Abrasive article and method of forming same

Abstract

The invention relates to an abrasive article and a method of forming the same. An abrasive article may include a body including a first abrasive region having a first average abrasive particle size and a second average abrasive particle size different than the first average abrasive particle size. The abrasive article may include a non-abrasive portion between the first abrasive region and the second abrasive region.

Description

Technical Field

[0001] The following relates to an abrasive article and a method of forming the same, and more particularly to an abrasive article including abrasive regions having different abrasive grain sizes and a method of forming the same.

[0002] Description of the Related Art

[0003] Abrasive tools have been used in various industries for the general function of removing material from a workpiece, including, for example, sawing, drilling, polishing, cleaning, engraving, and grinding. In the production of electronic devices, the workpiece may include hard and brittle materials such as sapphire, quartz, SiC, GaN, and certain glass and ceramic materials. To effectively grind the backside of a semiconductor wafer, a grinding machine equipped with a rough grinding unit and a fine grinding unit is typically used. Generally, the article used for the rough grinding process is a vitrified abrasive body or a grinding stone, and a polishing pad is typically used to achieve a surface finish with a certain roughness.

[0004] However, the industry continues to need improved grinding stone materials that can achieve improved grinding performance. Summary of the Invention

[0005] The present application relates to an abrasive article including a body having a plurality of abrasive regions, the abrasive regions including:

[0006] a first abrasive region including first abrasive grains having a first average grain size; and

[0007] a concentric second abrasive region including second abrasive grains having a second average grain size greater than the first average grain size,

[0008] wherein the second abrasive region is spaced from the first abrasive region and includes a diameter smaller than the first abrasive region. Brief Description of the Drawings

[0009] The present disclosure can be better understood by reference to the accompanying drawings, and many of the features and advantages thereof will become apparent to those skilled in the art.

[0010] Figure 1 A top view illustration of an abrasive article according to one embodiment.

[0011] Figure 2 Including Figure 1 a cross-sectional illustration of the abrasive article.

[0012] Figure 3 A flowchart showing a process of forming an abrasive article according to one embodiment.

[0013] Figure 4Includes an illustration of a dual grinding operation according to one embodiment.

[0014] Figure 5 Includes a top view illustration of an abrasive article.

[0015] Figures 6 to 11 Includes a top view illustration of an abrasive article according to the embodiments described herein.

[0016] Those skilled in the art will understand that the elements in the drawings are shown for simplicity and clarity and are not necessarily drawn to scale. For example, the dimensions of some elements in the drawings may be exaggerated relative to other elements to help improve understanding of the embodiments of the present invention. The same reference symbols are used in different drawings to indicate similar or identical items. Detailed Description

[0017] The following description in conjunction with the drawings is provided to assist in understanding the teachings disclosed herein. The following discussion will focus on specific implementations and embodiments of the present teachings. This focused discussion is provided to assist in describing the teachings and should not be construed as a limitation on the scope or applicability of the teachings.

[0018] 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 process, method, article, or apparatus that comprises a list of features is not necessarily limited to those features but may include other features not expressly listed or inherent to such process, method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive or and not an exclusive or. For example, 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).

[0019] The use of “a” to describe the elements and components described herein is done merely for convenience and to give a general sense of the scope of the invention. This description should be understood to include one or at least one, and the singular also includes the plural, or vice versa, unless expressly stated otherwise.

[0020] 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 limiting.

[0021] Embodiments of the present disclosure relate to an abrasive article that includes a body having a plurality of concentric grinding regions with different abrasive grain sizes. In particular, the body may include an inner grinding region and an outer grinding region, where the inner grinding region may include a larger average abrasive grain size than the outer grinding region. The abrasive article may have improved performance, including material removal rate, surface finish, service life, or any combination thereof. In one specific embodiment, the abrasive article may be particularly suitable for grinding brittle and hard workpieces and achieving low surface roughness and / or total thickness within a limited grinding time. Embodiments relate to a method of forming an abrasive article and using the abrasive article in a material removal operation. Exemplary operations may include wafer grinding, disk grinding, etc., or any combination thereof. In one specific example, a method of using the abrasive article may include a grinding operation involving a hard and brittle workpiece (such as sapphire, quartz, glass, ferrite, ceramic, silicon, SiC, GaN, etc., or any combination thereof).

[0022] In one embodiment, the abrasive article may include a body having concentric grinding regions that may be spaced apart from each other. In another embodiment, the body may include a plurality of grinding regions and one or more non-grinding portions, where the grinding regions may be spaced apart from each other by one or more non-grinding portions. In one example, adjacent grinding regions may be spaced apart from each other by a non-grinding portion. In one specific example, adjacent grinding regions may be completely spaced apart by a non-grinding portion. In another embodiment, the body may include alternating non-grinding portions and grinding regions that may be concentric. For example, the grinding regions and non-grinding portions may have a substantially annular shape.

[0023] In one embodiment, the body may include a substrate, and the grinding regions may be disposed on the substrate. The substrate may include a central opening that may facilitate the mounting of the abrasive article for a material removal operation. In one example, the grinding regions may be radially spaced apart from each other and from the central opening. In another example, each grinding region may be concentrically attached to the surface of the substrate and spaced apart from each other. In one specific embodiment, one or more non-grinding portions may include a part of the substrate. In another embodiment, the substrate may have a circular shape, such as a disk, a wheel, etc. In another embodiment, the substrate may include a material comprising an organic material, an inorganic material, or a combination thereof. Exemplary materials may include metals (such as aluminum alloy, steel, etc.), carbon fiber, synthetic resins (such as engineering plastics), or any combination thereof.

[0024] In one embodiment, one or more or all of the grinding regions may include a continuous annular body. For example, one or more or all of the grinding regions may be a single integral unit. See Figure 6, representative abrasive article 600 includes a body 601 that includes an unsegmented annular grinding region 602, an annular grinding region 603, and an annular grinding region 604.

[0025] In another embodiment, one or more or all of the plurality of grinding regions may include grinding segments. In one example, the grinding segments may be disposed on a substrate to form an annular grinding region. See Figure 7 , representative abrasive article 700 includes a body 710 that includes an annular grinding region 701, an annular grinding region 702, and an annular grinding region 703. Grinding region 701 includes a plurality of segments 711 that are spaced apart and arranged such that grinding region 701 has an annular shape. Similar to grinding region 701, grinding region 702 has a substantially annular shape that includes a plurality of segments 722. In the illustrated embodiment, grinding region 703 is unsegmented and has an integrated single body 733. In another example, one or more or all of the grinding regions may include segments that are spaced apart at a fixed interval. In another example, the interval between adjacent segments may be substantially the same in one or more or all of the grinding regions. In a specific example, at least some or all of the grinding segments may be adjacent to each other to form a grinding region. In another example, at least some or all of the grinding segments may be spaced apart from each other in the grinding region.

[0026] In another embodiment, one or more of the grinding regions may include segments that may be oriented at an angle with respect to the diameter of the body. For example, the segments may include a longitudinal axis, where the longitudinal axis may form a right angle, an acute angle, and / or an obtuse angle with respect to the diameter of the body. For example, a length, width, diagonal, diameter, or other dimension may extend along the longitudinal axis of the segment. The segments may be oriented such that the longitudinal axis may form an angle of 0° to 360° with respect to the outer diameter of the body. See Figure 9 , representative abrasive article 900 includes a body 901 that includes an annular grinding region 902, an annular grinding region 903, and an annular grinding region 904. Grinding region 903 includes a segment 933 that includes a longitudinal axis 960. In the illustrated embodiment, the length of segment 933 extends along longitudinal axis 960. As shown, segment 933 is positioned such that the longitudinal axis 960 of segment 933 may form an acute angle 961 with respect to the outer diameter 950 of body 901. All segments 933 are positioned circumferentially such that grinding region 903 is substantially annular.

[0027] The grinding regions 902 and 904 respectively include grinding segments 922 and 944. The segments 922 and 944 may have a curved shape and are arranged to form an annular grinding region 902 and an annular grinding region 904 respectively. The segments 922 and 944 may have a larger dimension (i.e., length) extending in the circumferential direction of the body 901 and a smaller dimension (i.e., width) extending in the radial direction. As shown, the segment 922 may have different lengths in the circumferential direction, and the longer segments may alternate with the shorter segments. The segment 922 may have a similar width in the radial direction. Similarly, the segment 944 may have different lengths in the circumferential direction, and the longer segments may alternate with the shorter segments. The segment 922 may also have a similar width in the radial direction.

[0028] See Figure 10 , the representative abrasive article 1000 includes a body 1001 that includes an annular grinding region 1002, an annular grinding region 1003, and an annular grinding region 1004. The grinding region 1003 includes a segment 1033 positioned along the circumferential direction of the body 100. The longitudinal axis 1060 of the segment 1033 is angled with respect to the outer diameter 1050. In the illustrated embodiment, the segments 1033 are differently oriented such that the longitudinal axes 1060 of adjacent segments intersect. The grinding regions 1002 and 1004 respectively include a curved segment 1022 and a curved segment 1044. The segment 1022 may have a similar length extending in the circumferential direction and a similar width aligned to form the annular grinding region 1002. The segment 1044 may have a similar length extending in the circumferential direction and a similar width aligned to form the annular grinding region 1004.

[0029] In another embodiment, the body may include segments having similar or different lengths and / or widths, substantially the same or different orientations relative to each other, or any combination thereof, wherein the segments within the same grinding region may be arranged such that the grinding region may have a substantially annular shape.

[0030] It should be understood that for a grinding area including a grinding section, the total volume (or weight) of the grinding section can be the volume (or weight) of the grinding area. Embodiments related to the component content in the grinding area can be applied to the grinding area including the grinding section as the average content of the components of all sections of the grinding area. For example, the volume% of abrasive grains in the grinding area can be the percentage of the volume of abrasive grains in the grinding area relative to the volume of the grinding area. For a grinding area including sections, the volume% of abrasive grains can be the total content of abrasive grains for the total volume of the sections within the grinding area and the average volume% for all sections within the grinding area. In a specific embodiment, the sections of the same grinding area can be similar or substantially the same. In another embodiment, the sections within the same or different grinding areas can be different in terms of the content of abrasive grains and / or binder material, average abrasive grain size, the material of abrasive grains and / or binder material, porosity, or any combination thereof.

[0031] In one embodiment, a plurality of grinding areas can include a binder material and abrasive grains contained in the binder material. Exemplary binder materials can include organic materials such as thermosetting materials, thermoplastic materials, or any combination thereof. In another embodiment, one or more or all of the grinding areas can include an organic binder material. In another embodiment, the grinding areas can include the same or different binder materials. In a specific example, the grinding areas can include the same binder material.

[0032] In one embodiment, one or more or all of the plurality of grinding regions may include a specific content of a bonding material, and this specific content of the bonding material may be beneficial to the improved performance and / or formation of the abrasive article. For example, each grinding region may independently include a bonding material that is at least 40% by volume, such as at least 42% by volume, at least 45% by volume, at least 48% by volume, at least 50% by volume, at least 53% by volume, at least 55% by volume, at least 58% by volume, at least 61% by volume, at least 64% by volume, at least 68% by volume, at least 70% by volume, at least 73% by volume, at least 75% by volume, at least 77% by volume, or at least 80% by volume of the volume of the grinding region. In another example, each grinding region may independently include a bonding material that is at most 98% by volume, such as at most 95% by volume, at most 92% by volume, at most 90% by volume, at most 85% by volume, at most 82% by volume, at most 78% by volume, at most 75% by volume, at most 72% by volume, at most 68% by volume, at most 64% by volume, at most 60% by volume, at most 57% by volume, at most 55% by volume, at most 52% by volume, at most 50% by volume, at most 47% by volume, or at most 45% by volume of the volume of the grinding region. Additionally, each grinding region may independently include a bonding material content within a range including any of the minimum percentages and maximum percentages mentioned herein. In another embodiment, any content of the bonding material in the grinding regions mentioned in the embodiments herein may be understood as the average content of the bonding material for the grinding portion.

[0033] In one embodiment, one or more or all of the grinding regions may include a filler. Examples of fillers may include powders, granules, spheres, fibers, hollow particles, or any combination thereof. Another example of fillers may include antistatic agents, pore formers, lubricants, colorants, or any combination thereof. In another example, the filler may include materials comprising: sand, foam alumina, chromite, magnetite, dolomite, foam mullite, borides, titanium dioxide, carbon products, silicon carbide, wood flour, clay, talc powder, hexagonal boron nitride, molybdenum disulfide, feldspar, nepheline syenite, glass spheres, glass fibers, CaF2, KBF4, cryolite (Na3AlF6), potassium cryolite (K3AlF6), pyrite, ZnS, copper sulfide, mineral oil, fluorides, carbonates, calcium carbonate, saran, phenoxy resin, CaO, K2SO4, mineral wool, MnCl2, KCl, or any combination thereof. In a specific embodiment, one or more or all of the grinding regions may include a filler material comprising lime, graphite, SiC, Al2O3, copper, or any combination thereof. In another embodiment, the grinding regions may include the same or different filler materials.

[0034] In another embodiment, one or more or all of the abrasive regions may include a specific content of filler, and this specific content of filler may be beneficial to the improved performance and / or formation of the abrasive article. For example, one or more or all of the abrasive regions may independently include a filler in an amount of at least 0.5 volume % based on the volume of the corresponding abrasive region, such as a filler in an amount of at least 1 volume %, at least 3 volume %, at least 5 volume %, at least 8 volume %, at least 10 volume %, at least 13 volume %, at least 15 volume %, at least 18 volume %, at least 20 volume %, at least 25 volume %, at least 27 volume %, at least 30 volume %, at least 34 volume %, at least 38 volume % or at least 40 volume % based on the volume of the corresponding abrasive region. In another example, one or more or all of the abrasive regions may independently include a filler in an amount of at most 40 volume % based on the volume of the corresponding abrasive region, such as a filler in an amount of at most 38 volume %, at most 35 volume %, at most 32 volume %, at most 30 volume %, at most 27 volume %, at most 24 volume %, at most 22 volume %, at most 20 volume %, at most 17 volume %, at most 15 volume %, at most 13 volume %, at most 11 volume %, at most 9 volume %, at most 7 volume %, at most 5 volume %, at most 3 volume % or at most 2 volume % based on the volume of the corresponding abrasive region. Additionally, one or more or all of the abrasive regions may independently include a filler content within the range including any of the minimum percentages and maximum percentages mentioned herein. In another embodiment, any content of the filler in the abrasive regions mentioned in the embodiments herein may be understood as the average content of the filler for the abrasive portion.

