According to an aspect, brown alumina can include an additional component, such as an oxide other than alumina. For example, brown alumina may include silica in a content, of not greater than 5 wt% for a total weight of the abrasive particles, such as not greater than 4 wt% or not greater than 3 wt%. In another instance, brown alumina can include at least 0.05 wt% silica for a total weight of the abrasive particles. It is to be understood that brown alumina can include a content of silica within a range including any of the minimum, and maximum percentages disclosed herein. For example, brown alumina can include silica within a range of at least 0.05 wt% to not greater than 5 wt% for a total weight of the abrasive particles, such as within a range of at least 0.05 wt% to not greater than 3 wt%.

According to an aspect, brown alumina may include a content of iron oxide of not greater than 4 wt% for a total weight of the abrasive particles, such as not greater than 3 wt% or not greater than 2 wt% or not greater than 1 wt% or not greater than 0.5 wt%. in another aspect, brown alumina can include at least 0.03 wt%, such as at least 0.1 wt%, iron oxide for a total weight of the abrasive particles. It is to be understood that brown alumina can include a content of iron oxide within a range including any of the minimum and maximum percentages disclosed herein. For example, brown alumina can include iron oxide within a range of at least 0.03 wt% to not greater than4 wt% for a total weight of the abrasive particles, such as within a range of at least 0.1 wt% to not greater than 1 wt%.

According to an aspect, brown alumina may include a content of titanium oxide of not greater than 5 wt% for a total weight of the abrasive particles, such as not greater than 4 wt% or not greater than 3 wt%. In another aspect, brown alumina can include at least 0.1 wt% of titanium oxide for a total weight of the abrasive particles. It is to be understood that brown alumina can include a content of titanium oxide within a range including any o the minimum and maximum percentages disclosed herein. For example, brown alumina can include a content of titanium oxide within a range of at least 0.1 wt% to not greater than 5 wt% for a total weight of the abrasive particles, such as within a range of at least 0.1 wt% to not greater than 3 wt%.

According to an aspect, brown alumina can have a density of at least 3.55 g/cm³, such as at least 3.60 g/cm³ or at least 3.70 g/cm³ or at least 3.80 g/cm^J or at least 3.90 g/cm³. In another aspect, the density of brown alumina may be not greater than 4.00 g cm³, such as not greater than 3.90 g/cm³. It is to be understood that brown alumina can have a density within a range including any of the minimum and maximum values disclosed herein, such as within a range of at least 3.55 g/cm³ to not greater than 4.00 g/cm³, such as within a range of at least 3.80 g/cm³ to not greater than 3.90 g/cm\

In some embodiments, an additional heat treatment process of brown alumina can be included. For example, brown alumina can be subjected to a heat treatment process including grain heat treatment at a temperature within a range of at least 800°C to not greater than 13 (MFC. In a non-limiting example, the heating rate can be 5°C/min, and the holding time at the maximum temperature can be 10 minutes before being furnace cooled to room

temperature. Heat treatment, of brown alumina may facilitate improved performance, such as G-ratio of cutting wheels. In a particular embodiment, the abrasive particles can include heal treated brown alumina.

In a particular embodiment, the abrasive particles can include brown alumina and may be essentially free of any other types of abrasive particles. That is, the abrasive particles can consist essentially of brown alumina. In another embodiment, the abrasive particles can include a blend of different types of abrasive particles including brown alumina. For example, the abrasive particles can include at least one other type of abrasive particle from the group including white alumina, black alumina, monocrystalline fused alumina, heat treated alumina, oxides, bo rides, nitrides, carbides, diamond, or a combination thereof. For those embodiments utilizing a blend of abrasive particles, the content of brown alumina can be at least 1 wt% for a total weight of the mixture, such as at least 10 wt%, at least 20 wt%, at least 30 wt%, at least 40 wt%, at least 50 wt%, at least 60 wt%, at least 70 wt %, at least 80 wt%, at least 90 wt% or at least 99 wt%. Alternatively or additionally, the content of brown alumina in blend of abrasive particles may be not greater than 99 wt%, such as not greater than 90 wt , not greater than 80 wt%, not greater than 70 wt%, not greater than 60 wt%, not greater than 50 wt%, not greater than 40 wt%, not greater than 30 wt%, not greater than 20 wt%, not greater than 10 wt%, not greater than 1 wt%. It is to be appreciated that the content of brown alumina in the blend of abrasive particles can be within a range including any of minimum and maximum percentages disclosed herein. For instance, the content of brown alumina can be within a range of at least 1 wt% to not greater than 99 wt%, such as within a range of at least 10 wt% to not greater than 90 wt%, within a range of at least 20 wt% to not greater than 70 wt%, or within a range of at least 30 wt% to not greater than 50 wt%.

In an embodiment, the mixture can include at least 15 wt% bond material for a total weight of the mixture, such as at least 20 wt%, at least 27 wt%, or at least 32 wt% bond material for a total weight of the mixture. In other embodiments, the mixture can include not greater than 43 wt% bond material for a total weight of the mixture, not greater than 39 wt% bond material for a total weight of t he mixture, or not greater than 35 wt% bond material for a total weight of the mixture. It will be appreciated that the content of bond material can be within a range between any of the percentages noted above. For example, the mixture can include an amount of bond material within a range of at least 15 wt% to not greater than 43 wt% for a total weight of the mixture, such as within a range of at least 20 wt% to not greater than 35 wt% for a total weight of the mixture.

In an embodiment, the bond material can include an organic material, such as a resin. In certain situations, the bond material can include at least 30 wt% of a resin bond material for a total weight of the bond material, such as at least 38 wt%, at least 40 wt%, at least 46 wt%, or at least 52 wt% of a resin bond material for a total weight of the bond material. In other instances, the bond material can include not greater than 67 wt% of a resin bond material for a total weight of the bond material, not greater than 61 wt% of a resin bond material for a total weight of the bond material, or not greater than 56 wt% of a resin bond material for a total weight of the bond material, it will be appreciated that the content of resin bond material can be within a range including any of the minimum and maximum percentages noted above. For example, the content of a resin bond material can be within a range of at least 30 wt% to not greater than 67 wt% of a total weight of the bond material. In another particular illustrative embodiment, the resin bond material can include an epoxy resin, a polyester resin, a phenolic resin, a cyanate ester resin, a polyurethane resin, shellacs, or a combination thereof.

In another embodiment, the mixture can include at least 4.5 wt% resin bond material for a total weight of the mixture, such as at least 6 wt%, at least 11 wt%, or at least 14 wt% resin bond material for a total weight of the mixture. Additionally, the mixture can include not greater than 31 wt% resin bond material for a total weight of the mixture, such as not greater than 24 wt%, not greater than 19 wt%, or not greater than 17 wt % resin bond material for a total weight of the mixture. It will be appreciated that the content of the resin bond material can be within a range including any of the minimum and maximum percentages noted above, such as within a range of at least 4.5 wt% to not greater than 1 wt% or within a range of at least 6 wt% to not greater than 24 wt% for a total weight of the mixture.

Furthermore, the resin bond material can be provided to the mixture as a liquid, a solid, or both. In an embodiment, the mixture can include a liquid phenolic resin, such as a resole resin, and a powdered phenolic resin, such as a novolac resin. In one illustrative embodiment, the powdered resin can include hexamine within a range of at least 6 wt% to not greater than 14 wt% for a total weight of the powdered resin. In certain embodiments, a ratio of powdered resin to liquid resin by weight can be at least 1 : 1, at least 1.5: 1, at least 2: 1, or at least 3: 1. In other embodiments, a ratio of powder resin to liquid resin by weight can be not greater than 6: 1, not greater than 5: 1, or not greater than 4: 1. In another non- limiting embodiment, the resin bond material may consist essentially of powder resin.

The bond material can also include a filler composition, which can include one or more compositions in certain contents and relative ratios that may facilitate improved performance of the abrasive article. In certain aspects, the bond material can include at least 33 wt% filler composition for a total weight of the bond material, such as at least 39 wt%, at least 44 wt%, or at least 48 wt%. In other aspects, the bond material can include not greater than 70 wt% filler composition for a total weight of the bond material, such as not greater than 68 wt , not greater than 65 wt%, not greater than 60 wt%, not greater than 57 wt%, or not greater than 52 wt%. It will be appreciated that the content of the filler composition can be within a range between any of the values noted above. In a particular illustrative embodiment, the content of the filler can be within a range of at least 33 wt% to not greater than 70 wt% or within a range of at least 44 wt% to not greater than 68 wt% for a total weight of the bond material.

In an additional embodiment, the mixture can include at least 4 wt% filler

composition for a total weight of the mixture, such as at least 5 wt%, at least 9 wt%, or at least 14 wt%. Additionally, the mixture can include not greater than 25 wt% filler composition for a total weight of the mixture, such as not greater than 23 wt%, not greater than 19 wt%, or not greater than 15 wt %. It will be appreciated that the content of the filler composition can be within a range between any of the values noted above. For example, the mixture can include a content of the filler composition within a range including any of the minimum and maximum percentages disclosed herein. For instance, the mixture can include a content of the filler composition within a range of at least 4 wt% to not greater than 25 wt%, such as within a range of at least 5 wt% to not greater than 23 wt% or within a range of at least 9 wt% to not greater than 19 wt%.

