Fixed abrasive with low wettability bond material

Abstract

This application relates to a fixed abrasive having a low wettability bond material. An abrasive article includes a fixed abrasive body having a specific MOR / EMOD ratio associated with a specific bond volume percentage. The body also has a micron 2 Average bond post area (BPA) of: b) 1536 mm 2 c) an average bond post count (BPC) of at least 140 per micron; or d) an average bond wetting radius of at least 30 per micron; or d) a combination of a) and b).

Description

[Technical Field]

[0001] The present invention relates generally to abrasive articles, and more particularly to fixed abrasive articles having low-wettability bond materials and unique microstructures. [Background technology]

[0002] Abrasives used in machining applications typically include bonded abrasives and coated abrasives. Bonded abrasives generally have a bond matrix containing abrasive particles. Bonded abrasives can be mounted on suitable machining equipment and used in a variety of applications, such as shaping, grinding, polishing, and cutting. The industry continues to seek improvements in abrasive tools. Summary of the Invention

[0003] In one embodiment, the present application provides an abrasive article, the abrasive article comprising: The main body is a bond material comprising an inorganic material; abrasive particles contained in a bond material; a body comprising a MOR / EMOD ratio of at least 0.92 and a bond volume % of less than 18%; The main body is a) 2400 microns 2 Average Bond Post Area (BPA) of: b) 1.536 mm 2 an average bond post count (BPC) of at least 140 per c) an average bond wetting radius of at least 30 microns; and d) a combination of a) and b).

[0004] In another embodiment, the present application provides an abrasive article, the abrasive article comprising: The main body is a bond material comprising an inorganic material; abrasive particles contained in a bond material; a body comprising a MOR / EMOD ratio of at least 1.05 and a bond volume percentage of at least 18% and no more than 30%; The main body is a) 2400 microns 2 Average Bond Post Area (BPA) of: b) 1.536 mm 2 an average bond post count (BPC) of at least 140 per c) an average bond wetting radius of at least 30 microns; and d) a combination of a) and b).

[0005] In yet another embodiment, the present application provides a method of making an abrasive article, the method comprising: providing a mixture of abrasive particles and a bond material precursor; pressing the mixture into a green body; and firing the green body into a fully formed abrasive article.

[0006] In yet another embodiment, the present application provides a method of abrading a workpiece using an abrasive article, the method including cutting, chamfering, sharpening, gear power honing, worm gear grinding, CMR, roughing, grinding, weld facing, or precision finishing. [Brief explanation of the drawings]

[0007] The present disclosure may be better understood, and its numerous features and advantages made apparent to those skilled in the art by referencing the accompanying drawings. [Figure 1] 1 includes a flow diagram for forming an abrasive article according to one embodiment. [Figure 2A] 1 includes a perspective view of an abrasive article according to one embodiment. [Figure 2B] 1 includes a perspective view of an abrasive article according to one embodiment. [Figure 3] Examples of multimodal particle size distributions include: [Figure 4A] 1 includes an SEM image of the bond microstructure of an abrasive article according to one embodiment. [Figure 4B] Includes SEM images of the bond microstructure of polished pieces from commercial samples. [Figure 4C] Includes SEM images of the bond microstructure of polished pieces from commercial samples. [Figure 5] Included are cumulative bond post size distributions for various embodiments, comparative samples, and commercial samples. [Figure 6] 1 includes an illustration of an exemplary bond post having a high wettability bond material. [Figure 7] 1 includes a diagram of an exemplary bond post having a low-wettability bond material. [Figure 8] 1 includes images of bond posts and pores in one embodiment. [Figure 9] Includes diagram of abrasives. [Figure 10] 1 includes plots of density variation for various embodiments and commercially available samples. [Figure 11A] 1 includes an exemplary image of a bond post for measuring the radius of curvature of the bond post. [Figure 11B] 1 includes an exemplary image of a bond post for measuring the radius of curvature of the bond post. DETAILED DESCRIPTION OF THE INVENTION

[0008] The following is generally directed to fixed abrasive articles suitable for use in material removal operations. Fixed abrasive articles can be used in a variety of applications, such as, for example, surface grinding, precision grinding operations (e.g., gear grinding operations), and the like.

[0009] References herein to a fixed abrasive article include references to a three-dimensional volume of abrasive material with abrasive particles contained within a volume of bond material. Fixed abrasive articles may differ from coated abrasive articles, which may use a single layer of abrasive particles contained within a layer of bond or adhesive material. Furthermore, fixed abrasive articles of some embodiments herein may include some porosity within the three-dimensional volume of the bond material.

[0010] 1 includes a flow diagram for forming an abrasive article according to one embodiment. As shown, the process for forming an abrasive article can begin in step 101 by forming a mixture including a bond precursor material. The mixture can be a slurry having multiple components uniformly mixed therein.

[0011] The bond precursor material can be a material that will become the bond material of the final formed abrasive article. According to one embodiment, the bond precursor material can include a powder material configured to form the bond material of the final formed abrasive article. In one embodiment, the bond precursor material can include an inorganic material such as, but not limited to, a metal, a metal alloy, a ceramic, a glassy material, or a frit material, or any combination thereof. The bond precursor material can include an inorganic material in an amorphous phase, a polycrystalline phase, a single crystalline phase, or any combination thereof.

[0012] The bond material precursor may have a particular composition that may facilitate improved performance or manufacturing of the abrasive article.

[0013] In one embodiment, the bond material precursor may have an Al2O3 content of at least 18 wt%, or at least 20 wt%, or at least 22 wt%. In one embodiment, the bond material precursor may have an Al2O3 content of 36 wt% or less, or 33 wt% or less, or 30 wt% or less, or 27 wt% or less, based on the total bond material content. It will be understood that the Al2O3 content may be between any of the minimum and maximum values ​​listed above.

[0014] In one embodiment, the bond material precursor may have a SiO content of at least 38 wt%, or at least 40 wt%, or at least 42 wt%, or at least 45 wt%. In one embodiment, the bond material precursor may have a SiO content of 55 wt% or less relative to the total bond material content. It will be understood that the SiO content may be between any of the minimum and maximum values ​​listed above.

[0015] In one embodiment, the bond material precursor may have a B2O3 content of at least 10 wt%. In one embodiment, the bond material precursor may have a B2O3 content of 18 wt% or less, or 15 wt% or less, based on the total bond material content. It will be understood that the B2O3 content may be between any of the above minimum and maximum values.

[0016] In an embodiment, the bond material precursor may have a BaO content of 0.6 wt. % or less, or 0.4 wt. % or less, or 0.2 wt. % or less, or 0.1 wt. % or less, or 0.05 wt. % or less, or 0.03 wt. % or less, relative to the total bond material content.

[0017] In one embodiment, the bond material precursor may include a CaO content of at least 0.3 wt. %. In one embodiment, the bond material precursor may include a CaO content of 2 wt. % or less, or 1.5 wt. % or less, or 1 wt. % or less, or 0.5 wt. % or less, based on the total bond material content. It will be understood that the CaO content may be between any of the minimum and maximum values ​​listed above.

[0018] In one embodiment, the bond material precursor may have a CoO content of less than or equal to 0.7 wt. % relative to the total bond material content.

[0019] In one embodiment, the bond material precursor may include a Cr2O3 content of less than or equal to 0.01 wt. % relative to the total bond material content.

[0020] In an embodiment, the bond material precursor may have a content of Fe2O3 of 0.8 wt. % or less, or 0.7 wt. % or less, relative to the total content of the bond material.

[0021] In one embodiment, the bond material precursor may include a CuO content of less than or equal to 0.01 wt. % relative to the total bond material content.

[0022] In one embodiment, the bond material precursor may include a content of HfO2 of less than or equal to 0.02 wt. % relative to the total content of the bond material.