[0035] In one embodiment, one or more or all of the abrasive regions can include certain porosity that can be beneficial to the improved performance and / or formation of the abrasive article. For example, one or more of the abrasive regions can independently include a porosity of at least 0.5 volume percent based on the volume of the corresponding abrasive region, such as a porosity of at least 1 volume percent, at least 3 volume percent, at least 5 volume percent, at least 8 volume percent, at least 10 volume percent, at least 13 volume percent, at least 15 volume percent, at least 18 volume percent, or at least 20 volume percent based on the volume of the corresponding abrasive region. In another example, one or more or all of the abrasive regions can independently include a porosity of at most 20 volume percent based on the volume of the corresponding abrasive region, such as a porosity of at most 17 volume percent, at most 15 volume percent, at most 13 volume percent, at most 11 volume percent, at most 9 volume percent, at most 7 volume percent, at most 5 volume percent, at most 3 volume percent, at most 2 volume percent, at most 1 volume percent, or at most 0.5 volume percent based on the volume of the corresponding abrasive region. In a specific example, one or more or all of the abrasive regions can be substantially free of porosity. Additionally, one or more or all of the abrasive regions can independently include a porosity within the range including any of the minimum and maximum percentages mentioned herein. In another embodiment, any porosity in the abrasive regions mentioned in the embodiments herein can be understood as the average porosity of the abrasive portion.

[0036] In one embodiment, the plurality of abrasive regions can include a specific content of abrasive particles, and this specific content of abrasive particles can be beneficial to the improved performance and / or formation of the abrasive article. For example, each abrasive region can independently include abrasive particles that are at least 1 volume % of the volume of the abrasive region, such as at least 3 volume %, at least 5 volume %, at least 8 volume %, at least 10 volume %, at least 13 volume %, at least 15 volume %, at least 18 volume %, at least 20 volume %, at least 25 volume %, at least 27 volume %, at least 30 volume %, at least 34 volume %, at least 38 volume %, at least 40 volume %, at least 42 volume %, at least 45 volume %, at least 48 volume %, at least 50 volume %, at least 53 volume % or at least 55 volume % of the volume of the abrasive region. In another example, each abrasive region can independently include abrasive particles that are at most 60 volume % of the volume of the abrasive region, such as at most 57 volume %, at most 55 volume %, at most 52 volume %, at most 50 volume %, at most 47 volume %, at most 45 volume %, at most 43 volume %, at most 40 volume %, at most 38 volume %, at most 35 volume %, at most 32 volume %, at most 30 volume %, at most 27 volume %, at most 24 volume %, at most 22 volume %, at most 20 volume %, at most 17 volume %, at most 15 volume %, at most 13 volume % or at most 11 volume % of the volume of the abrasive region. Additionally, each abrasive region can independently include an abrasive particle content within a range including any of the minimum percentages and maximum percentages mentioned herein. In another embodiment, any content of abrasive particles in the abrasive regions mentioned in the embodiments herein can be understood as the average content of abrasive particles in the abrasive portion.

[0037] In another embodiment, the plurality of abrasive regions can include different contents of abrasive particles from each other. In one example, at least two abrasive regions can include different contents of abrasive particles, and the differences can be within ±15%, ±12%, ±8% or ±5% of the greater content of the at least two abrasive regions. In another embodiment, at least some or all of the plurality of abrasive regions can include substantially the same content of abrasive particles.

[0038] In one embodiment, each abrasive region can include abrasive particles. The abrasive particles can have a certain hardness, which can be higher than the hardness of the filler. For example, the Mohs hardness of the abrasive particles can be at least 7, such as at least 7.5, at least about 8, at least about 8.5 or even at least about 9. The abrasive particles can include inorganic materials, including naturally occurring materials, synthetic materials or combinations thereof. Some exemplary abrasive particles can include materials such as oxides, carbides, nitrides, borides, carbon oxides, oxynitrides, oxyborides, carbon-containing materials, diamond or any combination thereof.

[0039] In one embodiment, one or more or all of the grinding regions may include abrasive particles that include superhard abrasive materials, oxides, carbides, nitrides, or any combination thereof. A specific example of the abrasive particles may include diamond, cubic boron nitride (cBN), aluminum oxide (Al2O3), silicon carbide (SiC), cerium oxide (CeO2), or any combination thereof. In a specific embodiment, the abrasive particles may include superhard abrasive materials that include diamond, cBN, or a combination thereof. In a more specific example, most (i.e., greater than 50 volume %) of the abrasive particles may include superhard abrasive materials; or even more particularly, substantially all of the abrasive particles may include superhard abrasive materials. In another specific embodiment, one or more or all of the grinding regions may include abrasive particles that may consist essentially of superhard abrasive materials. For example, the abrasive particles in one or more or all of the grinding regions may consist of diamond, cBN, or any combination thereof. The abrasive particles may include superhard abrasive materials and, more specifically, may consist essentially of superhard abrasive materials. For at least one embodiment, the abrasive particles in each grinding region may include diamond. In other cases, one or more of the grinding regions may include abrasive particles that contain cBN. In at least one non-limiting embodiment, the abrasive particles may consist essentially of diamond. In yet another embodiment, one or more or all of the grinding regions may include a blend of abrasive particles that contain superhard abrasive materials. In one example, one or more or all of the grinding regions may include secondary abrasive particles. Exemplary secondary particles may include Al2O3, SiC, flint, garnet grains, ceramic corundum, flint, cerium oxide, or any combination thereof.

[0040] In one embodiment, the body may include a first grinding region having a first diameter and a second grinding region having a second diameter that is smaller than the first diameter. For example, the first grinding region may be an outer grinding region and the second grinding region may be an inner grinding region that is closer to the center of the body compared to the first region.

[0041] In another embodiment, the first abrasive region may include abrasive particles having a specific first average particle size, which specific first average particle size may be conducive to improving the performance of the abrasive article. In one embodiment, the first average particle size may be at least 1 micron, such as at least 3 microns, at least 5 microns, at least 8 microns, at least 10 microns, at least 13 microns, at least 15 microns, at least 17 microns, at least 19 microns, at least 20 microns, at least 23 microns, at least 25 microns, at least 28 microns, at least 32 microns, at least 35 microns, at least 37 microns, at least 40 microns, at least 43 microns or at least 45 microns. Additionally or alternatively, the first average particle size may be at most 150 microns, at most 130 microns, at most 100 microns, at most 95 microns, at most 90 microns, at most 85 microns, at most 80 microns, at most 75 microns, at most 70 microns, at most 65 microns, at most 60 microns, at most 55 microns, at most 50 microns, at most 45 microns, at most 40 microns, at most 35 microns, at most 30 microns, at most 27 microns, at most 25 microns, at most 22 microns or at most 20 microns. Further, the first average particle size may be in a range including any of the minimum and maximum values mentioned herein. For example, the first average particle size may be in the range of 1 micron to 100 microns, in the range of 5 microns to 85 microns, in the range of 8 microns to 65 microns or in the range of 10 microns to 20 microns.

[0042] In another embodiment, the second abrasive region may include abrasive particles having a second average particle size, which second average particle size may be conducive to the improved performance of the abrasive article. In a specific embodiment, the second average particle size may be greater than the first average particle size.

[0043] In yet another embodiment, the second average particle size can be at least 10 microns, such as at least 13 microns, at least 15 microns, at least 17 microns, at least 19 microns, at least 20 microns, at least 25 microns, at least 30 microns, at least 35 microns, at least 40 microns, at least 40 microns, at least 45 microns, at least 50 microns, at least 55 microns, at least 60 microns, at least 65 microns, at least 70 microns, at least 80 microns, at least 90 microns, at least 100 microns, at least 110 microns, at least 130 microns, at least 150 microns, at least 180 microns, at least 200 microns, at least 250 microns, at least 300 microns, at least 350 microns or at least 400 microns. Additionally or alternatively, the second average particle size can be at most 500 microns, at most 450 microns, at most 400 microns, at most 350 microns, at most 300 microns, at most 250 microns, at most 200 microns, at most 150 microns, at most 100 microns, at most 90 microns, at most 85 microns, at most 80 microns, at most 75 microns, at most 70 microns, at most 65 microns, at most 60 microns, at most 55 microns, at most 50 microns, at most 45 microns, at most 40 microns, at most 35 microns, at most 30 microns, at most 27 microns, at most 25 microns, at most 22 microns or at most 20 microns. Further, the second average particle size can be in a range including any of the minimum and maximum values mentioned herein. For example, the second average particle size can be in the range of 10 microns to 500 microns, in the range of 15 microns to 400 microns, in the range of 20 microns to 300 microns or in the range of 30 microns to 200 microns.

[0044] In one specific embodiment, the body can include a specific particle size ratio R of the second average particle size to the first average particle size PSs / f , and this specific particle size ratio R PSs / f can be conducive to improved performance of the abrasive article. In one example, the particle size ratio R PSs / f can be at least 1.1:1, such as at least 1.3:1, at least 1.5:1, at least 1.7:1, at least 1.9:1, at least 2.2:1, at least 2.5:1, at least 2.8:1, at least 3.1:1 or at least 3.5:1. In another example, the particle size ratio R pSS / f can be at most 5.0:1, such as at most 4.8:1, at most 4.6:1, at most 4.4:1, at most 4.2:1, at most 4.0:1, at most 3.8:1, at most 3.6:1, at most 3.5:1, at most 3.3:1, at most 3.1:1, at most 2.8:1, at most 2.6:1, at most 2.4:1, at most 2.2:1, at most 1.8:1 or at most 1.5:1. Further, the particle size ratio R PSs / f can be in a range including any of the minimum and maximum values mentioned herein. For example, the particle size ratio R pSS / fIt can be in the range of 1.1 to 5.0:1 or in the range of 1.3 to 3.6:1.

[0045] In another embodiment, the body can include a ratio C of the abrasive particle content between a first grinding region and a second grinding region APR1 / C APR2 , this ratio C APR1 / C APR2 can be beneficial to the improved formation and / or performance of the abrasive article, wherein the first grinding region can include a first abrasive particle content C for the volume of the first grinding region APR1 , and the second grinding region can include a second abrasive particle content C for the volume of the second grinding region APR2 . In one example, the ratio C APR1 / C APR2 can be at least 0.1, at least 0.4, at least 0.6, at least 0.8, at least 1.0, at least 1.2, at least 1.5, at least 1.8, at least 2.0, at least 2.4, at least 2.7, at least 3.0, at least 3.2, at least 3.5, at least 3.8, at least 4, at least 4.2, at least 4.5, at least 4.8, at least 5.0, at least 5.3, at least 5.6, at least 6.0, at least 6.5, at least 6.8, at least 7 or at least 7.2. In another example, the ratio C APR1 / C APR2 can be at most 10, at most 9.5, at most 9, at most 8.7, at most 8.5, at most 8, at most 7.5, at most 7.2, at most 7.0, at most 6.8, at most 6.6, at most 6.2, at most 6, at most 5.7, at most 5.4, at most 5.2, at most 5.0, at most 4.8, at most 4.5, at most 4.2, at most 4.0, at most 3.8, at most 3.6, at most 3.2, at most 3, at most 2.8, at most 2.5, at most 2.2, at most 2.0, at most 1.8, at most 1.6, at most 1.4, at most 1.2 or at most 1.0. Additionally, the ratio C APR1 / C APR2 can be in a range including any minimum and maximum values mentioned herein.

[0046] In one embodiment, the body may include a third concentric grinding region that may be positioned closer to the central opening than the second grinding region, which may facilitate improved formation and / or performance of the abrasive article. For example, the third grinding region may have an outer diameter smaller than that of the second grinding region. In another embodiment, the third grinding region may include abrasive grains having a third average grain size, where the third average grain size may be smaller than the second abrasive grain size. In another embodiment, the third average grain size may be substantially the same as, larger than, or smaller than the first average abrasive grain size. For example, the third average grain size may include any average grain size described in the embodiments herein with respect to the first average grain size.

[0047] Figure 1 and Figure 2 respectively include top and cross-sectional views of an exemplary abrasive article 100 according to one embodiment. The abrasive article 100 may include a body 101 that includes a substrate 102 and a plurality of annular concentric grinding regions 103 to 105 disposed on a surface of the substrate 102. The substrate 102 or the body 101 may include a central opening 150, and the grinding regions 103 to 105 may be concentric with the central opening 150. In the example shown, the body 101 includes a first grinding region 103 having an outer diameter D1, a second grinding region 104 having an outer diameter D2, and a third grinding region 105 including an outer diameter D3, where D1 > D2 > D3. The total surface area of the first grinding region, the second grinding region, and the third grinding region may constitute the surface area of the grinding portion of the body 101. The outer diameter D1 may be the outer diameter of the body 101 that defines the outer circumference of the body 101. The body 101 may include an inner diameter D I , the inner diameter D I may be the inner diameter of the innermost (i.e., third) grinding region 105.

[0048] The first grinding region 103, the second grinding region 104, and the third grinding region 105 may be spaced apart from each other by non-grinding portions. In one specific embodiment, the non-grinding portions may be substantially free of abrasive grains, bonding materials, fillers, or any combination thereof. In an even more specific embodiment, the non-grinding portions may consist of a portion of the substrate.

[0049] As Figure 1 and Figure 2 shown, the body 101 may include an annular non-grinding portion 113 and a non-grinding portion 115, where the non-grinding portion 113 may be located between the first grinding region 103 and the second grinding region 104, and the non-grinding portion 115 may be located between the second grinding region 104 and the third grinding region 105.

[0050] In one specific embodiment, the body may include a specific grain size ratio R of a second average grain size to a third average grain size pSS / t , the grain size ratio R pSS / t may be beneficial to the improved performance of the abrasive article. For example, the grain size ratio R PSs / t may be at least 1.1:1, such as at least 1.3:1, at least 1.5:1, at least 1.7:1, at least 1.9:1, at least 2.2:1, at least 2.5:1, at least 2.8:1, at least 3.1:1 or at least 3.5:1. In another example, the grain size ratio R PSs / t may be at most 5.0:1, such as at most 4.8:1, at most 4.6:1, at most 4.4:1, at most 4.2:1, at most 4.0:1, at most 3.8:1, at most 3.6:1, at most 3.5:1, at most 3.3:1, at most 3.1:1, at most 2.8:1, at most 2.6:1, at most 2.4:1, at most 2.2:1, at most 1.8:1 or at most 1.5:1. Additionally, the grain size ratio R PSs / t may be within a range including any of the minimum and maximum values mentioned herein. For example, the grain size ratio R PSs / t may be in the range of 1.1 to 5.0:1 or in the range of 1.3 to 3.6:1.