The filler composition can include a material selected from the group consisting of powders, granules, spheres, fibers, and a combination thereof. In an embodiment, the filler can include a material selected from the group consisting of an inorganic material, an organic material, and a combination thereof. In a further embodiment, the filler can include a material selected from the group consisting of sand, bubble alumina, bauxite, chromites, magnesite, dolomites, bubble mullite, bo rides, titanium dioxide, carbon products (e.g., carbon black, coke or graphite), wood flour, clay, talc, hexagonal boron nitride, molybdenum disulfide, feldspar, nepheline syenite, glass spheres, glass fibers, . 'i\F >. KBF₄, Cryolite (Na_::jAlF₆), a potassium aluminum fluoride, such as potassium Cryolite ( K iA! F_fJ. pyrites, ZnS, copper sulfide, a material including l-^' ^S. such as Pyrox, mineral oil, fluorides, carbonates, calcium carbonate, and a combination thereof. The filler composition can include materials having a hardness that is significant less than the hardness of the abrasive particles and can be completely distinct from the abrasive particles. For example, any of the materials of the filler composition can have a Mohs hardness less than 7, such as less than 6 or even less than 5. In a particular embodiment, the filler composition can include pyrite. More particularly, the pyrite can include a sulfur content of at least 43 wt% for a total weight of the pyrite, which may facilitate improved grinding performance of the abrasive article. For instance, the pyrite can include at least 44 wt% sulfur for a total weight of the pyrite, such as at least 45 wt% or at least 46 wt% or at least 47 wt% or at least 48 wt% or at least 49 wt% or at least 50 wt%. In another embodiment, the pyrite can include a content of sulfur of not greater than 70 wt% for a total weight of the pyrite, s ch as not greater than 65wt% or not greater than 63 wt% or not greater than 60 wt% or not greater than 58 wt% or not greater than 55 wt% or not greater than 53 wt%. It will be appreciated that the pyrite can include a content of sulfur in a range including any of the minimum and maximum percentages disclosed herein. For example, the content of sulfur in the pyrite can be within a range of at least 44 wt% to not greater than 70 wt%, such as within a range of at least 46 wt% to not greater than 65 wt%, within a range of at least 48 wt% to not greater than 63 wt%, or within a range of at least 49 wt% to not greater than 58 wt%. It will be appreciated that reference herein to pyrite is reference to a high-sulfur content pyrite, which can have any of the features of the embodiments disclosed herein.

According to another aspect, the pyrite can have a particular density that may facilitate improved performance of the abrasive article. For example, the pyrite can have a density of at least 4.60 g/cm³ , such as at least 4.65 g/cm^J, at least 4.70 g/cm³, at least 4.75 g/cm³, or at least 4.80 g/cm³. in another aspect, the pyrite may have a density of not greater than 5.60 g/cm³, such as not greater than 5.50 g/cm³, not greater than 5.40 g cm³, not greater than 5.30 g/cm³, not greater than 5.20 g/cm³, not greater than 5.10 g/cm^J, not greater than 5.00 g/cm³, or not greater than 4.75 g/cm^J. It will be appreciated that the pyrite can have a density in a range including any of the minimum and maximum values noted herein. For instance, the pyrite can have a density within a range of at least 4.60 g/cm³ to not greater than 5.60 g/cm³, such as within a range of at least 4.65 g/cm³ to not greater than 5.50 g/cm³ or within a range of at least 4.70 g/cm ¹ to not greater than 5. 10 g/cm³.

According to an aspect, the pyrite (FeS₂) can have a sulfur-to-iron ratio (S/Fe) of at least 1.00 based on the weight percent of sulfur and iron in the pyrite, such as at least 1.01 or at least 1.02, which may facilitate improved performance of the abrasive article. In another aspect, the pyrite may include a sulfur to iron ratio of not greater than 2.00 based on the weight percent o sul ur and iron in the pyrite. such as not greater than 1.80 or not greater than 1.50 or not greater than 1.20 or not greater than 1.10. It will be appreciated that the pyrite can have a sulfur to iron ratio within a range including any of the minimum and maximum values disclosed herein. For instance, the pyrite can have a sulfur to iron ratio within a range of at least 1.00 to not greater than 2.00, such as within a range of at least 1.10 to not greater than 1.50.

According to an aspect, the pyrite may have an average particle size that may facilitate improved performance of the abrasive article. For example, the pyrite may have an average particle size of not greater than 80 microns, such as not greater than 75 microns, not greater than 70 microns, not greater than 65 microns, not greater than 60 microns, not greater than 55 microns, or not greater than 50 microns. In another instance, the pyrite can have an average particle size of at least 15 microns, such as at least 17 microns, at least 20 microns, at least 23 microns, at least 25 microns, or at least 30 microns. It will be appreciated that the pyrite can have an average particle size within a range including any of the minimum and maximum values disclosed herein. For instance, the pyrite can have an average particle size within a range of at least 15 microns to 80 microns, such as within a range of at least 20 microns to 70 microns, within a range f at least 25 microns to 60 microns, or within a range of at least 30 microns to 50 microns.

In an embodiment, the mixture can include a content of the pyrite of at least, 10 wt% for a total weight of the mixture, such as at least 11 wt% or at least 12 wt%, which may facilitate improved performance of the abrasive article. In another embodiment, the content of the pyrite in the mixture may be not greater than 25 wt% for a total weight of the mixture, such as, not greater than 22 wt%, not greater than 18 wt%, or not greater than 15 wt%. It is to be appreciated that the mixture can include a content of the pyrite in a range including any of the minimum and maximum percentages disclosed herein. For example, the content of the pyrite in the mixture can be within a range of at least 10 wt% to not greater than 25 wt%, such as within a range of at least 1 1 wt% to not greater than 15 wt% for a total weight of the mixture.

In a further embodiment, the bond material can include a content of the pyrite of at least 31 wt% for a total weight of the bond material, such as at least 32 wt% or at least 34 wt%, which may facilitate improved performance of the abrasive article. In another embodiment, the bond material may include a content of the pyrite of not greater than 56 wt% for a total weight of the bond material, such as not greater than 50 wt%, not greater than 45 wt%, not greater than 40 wt%, not greater than 39 wt% or not greater than 37 wt%. It is to be appreciated that the bond material can include a content of the pyrite in a range including any of the minimum and maximum percentages disclosed herein. For example, the content of the pyrite in the bond material can be within a range of at least 31 wt% to not, greater than 56 wt%, such as 32 wt% to 40 wt% for a total weight of the bond material.

In another embodiment, the filler composition can include pyrite disclosed herein and at least one of sodium aluminum fluoride (also known as cryolite), potassium aluminum fluoride, and calcium carbonate. In a particular embodiment, the filler composition can consist essentially of pyrite. sodium aluminum fluoride, potassium aluminum fluoride, and calcium carbonate. In certain instances, a filler composition consisting essentially of pyrite, sodium aluminum fluoride, potassium aluminum fluoride, and calcium carbonate may facilitate formation of an abrasive article having improved performance. In some other instances, sodium aluminum fluoride can be used in a filler composition to replace potassium aluminum fluoride. Accordingly, in an application, a filler composition may not include potassium aluminum fluoride, and can consist essentially of pyrite, sodium aluminum fluoride, and calcium carbonate. In another application, potassium aluminum fluoride can be used to replace sodium aluminum fluoride. For instance, a filler composition may not include sodium aluminum fluoride, and can consist essentially of pyrite. potassium aluminum fluoride, and calcium carbonate. However, it will be appreciated that in other embodiments, the filler composition can include other filler materials as described herein.

In an embodiment, the mixture can include a particular content of potassium aluminum fluoride that may facilitate formation of an abrasive article having improved properties. For example, the mixture can include a content of potassium aluminum, fluoride of at least 1 wt% for a total weight of the mixture, such as at least 1.5 wt% or at least 2 wt%. In another embodiment, the mixture may include a content of potassium aluminum fluoride of not greater than 4.5 wt% for a total weight of the mixture, such as not greater than 4 wt% or not greater than 3.5 wt% or not greater than 3 wt%. It is to be appreciated that the mixture can include a content of the potassium aluminum fluoride in a range including any of the minimum and maximum percentages disclosed herein. For example, the content of potassium aluminum fl oride in the mixture can be within a range of at least 1 wt% to not greater than 4.5 wt%, such as at least 1.5 wt% to not greater than 3 wt% for a total weight of t he mixture.

In certain instances, particularly, when a filler composition may not include sodium aluminum fluoride, the mixture can include a content of potassium aluminum, fluoride that may facilitate formation of an abrasive article having improved properties, such as not greater than 12.5 wt% for a total weight of the mixture, not greater than 1 1 wt% or not greater than 10 wt%. In another instance, a content of potassium aluminum fluoride can be at least 4 wt%, such as at least 5 wt% or at least 6 wt%. It is to be appreciated that the mixture can include a content of the potassium aluminum fluoride in a range including any of the minimum and maximum percentages disclosed herein for certain applications when a filler composition may not include sodium aluminum fluoride. For example, a content of potassium aluminum fluoride in the mixture can be within a range of at least 4 wt% to not greater than 12.5 wt%, such as at least 6 wt% to not greater than 1 1 wt% for a total weight of the mixture.