[0023] In one embodiment, the bond material precursor may include a KO content of at least 0.5 wt. %. In one embodiment, the bond material precursor may include a KO content of 2 wt. % or less, or 1 wt. % or less, based on the total bond material content. It will be understood that the KO content may be between any of the minimum and maximum values ​​listed above.

[0024] In one embodiment, the bond material precursor may include a La2O2 content of at least 1.3 wt%. In one embodiment, the bond material precursor may include a La2O2 content of 2.0 wt% or less, or 1.5 wt% or less, based on the total bond material content. It will be understood that the La2O2 content may be between any of the minimum and maximum values ​​listed above.

[0025] In one embodiment, the bond material precursor may have a LiO content of at least 0.2 wt%, or at least 0.5 wt%, or at least 0.7 wt%, or at least 0.9 wt%. In one embodiment, the bond material precursor may have a LiO content of 3 wt% or less, or 2.5 wt% or less, or 2.0 wt% or less, or 1.5 wt% or less, or 1.1 wt% or less, based on the total bond material content. It will be understood that the LiO content may be between any of the minimum and maximum values ​​stated above.

[0026] In one embodiment, the bond material precursor may have an MgO content of at least 0.5 wt. % or at least 0.7 wt. %. In one embodiment, the bond material precursor may have an MgO content of 1.5 wt. % or less, or 1.0 wt. % or less, relative to the total bond material content. It will be understood that the MgO content may be between any of the minimum and maximum values ​​listed above.

[0027] In one embodiment, the bond material precursor may include a MnO content of 0.05 wt. % or less. In one embodiment, the bond material precursor may include a MnO content of 0.02 wt. % or less, based on the total bond material content. It will be understood that the MnO content may be between any of the minimum and maximum values ​​listed above.

[0028] In one embodiment, the bond material precursor may include a Na2O content of at least 4 wt%. In one embodiment, the bond material precursor may include a Na2O content of 12 wt% or less, or 9 wt% or less, or 6 wt% or less, based on the total bond material content. It will be understood that the Na2O content may be between any of the minimum and maximum values ​​listed above.

[0029] In one embodiment, the bond material precursor may include a content of NiO of less than or equal to 0.01 wt. % relative to the total content of the bond material.

[0030] In one embodiment, the bond material precursor may include a content of SrO of less than or equal to 0.02 wt. % relative to the total content of the bond material.

[0031] In one embodiment, the bond material precursor may include a TiO2 content of at least 0.2 wt. % and not more than 0.8 wt. % relative to the total bond material content.

[0032] In one embodiment, the bond material precursor may include a V2O5 content of less than or equal to 0.02 wt. % relative to the total bond material content.

[0033] In one embodiment, the bond material precursor may include a Y2O3 content of at least 0.4 wt. % and not more than 1.0 wt. % relative to the total bond material content.

[0034] In one embodiment, the bond material precursor may include a ZnO content of less than or equal to 0.2 wt. % relative to the total bond material content.

[0035] In one embodiment, the bond material precursor may include a content of ZrO2 of less than or equal to 0.01 wt. % relative to the total content of the bond material.

[0036] According to one embodiment, the bond precursor material may be added in a specific content. For example, the mixture may comprise at least 1% by volume, for example, at least 2% by volume, or at least 3% by volume, or at least 4% by volume, or at least 5% by volume, or at least 6% by volume, or at least 7% by volume, or at least 8% by volume, or at least 9% by volume, or at least 10% by volume, or at least 12% by volume, or at least 14% by volume, or at least 16% by volume, or at least 18% by volume, or at least 20% by volume, or at least 22% by volume, or at least 24% by volume, or at least 26% by volume, or at least 28% by volume, or at least 30% by volume, or at least 32% by volume, or at least 34% by volume, or at least 36% by volume, or at least 38% by volume, or at least 40% by volume of the bond precursor material relative to the total volume of the mixture. In another embodiment, the mixture may comprise at least 1 wt. % bond precursor material, based on the total weight of the mixture, such as at least 2 wt. %, or at least 3 wt. %, or at least 4 wt. %, or at least 5 wt. %, or at least 6 wt. %, or at least 7 wt. %, or at least 8 wt. %, or at least 9 wt. %, or at least 10 wt. %, or at least 12 wt. %, or at least 14 wt. %, or at least 16 wt. %, or at least 18 wt. %, or at least 20 wt. %, or at least 22 wt. %, or at least 24 wt. %, or at least 26 wt. %, or at least 28 wt. %, or at least 30 wt. %, or at least 32 wt. %, or at least 34 wt. %, or at least 36 wt. %, or at least 38 wt. %, or at least 40 wt. % bond precursor material. Further, in one non-limiting embodiment, the mixture can include 40% or less by volume of bond precursor material, e.g., 38% or less, or 35% or less, or 32% or less, or 30% or less, or 28% or less, or 25% or less, or 22% or less, or 20% or less, or 18% or less, or 15% or less by volume, based on the total volume of the mixture.In another non-limiting embodiment, the mixture can include 40 wt% or less of bond precursor material, for example, 38 wt% or less, or 35 wt% or less, or 32 wt% or less, or 30 wt% or less, or 28 wt% or less, or 25 wt% or less, or 22 wt% or less, or 20 wt% or less, or 18 wt% or less, or 15 wt% or less, based on the total weight of the mixture. The mixture can include an amount of bond precursor material content within a range including any of the above minimum and maximum percentages.

[0037] The mixture may further include abrasive particles configured to form the abrasive component of the final formed abrasive article. The abrasive particles may be added to the mixture at various times, such as after the addition of the bond precursor material to the mixture. It will be appreciated that in other embodiments, the abrasive particles may be added in combination with one or more of the other components in the mixture, including, but not limited to, a gelling agent, a bond precursor material, or one or more additives. The abrasive particles may include materials from the group consisting of oxides, borides, nitrides, carbides, oxynitrides, oxycarbides, amorphous, single crystal, polycrystalline, superabrasive, diamond, or any combination thereof. In one embodiment, at least one material is from the group consisting of alumina, silica, zirconia, or any combination thereof. In a particular embodiment, the abrasive particles may include or consist essentially of alumina. In one embodiment, the abrasive particles include at least one of fused alumina, unseeded alumina, seeded sol-gel alumina, and alumina having one or more magnetoplumbite-containing phases. In one embodiment, the abrasive particles may include doped alumina. In one embodiment, the abrasive particles may include La or MgO, or a combination thereof.

[0038] In one embodiment, the abrasive particles may include at least one of non-shaped particles (eg, crushed particles), shaped particles, agglomerated particles, and non-agglomerated particles.

[0039] The mixture may include a specific content of abrasive particles to facilitate improved manufacturing and / or performance of the abrasive article. For example, in one embodiment, the mixture may include at least 20 volume %, e.g., at least 25 volume %, or at least 30 volume %, or at least 35 volume %, or at least 40 volume %, or at least 45 volume %, or at least 50 volume %, or at least 55 volume %, or at least 60 volume %, or at least 65 volume %, or at least 70 volume %, or at least 75 volume %, or at least 80 volume % abrasive particles, based on the total volume of the mixture. In one embodiment, the mixture may include at least 20 weight %, e.g., at least 25 weight %, or at least 30 weight %, or at least 35 weight %, or at least 40 weight %, or at least 45 weight %, or at least 50 weight %, or at least 55 weight %, or at least 60 weight %, or at least 65 weight %, or at least 70 weight %, or at least 75 weight %, or at least 80 weight % abrasive particles, based on the total weight of the mixture. In another non-limiting embodiment, the mixture can include 80% by weight or less, e.g., 75% by weight or less, or 70% by weight or less, or 65% by weight or less, or 60% by weight or less, or 55% by weight or less, or 50% by weight or less, or 45% by weight or less, or 40% by weight or less, or 35% by weight or less, or 30% by weight or less, or 25% by weight or less, of abrasive particles, based on the total weight of the mixture. In another non-limiting embodiment, the mixture can include 80% by weight or less, e.g., 75% by weight or less, or 70% by weight or less, or 65% by weight or less, or 60% by weight or less, or 55% by weight or less, or 50% by weight or less, or 45% by weight or less, or 40% by weight or less, or 35% by weight or less, or 30% by weight or less, or 25% by weight or less, of abrasive particles, based on the total weight of the mixture. The mixture can include an amount of abrasive particles within a range including any of the above minimum and maximum percentages.