[0051] In another embodiment, the body may include a ratio C of the abrasive grain content between a third grinding region and a second grinding region APR3 / C APR2 , the ratio C APR3 / C APR2 may be beneficial to the improved formation and / or performance of the abrasive article, wherein the third grinding region may include a third abrasive grain content C for the volume of the third grinding region APR3 . In one example, the ratio C APR3 / C APR2 may be at least 0.1, at least 0.4, at least 0.6, at least 0.8, at least 1.0, at least 1.2, at least 1.5, at least 1.8, at least 2.0, at least 2.4, at least 2.7, at least 3.0, at least 3.2, at least 3.5, at least 3.8, at least 4, at least 4.2, at least 4.5, at least 4.8, at least 5.0, at least 5.3, at least 5.6, at least 6.0, at least 6.5, at least 6.8, at least 7 or at least 7.2. In another example, the ratio C APR3 / C APR2can be at most 10, at most 9.5, at most 9, at most 8.7, at most 8.5, at most 8, at most 7.5, at most 7.2, at most 7.0, at most 6.8, at most 6.6, at most 6.2, at most 6, at most 5.7, at most 5.4, at most 5.2, at most 5.0, at most 4.8, at most 4.5, at most 4.2, at most 4.0, at most 3.8, at most 3.6, at most 3.2, at most 3, at most 2.8, at most 2.5, at most 2.2, at most 2.0, at most 1.8, at most 1.6, at most 1.4, at most 1.2 or at most 1.0. Additionally, the ratio C APR3 / C APR2 can be in a range including any of the minimum and maximum values mentioned herein.

[0052] In another embodiment, the body can include a ratio C APR3 / C APR1 , and this ratio C APR3 / C APR1 can be beneficial for the improved formation and / or performance of the abrasive article. In one example, C APR3 / C APR1 can be at least 0.1, at least 0.4, at least 0.6, at least 0.8, at least 1.0, at least 1.2, at least 1.5, at least 1.8, at least 2.0, at least 2.4, at least 2.7, at least 3.0, at least 3.2, at least 3.5, at least 3.8, at least 4, at least 4.2, at least 4.5, at least 4.8, at least 5.0, at least 5.3, at least 5.6, at least 6.0, at least 6.5, at least 6.8, at least 7 or at least 7.2. In another example, the ratio C APR3 / C APR1 can be at most 10, at most 9.5, at most 9, at most 8.7, at most 8.5, at most 8, at most 7.5, at most 7.2, at most 7.0, at most 6.8, at most 6.6, at most 6.2, at most 6, at most 5.7, at most 5.4, at most 5.2, at most 5.0, at most 4.8, at most 4.5, at most 4.2, at most 4.0, at most 3.8, at most 3.6, at most 3.2, at most 3, at most 2.8, at most 2.5, at most 2.2, at most 2.0, at most 1.8, at most 1.6, at most 1.4, at most 1.2 or at most 1.0. Additionally, the ratio C APR3 / C APR1 can be in a range including any of the minimum and maximum values mentioned herein.

[0053] In another embodiment, at least two of the first abrasive particle content, the second abrasive particle content, and the third abrasive particle content may be substantially the same or different. In a specific example, the first abrasive particle content, the second abrasive particle content, and the third abrasive particle content may be substantially the same. In another embodiment, the difference between at least two of the first abrasive particle content, the second abrasive particle content, and the third abrasive particle content may be within ±15%, ±12%, ±8%, or ±5% of the larger of the at least two abrasive particle contents.

[0054] In another embodiment, the body may include an outermost grinding region. For example, the outermost grinding region may include an outer circumference that may define the outer circumference of the body. For example, Figure 1 the first grinding region 103 shown in is the outermost grinding region of the body 101. In another example, the outer circumference of the outermost grinding region may be substantially aligned with and / or the same as the outer circumference of the substrate. In yet another example, the outer diameter of the outermost grinding region may define the outer diameter of the body. In another embodiment, the outermost grinding region may include one or more grinding portions. In one example, the outermost grinding region may include a plurality of grinding portions, and the grinding portions may be spaced apart from each other by non-grinding portions. In a specific example, the plurality of grinding portions may be concentric, and each grinding portion may have a substantially annular shape. In another example, the outermost grinding region may include at least 1 grinding portion or at least 2 concentric grinding portions, such as 3, 4, 5, or more concentric grinding portions.

[0055] In another embodiment, the outermost grinding region may include grinding portions having similar or different characteristics, the characteristics including one or more of grinding surface area, radial thickness, abrasive particle content, average abrasive particle size, binder material content, porosity, filler content, abrasive particle material, binder, and / or filler or any combination thereof. For example, the grinding portions may include similar or different average abrasive particle sizes. In another embodiment, the outermost grinding region may include one or more non-grinding portions. In one example, the non-grinding portions within the outermost grinding region may have substantially the same or different radial thicknesses.

[0056] In another embodiment, the outermost grinding region may include the average abrasive particle size of all the grinding portions within the outermost grinding region, where the average abrasive particle size may be smaller than the next inner grinding region. In a specific example, the average particle size of the outermost grinding region may include any value described with respect to the first average abrasive size. The average particle size may be determined by laser diffraction in accordance with ISO13320:2020.

[0057] In another embodiment, the body can include an innermost grinding region. The innermost grinding region can be spaced a radial distance from the central opening. In one example, the radial distance can be suitable for mounting and / or operating the abrasive article on certain grinding machines. In another embodiment, the innermost grinding region can include one or more grinding portions. In one example, the innermost grinding region can include a plurality of grinding portions that can be spaced from each other by non-grinding portions. In a specific example, the plurality of grinding portions can be concentric, where each grinding portion can have a substantially annular shape. In another example, the innermost grinding region can include at least 1 grinding portion or at least 2 concentric grinding portions, such as 3, 4, 5, or more concentric grinding portions.

[0058] In another embodiment, the innermost grinding region can include grinding portions having similar or different characteristics, where the characteristics include one or more of grinding surface area, radial thickness, abrasive particle content, average abrasive grain size, binder material content, porosity, filler content, abrasive particle material, binder, and / or filler or any combination thereof. For example, the grinding portions can include similar or different average abrasive grain sizes. In another embodiment, the innermost grinding region can include one or more non-grinding portions. In one example, the non-grinding portions within the innermost grinding region can have substantially the same or different radial thicknesses.

[0059] In another embodiment, the innermost grinding region can include the average abrasive grain size of all the grinding portions within the innermost grinding region, where the average abrasive grain size can be smaller than the next outer grinding region. In one example, the innermost grinding region can include an average grain size that includes any of the values described with respect to the first average abrasive size. In a specific example, the third grinding region can be the innermost grinding region.

[0060] In another embodiment, the body can include a first grinding region as the outermost grinding region, a third grinding region as the innermost grinding region, and a second grinding region as an intermediate grinding region between the innermost grinding region and the outermost grinding region. In one embodiment, the body can include an intermediate grinding region that includes one or more grinding portions. In one example, the intermediate grinding region can include a plurality of grinding portions that can be spaced from each other by non-grinding portions. In a specific example, the plurality of grinding portions can be concentric, where each grinding portion can have a substantially annular shape. In another example, the intermediate grinding region can include at least 1 grinding portion or at least 2 concentric grinding portions, such as 3, 4, 5, or more concentric grinding portions.

[0061] In another embodiment, the intermediate grinding region can include grinding portions having similar or different characteristics, which characteristics include grinding surface area, radial thickness, abrasive particle content, average abrasive grain size, binder material content, porosity, filler content, abrasive particle material, binder, and / or filler or any combination of one or more of them. For example, the grinding portions can include similar or different average abrasive grain sizes. In another embodiment, the intermediate grinding region can include one or more non-grinding portions. In one example, the non-grinding portions within the intermediate grinding region can have substantially the same or different radial thicknesses.

[0062] In another embodiment, the intermediate grinding region can include the average abrasive grain size of all the grinding portions within the intermediate grinding region, where the average abrasive grain size can be greater than the next outer grinding region (i.e., the outermost grinding region) and greater than the next inner grinding region (i.e., the innermost grinding region). In one example, the intermediate grinding region can include an average grain size that includes any of the values described with respect to the second average abrasive size.

[0063] See Figure 8 , which shows a representative abrasive article 800, including a body 801 that includes a grinding region 802, a grinding region 803, and a grinding region 804. The grinding region 802 is the outermost grinding region and includes concentric annular grinding portions 812 and grinding portion 822 and a non-grinding portion 852 between the grinding portions 812 and 822. The grinding portions 812 and 822 include segments 832. In another example, one or each of the grinding portions 812 and 822 can be unsegmented.

[0064] The intermediate grinding region 803 includes concentric annular grinding portions 813 and grinding portion 823 spaced apart by non-grinding portions. The grinding portions 813 and 823 include segments 833. In another example, one or each of the grinding portions 813 and 823 can be unsegmented.

[0065] The inner grinding region 804 includes concentric annular grinding portions 814 and concentric annular grinding portion 824 spaced apart by non-grinding portions. The grinding portions 814 and 824 include segments 834. In another example, one or each of the grinding portions 814 and 824 can be unsegmented.

[0066] In one embodiment, the body can include a specific percentage of the surface area of the grinding region, which specific percentage can be beneficial for improved performance and / or formation of the abrasive article. As used herein, the surface area of the grinding region is intended to refer to the total working surface area of the grinding region. The working surface of the grinding region is the surface intended to contact the workpiece, such as inFigure 2 The top surface of each abrasive region as observed in a cross-sectional view of the abrasive article 100 in []. In one embodiment, the body may include at least 15%, such as at least 18%, at least 20%, at least 22%, at least 25%, at least 28%, at least 30%, at least 32%, at least 35%, at least 38%, at least 41%, at least 45%, at least 48%, at least 50%, at least 52%, at least 55%, at least 58%, at least 60%, at least 63%, at least 65% or at least 68% of the surface area percentage of the abrasive regions. Alternatively or additionally, the surface area percentage of the abrasive regions may be at most 76%, such as at most 73%, at most 70%, at most 68%, at most 65%, at most 63%, at most 60%, at most 58%, at most 55%, at most 53%, at most 50%, at most 48%, at most 45%, at most 43%, at most 40%, at most 38%, at most 35%, at most 33%, at most 30%, at most 28% or at most 25%. Further, the body may include a surface area percentage of the abrasive regions within a range including any of the minimum and maximum percentages mentioned herein. For example, the surface area percentage of the abrasive regions may be within a range including at least 15% and at most 75%, or within a range including at least 22% and at most 72%, or within a range including at least 30% and at most 70%. The surface area percentage of the abrasive regions may be the surface area of all the abrasive regions relative to Figure 1 the inner circumference of the innermost abrasive region of the body 101 shown (i.e., defined by the inner diameter D I ), and the surface area of the body 101 between the outermost circumference (i.e., defined by the diameter D1).

[0067] In another embodiment, the first grinding region (i.e., the outermost grinding region) may include a specific first percentage of the grinding surface area relative to the surface area of the grinding region, and this specific first percentage of the grinding surface area may be beneficial to the improved performance of the abrasive article 100. For example, the first percentage of the grinding surface area may be at least 10% relative to the surface area of the grinding region, such as at least 13%, at least 15%, at least 18%, at least 20%, at least 22%, at least 25%, at least 28%, at least 30%, at least 33%, at least 35%, at least 37%, at least 40%, at least 43%, at least 45%, at least 50%, at least 55%, at least 60%, at least 64%, at least 68%, at least 70% or at least 75% relative to the surface area of the grinding region. In another example, the first percentage of the grinding surface area may be at most 80% relative to the surface area of the grinding region, such as at most 75%, at most 70%, at most 65%, at most 60%, at most 56%, at most 52%, at most 48%, at most 45%, at most 43%, at most 40%, at most 38%, at most 35%, at most 33%, at most 30%, at most 27%, at most 25%, at most 23% or at most 20% relative to the surface area of the grinding region. Additionally, the first percentage of the grinding surface area may be within a range including any of the minimum and maximum percentages mentioned herein. For example, the first percentage of the grinding surface area relative to the surface area of the grinding region may be in the range of 10% to 80% or in the range of 10% to 50% or in the range of 20% to 45%.

[0068] In another embodiment, the third grinding region (i.e., the innermost grinding region) may include a grinding surface area that is a third percentage of the surface area of the grinding region, and this third percentage of the grinding surface area may be conducive to improved performance of the abrasive article. For example, the third grinding surface area may be at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, at least 50%, at least 55%, at least 60%, at least 64%, at least 68%, at least 70%, or at least 75% relative to the surface area of the grinding region. In another example, the third percentage of the grinding surface area may be at most 80% relative to the surface area of the grinding region, such as at most 75%, at most 70%, at most 65%, at most 60%, at most 56%, at most 52%, at most 48%, at most 45%, at most 42%, at most 40%, at most 38%, at most 35%, at most 32%, at most 30%, at most 28%, at most 25%, at most 23%, or at most 20% relative to the surface area of the grinding region. Additionally, the third percentage of the grinding surface area may be within a range including any of the minimum and maximum percentages mentioned herein. For example, the third percentage of the grinding surface area may be within the range of 10% to 80% or within the range of 10% to 50% or within the range of 20% to 45% relative to the surface area of the grinding region. In another example, the third percentage of the grinding surface area may be substantially the same as or different from the first percentage of the grinding surface area.