In an embodiment, the bond material can include a particular content of potassium aluminum fluoride that may facilitate improved performance of the abrasive article. For example, the bond material can include a content of potassium aluminum fluoride of at least 5 wt% for a total weight of the bond material, such as at least 5.5 wt% or at least 6 wt%. In another embodiment, the bond material may include a content of potassium aluminum fluoride of not greater than 10 wt% for a total weight of the bond material, such as not greater than 9 wt% or not greater than 8.5 wt%. It is to be appreciated that the bond material can include a content of the potassium aluminum fluoride in a range including any of the minimum and maximum percentages disclosed herein. For example, the content of potassium aluminum fluoride in the bond material can be within a range of at least 5 wt% to not greater than 10 wt%, such as at least 6 wt% to not greater than 8.5 wt% for a total weight of the bond material.

In certain instances, particularly, when a filler composition may not include sodium aluminum fluoride, the bond material can include a particular content of potassium aluminum fluoride, such as at least 15 wt% for a total weight of the bond material, that may facilitate formation of an abrasive article having improved properties. For instance, the bond material can include at least 16.5 wt% or at least 18 wt% potassium aluminum fluoride for a total weight of the bond material, in another instance, a content of potassium aluminum fluoride may be not greater than 28 wt%, such as not greater than 25 or not greater than 23 wt%. It is to be appreciated that the bond material can include a content of the potassium aluminum fluoride in a range including any of the minimum and maximum percentages disclosed herein. For example, the content of potassium aluminum fluoride in the bond material can be within a range of at least 15 wt% to 28 wt%, such as within a range of at least 16.5 wt% to 25 wt% or within a range of at least 18 wt% to not greater than 23 wt%. [

In an embodiment, the mixture can include a particular content of sodium aluminum fluoride (Cryolite ) that may facilitate improved performance of the abrasive article. For example, the mixture can include a content of sodium aluminum fluoride of at least 3 wt% for a total weight of the mixture, such as at least 3.5 wt% or at least 4 wt% or at least 4.5 wt%. In another embodiment, the mixture may include a content of sodium aluminum fluoride of not greater than 8 wt% for a total weight of the mixture, such as not greater than 7 wt% or not greater than 6.5 wt% or not greater than 6 wt%. It is to be appreciated that the mixture can include a content of the sodium aluminum fluoride in a range including any of the minimum and maximum percentages disclosed herein. For example, the content of sodium aluminum fluoride in the mixture can be within a range of at least 3 wt% to not greater than 8 wt%, such as at least 4 wt% to not greater than 6.5 wt% for a total weight of the mixture.

In certain instances, particularly, when a filler composition may not include potassium aluminum fluoride, the mixture can include a particular content of sodium aluminum fluoride that may facilitate formation of an abrasive article having improved properties. For instance, a content of sodium aluminum fluoride may be not greater than 12.5 wt% for a total weight of the mixture, such as not greater than 1 1 wt% or not greater than 10 wt%. In another instance, a content of sodium aluminum fluoride can be at least 4 wt%, such as at least 5 wt% or at least 6 wt%. It is to be appreciated that the mixture can include a content of the sodium aluminum fluoride in a range including any of the minimum and maximum percentages disclosed herein for certain applications when a filler composition may not include potassium, aluminum fluoride. For example, a content of sodium aluminum fluoride in the mixture can be within a range of at least 4 wt% to not greater than 12.5 wt%, such as at least 6 wt% to not greater than 1 1 wt% for a total weight of the mixture.

In an embodiment, the bond material can include a particular content of sodium aluminum fluoride that may facilitate improved performance of the abrasive article. For example, the bond material can include a content of sodium aluminum fluoride of at least 10 wt% for a total weight of the bond material, such as at least 11 wt% or at least 12 wt% or at, least 13.5 wt%. In another embodiment, the bond material may include a content of sodium aluminum fluoride of not greater than 1 8 wt% for a total weight of the bond material, such as not greater than 17 wt% or not greater than 16.5 wt% or not greater than 15.5 wt%. It is to be appreciated that the bond material can include a content of the sodium aluminum fluoride in a range including any of the minimum and maximum percentages disclosed herein. For example, the content of sodium al min m fluoride in the bond material can be within a range of at least 10 wt% to not greater than 18 wt%, such as at least 12 wt% to not, greater than 16.5 wt% for a total weight of the bond material.

In certain instances, particularly, when a filler composition may not include potassium aluminum fluoride, the bond material can include a particular content of sodium aluminum fluoride that may facilitate formation of an abrasive article having improved properties. For instance, the bond material can include a content of sodium aluminum fluoride of at least 15 wt% for a total weight of the bond material, such as at least 16.5 wt% or at least 18 wt%. In another instance, a content of sodium aluminum fluoride may be not greater than 28 wt%, such as not greater than 25 or not greater than 23 wt%. It is to be appreciated that the bond material can include a content of the sodium aluminum fluoride in a range including any of the minimum and maximum percentages disclosed herein. For example, the content t sodium aluminum fluoride in the bond material can be within a range of at least 15 wt% to 28 wt%, such as within a range of at least 16.5 wt% to 25 wt% or within a range of at least 18 wt% to not greater than 23 wt%.

In an embodiment, the mixture may include a particular content of calcium carbonate that may facilitate improved performance of the abrasive article. For instance, the mixture can include a content of calcium carbonate of not greater than 0.3 wt% for a total weight of the mixture, such as not greater than 0.2 wt% or not greater than 0.1 wt%. In another embodiment, the mixture can include a content of calcium carbonate of at least 0.04 wt% for a total weight of the mixture, such as at least 0.06 wt%. It is to be appreciated that the mixture can include a content of calcium carbonate in a range including any of the minimum and maximum percentages disclosed herein. For example, the content of calcium carbonate in the mixture can be within a range of at least 0.04 wt% to not greater than 1 wt%, such as at least 0.06 wt% to not greater than 0.1 wt% for a total weight of the mixture.

In an embodiment, the bond material may include a particular content of calcium carbonate that may facilitate improved performance of the abrasive article. For example, the bond material may include a content of calcium carbonate of not greater than 1 wt% for a total weight of the bond material, such as not greater than 0.5 wt% or not greater than 0.3 wt%. In another embodiment, the bond material can include a content of calcium carbonate of at least 0. 1 wt% for a total weight of the mixture, such as at least 0.2 wt%. It is to be appreciated that the bond material can include a content of calcium carbonate in a range including any of the minimum and maximum percentages disclosed herein. For example, the content of calcium carbonate in the bond material can be within a range of at least 0. 1 wt% to not greater than 1 wt%, such as within a range of at least 0.1 wt% to not greater than 0.3 wt% for a total weight of the bond material.

In some instances, the mixture can be combined in multiple steps. In an example, the abrasive particles are mixed with a liquid resin material to cause the liquid resin to coat the abrasive particles. A powdered phenolic resin and filler materials are separately blended in a mixer and the wetted abrasive particles are then added to and mixed with the blended powders to uniformly coat the wetted abrasive particles with the blended powders.

At 104, the method 100 includes placing the mixture into a mold. The mold can be made of stainless-steel, high carbon-steel, high chrome-steel, another suitable material, or a combination thereof. In some situations, one or more layers of the mixture can be placed into the mold, such as by linear or rotational spreading. In an illustrative embodiment, other components, such as one or more reinforcement layers, can be placed above, below, or both above and below, at least one of the layers of the mixture. In certain embodiments, a reinforcement, layer can comprise a material selected from, the group consisting of an organic material, an inorganic material, and a combination thereof. Additionally, the reinforcement layer can comprise a material selected from the group consisting of a fabric, a fiber, a film, a woven material, a non-woven material, a glass, a fiberglass, a ceramic, a polymer, a resin, a polymer, a fluorinated polymer, an epoxy resin, a polyester resin, a polyurethane, a polyester, a rubber, a polyimide, a polybenzimidazole, an aromatic polyamide, a modified phenolic resin, and a combination thereof.

At 106, the method 100 includes applying a pressing process to the mixture while in the mold. In situations when multiple abrasive layers are formed, each of the abrasive layers can be subjected to a respective pressing process. The pressing process can include a cold pressing process, a warm pressing process, or a hot pressing process. In an illustrative embodiment, a warm pressing process can be applied at a temperature within a range of at least 35°C to not greater than 75°C.

At 108, the method 100 includes heating the mixture to produce a cutting wheel. In some embodiments, the heating of the mixture to produce the cutting wheel may be optional.

FIG. 2 includes a view of a cutting wheel 200 in accordance with an embodiment. The cutting wheel 200 includes a body 202 and a mounting hole 204 for mounting the cutting wheel 200 to a cutting tool. A diameter 206 of the mounting hole 204 can be an inner diameter of the body 202 and the body 202 can have an outer diameter 208. In an embodiment, the outer diameter 208 can be at least 220 mm, at least 270 mm, at least 310 mm, at least 380 nm. or at least 415 mm. In another embodiment, the outer diameter 208 can be not greater than 535 mm, such as not greater than 457 mm, or not greater than 430 mm. It will be appreciated that, the outer diameter 208 of the body 202 can be within a range between any of the values noted above. For example, the outer diameter 208 of the body 202 can be within a range of at least 380 nm to not greater than 535 nm, such as within a range of at least 415 nm to not greater than 430 nm.

In certain aspects, the inner diameter 206 can be at least 35 mm, such as at least 46 mm or at least 54 mm. In other instances, the inner diameter 206 can be not greater than 90 mm. such as not greater than 77 mm, or not greater than 62 mm. It will be appreciated that the inner diameter 206 of the abrasi ve portion 202 can be within a range between any of the values noted above.