[0040] In one embodiment, the abrasive particles may have a polycrystalline phase with crystalline domains, the crystalline domains having an average domain size, by uncorrected intercept, of 8 microns or less, or 7 microns or less, or 6 microns or less, or 5 microns or less, or 4 microns or less, or 3 microns or less, or 2 microns or less, or 1 micron or less, or 0.5 microns or less, or 0.3 microns or less. In one embodiment, the abrasive particles may have a polycrystalline phase with crystalline domains having an average domain size of at least 0.1 microns, or at least 0.2 microns, or at least 0.3 microns, or at least 0.4 microns, or at least 0.5 microns, or at least 0.75 microns, or at least 1 micron, or at least 1.5 microns, or at least 2 microns, or at least 2.5 microns, or at least 3 microns, or at least 3.5 microns, or at least 4 microns, or at least 4.5 microns, or at least 5 microns. It will be understood that the average crystalline domain size may be between any of the minimum and maximum values ​​recited above.

[0041] The mixture may include a specific ratio of abrasive particle to bond content (APv / ABv) that may facilitate improved abrasive article performance and / or manufacturing. In one embodiment, APv / ABv may be at least 1, or at least 1.1, or at least 1.2, or at least 1.3, or at least 1.4, or at least 1.5, or at least 1.6, or at least 1.7, or at least 1.8, or at least 1.9, or at least 2.0, or at least 2.1, or at least 2.2, or at least 2.3, or at least 2.4, or at least 2.5, or at least 2.6. In one embodiment, APv / ABv can be 10 or less, or 9 or less, or 8 or less, or 7 or less, or 6 or less, or 5 or less, or 4.5 or less, or 4.0 or less, or 3.9 or less, or 3.8 or less, or 3.7 or less, or 3.6 or less, or 3.5 or less, or 3.4 or less, or 3.3 or less, or 3.2 or less, or 3.1 or less, or 3.0 or less. It will be understood that APv / ABv can be between any of the minimum and maximum values ​​listed above.

[0042] In one embodiment, the abrasive particles may have a multimodal particle size distribution. An exemplary particle size distribution can be found in Figure 3. The multimodal particle size distribution may have a fine mode and a coarse mode, and a midpoint equal to the average of the particle sizes corresponding to the fine mode and the coarse mode.

[0043] In one embodiment, the coarse mode may correspond to a particular grain size, which may facilitate improved performance and / or manufacturing of the abrasive article. In one embodiment, the coarse mode may be at least 5 microns, or at least 10 microns, or at least 15 microns, or at least 20 microns, or at least 25 microns, or at least 30 microns, or at least 35 microns, or at least 40 microns, or at least 45 microns, or at least 50 microns, or at least 55 microns, or at least 60 microns, or at least 65 microns, or at least 70 microns, or at least 75 microns, or at least 80 microns. In one embodiment, the coarse mode can be 1000 microns or less, or 800 microns or less, or 600 microns or less, or 500 microns or less, or 400 microns or less, or 300 microns or less, or 200 microns or less, or 190 microns or less, or 185 microns or less, or 180 microns or less, or 175 microns or less, or 170 microns or less, or 165 microns or less, or 160 microns or less, or 155 microns or less, or 150 microns or less, or 145 microns or less, or 140 microns or less, or 135 microns or less, or 130 microns or less, or 125 microns or less, or 120 microns or less, or 115 microns or less, or 110 microns or less, or 105 microns or less, or 100 microns or less, or 95 microns or less, or 90 microns or less, or 85 microns or less, or 80 microns or less, or 75 microns or less, or 70 microns or less. It will be appreciated that the coarse mode can be any value between any of the minimum and maximum values ​​listed above.

[0044] In one embodiment, the fine mode can correspond to a particular grain size, which can facilitate improved performance and / or manufacturing of the abrasive article. In one embodiment, the fine mode can be at least 1 micron, or at least 2 microns, or at least 3 microns, or at least 4 microns, or at least 5 microns, or at least 6 microns, or at least 7 microns, or at least 8 microns, or at least 9 microns, or at least 10 microns, or at least 11 microns, or at least 12 microns, or at least 13 microns, or at least 14 microns, or at least 15 microns, or at least 16 microns, or at least 17 microns, or at least 18 microns, or at least 19 microns, or at least 20 microns, or at least 21 microns, or at least 22 microns, or at least 23 microns, or at least 24 microns, or at least 25 microns, or at least 26 microns, or at least 27 microns, or at least 28 microns. In one embodiment, a fine mode can be 80 microns or less, or 78 microns or less, or 76 microns or less, or 74 microns or less, or 72 microns or less, or 70 microns or less, or 68 microns or less, or 66 microns or less, or 64 microns or less, or 62 microns or less, or 60 microns or less, or 58 microns or less, or 56 microns or less, or 54 microns or less, or 52 microns or less, or 50 microns or less, or 48 microns or less, or 46 microns or less, or 44 microns or less, or 42 microns or less, or 40 microns or less, or 38 microns or less, or 36 microns or less, or 34 microns or less, or 32 microns or less, or 30 microns or less. It will be understood that a fine mode can be between any of the above minimum and maximum values.

[0045] In one embodiment, the difference between the fine and coarse modes can correspond to a particular grain size, which can facilitate improved performance and / or manufacturing of the abrasive article. In one embodiment, the difference between the fine and coarse modes can be at least 5 microns, or at least 10 microns, or at least 15 microns, or at least 20 microns, or at least 25 microns, or at least 30 microns, or at least 35 microns, or at least 40 microns, or at least 45 microns, or at least 50 microns, or at least 55 microns, or at least 60 microns, or at least 65 microns, or at least 70 microns, or at least 75 microns, or at least 80 microns. In one embodiment, the difference between the fine and coarse modes can be 1000 microns or less, or 800 microns or less, or 600 microns or less, or 500 microns or less, or 400 microns or less, or 300 microns or less, or 200 microns or less, or 190 microns or less, or 185 microns or less, or 180 microns or less, or 175 microns or less, or 170 microns or less, or 165 microns or less, or 160 microns or less, or 155 microns or less, or 150 microns or less, or 145 microns or less, or 140 microns or less, or 135 microns or less, or 130 microns or less, or 125 microns or less, or 120 microns or less, or 115 microns or less, or 110 microns or less, or 105 microns or less, or 100 microns or less, or 95 microns or less, or 90 microns or less, or 85 microns or less, or 80 microns or less, or 75 microns or less, or 70 microns or less. It will be understood that the difference between the fine and coarse modes can be between any of the minimum and maximum values ​​listed above.

[0046] In one embodiment, the multimodal particle size distribution can include a volume percent ratio [Vc / Vf], where Vc represents the volume percent of coarse abrasive particles having a size above the average of the fine and coarse modes, and Vf represents the volume percent of abrasive particles having a size below the average of the fine and coarse modes. In one embodiment, [Vc / Vf] can be at least 0.5, or at least 0.6, or at least 0.7, or at least 0.8, or at least 0.9, or at least 1, or at least 1.1, or at least 1.2, or at least 1.3, or at least 1.4, or at least 1.5, or at least 2, or at least 3, or at least 4, or at least 5, or at least 6, or at least 7, or at least 8. In one embodiment, [Vc / Vf] can be 100 or less, or 75 or less, or 50 or less, or 40 or less, or 30 or less, or 20 or less, or 15 or less, or 12 or less, or 10 or less, or 9 or less, or 8 or less, or 7 or less, or 6 or less, or 5 or less. It will be understood that [Vc / Vf] can be between any of the minimum and maximum values ​​listed above.