[0069] In another embodiment, the second grinding region (i.e., the intermediate grinding region) may include a grinding surface area that is a second percentage of the surface area of the grinding region, and this second percentage of the grinding surface area may be conducive to improved performance of the abrasive article. For example, the second grinding surface area may be at least 10% relative to the surface area of the grinding region, such as at least 12%, at least 15%, at least 20%, at least 23%, at least 25%, at least 30%, at least 33%, at least 35%, at least 38%, at least 40%, at least 42%, at least 45%, at least 50%, at least 55%, at least 60%, at least 64%, at least 68%, at least 70% or at least 75% relative to the surface area of the grinding region. In another example, the second percentage of the grinding surface area may be at most 80% relative to the surface area of the grinding region, such as at most 75%, at most 70%, at most 65%, at most 60%, at most 56%, at most 52%, at most 48%, at most 45%, at most 42%, at most 40%, at most 38%, at most 35%, at most 32%, at most 30%, at most 28%, at most 25%, at most 23% or at most 20% relative to the surface area of the grinding region. Additionally, the second percentage of the grinding surface area may be within a range that includes any of the minimum and maximum percentages mentioned herein. For example, the second percentage of the grinding surface area may be in the range of 10% to 80% or in the range of 10% to 50% or in the range of 20% to 45% relative to the surface area of the grinding region. In another example, the second percentage of the grinding surface area may be substantially the same as or different from the first percentage of the grinding surface area and / or the third percentage of the grinding surface area. In a specific embodiment, the second percentage of the grinding surface area may be substantially the same as the first percentage of the grinding surface area and / or the third percentage of the grinding surface area.

[0070] In one embodiment, the body may include a specific surface area ratio R of the first grinding region to the second grinding region SA1 / 2 , and this specific surface area ratio R SA1 / 2 may be conducive to improved performance of the abrasive article. In one example, the ratio R SA1 / 2 may be at least 1:10, such as at least 1:9, at least 1:8, at least 1:7, at least 1:6, at least 1:5, at least 1:3, at least 1:1, at least 2:1, at least 3:1, at least 4:1, at least 5:1, at least 6:1, at least 7:1, at least 8:1, at least 9:1 or at least 10:1. In another example, the ratio R SA1 / 2 may be at most 10:1, at most 9:1, at most 8:1, at most 7:1, at most 6:1, at most 5:1, at most 4:1, at most 2:1, at most 1:1, at most 1:2, at most 1:3, at most 1:4, at most 1:5, at most 1:6, at most 1:7, at most 1:8, at most 1:9 or at most 1:10. Additionally, the ratio RSA1 / 2 can be within a range including any of the minimum and maximum values mentioned herein. For example, the ratio R SA1 / 2 can be in the range of 1:10 to 10:1 or in the range of 1:5 to 5:1 or in the range of 1:3 to 3:1 or in the range of 1:2 to 2:1.

[0071] In one embodiment, the body can include a specific surface area ratio R of a first grinding region to a third grinding region SA1 / 3 , and this specific surface area ratio R SA1 / 3 can be conducive to improved performance of the abrasive article. In one example, the ratio R SA1 / 3 can be at least 1:10, such as at least 1:9, at least 1:8, at least 1:7, at least 1:6, at least 1:5, at least 1:3, at least 1:1, at least 2:1, at least 3:1, at least 4:1, at least 5:1, at least 6:1, at least 7:1, at least 8:1, at least 9:1 or at least 10:1. In another example, the ratio R SA1 / 3 can be at most 10:1, at most 9:1, at most 8:1, at most 7:1, at most 6:1, at most 5:1, at most 4:1, at most 2:1, at most 1:1, at most 1:2, at most 1:3, at most 1:4, at most 1:5, at most 1:6, at most 1:7, at most 1:8, at most 1:9 or at most 1:10. Additionally, the ratio R SA1 / 3 can be within a range including any of the minimum and maximum values mentioned herein. For example, the ratio R SA1 / 3 can be in the range of 1:10 to 10:1 or in the range of 1:5 to 5:1 or in the range of 1:3 to 3:1 or in the range of 1:2 to 2:1.

[0072] In one embodiment, the body can include a specific surface area ratio R of a second grinding region to a third grinding region SA2 / 3 , and this specific surface area ratio R SA2 / 3 can be conducive to improved performance and / or formation of the abrasive article. In one example, the ratio R SA2 / 3 can be at least 1:10, such as at least 1:9, at least 1:8, at least 1:7, at least 1:6, at least 1:5, at least 1:3, at least 1:1, at least 2:1, at least 3:1, at least 4:1, at least 5:1, at least 6:1, at least 7:1, at least 8:1, at least 9:1 or at least 10:1. In another example, the ratio R SA1 / 3 can be at most 10:1, at most 9:1, at most 8:1, at most 7:1, at most 6:1, at most 5:1, at most 4:1, at most 2:1, at most 1:1, at most 1:2, at most 1:3, at most 1:4, at most 1:5, at most 1:6, at most 1:7, at most 1:8, at most 1:9 or at most 1:10. Additionally, the ratio RSA2 / 3 can be within a range including any minimum and maximum values mentioned herein. For example, the ratio R SA1 / 3 can be in the range of 1:10 to 10:1 or in the range of 1:5 to 5:1 or in the range of 1:3 to 3:1 or in the range of 1:2 to 2:1.

[0073] In one embodiment, the first grinding region (e.g., Figure 1 the grinding region 103 shown in Figure 2 ) can include a specific first radial thickness t1 (shown in

[0074] which can be beneficial for improved performance and / or formation of the abrasive article. In another embodiment, the first radial thickness t1 can be at least 1% relative to the outer diameter D1 of the body, such as at least 2%, at least 5%, at least 7%, at least 8%, at least 10%, at least 12%, at least 15%, at least 18%, at least 20%, at least 22%, at least 25%, at least 28%, at least 30%, at least 33%, or at least 35% relative to the outer diameter D1 of the body. Alternatively or additionally, the first radial thickness t1 can be at most 40% relative to the outer diameter of the body, at most 35% relative to the outer diameter of the body, at most 33%, at most 30%, at most 27%, at most 25%, at most 22%, at most 20%, at most 17%, at most 15%, at most 12%, at most 10%, at most 8%, at most 6%, at most 5%, at most 3%, or at most 2%. Further, the first radial thickness t1 can be within a range including any minimum and maximum percentages mentioned herein. For example, t1 can be in the range of 1% to 40% of the outer diameter D1, or in the range of 1% to 35% of the outer diameter D1, or in the range of 1% to 25% of the outer diameter D1, or in the range of 1% to 15% of the outer diameter D1, or in the range of 2% to 7% of the outer diameter D1. In another embodiment, for the outermost grinding region including a plurality of grinding portions, t1 can be the total radial thickness of the grinding portions.

[0074] In another embodiment, the second grinding region (e.g., Figure 1 the grinding region 104 shown in Figure 2As shown (e.g., in ), this particular second radial thickness t2 can be beneficial for improved performance and / or formation of the abrasive article. For example, the second radial thickness t2 can be at least 1% relative to the outer diameter D1 of the body, such as at least 2%, at least 5%, at least 7%, at least 8%, at least 10%, at least 12%, at least 15%, at least 18%, at least 20%, at least 22%, at least 25%, at least 28%, at least 30%, at least 33%, or at least 35% relative to the outer diameter D1 of the body. In another example, the second radial thickness t2 can be at most 40% relative to the outer diameter of the body, at most 35%, at most 33%, at most 30%, at most 27%, at most 25%, at most 22%, at most 20%, at most 17%, at most 15%, at most 12%, at most 10%, at most 8%, at most 6%, at most 5%, at most 3%, or at most 2% relative to the outer diameter of the body. Additionally, the second radial thickness t2 can be within a range that includes any of the minimum and maximum percentages mentioned herein. For example, t2 can be in the range of 1% to 40% of the outer diameter D1, or in the range of 1% to 35% of the outer diameter D1, or in the range of 1% to 25% of the outer diameter D1, or in the range of 1% to 15% of the outer diameter D1, or in the range of 2% to 7% of the outer diameter D1. In another embodiment, for an intermediate grinding zone that includes a plurality of grinding segments, t2 can be the total radial thickness of the grinding segments.

[0075] In another embodiment, a third grinding zone (e.g., Figure 1 the grinding zone 105 shown in ) can include a particular third radial thickness t3 ( Figure 2as shown), this particular third radial thickness t3 can be beneficial to the improved performance and / or formation of the abrasive article. For example, the third radial thickness t3 can be at least 1% relative to the outer diameter D1 of the body, such as at least 2%, at least 5%, at least 7%, at least 8%, at least 10%, at least 12%, at least 15%, at least 18%, at least 20%, at least 22%, at least 25%, at least 28%, at least 30%, at least 33% or at least 35% relative to the outer diameter D1 of the body. In another example, the third radial thickness t3 can be at most 40% relative to the outer diameter of the body, at most 35% relative to the outer diameter of the body, at most 33%, at most 30%, at most 27%, at most 25%, at most 22%, at most 20%, at most 17%, at most 15%, at most 12%, at most 10%, at most 8%, at most 6%, at most 5%, at most 3% or at most 2%. Additionally, the third radial thickness t3 can be within a range including any of the minimum and maximum percentages mentioned herein. For example, t3 can be in the range of 1% to 40% of the outer diameter D1, or in the range of 1% to 35% of the outer diameter D1, or in the range of 1% to 25%, or in the range of 1% to 15%, or in the range of 2% to 7%. In another embodiment, the first radial thickness t1 can be substantially the same as the second radial thickness t2 and / or the third radial thickness t3. In another embodiment, for the innermost grinding region including a plurality of grinding portions, t3 can be the total radial thickness of the grinding portions.

[0076] In one embodiment, the body (e.g., Figures 1 to 2 101 as shown in Figures 1 to 2 can include an axial height Hb, and the first grinding region, the second grinding region, and the third grinding region (e.g., ar1 103 to 105 as shown in ar2 can respectively include an axial height H ar3 ( Figure 2 as shown). In another embodiment, for a grinding region including a plurality of grinding portions (e.g., the third / innermost grinding region, the second / intermediate grinding region, and / or the first / outermost grinding region), the axial height of the grinding region can be the average axial height of the grinding portions within the grinding region. In another embodiment, the first grinding region can include a specific first axial height H ar1 , and this specific first axial height H ar1 can be beneficial to the improved performance and / or formation of the abrasive article. For example, the first axial height H ar1The axial height Hb relative to the body 101 can be at least 1%, such as at least 2%, at least 4%, at least 6%, at least 8%, at least 10%, at least 12%, at least 15%, at least 18%, at least 20%, at least 22%, at least 24%, at least 26%, at least 28%, at least 30%, at least 33%, at least 35%, at least 38%, at least 40%, at least 42%, at least 45%, at least 47%, or at least 50% relative to the axial height of the body. In another example, the first axial height H ar1 The axial height Hb relative to the body can be at most 50%, such as at most 47%, at most 44%, at most 41%, at most 38%, at most 35%, at most 33%, at most 30%, at most 27%, at most 25%, at most 22%, at most 20%, at most 17%, at most 15%, at most 12%, at most 10%, at most 8%, at most 6%, at most 5%, at most 3%, or at most 2% relative to the axial height of the body 101. Additionally, the first axial height H ar1 can be in a range including any of the minimum and maximum percentages mentioned herein. For example, the first axial height H ar1 can be in the range of 1% to 50% or in the range of 2% to 30% or in the range of 4% to 24%.

[0077] In another embodiment, the second grinding area can include a specific second axial height H ar2 which can be beneficial for improved performance and / or formation of the abrasive article. For example, the second axial height H ar2 The axial height Hb relative to the body 101 can be at least 1%, such as at least 2%, at least 4%, at least 6%, at least 8%, at least 10%, at least 12%, at least 15%, at least 18%, at least 20%, at least 22%, at least 25%, at least 28%, at least 30%, at least 33%, at least 35%, at least 38%, at least 40%, at least 42%, at least 45%, at least 47%, or at least 50% relative to the axial height of the body. In another example, the second axial height H ar2 The axial height Hb relative to the body 101 can be at most 50%, such as at most 47%, at most 44%, at most 41%, at most 38%, at most 35%, at most 33%, at most 30%, at most 27%, at least 24%, at most 26%, at most 22%, at most 20%, at most 17%, at most 15%, at most 12%, at most 10%, at most 8%, at most 6%, at most 5%, at most 3%, or at most 2% relative to the axial height of the body. Additionally, the second axial height H ar2 can be in a range including any of the minimum and maximum percentages mentioned herein. For example, the second axial height H ar2 can be in the range of 1% to 50% or in the range of 2% to 30% or in the range of 4% to 24%.ar2 It may be in the range of 1% to 50%, or in the range of 2% to 30%, or in the range of 4% to 24%.

[0078] In another embodiment, the third grinding region may include a specific third axial height H ar3 , and this third axial height H ar3 may be beneficial to the improved performance and / or formation of the abrasive article. For example, the third axial height H ar3 relative to the axial height Hb of the body may be at least 1%, such as at least 2%, at least 4%, at least 6%, at least 8%, at least 10%, at least 12%, at least 15%, at least 18%, at least 20%, at least 22%, at least 24%, at least 26%, at least 28%, at least 30%, at least 33%, at least 35%, at least 38%, at least 40%, at least 42%, at least 45%, at least 47% or at least 50% relative to the axial height Hb of the body 101. In another example, the third axial height H ar3 relative to the axial height Hb of the body 101 may be at most 50%, such as at most 47%, at most 44%, at most 41%, at most 38%, at most 35%, at most 33%, at most 30%, at most 27%, at most 25%, at most 22%, at most 20%, at most 17%, at most 15%, at most 12%, at most 10%, at most 8%, at most 6%, at most 5%, at most 3% or at most 2% relative to the axial height Hb of the body 101. In addition, the third axial height H ar3 may be in the range including any of the minimum and maximum percentages mentioned herein. For example, the third axial height H ar3 may be in the range of 1% to 50%, or in the range of 2% to 30%, or in the range of 4% to 24%.

[0079] In another embodiment, the first axial height, the second axial height or the third axial height can be at least 1mm, such as at least 3mm, at least 5mm, at least 7mm, at least 8mm, at least 10mm, at least 11mm, at least 13mm, at least 15mm, at least 18mm or at least 20mm.Alternately or additionally, the first axial height, the second axial height or the third axial height can be at most 30mm, at most 28mm, at most 25mm, at most 23mm, at most 20mm, at most 18mm, at most 15mm, at most 12mm, at most 10mm, at most 8mm, at most 7mm, at most 5mm, at most 4mm, at most 3mm or at most 2mm.In addition, the first axial height, the second axial height or the third axial height can be in the scope of any minimum and maximum values ​​mentioned herein.For example, the first axial height, the second axial height or the third axial height can be in the scope of 1mm to 30mm or in the scope of 3mm to 20mm. In a specific embodiment, the axial heights of the first grinding region, the second grinding region, and the third grinding region can be substantially the same.

