Abrasive article and method for making the same

a technology of abrasive articles and abrasive particles, which is applied in the direction of abrasive equipment, pigmentation treatment, other chemical processes, etc., can solve the problems of hammering the performance and usable life of abrasive tools, limited cutting ability, and poor abrasive particle retention, so as to reduce the overall amount of abrasive particles needed, reduce the cost of making tools, and increase the service life of expensive abrasive particles

Inactive Publication Date: 2015-10-15
LI YUNDONG
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0015]The main feature of the present invention is that by use of previously coated abrasive grains, it provides ways to the desirable combination of chemical bonding and precise arrangement of grains in abrasive products compared to the products where naked grains are randomly placed and/or merely mechanically anchored. As a result, the service lif

Problems solved by technology

Despite their practical use in industries, a number of issues continue to hamper the performance and usable life of abrasive tools.
For example, grain retention remains problematic.
As a result, grains are often pulled out prematurely, or the height of protrusion of grains is compromised, e.g. less than ⅓ to ½ of the average diameter of the particles, resulting in a limited cutting ability.
Another limitation associated with the conventional abrasive tools is that the grains are not arranged to maximize efficiency for cutting, drilling, grinding, polishing, etc.
Though abrasive tools with abrasive chemically bonded and regularly arranged have been successfully developed by brazing (WO2012/162430, WO2010/141464, U.S. Pat. No. 6,416,560, U.S. Pat. No. 6,679,243 and U.S. Pat. No. 8,104,464), the bonding strength between grains and brazed material is limited because of thermal residual stress induced during cooling period from high brazing temperature; degradation of grain surface (e.g. graphitization of diamond) because of high brazing temperature; and com

Method used

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  • Abrasive article and method for making the same
  • Abrasive article and method for making the same
  • Abrasive article and method for making the same

Examples

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Effect test

example 1

[0109]A stainless steel disc (120D-0.65T) that is about 120 mm in diameter and about 0.65 mm in thickness is partially covered by an electrically non-conductive template having a plurality of apertures distributed in a lattice pattern. The template covers a generally circular area on a central portion of the disc of about 100 mm in diameter, leaving a width of about 10 mm around the perimeter of the disc. The perimeter area is covered by an insulating material to prevent deposition. The aperture separation measuring from the approximate center points of adjacent apertures is about 800 microns with each aperture about 400 microns in diameter. Nickel coated diamond particles with an average size of 300 microns are then dispersed into the apertures so that each aperture accommodates only a single grain. The excess diamond grains are discarded by brushing, titling, vibrating, shaking, etc. The located diamond grains are bonded to the steel substrate by an electroplating process. A 99.99...

example 2

[0110]The process of Example 1 is followed, except the diamond grains used in the present example are naked (with no metallic coating) and magnetically sensitive as a result of containing inclusions of catalysts such as nickel, cobalt, iron, manganese, or like. These grains are normally excluded in fabrication of electroplated diamond tools because they lead to the formation of nodules around diamond grains, over-plating of the grains, and pores in plated material between grains. Individual placement of the grains in the present invention successfully prevents the formation of such pores which are detrimental to the abrasive retention.

example 3

[0111]A substrate metal having a shape and a dimension of 240D-20T is prepared from stainless steel (SUS304) by working using a lathe. Then, the substrate surface is covered by an electrically non-conductive template, and the other part is masked with an insulation tape. The template has apertures in grid pattern with aperture diameter of 200 microns and aperture separation of 400 microns. The substrate is then treated for degreasing with an alkali and dipped into a pretreatment fluid containing 240 g / liter of nickel chloride and 100 g / liter of hydrochloric acid. The dipped substrate is set to an anode and electrolytically etched under a current density of 10 A / dm.sup.2 at an ordinary temperature for 2 minutes. Then, the substrate is set to a cathode, and strike plating is conducted for 3 minutes. The treated substrate is plated in a plating bath of nickel sulfamate under a current density of 1 A / dm.sup.2 for 15 minutes to form a thin plating underlayer. The purpose of the early pla...

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Abstract

An abrasive article comprising a plurality of abrasive grains that are precisely arranged in accordance with a predetermined pattern and are chemically bonded with a matrix material, and a method for the making thereof are disclosed. A coating layer on each of the abrasive grains functions as a bridge to form chemical bonding between the abrasive grains and the matrix material. In addition to a plated material, the matrix material can include a braze, a solder, a sintered material, an infiltrant, an organic material, and a vitrified material. The method for making the abrasive article comprises the steps of: coating abrasive grains with a coating layer that chemically bonds to each of the abrasive grains; arranging the coated abrasive grains in accordance with a predetermined pattern; and chemically bonding the coated abrasive grains with a matrix material.

Description

TECHNICAL FIELD[0001]The present invention relates generally to abrasive articles and processes for producing the same. More particularly, the present invention relates to an abrasive tool which comprises abrasive grains chemically bonded and precisely arranged in accordance with a predetermined pattern. Accordingly, the present invention involves the fields of materials science, mechanical engineering, and physics.BACKGROUND ART[0002]Diamond, the hardest abrasive currently known, is widely used on saws, drills, and other devices to cut, form, or polish materials such as aluminum, copper, carbide alloy, stone, concrete, asphalt, glass, ceramics, gem stone, semiconductor materials, rubber and resin, while the other super abrasive tool, cubic boron nitride (CBN) tool, is suitable to process steels including common steels and various tough alloy steels. According to their manufacturing methods or bond types, abrasive tools can be categorized into several types, such as metal-bonded (i....

Claims

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Application Information

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IPC IPC(8): B24D3/06B24D18/00
CPCB24D3/06B24D18/0018B24D18/0072
Inventor LI, YUNDONG
Owner LI YUNDONG
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