[0047] After mixing, the mixture can be shaped and pressed to form a green abrasive body. In one embodiment, the mixture can be pressed with a specific amount of force, which can facilitate improved abrasive article performance and / or manufacturing. In one embodiment, the pressing force can be at least 300 tons, or at least 310 tons, or at least 320 tons, or at least 330 tons, or at least 340 tons, or at least 350 tons, or at least 360 tons, or at least 370 tons, or at least 380 tons, or at least 390 tons, or at least 400 tons, or at least 410 tons, or at least 420 tons, or at least 430 tons, or at least 440 tons, or at least 450 tons, or at least 460 tons, or at least 470 tons, or at least 480 tons, or at least 490 tons, or at least 500 tons. In one embodiment, the press force may be 1000 tons or less, or 950 microns or less, or 900 tons or less, or 850 tons or less, or 800 tons or less, or 750 tons or less, or 700 tons or less, or 650 tons or less, or 600 tons or less, or 550 tons or less, or 500 tons or less, or 450 tons or less, or 400 tons or less, or 350 tons or less. It will be understood that the press force may be between any of the minimum and maximum values ​​stated above.

[0048] In one embodiment, the mixture can be pressed at a specific pressure, which can facilitate improved abrasive article performance and / or manufacturing. In one embodiment, the pressing force can be at least 90 MPa, or at least 95 MPa, or at least 100 MPa, or at least 105 MPa, or at least 110 MPa. In one embodiment, the pressing force can be 200 MPa or less, or 195 MPa or less, or 190 MPa or less, or 185 MPa or less, or 180 MPa or less.

[0049] After pressing, the green body can be dried under controlled humidity. Drying can be performed at a specific humidity, which can facilitate improved abrasive article performance and / or manufacturing. In one embodiment, drying can be performed at a humidity of at least 30%, or at least 32%, or at least 34%, or at least 36%, or at least 38%, or at least 40%, or at least 42%, or at least 44%, or at least 46%, or at least 48%, or at least 50%, or at least 52%, or at least 54%, or at least 56%, or at least 58%, or at least 60%. In one embodiment, drying may be performed at 60% humidity or less, or 58% humidity or less, or 56% humidity or less, or 54% humidity or less, or 52% humidity or less, or 50% humidity or less, or 48% humidity or less, or 46% humidity or less, or 44% humidity or less, or 42% humidity or less, or 40% humidity or less, or 38% humidity or less, or 36% humidity or less, or 34% humidity or less, or 32% humidity or less, or 30% humidity or less. It will be understood that the drying humidity may be between any of the minimum and maximum values ​​listed above.

[0050] Drying can be carried out at a particular temperature, which can facilitate improved performance and / or manufacturing of the abrasive article. In one embodiment, the drying temperature can be at least 40°C, at least 41°C, or at least 42°C, or at least 43°C, or at least 44°C, or at least 45°C, or at least 46°C, or at least 47°C, or at least 48°C, or at least 49°C, or at least 50°C, or at least 51°C, or at least 52°C, or at least 53°C, or at least 54°C, or at least 55°C, or at least 56°C, or at least 57°C, or at least 58°C, or at least 59°C, or at least 60°C. In one embodiment, the drying temperature can be 80° C. or less, or 79° C. or less, or 78° C. or less, or 77° C. or less, or 76° C. or less, or 75° C. or less, or 74° C. or less, or 73° C. or less, or 72° C. or less, or 71° C. or less, or 70° C. or less, or 69° C. or less, or 68° C. or less, or 67° C. or less, or 66° C. or less, or 65° C. or less, or 64° C. or less, or 63° C. or less, or 62° C. or less, or 61° C. or less, or 60° C. or less, or 59° C. or less, or 58° C. or less, or 57° C. or less, or 56° C. or less, or 55° C. or less, or 54° C. or less, or 53° C. or less, or 52° C. or less, or 51° C. or less, or 50° C. It will be understood that the drying temperature can be between any of the minimum and maximum values ​​recited above.

[0051] After drying, the green body is fired to form a fully formed abrasive article. In one embodiment, the green body may be fired at a particular temperature, which may facilitate improved performance and / or manufacturing of the abrasive article. In one embodiment, the firing temperature can be at least 800°C, or at least 810°C, or at least 820°C, or at least 830°C, or at least 840°C, or at least 850°C, or at least 860°C, or at least 870°C, or at least 880°C, or at least 890°C, or at least 900°C, or at least 905°C, or at least 910°C, or at least 915°C, or at least 920°C, or at least 925°C, or at least 930°C, or at least 935°C, or at least 940°C, or at least 945°C, or at least 950°C, or at least 955°C, or at least 960°C, or at least 965°C, or at least 970°C, or at least 975°C, or at least 980°C, or at least 995°C, or at least 1000°C.In one embodiment, the firing temperature is 1300°C or less, or 1290°C or less, or 1280°C or less, or 1270°C or less, or 1260°C or less, or 1250°C or less, or 1240°C or less, or 1230°C or less, or 1220°C or less, or 1210°C or less, or 1200°C or less, or 1190°C or less, or 1180°C or less, or 1170°C or less, or 1160°C or less, or 1150°C or less, or 1140°C or less, or 1130°C or less, or 1120°C or less, or 1110°C or less, or 1100°C or less, or 1090°C or less, or 1080°C or less, or 1070°C or less, or 1060°C or less, or 1050°C or less, or 1040°C or less, or 1030°C or less, or 1020°C. or less, or 1010°C or less, or 1000°C or less, or 995°C or less, or 990°C or less, or 985°C or less, or 980°C or less, or 975°C or less, or 970°C or less, or 965°C or less, or 960°C or less, or 955°C or less, or 950°C or less, or 945°C or less, or 940°C or less, or 935°C or less, or 930°C or less, or 925°C or less, or 920°C or less, or 915°C or less, or 910°C or less, or 905°C or less, or 900°C or less, or 890°C or less, or 880°C or less, or 870°C or less, or 860°C or less, or 850°C or less, or 840°C or less, or 830°C or less, or 820°C or less, or 810°C or less, or 800°C or less. It will be understood that the firing temperature can be between any of the minimum and maximum values ​​stated above.

[0052] The final formed abrasive article may be a fixed abrasive body defining an interconnected network of bond material containing abrasive particles within a three-dimensional volume (i.e., matrix) of the bond material. Additionally, the fixed abrasive body may have a quantity of porosity distributed throughout the body that defines a phase distinct from the phase of the bond material and abrasive particles.

[0053] According to one embodiment, the bond material can include a material configured to form the bond material of the final formed abrasive article. In one embodiment, the bond material can include an inorganic material such as, but not limited to, a metal, a metal alloy, a ceramic, a glassy material, or a frit material, or any combination thereof. The bond material can include an inorganic material in an amorphous phase, a polycrystalline phase, a single crystalline phase, or any combination thereof.

[0054] The bond material may have a specific composition that may facilitate improved abrasive article performance or manufacturing. In one embodiment, the bond material may have an Al2O3 content of at least 18 wt%, or at least 20 wt%, or at least 22 wt%. In one embodiment, the bond material may have an Al2O3 content of 36 wt% or less, or 33 wt% or less, or 30 wt% or less, or 27 wt% or less, based on the total content of the bond material. It will be understood that the Al2O3 content may be between any of the minimum and maximum values ​​listed above.