[0080] In one embodiment, the outermost abrasive region may be composed of a first non-abrasive portion (e.g., Figure 1 113) is spaced apart from the intermediate grinding region, the first non-grinding portion may include a specific radial thickness t4 ( Figure 2 ), the specific radial thickness t4 can be beneficial to the improved performance and / or formation of the abrasive article. For example, the radial thickness t4 relative to the body (e.g., Figures 1 to 2 101) shown in the figure may be at least 1%, such as at least 2%, at least 3%, at least 4%, at least 5%, at least 6%, at least 7%, at least 8%, at least 10%, at least 12%, or at least 15% relative to the outer diameter D1 of the body 101. In another example, the first non-abrasive portion may include a radial thickness t4 of at most 20% relative to the outer diameter D1 of the body 101, such as at most 19%, at most 18%, at most 16%, at most 15%, at most 12%, at most 10%, at most 8%, at most 7%, at most 6%, at most 5%, at most 4%, at most 3%, or at most 2% relative to the outer diameter D1 of the body 101. In addition, the radial thickness t4 may be within a range including any minimum and maximum percentages mentioned herein. For example, the radial thickness t4 may be in the range of 1% to 20% or in the range of 1% to 20% or in the range of 1% to 14% or in the range of 1% to 10% or in the range of 1% to 8% or in the range of 2% to 6%.

[0081] In one embodiment, the middle grinding region and the innermost grinding region may be formed by a second non-grinding portion (e.g., Figure 2spaced apart as shown in 115), the second non-abrasive portion may include a specific radial thickness t5( Figure 2 as shown in), the specific radial thickness t5 may facilitate improved performance and / or formation of the abrasive article. For example, the radial thickness t5 relative to the outer diameter D1 of the body 101 (e.g., Figures 1 to 2 as shown in) may be at least 1%, such as at least 2%, at least 3%, at least 4%, at least 5%, at least 6%, at least 7%, at least 8%, at least 10%, at least 12%, or at least 15% relative to the outer diameter D1 of the body 101. In another example, the second non-abrasive portion 115 may include a radial thickness t5 that is at most 20% relative to the outer diameter D1 of the body 101, such as at most 19%, at most 18%, at most 16%, at most 15%, at most 12%, at most 10%, at most 8%, at most 7%, at most 6%, at most 5%, at most 4%, at most 3%, or at most 2% relative to the outer diameter D1 of the body 101. Additionally, the radial thickness t5 may be within a range that includes any of the minimum and maximum percentages mentioned herein. For example, the radial thickness t5 may be in the range of 1% to 20% or in the range of 1% to 20% or in the range of 1% to 14% or in the range of 1% to 10% or in the range of 1% to 8% or in the range of 2% to 6%.

[0082] In another embodiment, one or more or all of the innermost abrasive region, the intermediate abrasive region, and the outermost abrasive region may include a plurality of abrasives, wherein adjacent abrasive portions may be spaced apart by non-abrasive portions. In another embodiment, the body may include at least 3, at least 4, or more non-abrasive portions alternating with the abrasive portions. In another embodiment, each non-abrasive portion may include any of the features described with respect to the first non-abrasive portion or the second non-abrasive portion.

[0083] In one embodiment, the body may include a working surface that may include at least a portion of the surface area of each of the first abrasive region, the second abrasive region, and the third abrasive region. In a specific embodiment, the working surface of the body (e.g., Figure 1 and Figure 2 the body 101 shown in) may include a first working surface 133 of the first abrasive region 103, a second working surface 134 of the second abrasive region 104, and a third working surface 135 of the third abrasive region 105( Figures 1 to 2(shown in). In another embodiment, the first grinding area 103 may be configured to wear at a first wear rate, and the second grinding area 104 may be configured to wear at a second wear rate, where the difference between the first wear rate and the second wear rate may be within 10% of the larger of the first wear rate and the second wear rate, such as within 9%, 7%, 5%, 3%, or 1% of the larger of the first wear rate and the second wear rate. In another embodiment, the third grinding area may be configured to wear at a third wear rate, where the difference between the third wear rate and the second wear rate may be within 10% of the larger of the second wear rate and the third wear rate, such as within 9%, 7%, 5%, 3%, or 1% of the larger of the second wear rate and the third wear rate. In yet another embodiment, the difference between the third wear rate and the first wear rate may be within 10% of the larger of the third wear rate and the first wear rate, such as within 9%, 7%, 5%, 3%, or 1% of the larger of the third wear rate and the first wear rate. In a specific embodiment, the first grinding area, the second grinding area, and the third grinding area are configured to wear at substantially the same rate.

[0084] In another embodiment, the body may include the total surface area of the non-grinding area, and the total surface area of the non-grinding area may be beneficial to the improved performance of the abrasive article. In another embodiment, the body may include a specific ratio R of the total surface area of the non-grinding portion to the total surface area of the grinding area SN / SA , the specific ratio R SN / SAMay be beneficial for improved performance and / or formation of the abrasive article. For example, the body may include at least 50% of the total surface area of the non-abrasive portion relative to the total surface area of the abrasive region, such as at least 60%, at least 70%, at least 80%, at least 90%, at least 100%, at least 120%, at least 130%, at least 140%, at least 150%, at least 160%, at least 170%, at least 180%, at least 190%, at least 200%, at least 210%, at least 220%, at least 230%, at least 240% or at least 250% of the total surface area of the non-abrasive portion relative to the total surface area of the abrasive region. In another example, the body may include at most 250% of the total surface area of the non-abrasive portion relative to the total surface area of the abrasive region, such as at most 240%, at most 230%, at most 220%, at most 210%, at most 200%, at most 190%, at most 180%, at most 170%, at most 160%, at most 150%, at most 140%, at most 130%, at most 120%, at most 110%, at most 100%, at most 90%, at most 80%, at most 70%, at most 60% or at most 50% of the total surface area of the non-abrasive portion relative to the total surface area of the abrasive region. Additionally, the percentage of the total surface area of the non-abrasive portion relative to the total surface area of the abrasive region may be within a range including any of the minimum and maximum percentages mentioned herein. After reading this disclosure, those skilled in the art will recognize that the surface area, radial thickness, and / or relative placement of the non-abrasive portion of the embodiments herein may be beneficial for improving chip removal, coolant flow, or any combination thereof during the grinding operation.

[0085] In another embodiment, the body may include a specific ratio D1 / D Figure 1 (shown in I ) of the outer diameter D1 (shown in Figure 1 ) to the inner diameter D I , and this specific ratio D1 / D I may be beneficial for improved formation and / or performance of the abrasive article. For example, the body may include a ratio D1 / D I of at least 10%, such as at least 15%, at least 20%, at least 25%, at least 30%, at least 33%, at least 37%, at least 40%, at least 45%, at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 73%, at least 77% or at least 80%. In another example, the body may include a ratio D1 / D I of at most 80, such as at most 77%, at most 75%, at most 70%, at most 68%, at most 65%, at most 63%, at most 60%, at most 56%, at most 53%, at most 50%, at most 45%, at most 40%, at most 35%, at most 32%, at most 30%, at most 25%, at most 20%, at most 15% or at most 10%.I In addition, the ratio D1 / D I can be within a range including any of the minimum and maximum percentages mentioned herein.

[0086] Figure 3 Includes a flowchart showing a process 300 for forming an abrasive article according to one embodiment. At block 302, a mixture including a bonding material and / or a precursor bonding material and abrasive grains can be prepared. The bonding material and / or the precursor bonding material can be a liquid, a powder, or a combination thereof. Exemplary bonding materials and / or bonding precursor materials can include one or more resins, such as phenolic resins, epoxy resins, polyester resins, polyurethanes, polyesters, rubbers, polyimides, polybenzimidazoles, aramids, modified phenolic resins (e.g., epoxy-modified and rubber-modified resins or phenolic resins blended with plasticizers, etc.), or any combination thereof. In a specific embodiment, the bonding material and / or the precursor bonding material can include a phenolic resin. In a specific example, the bonding material and / or the precursor bonding material can include a phenolic resin having crosslinked domains with a submicron average size.

[0087] The bonding material and / or the precursor bonding material can also include a curing agent or a crosslinking agent. Exemplary curing agents or crosslinking agents can include amines, such as ethylenediamine, triethylenetetramine, methylamine, etc. A specific example can include hexamethylenetetramine. Another specific example of the bonding material and / or the precursor bonding material can include a phenolic resin modified with a curing agent or a crosslinking agent, such as a hexamethylenetetramine-modified phenolic resin.

[0088] The mixture can optionally include one or more optional additives, including, for example, secondary abrasive grains, fillers, etc., or any combination thereof. In some cases, a mixing device can be utilized to help obtain a homogeneous mixture.

[0089] After reading this disclosure, those skilled in the art will recognize that separate mixtures can be formed for forming the grinding regions described in the embodiments herein.

[0090] Process 300 can continue to block 304 after forming one or more mixtures. In one embodiment, process 300 can include forming a green grinding region that includes abrasive grains contained in the bonding material and / or the bonding precursor material. The green grinding region or body is an unfinished grinding region or body and can be subjected to further processing before forming the finally formed grinding region or body. The formation of the green grinding region can include techniques such as pressing, molding, casting, printing, spraying, or a combination thereof. In a specific embodiment, the formation of the green grinding region can include pressing the mixture into a specific shape, including, for example, performing a pressing operation to form a green grinding region having an annular shape.

[0091] In one embodiment, process 300 may include forming a plurality of green grinding regions from a suitable mixture.

[0092] Process 300 may continue by processing one or more of the green grinding regions to form one or more finally formed grinding regions. Some suitable examples of processing may include curing, heating, sintering, crystallization, polymerization, pressing, or any combination thereof.

[0093] In one example, the process may include processing the green grinding region at the final cure temperature of the binder material and / or precursor binder material. For example, the cure temperature may be in the range of 150 °C to 250 °C, such as in the range of 150 °C to 230 °C, in the range of 110 °C to 225 °C, or in the range of 140 °C to 225 °C. Certain novolac resins suitable for the embodiments herein may cure at temperatures in the range of 110 °C to 195 °C. In another example, the green grinding region may be held at the final cure temperature for a period of time, such as between 6 hours and 48 hours, between 10 hours and 36 hours, or until the green grinding region reaches a crosslinking temperature or obtains a desired density.

[0094] After forming the grinding region, process 300 may proceed to block 306 to form an abrasive article including the finally formed body. The grinding region may be attached to a major surface of a substrate. In one embodiment, an adhesive may be used to facilitate attachment of the grinding region. Exemplary adhesives may include pressure sensitive adhesives, hot melt adhesives, two-part adhesives, etc. Particularly suitable adhesives may include epoxy resins. In another embodiment, the grinding region may be bonded to the substrate via an adhesive to form the body. In another embodiment, the body may be further processed to have a desired shape, such as a wheel, a disk, etc.

[0095] In one embodiment, a grinding system may include one or more abrasive articles. Figure 4 An illustration of a system 400 according to one embodiment is shown, the system including a grinding device 430 that includes exemplary abrasive articles 401 and 403 mounted on a shaft 410. Abrasive articles 401 and 403 may be similar to Figure 1 abrasive article 101. The working surfaces of abrasive articles 401 and 403 may face each other. At least a portion of workpiece 402 may be positioned between the working surfaces such that opposing surfaces of workpiece 402 may be ground simultaneously or separately during a grinding operation. As shown, in one particular operation, abrasive body 401 may rotate in direction 404, abrasive body 403 may rotate in direction 405, and workpiece 402 may rotate in direction 406 for grinding opposing surfaces of workpiece 402.

[0096] Figure 11 Top view of an abrasive article 1100 including a body 1101 according to one embodiment. The outermost grinding region 1102 may include grinding portions 1121 and 1122 spaced apart from each other by non-grinding portions 1151. In the specific embodiment shown, the intermediate grinding region 1103 may be in contact with the grinding portion 1121 while being spaced apart from the grinding portion 1122. In one specific embodiment, the outermost grinding region 1102 may include an average abrasive grain size, which includes any value disclosed with respect to the first grinding region.

[0097] The intermediate grinding region 1103 may be spaced apart from the innermost grinding region 1104 by a second non-grinding portion 1152. As shown, each of the grinding regions 1102, 1103, and 1104 may include a plurality of grinding segments that may be spaced apart from each other.

[0098] After reading this disclosure, those skilled in the art will understand that the inner grinding region may include grinding portions, where one of the grinding portions may be in contact with the intermediate grinding region while being spaced apart from another grinding portion that may be positioned closer to the central opening by a non-grinding portion. In another embodiment, the intermediate grinding region may be in contact with the grinding portions of the outermost grinding region and the innermost grinding region.

[0099] Embodiment

[0100] Embodiment 1. An abrasive article comprising a body having a plurality of grinding regions, the grinding regions comprising:

[0101] A first grinding region comprising first abrasive grains having a first average grain size; and

[0102] A concentric second grinding region comprising second abrasive grains having a second average grain size greater than the first average grain size,

[0103] wherein the second grinding region is spaced apart from the first grinding region and has a diameter smaller than that of the first grinding region.

[0104]

[0105] Embodiment 2. The abrasive article according to Embodiment 1, wherein the body includes an inner diameter (D I ) defining a central region of the body and an outermost diameter (D1) defining an outer circumference of the body, wherein the surface area percentage of the plurality of grinding regions is at least 30% and not greater than 70% with respect to the surface area of the body between D I and D1.

[0106] Embodiment 3. The abrasive article according to Embodiment 1 or 2, wherein the body includes an annular non-abrasive portion between the first abrasive region and the second abrasive region.

[0107] Embodiment 4. The abrasive article according to any one of Embodiments 1 to 3, wherein the plurality of abrasive regions includes a third abrasive region concentric with the first abrasive region and the second abrasive region, wherein the third abrasive region has a diameter smaller than that of the second abrasive region and includes third abrasive grains having a third average abrasive grain size smaller than the second average abrasive grain size.

[0108] Embodiment 5. The abrasive article according to Embodiment 4, wherein the body includes an annular non-abrasive portion between the third abrasive region and the second abrasive region.

[0109] Embodiment 6. The abrasive article according to Embodiment 4 or 5, wherein the first abrasive region, the second abrasive region, or the third abrasive region is annular.

[0110] Embodiment 7. The abrasive article according to any one of Embodiments 4 to 6, wherein the body includes a surface having a central opening, wherein the first abrasive region, the second abrasive region, and the third abrasive region are coupled to the surface and are concentric with the central opening.

[0111] Embodiment 8. The abrasive article according to any one of Embodiments 4 to 7, wherein the first abrasive region, the second abrasive region, or the third abrasive region includes adjacent abrasive segments, spaced-apart abrasive segments, or any combination thereof.