The body 202 can also have a thickness of at least 0.7 mm, such as at least 1.5 mm, or at least 1.9 mm. in some cases, the body can have a thickness of not greater than 6.5 mm, such as not greater than 5.7 mm, or not greater than 4.8 mm, or not greater than 3.5 mm, or not greater than 2.2 mm. It will be appreciated that the thickness of the body 202 can be within a range between any of the values noted above.

Furthermore, the body 202 can have a ratio of outer diameter 208 to thickness of at least 2: 1 , such as at least 3: 1 , at least 3.5: 1, at least 4: 1, at least 4.5: 1 , at least 5: 1, at least 6.5: 1 , at least 8: 1, at least 10: 1, or at least 15: 1. Additionally or alternatively, the ratio of outer diameter 208 to thickness may be not greater than 765: 1, such as not greater than 650: 1, not greater than 600: 1, not greater than 500: 1, not greater than 450: 1, not greater than 350: 1, not greater than 250: 1, not greater than 200: 1 , not greater than 160: 1, not greater than 150: 1, not greater than 140: 1, not greater than 130: 1 , or not greater than 125: 1. It is to be appreciated that the ratio of outer diameter to thickness can be within a range including any of the minimum ratio and maximum ratio noted above. For instance, the ratio can be within a range of at least 2.1 to not greater than 765: 1, such as within a range of at least 5: 1 to not greater than 500: 1 , within a range of at least at least 7.5: 1 to not greater than 250: 1 , or within a range of at least 125: 1 to not greater thanl5: 1.

The body 202 can include materials included in the mixture used to form the cutting wheel 200 as described previously with respect to FIG. 1. Additionally, the body 202 can also include one or more abrasive portions, which may be in the form of layers extending radially within the body 202. The abrasive portion can include the abrasive particles, the bond material, the filler composition, and any other additives that are used in the mixture. In certain instances, one or more reinforcement members, which may be in the form of a layer extending radially within the body, can be positioned adjacent to the one or more abrasive portions to separate the abrasive portions from one another. In certain constructions, one or more of the reinforcement members can be overlying or underlying material for an abrasive portion, in at least one embodiment, a reinforcement member can be in direct contact with an abrasive portion. In a particular embodiment, a reinforcement member can be bonded directly to and at least partially impregnating portions of an abrasive portion. In other designs of embodiments herein, at, least one abrasive portion (or a plurality of abrasive portions) can be disposed between a first reinforcement member and a second reinforcement member. According to one construction, a plurality of abrasive portions can be employed as discrete intervening layers separating at least first and second reinforcement members.

In some cases, the body 202 can include abrasive portions that may be made from the same mixture, and thus have substantially the same contents of abrasive particles, bond material, filler composition, and/or additives relative to each other. Still, it will be appreciated that in at least one embodiment, the body can include at least a first abrasive portion and a second abrasive portion, wherein the first abrasive portion can at least one feature that is distinct from the second abrasive portion, wherein such features can include content of abrasive particles, type of abrasive particles, content of bond material, type of bond material, content of filler composition, type of filler composition, and the like. It will be appreciated that any combination of reinforcement members and abrasive portions are contemplated herein.

FIG. 3 includes cross-sectional view of the cutting wheel 200 of FIG. 2 according to an embodiment. In the illustrative embodiment of FIG. 3, the cutting wheel has a mounting hole 204 and an abrasive portion 302. The abrasive portion 302 can include abrasive particles contained within a bond material and a filler composition contained within the bond material. The abrasive portion 302 can also have a thickness 304.

FIG. 4 includes a cross-sectional view of the cutting wheel 200 of FIG. 2 in accordance with another embodiment. In the illustrative embodiment of FIG. 4, the cutting wheel has a mounting hole 204, a first abrasive portion 402 and a second abrasive portion 404. The cutting wheel 200 can also include a reinforcement member 406. The first abrasive portion 402 and the second abrasive portion 404 can include abrasive particles contained within a bond material and a filler composition contained within the bond material. In some cases, the content of abrasive particles, the content of bond material, and the content of the filler composition contained within the bond material of the first abrasive portion 402 and the second abrasive portion 404 can be substantially the same, while in other situations, at least one of the content of the abrasive particles, the content of the bond material, and a filler composition contained within the bond material of the first abrasive portion 402 and the second abrasive portion 404 can be different.

The first abrasive portion 402 can have a thickness 408 and the second abrasive portion 404 can have a thickness 410. In addition, the reinforcement member 406 can have a thickness 412. In some scenarios, the thickness 408 can be substantially the same as the thickness 410, while in other embodiments, the thickness 408 can be different from the thickness 410. Furthermore, the thickness 412 can be substantially the same or different with respect to the thickness 408, the thickness 410, or both.

In an embodiment, an abrasive portion within the body can include at least 20 vo1% abrasive particles for the total volume of the abrasive portion, such as at least 25 vol% or at least 30 vol% or at least 35 vol% or at least 40 vol% or at least 45 vol% or at least 50 vol% or at least 55 vol% or at least 60 vol%. In another embodiment, the abrasive portion may include not greater than 90 vol% abrasive particles for a total volume of the abrasive portion, such as not greater than 85 vol% or not, greater than 80 vol% or not greater than 75 vol% or not greater than 70 vol% or not greater than 65 vol% or not greater than 60 vol% or not greater than 55 vol% or not greater than 50 vol%. It is to be understood that the abrasive portion can include abrasive particles in a range including any of the minimum and maximum percentages disclosed herein. For instance, the abrasive portion may include abrasive particles within a range of at least 20 vol% to not greater than 90 vol% abrasive particles for a total volume of the abrasive portion, such as within a range of at least 30 vol% to not greater than 80 vol% or within a range of at least 40 vol% to not greater than 70 vol%.

In an embodiment, the abrasive portion can include at least 5 vol% bond material for a total volume of the abrasive portion, such as at least 8 vol% or at least 10 vol% or at least 12 vol% or at least 15 vol% or at least 18 vol% or at least 20 vol% or at least 25 vol% or at least 30 vol% or at least 35 vol% or at least 40 vol% or at least 45 vol% or at least 55 vol% or at least 60 vol% or at least 65 vol%. In another embodiment, the abrasive portion may include not greater than 65 vol% bond material for a total volume of the abrasive portion, such as not greater than 60 vol% or not greater than 55 vol% or not greater than 50 vol% or not greater than 45 vol% or not greater than 40 vol% or not greater than 35 vol% or not greater than 30 vol% or not greater than 25 vol% or not greater than 20 vol% or not greater than 15 vol%. It is to be understood that the abrasive portion can include a content of the bond material in a range including any of the minimum and maximum percentages disclosed herein. For instance, the abrasive portion may include a content of the bond material within a range of at least 8 vol% to not greater than 65 vol% for a total volume of the abrasive portion, such as within a range of at least 12 vol% to not greater than 50 vol% or within a range of at least 20 vol% to not greater than 40 vol%.

In another embodiment, the abrasive portion can include at least 22 vol% of the resin bond material for a total volume of the abrasive portion, such as at least 29 vol% of the resin bond material for a total volume of the abrasive portion, or at least 34 vol% of the resin bond material for a total volume of the abrasive portion. Additionally, the abrasive portion can include not greater than 47 vol%, such as not greater than 42 vol%, or not greater than 37 vol% of the resin bond material for a total volume of the abrasive portion. It will be appreciated that the content of the resin bond material can be within a range between any of the values noted above. In a particular illustrative embodiment, the abrasive portion can include a resin bond material within a range of at least 28 vol% to not greater than 37 vol% for a total volume of the abrasive portion.

In an embodiment, the abrasive portion can include at least 1 vol% of a filler composition for a total volume of the abrasive portion, which may facilitate formation of an abrasive article having improved properties. The filler composition can be contained within the bond material. In more particular instances, the abrasive portion can include at least 2 vol%, such as at least 3 vol% or at least 5 vol% or at least 8 vol or at least 10 vol% or at least 12 vol% or at least 14 vol% or at least 16 vol% of a filler composition for an entire volume of the abrasive portion. In another embodiment, the abrasive port ion can include not greater than 25 vol% for a total volume of the abrasive portion, such as not greater than 20 vol% or not greater than 19 vol% or not greater than 18 vol% or not greater than 17 vol% or not greater than 16 vol% or not greater than 15 vol% or not greater than 14 vol% or not greater than 13 vol% or not greater than 12 vol%. It is to be understood that the abrasive portion can include a content of the filler composition in a range including any of the minimum and maximum percentages disclosed herein. For instance, the abrasive portion may include a content of the filler composition within a range of at least 1 vol% to not greater than 25 vol% for a total volume of the abrasive portion, such as within a range of at least 8 vol to not greater than 20 vol% or within a range of at least 12 vol% to not greater than 18 vol%.

In a particular embodiment, the abrasive portion can include the filler composition including pyrite. which may be a particular type of pyrite. and which may be present in a particular content that may facilitate formation of an abrasive article having improved properties. In an embodiment, the abrasive portion can include at least 1 vol% pyrite for a total volume of the abrasive portion, such as at least 2 vol% or at least 3 vol% or at least 4 vol or at least 5 vol% or at least 6 vol% or at least 7 vol%. In another embodiment, the abrasive portion may include not greater than 20 vol% pyrite for a total volume of the abrasive portion, such as not greater than 18 vol% or not greater than 16 vol% or not greater than 14 vol% or not greater than 12 vol% or not greater than 10 vol%. It is to be understood that the abrasive portion can include a content of pyrite in a range including any of the minimum and maximum percentages disclosed herein. For instance, the abrasive portion may include a content of pyrite within a range of at least 1 vol% to not greater than 20 vol%, such as within a range of at least 4 vol% to not greater than 1 8 vol% or within a range of at least 6 vol% to not greater than 16 vo1%.