[0055] In one embodiment, the bond material may have a SiO2 content of at least 38 wt%, or at least 40 wt%, or at least 42 wt%, or at least 45 wt%. In one embodiment, the bond material may have a SiO2 content of 55 wt% or less relative to the total content of the bond material. It will be understood that the SiO2 content may be between any of the minimum and maximum values ​​listed above.

[0056] In one embodiment, the bond material may have a B2O3 content of at least 10 wt%. In one embodiment, the bond material may have a B2O3 content of 18 wt% or less, or 15 wt% or less, based on the total content of the bond material. It will be understood that the B2O3 content may be between any of the minimum and maximum values ​​listed above.

[0057] In an embodiment, the bond material may have a BaO content of 0.6 wt. % or less, or 0.4 wt. % or less, or 0.2 wt. % or less, or 0.1 wt. % or less, or 0.05 wt. % or less, or 0.03 wt. % or less, relative to the total content of the bond material.

[0058] In one embodiment, the bond material may include a CaO content of at least 0.3 wt. %. In one embodiment, the bond material may include a CaO content of 2 wt. % or less, or 1.5 wt. % or less, or 1 wt. % or less, or 0.5 wt. % or less, based on the total content of the bond material. It will be understood that the CaO content may be between any of the minimum and maximum values ​​listed above.

[0059] In one embodiment, the bond material may have a CoO content of less than or equal to 0.7 wt. % relative to the total content of the bond material.

[0060] In one embodiment, the bond material may include a Cr2O3 content of less than or equal to 0.01 wt. % relative to the total content of the bond material.

[0061] In one embodiment, the bond material may include a content of Fe2O3 of 0.8 wt. % or less, or 0.7 wt. % or less, relative to the total content of the bond material.

[0062] In one embodiment, the bond material may include a CuO content of less than or equal to 0.01% by weight relative to the total content of the bond material.

[0063] In one embodiment, the bond material may include a content of HfO2 of less than or equal to 0.02 wt. % relative to the total content of the bond material.

[0064] In one embodiment, the bond material may include a KO content of at least 0.5 wt. %. In one embodiment, the bond material may include a KO content of 2 wt. % or less, or 1 wt. % or less, based on the total bond material content. It will be understood that the KO content may be between any of the minimum and maximum values ​​listed above.

[0065] In one embodiment, the bond material may include a La2O2 content of at least 1.3 wt%. In one embodiment, the bond material may include a La2O2 content of 2.0 wt% or less, or 1.5 wt% or less, based on the total content of the bond material. It will be understood that the La2O2 content may be between any of the minimum and maximum values ​​listed above.

[0066] In one embodiment, the bond material may have a LiO content of at least 0.2 wt%, or at least 0.5 wt%, or at least 0.7 wt%, or at least 0.9 wt%. In one embodiment, the bond material may have a LiO content of 3 wt% or less, or 2.5 wt% or less, or 2.0 wt% or less, or 1.5 wt% or less, or 1.1 wt% or less, based on the total content of the bond material. It will be understood that the LiO content may be between any of the minimum and maximum values ​​stated above.

[0067] In one embodiment, the bond material may have an MgO content of at least 0.5 wt. % or at least 0.7 wt. %. In one embodiment, the bond material may have an MgO content of 1.5 wt. % or less, or 1.0 wt. % or less, relative to the total content of the bond material. It will be understood that the MgO content may be between any of the above minimum and maximum values.

[0068] In one embodiment, the bond material may include a MnO2 content of 0.05 wt. % or less. In one embodiment, the bond material may include a MnO2 content of 0.02 wt. % or less, based on the total content of the bond material. It will be understood that the MnO2 content may be between any of the minimum and maximum values ​​listed above.

[0069] In one embodiment, the bond material may include a Na2O content of at least 4 wt. %. In one embodiment, the bond material may include a Na2O content of 12 wt. % or less, or 9 wt. % or less, or 6 wt. % or less, based on the total content of the bond material. It will be understood that the Na2O content may be between any of the minimum and maximum values ​​listed above.

[0070] In one embodiment, the bond material may include a content of NiO of less than or equal to 0.01 wt. % relative to the total content of the bond material.

[0071] In one embodiment, the bond material may include a content of SrO of less than or equal to 0.02% by weight relative to the total content of the bond material.

[0072] In one embodiment, the bond material may include a TiO2 content of at least 0.2 wt. % and not more than 0.8 wt. % relative to the total content of the bond material.

[0073] In one embodiment, the bond material may include a V2O5 content of less than or equal to 0.02 wt. % relative to the total content of the bond material.

[0074] In one embodiment, the bond material may include a Y2O3 content of at least 0.4 wt. % and not more than 1.0 wt. % relative to the total content of the bond material.

[0075] In one embodiment, the bond material may include a ZnO content of less than or equal to 0.2 wt. % relative to the total content of the bond material.

[0076] In one embodiment, the bond material may include a content of ZrO2 of less than or equal to 0.01 wt. % relative to the total content of the bond material.

[0077] According to one embodiment, the bond material can be added at a specific content. For example, in one embodiment, the abrasive article can include at least 1 vol% of bond material relative to the total volume of the body, or at least 2 vol%, or at least 3 vol%, or at least 4 vol%, or at least 5 vol%, or at least 6 vol%, or at least 7 vol%, or at least 8 vol%, or at least 9 vol%, or at least 10 vol%, or at least 11 vol%, or at least 12 vol%, or at least 13 vol%, or at least 14 vol%, or at least 15 vol%, or at least 16 vol%, or at least 17 vol%, or at least 18 vol%, or at least 19 vol%, or at least 20 vol%, or at least 22 vol%, or at least 24 vol%, or at least 26 vol%, or at least 28 vol%, or at least 30 vol%, or at least 32 vol%, or at least 34 vol%, or at least 36 vol%, or at least 38 vol%, or at least 40 vol% of bond material relative to the total volume of the body.In one embodiment, the abrasive article may comprise at least 1 wt% bond material based on the total weight of the body, or at least 2 wt%, or at least 3 wt%, or at least 4 wt%, or at least 5 wt%, or at least 6 wt%, or at least 7 wt%, or at least 8 wt%, or at least 9 wt%, or at least 10 wt%, or at least 11 wt%, or at least 12 wt%, or at least 13 wt%, or at least 14 wt%, or at least 15 wt%, or at least 16 wt%, or at least 17 wt%, or at least 18 wt%, or at least 19 wt%, or at least 20 wt%, or at least 22 wt%, or at least 24 wt%, or at least 26 wt%, or at least 28 wt%, or at least 30 wt%, or at least 32 wt%, or at least 34 wt%, or at least 36 wt%, or at least 38 wt%, or at least 40 wt% bond material based on the total weight of the body. Further, in one non-limiting embodiment, the abrasive article can include 50% or less by volume of bond material relative to the total volume of the body, or 48% or less by volume, or 46% or less by volume, or 44% or less by volume, or 42% or less by volume, or 40% or less by volume, or 38% or less by volume, or 36% or less by volume, or 34% or less by volume, or 32% or less by volume, or 30% or less by volume, or 28% or less by volume, or 26% or less by volume, or 24% or less by volume, or 22% or less by volume, or 20% or less by volume of bond material relative to the total volume of the body. In one non-limiting embodiment, the abrasive article can include 50% or less by weight of bond material, based on the total weight of the body, or 48% or less by weight, or 46% or less, or 44% or less, or 42% or less, or 40% or less, or 38% or less, or 36% or less, or 34% or less, or 32% or less, or 30% or less, or 28% or less, or 26% or less, or 24% or less, or 22% or less, or 20% or less by weight of bond material, based on the total weight of the body.The abrasive article may contain an amount of bond material within a range including any of the minimum and maximum percentages listed above.