[0112] Embodiment 9. The abrasive article according to any one of Embodiments 4 to 7, wherein the first abrasive region, the second abrasive region, or the third abrasive region is unsegmented.

[0113] Embodiment 10. The abrasive article according to any one of Embodiments 7 to 9, wherein the surface is annular and the abrasive portion is coupled to the surface via an adhesive.

[0114] Embodiment 11. The abrasive article according to any one of Embodiments 4 to 10, wherein the first abrasive region, the second abrasive region, or the third abrasive region includes a bonding material, and the bonding material includes an organic material.

[0115] Embodiment 12. The abrasive article according to Embodiment 11, wherein the bonding material of each of the first abrasive region, the second abrasive region, and the third abrasive region includes the same organic material.

[0116] Embodiment 13. The abrasive article according to any one of Embodiments 4 to 12, wherein the first abrasive particle, the second abrasive particle, or the third abrasive particle comprises a superhard abrasive material, an oxide, a carbide, a nitride, or any combination thereof, and wherein the first abrasive particle, the second abrasive particle, or the third abrasive particle comprises diamond, cBN, or a combination thereof, Al2O3, SiC, CeO2, or any combination thereof.

[0117] Embodiment 14. The abrasive article according to any one of Embodiments 1 to 13, wherein the first average particle size is at least 1 micron, at least 3 microns, at least 5 microns, at least 8 microns, at least 10 microns, at least 13 microns, at least 15 microns, at least 17 microns, at least 19 microns, at least 20 microns, at least 23 microns, at least 25 microns, at least 28 microns, at least 32 microns, at least 35 microns, at least 37 microns, at least 40 microns, at least 43 microns, or at least 45 microns; or wherein the first average particle size is at most 150 microns, at most 130 microns, at most 100 microns, at most 95 microns, at most 90 microns, at most 85 microns, at most 80 microns, at most 75 microns, at most 70 microns, at most 65 microns, at most 60 microns, at most 55 microns, at most 50 microns, at most 45 microns, at most 40 microns, at most 35 microns, at most 30 microns, at most 27 microns, at most 25 microns, at most 22 microns, or at most 20 microns; or wherein the first average particle size is in the range of 1 micron to 100 microns, in the range of 5 microns to 85 microns, in the range of 8 microns to 65 microns, or in the range of 10 microns to 20 microns.

[0118] Embodiment 15. The abrasive article according to any one of Embodiments 1 to 14, wherein the second average particle size is at least 10 microns, at least 13 microns, at least 15 microns, at least 17 microns, at least 19 microns, at least 20 microns, at least 25 microns, at least 30 microns, at least 35 microns, at least 40 microns, at least 45 microns, at least 50 microns, at least 55 microns, at least 60 microns, at least 65 microns, at least 70 microns, at least 80 microns, at least 90 microns, at least 100 microns, at least 110 microns, at least 130 microns, at least 150 microns, at least 180 microns, at least 200 microns, at least 250 microns, at least 300 microns, at least 350 microns or at least 400 microns; or wherein the second average particle size is at most 500 microns, at most 450 microns, at most 400 microns, at most 350 microns, at most 300 microns, at most 250 microns, at most 200 microns, at most 150 microns, at most 100 microns, at most 90 microns, at most 85 microns, at most 80 microns, at most 75 microns, at most 70 microns, at most 65 microns, at most 60 microns, at most 55 microns, at most 50 microns, at most 45 microns, at most 40 microns, at most 35 microns, at most 30 microns, at most 27 microns, at most 25 microns, at most 22 microns or at most 20 microns; or wherein the second average particle size is in the range of 10 microns to 500 microns, in the range of 15 microns to 400 microns, in the range of 20 microns to 300 microns or in the range of 30 microns to 200 microns.

[0119] Embodiment 16. The abrasive article according to any one of Embodiments 1 to 15, wherein the body includes a particle size ratio of the second average particle size to the first average particle size of at least 1.1:1, such as at least 1.3:1, at least 1.5:1, at least 1.7:1, at least 1.9:1, at least 2.2:1, at least 2.5:1, at least 2.8:1, at least 3.1:1 or at least 3.5:1; or wherein the particle size ratio of the second average particle size to the first average particle size is at most 5:1, such as at most 4.8:1, at most 4.6:1, at most 4.4:1, at most 4.2:1, at most 4.0:1, at most 3.8:1, at most 3.6:1, at most 3.5:1, at most 3.3:1, at most 3.1:1, at most 2.8:1, at most 2.6:1, at most 2.4:1, at most 2.2:1, at most 1.8:1 or at most 1.5:1.

[0120] Embodiment 17. The abrasive article according to any one of Embodiments 4 to 16, wherein the third average particle size is at least 1 micron, at least 3 microns, at least 5 microns, at least 8 microns, at least 10 microns, at least 13 microns, at least 15 microns, at least 17 microns, at least 19 microns, at least 20 microns, at least 23 microns, at least 25 microns, at least 28 microns, at least 32 microns, at least 35 microns, at least 37 microns, at least 40 microns, at least 43 microns or at least 45 microns; or wherein the third average particle size is at most 150 microns, at most 130 microns, at most 100 microns, at most 95 microns, at most 90 microns, at most 85 microns, at most 80 microns, at most 75 microns, at most 70 microns, at most 65 microns, at most 60 microns, at most 55 microns, at most 50 microns, at most 45 microns, at most 40 microns, at most 35 microns, at most 30 microns, at most 27 microns, at most 25 microns, at most 22 microns or at most 20 microns; or wherein the third average particle size is in the range of 1 micron to 100 microns, in the range of 5 microns to 85 microns, in the range of 8 microns to 65 microns or in the range of 10 microns to 20 microns.

[0121] Embodiment 18. The abrasive article according to any one of Embodiments 4 to 17, wherein the grinding portion comprises a particle size ratio of the second average particle size to the third average particle size of at least 1.1, at least 1.3, at least 1.5, at least 1.7, at least 1.9, at least 2.2, at least 2.5, at least 2.8, at least 3.1 or at least 3.5; or wherein the particle size ratio of the second average particle size to the third average particle size is at most 5:1, such as at most 4.8:1, at most 4.6:1, at most 4.4:1, at most 4.2:1, at most 4.0:1, at most 3.8:1, at most 3.6:1, at most 3.5:1, at most 3.3:1, at most 3.1:1, at most 2.8:1, at most 2.6:1, at most 2.4:1, at most 2.2:1, at most 1.8:1 or at most 1.5:1.

[0122] Embodiment 19. The abrasive article according to any one of Embodiments 4 to 18, wherein the first average particle size is substantially the same as the third average particle size; or wherein the first average particle size is different from the third average particle size; and wherein the second average particle size is greater than the first average particle size.

[0123] Embodiment 20. The abrasive article according to any one of Embodiments 1 to 19, wherein the first abrasive region includes a first abrasive particle content for the volume of the first abrasive region, the second abrasive region includes a second abrasive particle content for the volume of the second abrasive region, and the third abrasive region includes a third abrasive particle content for the volume of the third abrasive region, wherein the first abrasive particle content, the second abrasive particle content, or the third abrasive particle content is independently at least 1% by volume, at least 3% by volume, at least 5% by volume, at least 8% by volume, at least 10% by volume, at least 13% by volume, at least 15% by volume, at least 18% by volume, at least 20% by volume, at least 25% by volume, at least 27% by volume, at least 30% by volume, at least 34% by volume, at least 38% by volume, at least 40% by volume, at least 42% by volume, at least 45% by volume, at least 48% by volume, at least 50% by volume, at least 53% by volume, or at least 55% by volume; or wherein the first abrasive particle content, the second abrasive particle content, or the third abrasive particle content is independently at most 60% by volume, at most 57% by volume, at most 55% by volume, at most 52% by volume, at most 50% by volume, at most 47% by volume, at most 45% by volume, at most 43% by volume, at most 40% by volume, at most 38% by volume, at most 35% by volume, at most 32% by volume, at most 30% by volume, at most 27% by volume, at most 24% by volume, at most 22% by volume, at most 20% by volume, at most 17% by volume, at most 15% by volume, at most 13% by volume, or at most 11% by volume.

[0124] Embodiment 21. The abrasive article according to Embodiment 20, wherein the first abrasive particle content, the second abrasive particle content, and the third abrasive particle content are substantially the same; or wherein at least two of the first abrasive particle content, the second abrasive particle content, and the third abrasive particle content are different.

[0125] Embodiment 22. The abrasive article according to any one of Embodiments 1 to 21, wherein the body comprises a ratio of the abrasive grain content of the first abrasive region to the second abrasive region of at least 0.1, at least 0.4, at least 0.6, at least 0.8, at least 1.0, at least 1.2, at least 1.5, at least 1.8, at least 2.0, at least 2.4, at least 2.7, at least 3.0, at least 3.2, at least 3.5, at least 3.8, at least 4, at least 4.2, at least 4.5, at least 4.8, at least 5.0, at least 5.3, at least 5.6, at least 6.0, at least 6.5, at least 6.8, at least 7 or at least 7.2; or wherein the ratio of the abrasive grain content of the first abrasive region to the second abrasive region is at most 10, at most 9.5, at most 9, at most 8.7, at most 8.5, at most 8, at most 7.5, at most 7.2, at most 7.0, at most 6.8, at most 6.6, at most 6.2, at most 6, at most 5.7, at most 5.4, at most 5.2, at most 5.0, at most 4.8, at most 4.5, at most 4.2, at most 4.0, at most 3.8, at most 3.6, at most 3.2, at most 3, at most 2.8, at most 2.5, at most 2.2, at most 2.0, at most 1.8, at most 1.6, at most 1.4, at most 1.2 or at most 1.0.

[0126] Embodiment 23. The abrasive article according to any one of Embodiments 4 to 22, wherein the body comprises a ratio of the abrasive grain content of the third abrasive region to the second abrasive region of at least 0.1, at least 0.4, at least 0.6, at least 0.8, at least 1.0, at least 1.2, at least 1.5, at least 1.8, at least 2.0, at least 2.4, at least 2.7, at least 3.0, at least 3.2, at least 3.5, at least 3.8, at least 4, at least 4.2, at least 4.5, at least 4.8, at least 5.0, at least 5.3, at least 5.6, at least 6.0, at least 6.5, at least 6.8, at least 7 or at least 7.2; or wherein the ratio of the abrasive grain content of the third abrasive region to the second abrasive region is at most 10, at most 9.5, at most 9, at most 8.7, at most 8.5, at most 8, at most 7.5, at most 7.2, at most 7.0, at most 6.8, at most 6.6, at most 6.2, at most 6, at most 5.7, at most 5.4, at most 5.2, at most 5.0, at most 4.8, at most 4.5, at most 4.2, at most 4.0, at most 3.8, at most 3.6, at most 3.2, at most 3, at most 2.8, at most 2.5, at most 2.2, at most 2.0, at most 1.8, at most 1.6, at most 1.4, at most 1.2 or at most 1.0.

[0127] Embodiment 24. The abrasive article according to any one of Embodiments 4 to 23, wherein the body comprises a ratio of the abrasive particle content of the third abrasive region to the first abrasive region of at least 0.1, at least 0.4, at least 0.6, at least 0.8, at least 1.0, at least 1.2, at least 1.5, at least 1.8, at least 2.0, at least 2.4, at least 2.7, at least 3.0, at least 3.2, at least 3.5, at least 3.8, at least 4, at least 4.2, at least 4.5, at least 4.8, at least 5.0, at least 5.3, at least 5.6, at least 6.0, at least 6.5, at least 6.8, at least 7 or at least 7.2; or wherein the ratio of the abrasive particle content of the third abrasive region to the first abrasive region is at most 10, at most 9.5, at most 9, at most 8.7, at most 8.5, at most 8, at most 7.5, at most 7.2, at most 7.0, at most 6.8, at most 6.6, at most 6.2, at most 6, at most 5.7, at most 5.4, at most 5.2, at most 5.0, at most 4.8, at most 4.5, at most 4.2, at most 4.0, at most 3.8, at most 3.6, at most 3.2, at most 3, at most 2.8, at most 2.5, at most 2.2, at most 2.0, at most 1.8, at most 1.6, at most 1.4, at most 1.2 or at most 1.0.

[0128] Embodiment 25. The abrasive article according to any one of Embodiments 20 to 24, wherein at least two of the first abrasive particle content, the second abrasive particle content, and the third abrasive particle content are different, and the difference between at least two of the first abrasive particle content, the second abrasive particle content, and the third abrasive particle content is within ±15%, ±12%, ±8%, or ±5% of the larger of the at least two abrasive particle contents.

[0129] Embodiment 26. The abrasive article according to any one of Embodiments 1 to 25, wherein the first grinding region includes a plurality of segments, the plurality of segments including a first average content of first abrasive grains, wherein the first average content is at least 1% by volume, at least 3% by volume, at least 5% by volume, at least 8% by volume, at least 10% by volume, at least 13% by volume, at least 15% by volume, at least 18% by volume, at least 20% by volume, at least 25% by volume, at least 27% by volume, at least 30% by volume, at least 34% by volume, at least 38% by volume, at least 40% by volume, at least 42% by volume, at least 45% by volume, at least 48% by volume, at least 50% by volume, at least 53% by volume or at least 55% by volume; or wherein the first average content of the first abrasive grains is at most 60% by volume, at most 57% by volume, at most 55% by volume, at most 52% by volume, at most 50% by volume, at most 47% by volume, at most 45% by volume, at most 43% by volume, at most 40% by volume, at most 38% by volume, at most 35% by volume, at most 32% by volume, at most 30% by volume, at most 27% by volume, at most 24% by volume, at most 22% by volume, at most 20% by volume, at most 17% by volume, at most 15% by volume, at most 13% by volume or at most 11% by volume.

[0130] Embodiment 27. The abrasive article according to Embodiment 26, wherein the first grinding region includes a fixed spacing between adjacent grinding segments, and the spacing between adjacent segments is substantially the same.