In an embodiment, the filler composition within the abrasive portion can include a particular content of sodium aluminum fluoride that may facilitate formation of an abrasive article having improved properties. For example, the abrasive portion may include at least 1 vol sodium aluminum fluoride for a total volume of the abrasive portion 202, such as at least 2 vol% or at least 3 vol% or at least, 4 vol%. In another embodiment, the abrasive portion may include not greater than 20 vol% sodium aluminum fluoride for a total volume of the abrasive portion 202, such as not greater than 18 vol% or not greater than 16 vol% or not greater than 14 vol% or not greater than 12 vol% or not greater than 10 vol% or not greater than 8 vol% or not greater than 6 vol%. It is to be understood that the abrasive portion 202 can include a content of sodium aluminum fluoride in a range including any of the minimum and maximum percentages disclosed herein. For instance, the abrasive portion may include a content of sodium aluminum fluoride within a range of at, least 1 vol% to not greater than 20 vol%, such as within a range of at least 2 vol% to not greater than 14 vol% or within a range of at least 3 vol% to not greater than 12 vol%.

In an embodiment, the filler composition within the abrasive portion can include a particular content of potassium aluminum fluoride that may facilitate formation of an abrasive article having improved properties. For example, the abrasive portion can include at least 0.5 vol% potassium aluminum fluoride for a total volume of the abrasive portion, such as at least 1 vol% or at least 1.5 vol% or at least 2 vol%. In another embodiment, the abrasive portion may include not greater than 10 vol% potassium aluminum fluoride for a total volume of the abrasive portion, such as not greater than 8 vol% or not greater than 6 vol% or not greater than 5 vol% or not greater than 4 vol% or not greater than 3 vol%. It is to be understood that the abrasive portion can include a content of potassium aluminum fluoride in a range including any of the minimum and maximum percentages disclosed herein. For instance, the abrasive portion may include a content of potassium aluminum fluoride within a range of at least 0.5 vol% to not greater than 10 vol%, such as within a range of at least 1 vol% to not greater than 8 vol% or within a range of at least 2 vol% to not greater than 6 vol%.

In an embodiment, the filler composition within the abrasive portion can include a particular content of calcium carbonate that may facilitate formation of an abrasive article having improved properties. For example, the abrasive portion can include at least 0.001 vol% calcium, carbonate for a total volume of the abrasive portion, such as at least 0.005 vol% or at least 0.01 vol%. In another embodiment, the abrasive portion may include not greater than 10 vol% calcium carbonate for a total volume of the abrasive portion, such as not greater than 8 vol% or not greater than 6 vol% or not greater than 4 vol% or not greater than 2 vol% or not greater than 1 vol% or not greater than 0.8 vol% or not greater than 0.5 vol%. It is to be understood that the abrasive portion can include a content of calcium carbonate in a range including any of the minimum and maximum percentages disclosed herein. For instance, the abrasive portion may include a content of calcium carbonate within a range of at least 0.001 vol% to not greater than 10 vol%, such as within a range of at least 0.005 vol% to not greater than 4 vol% or within a range of at least 0.01 vol% to not greater than 2 vol%.

In an embodiment, the abrasive portion can include a content (vol%) of pyrite that is greater than a content (vol%) of sodium aluminum fluoride. For instance, the filler composition can include a certain ratio of pyrite to sodium aluminum fluoride, which may facilitate improved performance of the abrasive article. In this disclosure, sodium aluminum fluoride is also referred to as cryolite (Py/Cryolite). The ratio of pyrite to sodium aluminum fluoride(Py/Cryolit,e) can be at, least 1, such as at least or at least 1.1 or at least, 1.2 or at least 1.3 or at least 1.4, which may facilitate improved performance of the abrasive article. In still another embodiment, the filler composition may include a ratio o pyrite to sodium aluminum fluoride (Py/ Cryolite) of not greater than 10, such as not greater than 8 or not greater than 7 or not greater than 5 or not greater than 3 or not greater than 2. It is to be understood that the filler composition can include a ratio of pyrite to sodium aluminum fluoride (Py/Cryolite) in a range including any of the minimum and maximum values disclosed herein. For instance, the ratio of pyrite to sodium aluminum fluoride (Py/Cryolite) can be within a range of at least 1.1 to not greater than 10, such as within a range of at least 1.3 to not greater than 5.

In an embodiment, the abrasive portion can include a content (vol%) of pyrite that is greater than a content (vol%) of potassium aluminum fluoride. In another embodiment, the filler composition can include a ratio of pyrite to potassium aluminum fluoride (Py/PAF) of at least 1, such as at least 1.2 or at least 1.3 or at least 1.8 or at least 2 or at least 2.4 or at least 2.8 or at least 3, which may facilitate improved performance of the abrasive article. In still another embodiment, the filler composition may include a ratio of pyrite to potassium aluminum fluoride (Py/PAF) of not greater than 10, such as not, greater than 8 or not, greater than 7 or not greater than 5 or not greater than 4. It is to be understood that the filler composition can include a ratio of pyrite to potassium aluminum fluoride (Py/PAF) in a range including any of the minimum and maximum values disclosed herein. For instance, the ratio of pyrite to potassium, aluminum fluoride (Py/PAF) can be within a range of at, least 1.2 to not greater than 10, such as within a range of at least 2 to 7 or within a range of at least 3 to not greater than 5. %.

In an embodiment, the abrasive portion can include a content (vol%) of sodium aluminum fluoride that is greater than a content (vol%) of potassium aluminum, fluoride. In another embodiment, the filler composition can include a ratio of sodium aluminum fluoride to potassium aluminum fluoride (Cryolite/PAF) of at least 1 or at least or at least 1. 1 or at least 1.3 or at least 1.5 or at least 1.8 or at least 2, which may facilitate improved performance of the abrasive article. In still another embodiment, the filler composition may include a ratio of pyrite to potassium aluminum fluoride (Cryolite/PAF) of not greater than 10, such as not greater than 8 or not greater than 7 or not greater than 5 or not greater than 4 or not greater than 3. It is to be understood that the filler composition can include a ratio of sodium aluminum fluoride to potassium aluminum fluoride (Cryolite/PAF) in a range including any of the minimum and maximum values disclosed herein. For instance, the ratio of sodium aluminum fluoride to potassium aluminum fluoride (Cryolite/PAF) can be within a range of at least 1 to not greater than 10, such as within a range of at least 1.3 to not greater than 7 or within a range of at least 1.8 to not greater than 4.

In an embodiment, the abrasive portion can include a content (vol%) of pyrite in the abrasive portion that is greater than a content (vol%) of calcium carbonate. In another embodiment, the filler composition can include a ratio of pyrite to calcium carbonate (Py/CC) of at least 1, such as at least 1.5 or at least 2 or at least 3 or at least 5 or at least 10 or at least 20 or at least 50 or at least 80 or at least 100, which may facilitate improved performance of the abrasive article. In still another embodiment, the filler composition may include a ratio of pyrite to calcium carbonate (Py/CC) of not greater than 1000, such as not greater than 800 or not greater than 700 or not greater than 500 or not greater than 300. It is to be understood that the filler composition can include a ratio of pyrite to calcium carbonate (Py/CC) in a range including any of the minimum and maximum values disclosed herein. For instance, the ratio of pyrite to calcium carbonate (Py/CC) can be within a range of at least 1 to not greater than 1000, such as within a range of at least 5 to not greater than 800 or within a range of at least 10 to not greater than 500.

In an embodiment, the abrasive portion can include a content (vol%) of sodium aluminum fluoride in the abrasive portion that is greater than a content (vol%) of calcium carbonate. In another embodiment, the filler composition can include a ratio of sodium aluminum fluoride to calcium carbonate (Cryolite/CC) of at least 1 or at least or at least 2 or at least, 3 or at least 5 or at least 10 or at least 20 or at least 40 or at least 60, which may facilitate improved performance of the abrasive article, in still another embodiment, the filler composition may include a ratio of sodium aluminum fluoride to calcium carbonate

(Cryolite/CC ) of not greater than 1000 or not greater than 700 or not greater than 500 or not greater than 200 or not greater than 100. It is to be understood that the filler composition can include a ratio of pyrite to calcium carbonate (Cryolite/CC) in a range including any of the minimum and maximum values disclosed herein. For instance, the ratio of sodium aluminum fluoride to calcium carbonate (Cryolite/CC) can be within a range of at least 1 to not greater than 1000, such as within a range of at least 5 to not greater than 700 or within a range of at least 10 to not greater than 500.