[0078] The abrasive article may further include abrasive particles configured to form the abrasive component of the final abrasive article. The abrasive particles may be added to the abrasive article at various times, such as after the addition of the bond material to the abrasive article. It will be appreciated that in other embodiments, the abrasive particles may be added in combination with one or more of the other components in the abrasive article, including, but not limited to, a gelling agent, a bond material, or one or more additives. The abrasive particles may include materials from the group consisting of oxides, borides, nitrides, carbides, oxynitrides, oxycarbides, amorphous, single crystal, polycrystalline, superabrasive, diamond, or any combination thereof. In one embodiment, at least one material is from the group consisting of alumina, silica, zirconia, or any combination thereof. In a particular embodiment, the abrasive particles may include or consist essentially of alumina. In one embodiment, the abrasive particles include at least one of fused alumina, unseeded alumina, seeded sol-gel alumina, and alumina having one or more magnetoplumbite-containing phases. In one embodiment, the abrasive particles may include doped alumina. In one embodiment, the abrasive particles may include La or MgO, or a combination thereof.

[0079] In one embodiment, the abrasive particles may include at least one of non-shaped particles (eg, crushed particles), shaped particles, agglomerated particles, and non-agglomerated particles.

[0080] The abrasive article may include a specific content of abrasive particles to facilitate improved manufacturing and / or improved performance of the abrasive article. For example, in one embodiment, the abrasive article may include at least 1% by volume of abrasive particles, or at least 5% by volume, or at least 10% by volume, or at least 15% by volume, or at least 20% by volume, or at least 25% by volume, or at least 30% by volume, or at least 32% by volume, or at least 34% by volume, or at least 36% by volume, or at least 38% by volume, or at least 40% by volume, or at least 42% by volume, or at least 44% by volume, or at least 46% by volume, or at least 48% by volume, or at least 50% by volume of abrasive particles, based on the total volume of the body. In another non-limiting embodiment, the abrasive article can include 80% by volume or less abrasive particles, based on the total volume of the body, or 78% by volume or less, or 76% by volume or less, or 74% by volume or less, or 72% by volume or less, or 70% by volume or less, or 68% by volume or less, or 66% by volume or less, or 64% by volume or less, or 62% by volume or less, or 60% by volume or less, or 58% by volume or less, or 56% by volume or less, or 54% by volume or less, or 52% by volume or less, or 50% by volume or less abrasive particles, based on the total volume of the body. The abrasive article can include an amount of abrasive particle content within a range including any of the above minimum and maximum percentages.

[0081] In one embodiment, the abrasive particles may have a polycrystalline phase with crystalline domains, the crystalline domains having an average domain size, by uncorrected intercept, of 8 microns or less, or 7 microns or less, or 6 microns or less, or 5 microns or less, or 4 microns or less, or 3 microns or less, or 2 microns or less, or 1 micron or less, or 0.5 microns or less, or 0.3 microns or less. In one embodiment, the abrasive particles may have a polycrystalline phase with crystalline domains having an average domain size of at least 0.1 microns, or at least 0.2 microns, or at least 0.3 microns, or at least 0.4 microns, or at least 0.5 microns, or at least 0.75 microns, or at least 1 micron, or at least 1.5 microns, or at least 2 microns, or at least 2.5 microns, or at least 3 microns, or at least 3.5 microns, or at least 4 microns, or at least 4.5 microns, or at least 5 microns. It will be understood that the average crystalline domain size may be between any of the minimum and maximum values ​​recited above.

[0082] The abrasive article may include a particular ratio of abrasive particle to bond content (APv / ABv) that may facilitate improved performance and / or manufacturing of the abrasive article. In one embodiment, APv / ABv may be at least 1, or at least 1.1, or at least 1.2, or at least 1.3, or at least 1.4, or at least 1.5, or at least 1.6, or at least 1.7, or at least 1.8, or at least 1.9, or at least 2.0, or at least 2.1, or at least 2.2, or at least 2.3, or at least 2.4, or at least 2.5, or at least 2.6. In one embodiment, APv / ABv can be 10 or less, or 9 or less, or 8 or less, or 7 or less, or 6 or less, or 5 or less, or 4.5 or less, or 4.0 or less, or 3.9 or less, or 3.8 or less, or 3.7 or less, or 3.6 or less, or 3.5 or less, or 3.4 or less, or 3.3 or less, or 3.2 or less, or 3.1 or less, or 3.0 or less. It will be understood that APv / ABv can be between any of the minimum and maximum values ​​listed above.

[0083] In one embodiment, the abrasive particles may have a multimodal particle size distribution. An exemplary particle size distribution can be found in Figure 3. The multimodal particle size distribution may have a fine mode and a coarse mode, and a midpoint equal to the average of the particle sizes corresponding to the fine mode and the coarse mode.

[0084] In one embodiment, the coarse mode may correspond to a particular grain size, which may facilitate improved performance and / or manufacturing of the abrasive article. In one embodiment, the coarse mode may be at least 5 microns, or at least 10 microns, or at least 15 microns, or at least 20 microns, or at least 25 microns, or at least 30 microns, or at least 35 microns, or at least 40 microns, or at least 45 microns, or at least 50 microns, or at least 55 microns, or at least 60 microns, or at least 65 microns, or at least 70 microns, or at least 75 microns, or at least 80 microns. In one embodiment, the coarse mode can be 1000 microns or less, or 800 microns or less, or 600 microns or less, or 500 microns or less, or 400 microns or less, or 300 microns or less, or 200 microns or less, or 190 microns or less, or 185 microns or less, or 180 microns or less, or 175 microns or less, or 170 microns or less, or 165 microns or less, or 160 microns or less, or 155 microns or less, or 150 microns or less, or 145 microns or less, or 140 microns or less, or 135 microns or less, or 130 microns or less, or 125 microns or less, or 120 microns or less, or 115 microns or less, or 110 microns or less, or 105 microns or less, or 100 microns or less, or 95 microns or less, or 90 microns or less, or 85 microns or less, or 80 microns or less, or 75 microns or less, or 70 microns or less. It will be appreciated that the coarse mode can be any value between any of the minimum and maximum values ​​listed above.

[0085] In one embodiment, the fine mode can correspond to a particular grain size, which can facilitate improved performance and / or manufacturing of the abrasive article. In one embodiment, the fine mode can be at least 1 micron, or at least 2 microns, or at least 3 microns, or at least 4 microns, or at least 5 microns, or at least 6 microns, or at least 7 microns, or at least 8 microns, or at least 9 microns, or at least 10 microns, or at least 11 microns, or at least 12 microns, or at least 13 microns, or at least 14 microns, or at least 15 microns, or at least 16 microns, or at least 17 microns, or at least 18 microns, or at least 19 microns, or at least 20 microns, or at least 21 microns, or at least 22 microns, or at least 23 microns, or at least 24 microns, or at least 25 microns, or at least 26 microns, or at least 27 microns, or at least 28 microns. In one embodiment, a fine mode can be 80 microns or less, or 78 microns or less, or 76 microns or less, or 74 microns or less, or 72 microns or less, or 70 microns or less, or 68 microns or less, or 66 microns or less, or 64 microns or less, or 62 microns or less, or 60 microns or less, or 58 microns or less, or 56 microns or less, or 54 microns or less, or 52 microns or less, or 50 microns or less, or 48 microns or less, or 46 microns or less, or 44 microns or less, or 42 microns or less, or 40 microns or less, or 38 microns or less, or 36 microns or less, or 34 microns or less, or 32 microns or less, or 30 microns or less. It will be understood that a fine mode can be between any of the above minimum and maximum values.