[0131] Embodiment 28. The abrasive article according to any one of Embodiments 1 to 27, wherein the second grinding region includes a plurality of segments, the plurality of segments including a second average content of second abrasive grains of at least 1% by volume, at least 3% by volume, at least 5% by volume, at least 8% by volume, at least 10% by volume, at least 13% by volume, at least 15% by volume, at least 18% by volume, at least 20% by volume, at least 25% by volume, at least 27% by volume, at least 30% by volume, at least 34% by volume, at least 38% by volume, at least 40% by volume, at least 42% by volume, at least 45% by volume, at least 48% by volume, at least 50% by volume, at least 53% by volume or at least 55% by volume; or wherein the second average content of the second abrasive grains is at most 60% by volume, at most 57% by volume, at most 55% by volume, at most 52% by volume, at most 50% by volume, at most 47% by volume, at most 45% by volume, at most 43% by volume, at most 40% by volume, at most 38% by volume, at most 35% by volume, at most 32% by volume, at most 30% by volume, at most 27% by volume, at most 24% by volume, at most 22% by volume, at most 20% by volume, at most 17% by volume, at most 15% by volume, at most 13% by volume or at most 11% by volume.

[0132] Embodiment 29. The abrasive article according to Embodiment 28, wherein the second abrasive region includes a fixed spacing between adjacent abrasive segments, and the spacing between adjacent segments is substantially the same.

[0133] Embodiment 30. The abrasive article according to any one of Embodiments 4 to 29, wherein the third abrasive region includes a plurality of segments, and the plurality of segments includes at least 1 vol%, at least 3 vol%, at least 5 vol%, at least 8 vol%, at least 10 vol%, at least 13 vol%, at least 15 vol%, at least 18 vol%, at least 20 vol%, at least 25 vol%, at least 27 vol%, at least 30 vol%, at least 34 vol%, at least 38 vol%, at least 40 vol%, at least 42 vol%, at least 45 vol%, at least 48 vol%, at least 50 vol%, at least 53 vol% or at least 55 vol% of the third average content of the third abrasive grains; or wherein the third average content of the third abrasive grains is at most 60 vol%, at most 57 vol%, at most 55 vol%, at most 52 vol%, at most 50 vol%, at most 47 vol%, at most 45 vol%, at most 43 vol%, at most 40 vol%, at most 38 vol%, at most 35 vol%, at most 32 vol%, at most 30 vol%, at most 27 vol%, at most 24 vol%, at most 22 vol%, at most 20 vol%, at most 17 vol%, at most 15 vol%, at most 13 vol% or at most 11 vol%.

[0134] Embodiment 31. The abrasive article according to Embodiment 30, wherein the third abrasive region includes a fixed spacing between adjacent abrasive segments, and the spacing between adjacent segments is substantially the same.

[0135] Embodiment 32. The abrasive article according to any one of Embodiments 1 to 31, wherein the first abrasive region includes a first binder content for the total volume of the first abrasive region, the second abrasive region includes a second binder content for the total volume of the second abrasive region, and the third abrasive region includes a third binder content for the total volume of the third abrasive region, wherein the first binder content, the second binder content, or the third binder content is independently at least 40 vol%, at least 42 vol%, at least 45 vol%, at least 48 vol%, at least 50 vol%, at least 53 vol%, at least 55 vol%, at least 58 vol%, at least 61 vol%, at least 64 vol%, at least 68 vol%, at least 70 vol%, at least 73 vol%, at least 75 vol%, at least 77 vol%, or at least 80 vol%; or wherein the first binder content, the second binder content, or the third binder content is independently at most 98 vol%, at most 95 vol%, at most 92 vol%, at most 90 vol%, at most 85 vol%, at most 82 vol%, at most 78 vol%, at most 75 vol%, at most 72 vol%, at most 68 vol%, at most 64 vol%, at most 60 vol%, at most 57 vol%, at most 55 vol%, at most 52 vol%, at most 50 vol%, at most 47 vol%, or at most 45 vol%.

[0136] Embodiment 33. The abrasive article according to any one of Embodiments 4 to 32, wherein the first abrasive region, the second abrasive region, or the third abrasive region independently includes a filler material, the filler material including lime, graphite, SiC, Al2O3, copper, or any combination thereof.

[0137] Embodiment 34. The abrasive article according to Embodiment 32, wherein the first grinding area includes a first filler content for the total volume of the first grinding area, the second grinding area includes a second filler content for the total volume of the second grinding area, and the third grinding area includes a third filler content for the total volume of the third grinding area, wherein the first filler content, the second filler content, or the third filler content is independently at least 0.5 vol%, at least 1 vol%, at least 3 vol%, at least 5 vol%, at least 8 vol%, at least 10 vol%, at least 13 vol%, at least 15 vol%, at least 18 vol%, at least 20 vol%, at least 25 vol%, at least 27 vol%, at least 30 vol%, at least 34 vol%, at least 38 vol%, or at least 40 vol%; or wherein the first filler content, the second filler content, or the third filler content is at most 40 vol%, at most 38 vol%, at most 35 vol%, at most 32 vol%, at most 30 vol%, at most 27 vol%, at most 24 vol%, at most 22 vol%, at most 20 vol%, at most 17 vol%, at most 15 vol%, at most 13 vol%, at most 11 vol%, at most 9 vol%, at most 7 vol%, at most 5 vol%, at most 3 vol%, or at most 2 vol%.

[0138] Embodiment 35. The abrasive article according to any one of Embodiments 4 to 34, wherein the first grinding area, the second grinding area, or the third grinding area includes porosity; or wherein the first grinding area, the second grinding area, or the third grinding area is substantially free of porosity.

[0139] Embodiment 36. The abrasive article according to any one of Embodiments 4 to 34, wherein the first grinding area includes a first porosity for the total volume of the first grinding area, the second grinding area includes a second porosity for the total volume of the second grinding area, and the third grinding area includes a third porosity for the total volume of the third grinding area, wherein the first porosity, the second porosity, or the third porosity is independently at least 0.5 vol%, at least 1 vol%, at least 3 vol%, at least 5 vol%, at least 8 vol%, at least 10 vol%, at least 13 vol%, at least 15 vol%, at least 18 vol%, or at least 20 vol%; or wherein the first porosity, the second porosity, or the third porosity is at most 20 vol%, at most 17 vol%, at most 15 vol%, at most 13 vol%, at most 11 vol%, at most 9 vol%, at most 7 vol%, at most 5 vol%, at most 3 vol%, at most 2 vol%, at most 1 vol%, or at most 0.5 vol%.

[0140] Embodiment 37. The abrasive article according to any one of Embodiments 4 to 36, wherein the first abrasive region comprises a first percentage of the abrasive surface area of the total surface area of the abrasive portion, and the third abrasive region comprises a third percentage of the abrasive surface area of the total surface area of the abrasive portion, where the first percentage of the abrasive surface area or the third percentage of the abrasive surface area is independently at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40% or at least 45%; or wherein the first percentage of the abrasive surface area or the third percentage of the abrasive surface area is independently at most 50%, at most 45%, at most 40%, at most 35%, at most 30%, at most 25% or at most 20%.

[0141] Embodiment 38. The abrasive article according to any one of Embodiments 1 to 37, wherein the second abrasive region comprises at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, at least 50%, at least 55%, at least 60%, at least 65% or at least 70% of a second percentage of the abrasive surface area; or wherein the second percentage of the abrasive surface area is at most 80%, at most 75%, at most 70%, at most 65%, at most 60%, at most 55%, at most 50%, at most 45%, at most 40%, at most 35%, at most 30%, at most 25% or at most 20% of the total surface area of the abrasive portion.

[0142] Embodiment 39. The abrasive article according to any one of Embodiments 1 to 28, the abrasive article comprising a surface area ratio of the first abrasive region to the second abrasive region of at least 1:10, at least 1:9, at least 1:8, at least 1:7, at least 1:6, at least 1:5, at least 1:3, at least 1:1, at least 2:1, at least 3:1, at least 4:1 or at least 5:1; wherein the surface area ratio of the first abrasive region to the second abrasive region is at most 10:1, at most 9:1, at most 8:1, at most 7:1, at most 6:1, at most 5:1, at most 4:1, at most 2:1, at most 1:1, at most 1:2, at most 1:4 or at most 1:5.

[0143] Embodiment 40. The abrasive article according to any one of Embodiments 4 to 39, the abrasive article comprising a surface area ratio of the first grinding area to the third grinding area of at least 1:10, at least 1:9, at least 1:8, at least 1:7, at least 1:6, at least 1:5, at least 1:3, at least 1:1, at least 2:1, at least 3:1, at least 4:1 or at least 5:1; wherein the surface area ratio of the first grinding area to the third grinding area is at most 10:1, at most 9:1, at most 8:1, at most 7:1, at most 6:1, at most 5:1, at most 4:1, at most 2:1, at most 1:1, at most 1:2, at most 1:4 or at most 1:5.

[0144] Embodiment 41. The abrasive article according to any one of Embodiments 4 to 40, the abrasive article comprising a surface area ratio of the second grinding area to the third grinding area of at least 1:10, at least 1:9, at least 1:8, at least 1:7, at least 1:6, at least 1:5, at least 1:3, at least 1:1, at least 2:1, at least 3:1, at least 4:1 or at least 5:1; wherein the surface area ratio of the second grinding area to the third grinding area is at most 10:1, at most 9:1, at most 8:1, at most 7:1, at most 6:1, at most 5:1, at most 4:1, at most 2:1, at most 1:1, at most 1:2, at most 1:4 or at most 1:5.

[0145] Embodiment 42. The abrasive article according to any one of Embodiments 4 to 41, wherein the first grinding area, the second grinding area or the third grinding area comprises a radial thickness of at least 1%, at least 2%, at least 5%, at least 7%, at least 8%, at least 10%, at least 12%, at least 15%, at least 18%, at least 20%, at least 22%, at least 25%, at least 28%, at least 30%, at least 33% or at least 35% relative to the outer diameter of the body; or wherein the first grinding area, the second grinding area or the third grinding area comprises a radial thickness of at most 35%, at most 33%, at most 30%, at most 27%, at most 25%, at most 22%, at most 20%, at most 17%, at most 15%, at most 12%, at most 10%, at most 8%, at most 6%, at most 5%, at most 3% or at most 2% relative to the outer diameter of the body.

[0146] Embodiment 43. The abrasive article according to any one of Embodiments 4 to 42, wherein the first grinding region, the second grinding region, or the third grinding region comprises an axial height that is at least 1%, at least 3%, at least 5%, at least 7%, at least 8%, at least 10%, at least 12%, at least 15%, at least 18%, at least 20%, at least 22%, at least 25%, at least 28%, at least 30%, at least 33%, at least 35%, at least 38%, at least 40%, at least 42%, at least 45%, at least 47%, or at least 50% of the total axial height of the body; or wherein the first grinding region, the second grinding region, or the third grinding region comprises an axial height that is at most 50%, at most 47%, at most 44%, at most 41%, at most 38%, at most 35%, at most 33%, at most 30%, at most 27%, at most 25%, at most 22%, at most 20%, at most 17%, at most 15%, at most 12%, at most 10%, at most 8%, at most 6%, at most 5%, at most 3%, or at most 2% of the total axial height of the body.

[0147] Embodiment 44. The abrasive article according to Embodiment 43, wherein the axial heights of the first grinding region, the second grinding region, and the third grinding region are substantially the same.

[0148] Embodiment 45. The abrasive article according to any one of Embodiments 1 to 44, wherein the first grinding region and the second grinding region are separated by an annular non-grinding portion, and wherein the annular non-grinding portion comprises a radial thickness that is at least 5%, at least 7%, at least 8%, at least 10%, at least 12%, at least 15%, at least 18%, or at least 20% of the outer diameter of the body; or wherein the first grinding region and the second grinding region are separated by an annular non-grinding portion, and wherein the annular non-grinding portion comprises a radial thickness that is at most 20%, at most 17%, at most 15%, at most 12%, at most 10%, at most 8%, at most 6%, or at most 5% of the outer diameter of the body.

[0149] Embodiment 46. The abrasive article according to any one of Embodiments 4 to 45, wherein the third abrasive region and the second abrasive region are separated by an annular non-abrasive portion, and the annular non-abrasive portion includes a radial thickness that is at least 5%, at least 7%, at least 8%, at least 10%, at least 12%, at least 15%, at least 18%, or at least 20% of the outer diameter of the body; or wherein the third abrasive region and the second abrasive region are separated by an annular non-abrasive portion, and the annular non-abrasive portion includes a radial thickness that is at most 20%, at most 17%, at most 15%, at most 12%, at most 10%, at most 8%, at most 6%, or at most 5% of the outer diameter of the body.

[0150] Embodiment 47. The abrasive article according to any one of Embodiments 4 to 46, wherein the body includes a working surface, and the working surface includes at least a portion of the surface area of each of the first abrasive region, the second abrasive region, and the third abrasive region.

[0151] Embodiment 48. The abrasive article according to any one of Embodiments 1 to 47, wherein the first abrasive region is configured to wear at a first wear rate, and the second abrasive region is configured to wear at a second wear rate, and the difference between the first wear rate and the second wear rate is within 10% of the larger of the first wear rate and the second wear rate.

[0152] Embodiment 49. The abrasive article according to Embodiment 48, wherein the third abrasive region is configured to wear at a third wear rate, the difference between the third wear rate and the first wear rate is within 10% of the larger of the first wear rate and the third wear rate, and the difference between the third wear rate and the second wear rate is within 10% of the larger of the third wear rate and the second wear rate.

[0153] Embodiment 50. The abrasive article according to any one of Embodiments 4 to 49, wherein the first abrasive region, the second abrasive region, and the third abrasive region are configured to wear at substantially the same rate.

[0154] Embodiment 51. The abrasive article according to any one of Embodiments 4 to 50, wherein at least one of the first abrasive region, the second abrasive region, and the third abrasive region includes a plurality of concentric abrasive portions spaced apart from each other.

[0155] Embodiment 52. The abrasive article according to any one of Embodiments 4 to 51, wherein the first grinding region is the outermost grinding region, the third grinding region is the innermost grinding region, and the second grinding region is an intermediate grinding region between the innermost grinding region and the outermost grinding region.

[0156] Embodiment 53. A system comprising at least one abrasive article according to any one of Embodiments 1 to 52.

[0157] Embodiment 54. A system comprising a plurality of abrasive articles according to any one of Embodiments 1 to 52, wherein a first abrasive article among the plurality of abrasive articles includes a first working surface and is mounted such that the first working surface faces a second working surface of a second abrasive article among the plurality of abrasive articles, and wherein the first abrasive article and the second abrasive article are configured to simultaneously grind opposite surfaces of a workpiece.