In an embodiment, the abrasive portion can include a content (vol%) of potassium aluminum fluoride in the abrasive portion that is greater than a content (vol%) of calcium carbonate. In another embodiment, the filler composition can include a ratio of potassium aluminum fluoride to calcium carbonate (PAF/CC) of at least 1 or at least or at least 2 or at least 3 or at least 5 or at least 10 or at least 20 or at least 30, which may facilitate improved performance of the abrasi ve article. In still another embodiment, the filler composition may include a ratio of potassium aluminum fluoride to calcium carbonate (PAF/CC) of not greater than 200 or not greater than 1 0 or not greater than 100 or not greater than 70 or not greater than 50. It is to be understood that the filler composition can include a ratio of pyrite to calcium carbonate (PAF/CC) in a range including any of the minimum and maximum values disclosed herein. For instance, the ratio of sodium aluminum fluoride to calcium carbonate (PAF/CC) can be within a range of at least 1 to not greater than 200, such as within a range of at least 5 to not greater than 100 or within a range of at least 10 to not greater than 70.

In a particular embodiment, the abrasive portion can include the filler composition within the bond material including pyrite, sodium aluminum fluoride potassium aluminum fluoride, calcium carbonate, wherein a content (vol%) of pyrite is greater than a content (vol%) of sodium aluminum fluoride, the content (vol%) of sodium aluminum fluoride is greater than a content (vol%) of potassium aluminum fluoride, and the content (vol%) of potassium aluminum fluoride is greater than a content (vol%) of calcium carbonate.

In an embodiment, the abrasive portion can include an amount of porosity, such as at least 6 vol% porosity for a total volume of the abrasive portion, at least 11 vol% porosity, or at least 14 vol% porosity. In additional cases, the abrasive portion can include not greater than 3 1 vol% porosity for a total volume of the abrasive portion, such as not greater than 25 vol% porosity or not greater than 20 vol% porosity. It will be appreciated that the porosity of the abrasive portion can be within a range between any of the values noted above. In a particular illustrative embodiment, the porosity of the abrasive portion can be within a range of at least 14 vol% to not greater than 25 vol% for a total volume of the abrasive portion 202.

FIG. 5 incl des a cross-sectional view of the cutting wheel 200 of FIG. 2 in accordance with an additional embodiment. In the illustrative embodiment of FIG. 5, the cutting wheel 200 includes a mounting hole 204. a first reinforcement member 502 and a second reinforcement member 504. The cutting wheel 200 also includes an abrasive portion 506.

FIG. 6 includes a cross-sectional view of the cutting wheel 200 of FIG. 2 having a depressed center configuration in accordance with an embodiment. In the illustrative embodiment of FIG. 6, the cutting wheel 200 includes a mounting hole 204 having a diameter 206 and an abrasive portion 602 having a thickness 604. The cutting wheel 200 also includes an outer diameter 208.

FIG. 7 includes a cross-sectional view of the cutting wheel 200 of FIG. 2 having a depressed center configuration in accordance with another embodiment. In the illustrative embodiment of FIG. 7, the cutting wheel 200 includes a mounting hole 204. The cutting wheel 200 also includes a first abrasive portion r 702 and a second abrasive portion 704. Additionally, the cutting wheel 200 includes a first reinforcement member 706 and a second reinforcement member 708. Further, the first abrasive portion 702 and the second abrasive portion 704 can each have a respective thickness, such as thickness 710. The first, reinforcement member 706 and the second reinforcement member 708 can each have a respective thickness, such as thickness 712.

FIG. 8 includes a cross-sectional view of the cutting wheel 200 of FIG. 2 having a depressed center configuration in accordance with an additional embodiment. In the illustrative embodiment of FIG. 8, the cutting wheel 200 includes a mounting hole 204, a first abrasive portion 802, and a second abrasive portion 804. The cutting wheel 200 also includes a first reinforcement member 806, a second reinforcement member 808, and a third reinforcement member 810. In some cases, as in the illustrative embodiment of FIG. 8, a portion of the second abrasive portion 804 can be in contact with the third reinforcement member 810.

FIG. 9 includes a cross-sectional view of the cutting wheel 200 of FIG. 2 having a depressed center configuration in accordance with a further embodiment. In the illustrative embodiment of FIG. 9, the cutting wheel 200 includes a mounting hole 204, a first abrasive portion 902, a second abrasive portion 904, and a third abrasive portion 906. The cutting wheel 200 also includes a first reinforcement member 908 and a second reinforcement member 910.

Many different aspects and embodiments are possible. Some of those aspects and embodiments are described herein. After reading this specification, skilled artisans will appreciate that those aspects and embodiments are only illustrative and do not limit the scope of the present invention. Embodiments may be in accordance with any one or more of the embodiments as listed below.

Embodiment 1. An abrasive article comprising:

a body including and abrasive portion comprising:

a bond material;

abrasive particles contained within the bond material; and

a filler composition within the bond material including pyrite, wherein the pyrite has a sulfur content, of at, least 43 wt,% for a total weight of the pyrite.

Embodiment 2. An abrasive article comprising:

a body including an abrasive portion comprising

a bond material;

abrasive particles comprising brown alumina contained within the bond material; and a filler composition within the bond material including pyrite, wherein the pyrite has a sulfur content of at least 43 wt% for a total weight of the pyrite.

Embodiment 3. An abrasive article comprising:

a body including an abrasive portion comprising:

a bond material comprising an organic material;

abrasive particles comprising brown alumina contained within the bond material; and a filler composition within the bond material including pyrite, sodium aluminum fluoride, potassium aluminum fluoride, and calcium carbonate, wherein a content (vol%) of pyrite is greater than a content (vol%) of sodium aluminum fluoride, wherein the content

(vol%) of sodium aluminum fluoride is greater than a content (vol%) of potassium aluminum fluoride, and wherein the content (vol%) of potassium aluminum fluoride is greater than a content (vol%) of lime.

Embodiment 4. The abrasive article of any one of embodiments 1 , 2, and 3, wherein the abrasive portion comprises at least 20 vol% abrasive particles for the total volume of the abrasive portion or at least 25 vol% or at least 30 vol% or at least 35 vol% or at least 40 vol% or at least 45 vol% or at least 50 vol% or at least 55 vol% or at least 60 vol%.

Embodiment 5. The abrasive article of any one of embodiments 1, 2, and 3, wherein the abrasive portion comprises not greater than 90 vol% abrasive particles for a total volume ot^* the abrasive portion or not greater than 85 vol% or not greater than 80 vol% or not greater than 75 vol% or not greater than 70 vol% or not greater than 65 vol% or not greater than 60 vol% or not greater than 55 vol% or not greater than 50 vol%.

Embodiment 6. The abrasive article of any one of embodiments 1 and 2, wherein the abrasive particles include brown alumina.

Embodiment 7. The abrasive article of any one of embodiments 3 and 6. wherein the brown alumina includes at least 88 wt% alumina for a total weight of the abrasive particles or at least 90 wt% or at least 92 wt% or at least 95 wt%.

Embodiment 8. The abrasive article of embodiment 7, wherein the brown alumina includes not greater than 99.0 wt% alumina for a total weight of the abrasive particles.

Embodiment 9. The abrasive article of any one of embodiments 3 and 6, wherein the brown alumina includes a content of silica not, greater than 5 wt% for a total weight of the abrasive particles or not greater than 4 wt% or not greater than 3 wt%.

Embodiment 10. The abrasive article of any one of embodiments 3 and 6. wherein the brown alumina includes a content, of iron oxide of not greater than 4 wt% for a total weight of the abrasive particles or not greater than 3 wt% or not, greater than 2 wt% or not greater than 1 wt% or not greater than 0.5 wt%.

Embodiment 11. The abrasive article of embodiments 10, wherein the brown alumina includes at least, 0.1 wt% of iron oxide for a total weight of the abrasive particles.

Embodiment 12. The abrasive article of any one of embodiments 3 and 6, the brown alumina includes a content of titanium oxide of not greater than 4 wt% for a total weight of the abrasive particles or not greater than 3 wt% or not greater than 2 wt or not greater than 1 wt% or not greater than 0.5 wt,%.

Embodiment 1 . The abrasive article of embodiment 12. wherein the brown alumina includes at least 0. 1 wt% of titanium oxide for a total weight of the abrasive particles.

Embodiment 14. The abrasive article of any one of embodiments 3 and 6, wherein the brown alumina includes at least 88 wt% alumina for a total weight of the abrasive particles, or at least 90 wt% or at least 92 wt% or at least 95 wt%.

Embodiment 15. The abrasive article of any one of embodiments 3 and 6, wherein the brown alumina has a density of at, least 3.55 g/cm3, or at least 3.60 g/cm3 or at least 3.70 g/cm3 or at least 3.80 g/cm3 or at least 3.90 g/cm3.

Embodiment 16. The abrasive article of any one of embodiments 3 and 6, wherein the abrasive particles consist essentially of brown alumina.

Embodiment 17. The abrasive article of any one of embodiments 3 and 6, wherein the abrasive particles include brown alumina and are essentially free of any other types of abrasive particles.

Embodiment 18. The abrasive article of any one of embodiments 3 and 6, wherein the abrasive particles include a blend of different types of abrasive particles including brown alumina and at least one other type of abrasive particle from the group including white alumina, black alumina, monoerystalline fused alumina, heat treated alumina, oxides, bo rides, nitrides, carbides, diamond, or a combination thereof.

Embodiment 19. The abrasive article of embodiment 3, wherein the pyrite has a sulfur content of at least 43 wt% for a total weight of the pyrite.

Embodiment 20. The abrasive article of any one of embodiments 1, 2, and 1 .

wherein the pyrite includes at least 44 wt% sulfur for a total weight of the pyrite, or at least 45 wt% or at least 46 wt% or at least 47 wt% or at least 48 wt% or at least 49 wt% or at least 50 wt%.