[0086] In one embodiment, the difference between the fine and coarse modes can correspond to a particular grain size, which can facilitate improved performance and / or manufacturing of the abrasive article. In one embodiment, the difference between the fine and coarse modes can be at least 5 microns, or at least 10 microns, or at least 15 microns, or at least 20 microns, or at least 25 microns, or at least 30 microns, or at least 35 microns, or at least 40 microns, or at least 45 microns, or at least 50 microns, or at least 55 microns, or at least 60 microns, or at least 65 microns, or at least 70 microns, or at least 75 microns, or at least 80 microns. In one embodiment, the difference between the fine and coarse modes can be 1000 microns or less, or 800 microns or less, or 600 microns or less, or 500 microns or less, or 400 microns or less, or 300 microns or less, or 200 microns or less, or 190 microns or less, or 185 microns or less, or 180 microns or less, or 175 microns or less, or 170 microns or less, or 165 microns or less, or 160 microns or less, or 155 microns or less, or 150 microns or less, or 145 microns or less, or 140 microns or less, or 135 microns or less, or 130 microns or less, or 125 microns or less, or 120 microns or less, or 115 microns or less, or 110 microns or less, or 105 microns or less, or 100 microns or less, or 95 microns or less, or 90 microns or less, or 85 microns or less, or 80 microns or less, or 75 microns or less, or 70 microns or less. It will be understood that the difference between the fine and coarse modes can be between any of the minimum and maximum values ​​listed above.

[0087] In one embodiment, the multimodal particle size distribution can include a volume percent ratio [Vc / Vf], where Vc represents the volume percent of coarse abrasive particles having a size above the average of the fine and coarse modes, and Vf represents the volume percent of abrasive particles having a size below the average of the fine and coarse modes. In one embodiment, [Vc / Vf] can be at least 0.5, or at least 0.6, or at least 0.7, or at least 0.8, or at least 0.9, or at least 1, or at least 1.1, or at least 1.2, or at least 1.3, or at least 1.4, or at least 1.5, or at least 2, or at least 3, or at least 4, or at least 5, or at least 6, or at least 7, or at least 8. In one embodiment, [Vc / Vf] can be 100 or less, or 75 or less, or 50 or less, or 40 or less, or 30 or less, or 20 or less, or 15 or less, or 12 or less, or 10 or less, or 9 or less, or 8 or less, or 7 or less, or 6 or less, or 5 or less.

[0088] Fixed abrasive bodies formed by the processes of embodiments herein can have certain characteristics.

[0089] FIG. 2A includes a perspective view of a fixed abrasive body according to one embodiment. The abrasive article 200 may include a fixed abrasive body 201. The fixed abrasive body 201 may include an opening 202. As further shown in FIG. 2A , the fixed abrasive body includes an axial axis 203 defining an axial direction and a transverse axis 204 defining a radial axis. The axial axis 203 extends vertically as defined by the thickness (t) of the fixed abrasive body 201. The transverse axis 204 extends radially, defining the radius, or outer diameter (OD), of the fixed abrasive body 201. The abrasive body may have an inner diameter (ID) corresponding to the diameter of the opening 202 in the center of the abrasive body. The abrasive body may have a first major surface 205, a second major surface 206 opposite the first major surface and separated by the thickness t, and a side surface 207 extending between the first and second major surfaces.

[0090] In one embodiment, the abrasive article may have a particular OD, which may facilitate improved performance and / or manufacturing of the abrasive article. In one embodiment, the OD may be at least 155 mm, or at least 160 mm, or at least 165 mm, or at least 170 mm, or at least 175 mm, or at least 180 mm, or at least 190 mm, or at least 210 mm, or at least 220 mm, or at least 230 mm, or at least 240 mm, or at least 250 mm, or at least 260 mm. In one embodiment, the OD may be 500 mm or less, or 475 mm or less, or 450 mm or less, or 425 mm or less, or 400 mm or less, or 380 mm or less, or 360 mm or less, or 340 mm or less, or 320 mm or less, or 300 mm or less, or 280 mm or less. It will be understood that the OD may be between any of the minimum or maximum values ​​recited above.

[0091] In one embodiment, the abrasive article may have a specific ID, which may facilitate improved performance and / or manufacturing of the abrasive article. In one embodiment, the ID may be at least 100 mm, or at least 110 mm, or at least 120 mm, or at least 130 mm, or at least 140 mm, or at least 150 mm, or at least 155 mm, or at least 160 mm, or at least 165 mm, or at least 170 mm, or at least 175 mm, or at least 180 mm, or at least 190 mm, or at least 210 mm, or at least 220 mm, or at least 230 mm, or at least 240 mm, or at least 250 mm, or at least 260 mm. In one embodiment, the ID may be 350 mm or less, or 340 mm or less, or 330 mm or less, or 320 mm or less, or 310 mm or less, or 300 mm or less, or 290 mm or less, or 280 mm or less, or 270 mm or less, or 260 mm or less, or 250 mm or less, or 240 mm or less, or 230 mm or less, or 220 mm or less, or 210 mm or less, or 200 mm or less, or 190 mm or less, or 180 mm or less. It will be understood that the ID may be between any of the minimum or maximum values ​​listed above.

[0092] In one embodiment, the abrasive article may have a particular thickness, which may facilitate improved performance and / or manufacturing of the abrasive article. In one embodiment, the thickness may be at least 10 mm, or at least 11 mm, or at least 12 mm, or at least 13 mm, or at least 14 mm, or at least 15 mm, or at least 16 mm, or at least 17 mm, or at least 18 mm, or at least 19 mm, or at least 20 mm. In one embodiment, the thickness may be 100 mm or less, or 95 mm or less, or 90 mm or less, or 85 mm or less, or 80 mm or less, or 75 mm or less, or 70 mm or less, or 65 mm or less, or 60 mm or less, or 55 mm or less, or 50 mm or less, or 45 mm or less, or 40 mm or less, or 35 mm or less, or 30 mm or less. It will be understood that the thickness may be between any of the minimum or maximum values ​​recited above.

[0093] 2B includes a perspective view of a fixed abrasive body according to a different embodiment. The abrasive article 200 may include a fixed abrasive body 201. The body may include a length (L), a width (W), and a thickness (t), where the thickness (t) is the shortest dimension. The abrasive body may have a first major surface 205, a second major surface 206 opposite the first major surface and separated by a thickness t, and a side surface 207 extending between the first and second major surfaces.

[0094] The porosity of the fixed abrasive body 201 may include open porosity, closed porosity, or a combination thereof. Open porosity may be defined as interconnected channels extending through the fixed abrasive body 201. Closed porosity may define separate, independent voids contained in the bond material.

[0095] In one embodiment, the abrasive article may include a particular porosity content, which may facilitate improved performance and / or manufacturing of the abrasive article. In one embodiment, the abrasive article may include a porosity content of at least 1 vol%, or at least 2 vol%, or at least 3 vol%, or at least 4 vol%, or at least 5 vol%, or at least 6 vol%, or at least 7 vol%, or at least 8 vol%, or at least 9 vol%, or at least 10 vol%, or at least 11 vol%, or at least 12 vol%, or at least 13 vol%, or at least 14 vol%, or at least 15 vol%, or at least 16 vol%, or at least 17 vol%, or at least 18 vol%, or at least 19 vol%, or at least 20 vol%, or at least 21 vol%, or at least 22 vol%, or at least 23 vol%, or at least 24 vol%, or at least 25 vol%, or at least 26 vol%, or at least 27 vol%, or at least 28 vol%, or at least 29 vol%, or at least 30 vol%. In one embodiment, the abrasive article may comprise a porosity content of 65% or less by volume, based on the total volume of the body, or 60% or less by volume, or 55% or less by volume, or 50% or less by volume, or 48% or less by volume, or 46% or less by volume, or 44% or less by volume, or 42% or less by volume, or 40% or less by volume, or 38% or less by volume, or 36% or less by volume, or 34% or less by volume, or 32% or less by volume, or 30% or less by volume, based on the total volume of the body. It will be understood that the porosity content may be between any of the minimum and maximum values ​​recited above.