[0158] Example

[0159] Example 1

[0160] A representative grinding wheel sample S1 is formed according to the embodiments herein. The layout of the grinding regions and non-grinding portions is similar to Figure 1 the illustration. For each grinding region, a mixture is formed that includes 30 wt% of an organic material (including phenolic resin and hexamethylenetetramine), 35 wt% of a filler SiC, and 35 wt% of diamond abrasive particles based on the total weight of the mixture. The mixture is pressed in a mold that separately forms a green grinding region and cured at 180 °C for 720 min. The finally formed grinding region is attached to an aluminum alloy substrate via an epoxy adhesive (commercially available as KAFUTER K-960).

[0161] The first (outermost) and third (innermost) grinding regions of sample S1 include diamond grains having an average grain size of 9 μm. The second (intermediate) grinding region includes diamond grains having an average grain size of 15 μm. With respect to the total volume of the respective grinding regions, each of the first, second, and third grinding regions includes approximately 25 vol% diamond abrasive particles, 70 vol% of the same bonding material, and a porosity of at most 5 vol%. For the total surface area of the first, second, and third grinding regions, the first grinding region has approximately 40% of the grinding surface area, the third grinding region has approximately 27% of the grinding surface area, and the second grinding region has approximately 33% of the grinding surface area. The first annular non-grinding portion between the first and second grinding regions and the second annular non-grinding portion between the second and third grinding regions have substantially the same radial thickness, which is approximately 4% of the outer diameter of the wheel. The ratio of the total surface area of the first, second, and third regions to the total surface area of the non-grinding portion of the wheel sample is approximately 3:2.

[0162] A wheel sample S2 is formed having a layout of grinding regions and non-grinding portions similar to S1 and the same composition, except that the outermost and innermost grinding regions of sample S2 include diamond grains having an average grain size of 15 μm and the intermediate grinding region includes diamond grains having an average grain size of 9 μm.

[0163] A batch of 3 wheels of each of wheel samples S1 and S2 are tested for grinding a quartz workpiece. Each wheel sample grinds 4"×5 pcs of quartz at a grinding speed of 0.03 mm / min for a grinding time of 30 min. The surface roughness of each workpiece is evaluated using a laser confocal microscope to measure 5 areas of 2 mm×5 mm, and the average value thereof is used as the roughness of the workpiece. The range of roughness and total thickness variation (TTV) of the workpieces ground by each sample is included in Table 1 below. Sample S1 exhibits significantly improved surface finish compared to sample S2 and achieves a satisfactory MRR / time (MRR"). For the grinding test, an MRR” of 0.020 mm / min or higher is considered satisfactory. The total thickness variation of the workpieces is determined by measuring the thickness at 7 different locations of each workpiece using a thickness gauge. Samples S1 and S2 achieve similar TTVs. A TTV of less than 10 μm is considered acceptable for the grinding test.

[0164] Table 1

[0165] Sample Surface Roughness / Sa (nm) Achieved MRR” (mm / min) TTV (μm) S1 240-270 0.022 3-8 S2 335-367 0.026 3-8

[0166] Example 2

[0167] A set of wheel samples CS3 was formed in a similar manner to sample S1, except that a grinding region was formed which had about 25 vol% of diamond abrasive grains with an average grain size of 15 μm, 70 vol% of the same bonding material as sample S1, and a porosity of at most 5 vol% with respect to the total volume of the grinding region. Figure 5 Illustration of a top view of sample CS3 including a grinding region 501 and a non-grinding portion 502.

[0168] A set of wheel samples CS4 was formed in a similar manner to sample S1, except that a grinding region was formed which had about 25 vol% of diamond abrasive grains with an average grain size of 9 μm, 70 vol% of the same bonding material as sample S1, and a porosity of at most 5 vol% with respect to the total volume of the grinding region. Sample CS4 had a top view similar to that of sample CS3.

[0169] Three wheels of another set of wheel samples S1 and three wheels each of CS3 and CS4 were tested on quartz using 4"×5pcs quartz grinding at a grinding speed of 0.03 mm / min and a grinding time of 30 min. After completion of the test, the surface roughness of the workpiece was evaluated using a laser confocal microscope as described in Example 1. The ranges of MRR" and the surface roughness of the workpiece ground by each wheel sample are included in Table 2 below. Compared with CS3 and CS4, sample S1 exhibited an improved balance of high MRR" and low surface roughness. Sample S1 further exhibited improved TTV compared to sample CS4 and similar TTV compared to sample CS3.

[0170] Table 2

[0171] Sample Surface Roughness / Sa (nm) Achieved MRR” (mm / min) TTV (μm) S1 240-270 0.022 3-8 CS3 420-455 0.029 3-7 CS4 225-235 0.014 5-10

[0172] Example 3

[0173] Form a grinding wheel sample having a first (outermost) grinding region, a second (intermediate) grinding region, and a third (innermost) grinding region including diamond abrasive grains. The layout of the grinding regions and non-grinding regions of all wheel samples is similar to Figure 1Illustration. For each wheel sample, the diamond abrasive grains in the first grinding area and the third grinding area have substantially the same average particle size of about 9 microns. With respect to the total volume of the corresponding grinding area, each wheel sample includes about 25 vol% diamond abrasive grains, 70 vol% of the same bonding material, and a porosity of at most 5 vol% in the first grinding area, the second grinding area, and the third grinding area. For each wheel sample, with respect to the total surface area of the first grinding area, the second grinding area, and the third grinding area, the first grinding area has about 40% of the grinding surface area, the third grinding area has about 27% of the grinding surface area, and the second grinding area has about 33% of the grinding surface area. The annular non-grinding portions between the first grinding area and the second grinding area and between the second grinding area and the third grinding area have the same radial thickness of about 4% of the wheel diameter. The ratio of the total surface area of the first area, the second area, and the third area to the total surface area of all non-grinding portions of each wheel sample is about 3:2.

[0174] The wheel samples were tested on grinding 4”×5pcs quartz. The material removal and the surface roughness of the workpiece were evaluated in the same manner as described in Example 1 for each 30 min grinding time at a grinding speed of 0.03 mm / min.

[0175] The particle size ratio of the second grinding area to the first grinding area and the grinding test results of the grinding wheel samples are included in Table 3 below.

[0176] Table 3

[0177]

[0178] Example 4

[0179] The grinding wheel samples were formed in the same manner as described for sample S1. The grinding wheel samples have different percentages of surface area and their ratios with respect to the total grinding surface area of the first grinding area, the second grinding area, or the third grinding area, but have the same composition as sample S1 for each grinding area. The grinding of the grinding wheel samples was tested using 4"×5pcs quartz at a grinding speed of 0.03 mm / min and a grinding time of 30 min.

[0180] Table 5

[0181]

[0182] Table 6 23-BD-0218CN01

[0183]

[0184] Compared with other samples, sample S17 exhibits satisfactory MRR" and improved surface roughness and TTV.

[0185] The foregoing embodiments represent a departure from the prior art. The embodiments relate to an abrasive article that includes a body that includes concentric grinding regions and one or more non-grinding portions that alternate with the grinding regions. The outermost grinding region and the innermost grinding region may include relatively fine abrasive grains, and one or more intermediate grinding regions may include relatively coarse abrasive grains. The abrasive article may permit improved material removal rates, such as improved stock removal over a limited period of time, and at the same time improve the surface finish of the workpiece, such as total thickness variation, surface roughness, or both, of the workpiece. Specifically, improved performance may be facilitated by the particular placement of grinding regions that include coarse and fine abrasive particles, the placement of non-grinding portions, the surface area of the grinding regions, the surface area of the non-grinding portions, their ratios, the grit ratio between the coarse and fine abrasive particles, or any combination thereof. For example, one or more intermediate grinding regions may facilitate improved material removal, and the total surface area of the outermost grinding region and / or the innermost grinding region and / or the non-grinding portions may facilitate improved surface finish (e.g., improved roughness).

[0186] Benefits, other advantages, and solutions to problems have been described above with respect to specific embodiments. However, these benefits, advantages, solutions to problems, and any features that may cause any benefit, advantage, or solution to occur or become more pronounced should not be construed as critical, required, or essential features of any or all claims. A material that includes one or more components as referred to herein may be construed to include at least one embodiment where the material consists essentially of the identified one or more components. The term "consisting essentially of" will be construed to include a composition that includes those materials identified and excludes all other materials except for minor amounts (e.g., impurity amounts) that do not significantly alter the characteristics of the material. Additionally, or in the alternative, in certain non-limiting embodiments, any composition identified herein may be substantially free of materials not expressly disclosed. Embodiments herein include ranges of the amounts of certain components within a material, and it should be understood that the amounts of the components within a given material total 100%.

[0187] The description and illustration of the embodiments described herein are intended to provide a general understanding of the structure of various embodiments. The description and illustration are not intended to be used as a detailed and comprehensive description of all elements and features of the device and system using the structure or method described herein. A separate embodiment can also be provided in combination in a single embodiment, and on the contrary, for the sake of brevity, the various features described in the context of a single embodiment can also be provided individually or in any sub-combination. In addition, reference to the values ​​described in the range includes each value within the range. Many other embodiments are only apparent to those skilled in the art after they have read this specification. Other embodiments can be used and derived from the present disclosure, so that structural substitution, logical substitution or another change can be performed without departing from the scope of the present disclosure. Therefore, the present disclosure should be considered to be illustrative and not restrictive.

Claims

1. An abrasive article, the abrasive article comprising a body having a plurality of abrasive regions, the abrasive regions comprising: a first abrasive region, the first abrasive region comprising first abrasive grains having a first average grain size; and a concentric second abrasive region, the concentric second abrasive region comprising second abrasive grains having a second average grain size greater than the first average grain size, wherein the second abrasive region is spaced apart from the first abrasive region and has a diameter smaller than that of the first abrasive region.

2. The abrasive article according to claim 1, wherein the body includes an inner diameter (D I ) that defines a central region of the body and an outermost diameter (D1) that defines an outer circumference of the body, wherein the surface area percentage of the plurality of abrasive regions is at least 30% and no greater than 70% relative to the surface area of the body between D I and D1.

3. The abrasive article according to claim 1 or 2, wherein the body comprises an annular non-abrasive portion between the first abrasive region and the second abrasive region.

4. The abrasive article according to any one of claims 1 to 3, wherein the plurality of abrasive regions comprises a third abrasive region concentric with the first abrasive region and the second abrasive region, wherein the third abrasive region has a diameter smaller than that of the second abrasive region and comprises third abrasive grains having a third average abrasive grain size smaller than the second average abrasive grain size.

5. The abrasive article according to claim 4, wherein the body comprises an annular non-abrasive portion between the third abrasive region and the second abrasive region.

6. The abrasive article according to claim 4 or 5, wherein the first abrasive region, the second abrasive region or the third abrasive region comprises a bonding material, the bonding material comprising an organic material.

7. The abrasive article according to any one of claims 4 to 6, wherein the first abrasive grains, the second abrasive grains or the third abrasive grains comprise a superhard abrasive material, an oxide, a carbide, a nitride or any combination thereof, wherein the first abrasive grains, the second abrasive grains or the third abrasive grains comprise diamond, cBN or a combination thereof, Al2O3, SiC, CeO2, or any combination thereof.

8. The abrasive article according to any one of claims 4 to 7, wherein the first average particle size and the third average particle size are independently at least 1 micron, at least 3 microns, at least 5 microns, at least 8 microns, at least 10 microns, at least 13 microns, at least 15 microns, at least 17 microns, at least 19 microns, at least 20 microns, at least 23 microns, at least 25 microns, at least 28 microns, at least 32 microns, at least 35 microns, at least 37 microns, at least 40 microns, at least 43 microns or at least 45 microns; or wherein the first average particle size is at most 150 microns, at most 130 microns, at most 100 microns, at most 95 microns, at most 90 microns, at most 85 microns, at most 80 microns, at most 75 microns, at most 70 microns, at most 65 microns, at most 60 microns, at most 55 microns, at most 50 microns, at most 45 microns, at most 40 microns, at most 35 microns, at most 30 microns, at most 27 microns, at most 25 microns, at most 22 microns or at most 20 microns; or wherein the first average particle size is in the range of 1 micron to 100 microns, in the range of 5 microns to 85 microns, in the range of 8 microns to 65 microns or in the range of 10 microns to 20 microns.

9. The abrasive article according to any one of claims 1 to 8, wherein the second average particle size is at least 10 microns, at least 13 microns, at least 15 microns, at least 17 microns, at least 19 microns, at least 20 microns, at least 25 microns, at least 30 microns, at least 35 microns, at least 40 microns, at least 40 microns, at least 45 microns, at least 50 microns, at least 55 microns, at least 60 microns, at least 65 microns, at least 70 microns, at least 80 microns, at least 90 microns, at least 100 microns, at least 110 microns, at least 130 microns, at least 150 microns, at least 180 microns, at least 200 microns, at least 250 microns, at least 300 microns, at least 350 microns or at least 400 microns; or wherein the second average particle size is at most 500 microns, at most 450 microns, at most 400 microns, at most 350 microns, at most 300 microns, at most 250 microns, at most 200 microns, at most 150 microns, at most 100 microns, at most 90 microns, at most 85 microns, at most 80 microns, at most 75 microns, at most 70 microns, at most 65 microns, at most 60 microns, at most 55 microns, at most 50 microns, at most 45 microns, at most 40 microns, at most 35 microns, at most 30 microns, at most 27 microns, at most 25 microns, at most 22 microns or at most 20 microns; or wherein the second average particle size is in the range of 10 microns to 500 microns, in the range of 15 microns to 400 microns, in the range of 20 microns to 300 microns or in the range of 30 microns to 200 microns.

10. An abrasive article according to any one of claims 1 to 15, wherein the particle size ratio of the second average particle size to the first average particle size and the particle size ratio of the second average particle size to the third average particle size are independently at least 1.1:1, such as at least 1.3:1, at least 1.5:1, at least 1.7:1, at least 1.9:1, at least 2.2:1, at least 2.5:1, at least 2.8:1, at least 3.1:1 or at least 3.5:1; or wherein the particle size ratio of the second average particle size to the first average particle size and the particle size ratio of the second average particle size to the third average particle size are independently at most 5:1, such as at most 4.8:1, at most 4.6:1, at most 4.4:1, at most 4.2:1, at most 4.0:1, at most 3.8:1, at most 3.6:1, at most 3.5:1, at most 3.3:1, at most 3.1:1, at most 2.8:1, at most 2.6:1, at most 2.4:1, at most 2.2:1, at most 1.8:1 or at most 1.5:1.

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