Embodiment 2 1 . The abrasive article of embodiment 20. wherein pyrite includes a content of sulfur of not greater than 70 wt% for a total weight of the pyrite, or not greater than 65wt% or not greater than 63 wt% or not greater than 60 wt% or not greater than 58 wt% or not greater than 55 wt% or not greater than 53 wt%.

Embodiment 22. The abrasive article of any one of embodiments 1, 2, and 3, wherein the pyrite has a density of at least 4.60 g/cm.3 or at least 4.70 g/cm3 or at least 4.75 g/cm3 or at least 4.80 g/cm3.

Embodiment 23. The abrasive article of any one of embodiments 1, 2, and 3, wherein the pyrite has a density of not greater than 5. 60 g/cm3 or not greater than 5.50 g/cm3 or not greater than 5.40 g/cm3 or not greater than 5.30 g/cm3 or not greater than 5.20 g/cm3 or not greater than 5.10 g/cm3 or not greater than 5.00 g/cm3.

Embodiment 24. The abrasive article of any one of embodiments 1, 2. and 3, wherein the pyrite includes a sulfur/iron ratio of at least 1.00 based on the weight percent of sulfur and iron in the pyrite, or at least 1.01 or at least 1.02.

Embodiment 25. The abrasive article of any one of embodiments 1, 2, and 3, wherein the pyrite includes a sulfur/iron ratio of not greater than 2.00 based on the weight percent of sulfur and iron in the pyrite, or not greater than 1.80 or not greater than 1.50 or not greater than 1 .20 or not greater than 1 . 10.

Embodiment 26. The abrasive article of any one of embodiments 1, 2. and 3, wherein the pyrite has an average particle size of not greater than 80 microns or not greater than 75 microns or not greater than 70 microns or not greater than 65 microns or not greater than 60 microns or not greater than 55 microns or not greater than 50 microns.

Embodiment 27. The abrasive article of any one of embodiments 1, 2, and 3, wherein the abrasive portion includes at least 1 vol% pyrite for a total volume of the abrasive portion or at least 2 vol% or at least 3 vol% or at least 4 vol% or at least 5 vol% or at least 6 vol% or at least 7 vol%.

Embodiment 28. The abrasive article of any one of embodiments 1, 2, and 3, wherein the abrasive portion includes not greater than 20 vol pyrite for a total volume of the abrasive portion or not greater than 18 vol% or not greater than 16 vol% or not greater than 14 vol% or not greater than 12 vol% or not greater than 10 vol%.

Embodiment 29. The abrasive article of any one of embodiments 1 and 2, wherein the filler composition includes pyrite, sodium aluminum fluoride, potassium aluminum fluoride, and calcium carbonate.

Embodiment 30. The abrasive article of any one of embodiments 3 and 29, wherein the abrasive portion includes at least 1 vol% sodium aluminum fluoride for a total volume of the abrasive portion or at least 2 vol% or at least 3 vol% or at least 4 vol%.

Embodiment 31. The abrasive article of any one of embodiments 3 and 29, wherein the abrasive portion includes not greater than 20 vol% sodium aluminum fluoride for a total volume of the abrasive portion or not greater than 18 vol% or not greater than 16 vol% or not greater than 14 vol% or not greater than 12 vol% or not greater than 10 vol% or not greater than 8 vol% or not greater than 6 vol%.

Embodiment 32. The abrasive article of any one of embodiments 3 and 29, wherein the abrasive portion includes at least 0.5 vol potassium aluminum fluoride for a total volume of the abrasive portion or at least 1 vol% or at least 1.5 vol% or at least 2 vol%.

Embodiment 33. The abrasive article of any one of embodiments 3 and 29, wherein the abrasive portion includes not greater than 10 vol% potassium aluminum fluoride for a total volume of the abrasive portion or not greater than 8 vol% or not greater than 6 vol% or not greater than 5 vol% or not greater than 4 vol% or not greater than 3 vol%.

Embodiment 34. The abrasive article of any one of embodiments 3 and 29, wherein the abrasive portion includes at least 0.001 vol% calcium carbonate for a total volume of the abrasive portion or at least 0.005 vol% or at least 0.01 vol%.

Embodiment 35. The abrasive article of any one of embodiments 3 and 29, wherein the abrasive portion includes not greater than 10 vol% calcium carbonate for a total volume of the abrasive portion or not greater than 8 vol% or not greater than 6 vol% or not greater than 4 vol% or not greater than 2 vol% or not greater than 1 vol% or not greater than 0.8 vol% or not greater than 0.5 vol%.

Embodiment 36. The abrasive article of any one of embodiments 3 and 29, wherein the filler composition consists essentially of pyrite, sodium aluminum fluoride, potassium aluminum fluoride, and calcium, carbonate.

Embodiment 37. The abrasive article of any one of embodiments 3 and 29, wherein a content (vol%) of pyrite is greater than a content (vol%) of sodium aluminum fluoride.

Embodiment 38. The abrasive article of embodiment 37, wherein the filler composition includes a ratio of pyrite to sodium aluminum fluoride (Py/Cryolite) of at least 1 or at least 1.1 or at least 1.2 or at least 1.3 or at least 1.4.

Embodiment 39. The abrasive article of embodiment 38, wherein the filler composition includes a ratio of pyrite to sodium aluminum fluoride (Py/Cryolite) of not greater than 10 or not greater than 8 or not greater than 7 or not greater than 5 or not greater than 3 or not greater than 2.

Embodiment 40. The abrasive article of any one of embodiments 3 and 29, wherein a content (vol%) of pyrite is greater than a content (vol%) of potassium aluminum, fluoride.

Embodiment, 41. The abrasive article of embodiment 40, wherein the filler

composition includes a ratio of pyrite to potassium aluminum fluoride (Py/PAF) of at least 1 or at least 1.3 or at least 1.8 or at least 2 or at least 2.4 or at least 2.8 or at least 3.

Embodiment 42. The abrasive article of embodiment 40, wherein the filler composition includes a ratio of pyrite to potassium aluminum fluoride (Py/PAF) of not greater than 10 or not greater than 8 or not greater than 7 or not greater than 5 or not greater than 4.

Embodiment, 43. The abrasive article of any one of embodiments 3 and 29, wherein a content (vol%) of sodium aluminum fluoride is greater than a content (vol%) of potassium aluminum fluoride.

Embodiment 44. The abrasive article of embodiment 43, wherein the filler

composition includes a ratio of sodium aluminum fluoride to potassium aluminum fluoride (Cryoliie/PAF) of at least 1 or at least or at least 1.1 or at least 1.3 or at least 1.5 or at least 1.8 or at least 2.

Embodiment, 45. The abrasive article of embodiment 43, wherein the filler

composition includes a ratio of pyrite to potassium aluminum fluoride (Cryolite/PAPj of not greater than 10 or not greater than 8 or not greater than 7 or not greater than 5 or not greater than 4 or not greater than 3.

Embodiment 46. The abrasive article of any one of embodiments 3 and 29, wherein a content (vol%) of pyrite in the abrasive portion is greater than a content (vol%) of calcium carbonate.

Embodiment 47. The abrasive article of embodiment 46, wherein the filler composition includes a ratio of pyrite to calcium carbonate (Py/CC) of at, least 1 or at least 2 or at least 3 or at least 5 or at least 10 or at least 20 or at least 50 or at least 80 or at least 100.

Embodiment 48. The abrasive article of embodiment 46, wherein the filler composition includes a ratio of pyrite to calcium carbonate (Py/CC) of not greater than 1000 or not greater than 800 or not greater than 700 or not greater than 500 or not greater than 300.

Embodiment 49. The abrasive article of any one of embodiments 3 and 29, wherein a content (vol%) of sodium aluminum fluoride in the abrasive portion is greater than a content (vol%) of calcium carbonate.

Embodiment 50. The abrasive article of embodiment 49, wherein the filler composition includes a ratio of sodium aluminum fluoride to calcium carbonate

(Cryolite/CC ) of at least 1 or at least 1.5 or at least 2 or at least 3 or at least 5 or at least 10 or at least 20 or at least 40 or at least 60.

Embodiment, 51. The abrasive article of embodiment 49, wherein the filler composition includes a ratio of sodium aluminum fluoride to calcium carbonate

(Cryolite/CC) of not greater than 1000 or not greater than 700 or not greater than 500 or not greater than 200 or not, greater than 100.

Embodiment 52. The abrasive article of any one of embodiments 3 and 29, wherein a content (vol%) of potassium aluminum fluoride in the abrasive portion is greater than a content (vol%) of calcium carbonate.

Embodiment, 53. The abrasive article of embodiment 52, wherein the filler composition includes a ratio of potassium aluminum fluoride to calcium carbonate (PAF/CC) of at least 1 or at least 2 or at least 3 or at least 5 or at least 10 or at least 20 or at least 30.

Embodiment 54. The abrasive article of embodiment 52, wherein the filler composition includes a ratio of potassium aluminum fluoride to calcium carbonate (PAF/CC) of not greater than 200 or not greater than 150 or not greater than 100 or not greater than 70 or not greater than 50.

Embodiment 55. The abrasive article of any one of embodiments 1 , 2, and 3, wherein the abrasive portion includes at least 5 vol% bond material for a total volume of the abrasive portion, or at least 8 vol% or at least 10 vol% or at least 12 vol% or at least 15 vol% or at least 18 vol% or at least 20 vol% or at least 25 vol% or at least 30 vol% or at least 35 vol% or at least, 40 vol% or at least 45 vol% or at least 55 vol% or at least 60 vol% or at least 65 vol%.

