Agglomerate abrasive grains and methods of making the same

Abstract

An abrasive agglomerate includes a plurality of abrasive grains bonded together in a three-dimensional structure by a substantially continuous, non-porous inorganic binder, wherein the abrasive grains have an average size of between about 0.5 microns and about 1500 microns, the inorganic binder is less than about 75 percent, by weight, of the abrasive agglomerate, and the bulk density of the abrasive agglomerate is less than about 90 percent of the bulk density of the abrasive grains.

Description

Agglomerated abrasive particles and method of making the same technical field The present invention relates to abrasive agglomerates useful in a variety of abrasive articles including bonded abrasives, coated abrasives, nonwoven abrasives and abrasive brushes. Background technique Abrasive particles or grains have long been used in abrasive articles, including coated abrasives, bonded abrasives, and nonwoven abrasives. Abrasive particles traditionally comprise fine particles of hard substances such as alumina, alumina-zirconia, diamond, cubic boron nitride, and sol-gel produced abrasive particles. Criteria used to evaluate the effectiveness of a particular abrasive grain in a particular abrasive application typically include abrasive life, stock removal rate, substrate surface finish, abrasive efficiency, and product cost. Such conventional abrasive particles are effective for removing some material from a workpiece in a short period of time, however, many abrasive parti...

AI Technical Summary

Problems solved by technology

This type of conventional abrasive grain is effective for removing some material from a workpiece for a short period of time, however, many abrasive grains become smooth or polished over time to the point where little additional material can be removed

When a large number of abrasive particles are smoothed, the grinding effect of the abrasive article on the workpiece is generally poor

Additionally, the stock removal rate of abrasive articles may become inconsistent as more and more abrasive particles become smooth over time

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