Embodiment 56. The abrasive article of any one of embodiments 1, 2, and 3, wherein the abrasive portion includes not greater than 65 vol% bond material for a total volume of the abrasive portion, or not greater than 60 vol% or not greater than 55 vol% or not greater than 50 vol% or not greater than 45 vol% or not greater than 40 vol% or not greater than 5 vol% or not greater than 30 vol% or not greater than 25 vol% or not greater than 20 vol% or not greater than 15 vol%.

Embodiment 57. The abrasive article of any one of embodiments 1 , 2, and 3, wherein the abrasive portion includes at least 1 vol% filler composition for a total volume of the abrasive portion, or at least 2 vol% or at least 10 vol% or at least 3 vol% or at least 5 vol% or at least 8 vol '/< or at least 10 vol% or at least 12 vol or at least 14 vol% or at least 16 vol%.

Embodiment 58. The abrasive article of any one of embodiments 1, 2, and 3, wherein the abrasive portion includes not greater than 25 vol% filler composition for a total volume of the abrasive portion, or not greater than 20 vol% or not greater than 19 vol% or not greater than 18 vol% or not greater than 17 vol% or not greater than 16 vol% or not greater than 15 vol% or not greater than 14 vol% or not greater than 13 vol% or not greater than 12 vol%. EXAMPLES

Example 1

Table 1 includes characteristics of two pyrite samples. Pyrite 1 is a conventional pyrite sample. Pyrite 2 is representative of embodiments herein. In addition to Fe and S disclosed in Table 1, the pyrite samples included other additives (e.g., SiO_?.) in minor amounts. A skilled artisan would appreciate that the total contents of all of the components of each pyrite sample added up to 100 wt%.

The samples of Pyrite 1 and 2 were subjected to magnetic substance analysis. The results are included in Table 2, which indicates significant difference in the compositions of Pyrite 1 and 2.

Table 1 Characteristics of Pyrite Samples

Table 2 Magnetic Substance of Pyrite 1 and 2

FIG. 10 includes particle size distributions of Pyrite 1 and 2 samples. Pyrite 1 exhibits an average particle size of 10 to 30 microns. Pyrite 2 has an average particle si/e of 30 to 50 microns.

Example 2

3 to 5 sample cutting wheels were formed with Pyrite 1 and 2, respectively, according to embodiments described herein. The samples were formed with the composition included in Table 3 below except that the Group 1 samples were formed with Pyrite 1 and Group 2 Pyrite 2. All of the samples were used to cut a 60 mm stainless steel workpiece with a 5.5 KW, 380 volt SQ-40- 1 cutting tool from Jinnan Keruite Machinery Co., Ltd. The cutting tool is operated at a speed of 2800 rotations per minute to 2900 rotations per minute wi th a working current of 9 to 11 amps. Twenty cuts were made to the workpiece.

Table 3 Composition for Forming Wheels

FIG. 11 includes a bar histogram indicating a mean G-ratio (represented by the bars in the figure) and material removal rate (MRR, represented by squares in the figure) for the cutting wheel samples 1 and 2 and further includes current generated by the samples (represented by the triangles in the figure) during the cutting test. G-ratio as used herein indicates an amount of material removed from the workpiece relative to an amount of material removed from the cutting wheel. Group 2 had a significantly higher mean G-ratio than that of Group 1, 2.52 vs. 1.96, while Group 1 and Group 2 demonstrated similar MRR and generated similar level of current. As indicated in FIG. 11, the cutting wheels of the embodiments herein having pyrite with a higher content of sulfur demonstrated higher material removal rates and improved G-ratio ( 28% increase) compared to wheels having a similar composition but with conventional pyrite. Such unexpected improvement on performance will extend the lifespan of the cutting wheels.

The foregoing embodiments are directed to abrasive products, and particularly bonded abrasive cutting wheels, which represent a departure from the state-of-the-art. The cutting wheels of the embodiments herein utilize a combination of features that facilitate improved performance over conventional cutting wheels. As described in the present application, certain abrasive articles of the embodiments herein utilize a particular type and content of certain components, including a filler composition, bond material, and abrasive particles, which has led to significant and unexpected results in terms of the performance of the abrasive articles. Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims. Reference herein to a material including one or more components may be interpreted to include at least one embodiment wherein the material consists essentially of the one or more components identified. The term "consisting essentially" will be interpreted to include a composition including those materials identified and excluding all other materials except in minority contents (e.g., impurity contents), which do not significantly alter the properties of the material. Additionally, or in the alternative, in certain non-limiting embodiments, any of the compositions identified herein may be essentially free of materials tha are not, expressly disclosed. The embodiments herein include range of contents for certain components within a material, and it will be appreciated that the contents of the components within a given material total 100%.

The specification and illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The specification and illustrations are not intended to serve as an exhaustive and comprehensive description of all of the elements and features of apparatus and systems that use the structures or methods described herein. Separate embodiments may also be provided in combination in a single embodiment, and conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any subcombination. Further, reference to values stated in ranges includes each and every value within that range. Many other embodiments may be apparent to skilled artisans only after reading this specification. Other embodiments may be used and derived from the disclosure, such that a structural substitution, logical substitution, or another change may be made without departing from the scope of the disclosure. Accordingly, the disclosure is to be regarded as illustrative rather than restrictive.

Claims

WHAT IS CLAIMED IS:

1. An abrasive article comprising:

a body including and abrasi ve portion comprising:

a bond material;

abrasive particles contained within the bond material; and

a filler composition within the bond material including pyrite. wherein the pyrite has a sulfur content of at least 43 wt for a total weight of the pyrite.

2. The abrasive article of claim 1, wherein the abrasive particles comprise brown alumina.

3. The abrasive article of claim 2, wherein the brown alumina includes at least 88 wt% alumina for a total weight of the abrasive particles or at least 90 wt% or at least 92 wt% or at least 95 wt% and not greater than 99.0 wt% alumina for a total weight of the abrasive particles.

4. The abrasive article of claim 2, wherein the brown alumina includes a content of silica not greater than 5 wt% for a total weight of the abrasive particles or not greater than 4 wt% or not greater than 3 wt%.

5. The abrasive article of claim 2, wherein the brown alumina includes a content of iron oxide of not greater than 4 wt% for a total weight of the abrasive particles or not greater than 3 wt% or not greater than 2 wt% or not greater than 1 wt% or not greater than 0.5 wt%.

6. The abrasive article of claim 2, wherein the brown alumina includes a content of titanium oxide of not greater than 4 wt% for a total weight of the abrasive particles or not greater than 3 wt% or not greater than 2 wt% or not greater than 1 wt% or not greater than 0.5 wt%.

7. The abrasive article of claim 1, wherein the filler composition further comprises sodium aluminum fluoride, potassium aluminum, fluoride, and calcium carbonate, wherein a content (vol%) of pyrite is greater than a content (vol%) of sodium aluminum fluoride, wherein the content (vol%) of sodium aluminum fluoride is greater than a content (vol%) of potassium aluminum fluoride, and wherein the content (vol%) of potassium aluminum fluoride is greater than a content (vol%) of calcium carbonate.

8. The abrasive article of any one of claims 1 to 7, wherein the pyrite includes at least 44 wt% sulfur for a total weight of the pyrite, or at least 45 wt% or at least 46 wt% or at least 47 wt% or at least 48 wt% or at least, 49 wt% or at least 50 wt%, and not greater than 70 wt% for a total weight of the pyrite.

9. The abrasive article of any one of claims 1 to 7. wherein the pyrite has a density of at least at least 4.60 g/cm³ or at least 4.70 g/cm³ or at least 4.75 g/cm³ or at least 4.80 g/cm^J, and not greater than 5. 60 g/cm³.

10. The abrasive article of any one of claims 1 to 7, wherein the pyrite includes a sulfur/iron ratio of at least 1.00 based on the weight percent of sulfur and iron in the pyrite, or at least 1.01 or at least 1.02, and not greater than 2.00.

11. The abrasive article of any one of claims 1 to 7, wherein the pyrite has an average particle size of not greater than 80 microns or not greater than 75 microns or not greater than 70 microns or not greater than 65 microns or not greater than 60 microns or not greater than 55 microns or not greater than 50 microns.

12. The abrasive article of any one of claims 1 to 7, wherein the abrasive portion includes at least 1 vol% pyrite for a total volume of the abrasive portion or at least 2 vol% or at least 3 vol% or at least 4 vol% or at least 5 vol% or at least 6 vol% or at least 7 vol%, and not greater than 20 vol% pyrite for a total volume of the abrasive portion.

13. The abrasive article of any one of claims 1 to 7, wherein the filler composition consists essentially of pyrite, sodium aluminum fluoride, potassium aluminum fluoride, and calcium carbonate.

14. The abrasive article of any one of claims 1 to 7, wherein the abrasive portion comprises at least 20 vol% abrasive particles for the total volume of the abrasive portion or at least 25 vol% or at least 30 vol% or at least 35 vol% or at least 40 vol% or at least 45 vol% or at least 50 vol or at least 55 vol% or at least 60 vol and not greater than 90 vol% abrasive particles for a total volume of the abrasive portion.

15. The abrasive article of any one of claims 1 to 7, wherein the abrasive particles consist essentially of brown alumina.