[0096] In one embodiment, the abrasive article may include a particular density that may facilitate improved performance and / or manufacturing of the abrasive article. 3 , or at least 2.15 g / cm 3 , or at least 2.20 g / cm 3 , or at least 2.25 g / cm 3 , or at least 2.3 g / cm 3 , or at least 2.35 g / cm 3 In one embodiment, the abrasive article may have a density of 2.60 g / cm3 Less than or equal to 2.55g / cm 3 The following densities may be included: It will be understood that the density may be between any of the minimum and maximum values ​​listed above.

[0097] In one embodiment, the abrasive article may include a specific density variation that may facilitate improved performance and / or manufacturing of the abrasive article. Density variation can be measured according to the process outlined in the Examples. In one embodiment, the abrasive article has a density of 0.040 g / cm 3 or less, or 0.035 g / cm 3 or less, or 0.030 g / cm 3 or less, or 0.025g / cm 3 or less, or 0.022 g / cm 3 or less, or 0.020 g / cm 3 or less, or 0.019 g / cm 3 or less, or 0.018 g / cm 3 or less, or 0.017 g / cm 3 or less, or 0.016 g / cm 3 or less, or 0.015g / cm 3 or less than 0.014 g / cm 3 or less, or 0.013 g / cm 3 or less, or 0.012 g / cm 3 or less, or 0.011 g / cm 3 or less than 0.010g / cm 3 The abrasive article may include the following density variations: In one embodiment, the abrasive article has a density of at least 0.0001 g / cm 3 , or at least 0.0005 g / cm 3 , or at least 0.001 g / cm 3 , or at least 0.005 g / cm 3 may include density variations of

[0098] In one embodiment, the abrasive article may have a particular MOR, which may facilitate improved performance and / or manufacturing of the abrasive article. The MOR may be measured as described in the Examples section of this specification. In one embodiment, the MOR may be at least 55 MPa, or at least 56 MPa, or at least 57 MPa, or at least 58 MPa, or at least 59 MPa, or at least 60 MPa, or at least 61 MPa, or at least 62 MPa, or at least 63 MPa, or at least 64 MPa, or at least 65 MPa, or at least 66 MPa, or at least 67 MPa, or at least 68 MPa, or at least 69 MPa, or at least 70 MPa, or at least 71 MPa, or at least 72 MPa, or at least 73 MPa, or at least 74 MPa, or at least 75 MPa, or at least 76 MPa, or at least 77 MPa, or at least 78 MPa, or at least 79 MPa, or at least 80 MPa.In another embodiment, the MOR is 120 MPa or less, or 119 MPa or less, or 118 MPa or less, or 117 MPa or less, or 116 MPa or less, or 115 MPa or less, or 114 MPa or less, or 113 MPa or less, or 112 MPa or less, or 111 MPa or less, or 110 MPa or less, or 109 MPa or less, or 108 MPa or less, or 107 MPa or less, or 106 MPa or less, or 105 MPa or less, or 104 MPa or less, or 103 MPa or less, or 102 MPa or less, or 101 MPa or less, or 100 MPa or less, or 99 MPa or less, or 98 MPa or less, or 97 MPa or less, or 96 MPa or less, may be 95 MPa or less, or 94 MPa or less, or 93 MPa or less, or 92 MPa or less, or 91 MPa or less, or 90 MPa or less, or 89 MPa or less, or 88 MPa or less, or 87 MPa or less, or 86 MPa or less, or 85 MPa or less, or 84 MPa or less, or 83 MPa or less, or 82 MPa or less, or 81 MPa or less, or 80 MPa or less, or 79 MPa or less, or 78 MPa or less, or 77 MPa or less, or 76 MPa or less, or 75 MPa or less, or 74 MPa or less, or 73 MPa or less, or 72 MPa or less, or 71 MPa or less, or 70 MPa or less, or 69 MPa or less, or 68 MPa or less. It will be understood that the MOR may be between any of the minimum and maximum values ​​recited above.

[0099] In one embodiment, the abrasive article may have a particular MOE (or EMOD), which may facilitate improved performance and / or manufacturing of the abrasive article. The MOE may be measured as described in the Examples section herein. In one embodiment, the MOE may be at least 55 GPa, or at least 56 GPa, or at least 57 GPa, or at least 58 GPa, or at least 59 GPa, or at least 60 GPa, or at least 61 GPa, or at least 62 GPa, or at least 63 GPa, or at least 64 GPa, or at least 65 GPa, or at least 66 GPa, or at least 67 GPa, or at least 68 GPa, or at least 69 GPa, or at least 70 GPa, or at least 71 GPa, or at least 72 GPa, or at least 73 GPa, or at least 74 GPa, or at least 75 GPa, or at least 76 GPa, or at least 77 GPa, or at least 78 GPa, or at least 79 GPa, or at least 80 GPa. In another embodiment, the MOE may be 90 GPa or less, or 89 GPa or less, or 88 GPa or less, or 87 GPa or less, or 86 GPa or less, or 85 GPa or less, or 84 GPa or less, or 83 GPa or less, or 82 GPa or less, or 81 GPa or less, or 80 GPa or less, or 79 GPa or less, or 78 GPa or less, or 77 GPa or less, or 76 GPa or less, or 75 GPa or less, or 74 GPa or less, or 73 GPa or less, or 72 GPa or less, or 71 GPa or less, or 70 GPa or less, or 69 GPa or less, or 68 GPa or less, or 67 GPa or less, or 66 GPa or less, or 65 GPa or less, or 64 GPa or less, or 63 GPa or less, or 62 GPa or less, or 61 GPa or less, or 60 GPa or less. It will be understood that the MOE may be between any of the minimum and maximum values ​​recited above.

[0100] In one embodiment, the abrasive article may have a particular MOR / MOE, which may facilitate improved performance and / or manufacturing of the abrasive article. In one embodiment, the MOR / MOE is at least 0.91, or at least 0.92, or at least 0.93, or at least 0.94, or at least 0.95, or at least 0.96, or at least 0.97, or at least 0.98, or at least 0.99, or at least 1.00, or at least 1.01, or at least 1.02, or at least 1.03, or at least 1.04, or at least 1.05, or at least 1.06, or at least 1.07, or at least 1.08, or at least 1.09, or at least The α-to-β ratio may be at least 1.1, or at least 1.11, or at least 1.12, or at least 1.13, or at least 1.14, or at least 1.15, or at least 1.16, or at least 1.17, or at least 1.18, or at least 1.19, or at least 1.2, or at least 1.21, or at least 1.22, or at least 1.23, or at least 1.24, or at least 1.25, or at least 1.26, or at least 1.27, or at least 1.28, or at least 1.29, or at least 1.3. In another embodiment, the MOR / MOE can be 2 or less, or 1.95 or less, or 1.9 or less, or 1.85 or less, or 1.8 or less, or 1.75 or less, or 1.7 or less, or 1.65 or less, or 1.6 or less, or 1.55 or less, or 1.5 or less, or 1.45 or less, or 1.4 or less, or 1.35 or less, or 1.3 or less, or 1.25 or less, or 1.2 or less, or 1.15 or less, or 1.14 or less, or 1.13 or less, or 1.12 or less, or 1.11 or less, or 1.10 or less, or 1.09 or less, or 1.08 or less. It will be understood that the MOR / MOE can be between any of the minimum and maximum values ​​recited above.

[0101] In one embodiment, the preferred MOR / MOE ratio may depend in part on the bond volume percent of the abrasive article. If the bond volume percent of the abrasive article is at least 18%, the MOR / MOE ratio may be at least 0.92. If the bond volume percent of the abrasive article is less than 18% or is in the range of 18-14% by volume, the MOR / MOE ratio may be at least 1.05.

[0102] In one embodiment, the abrasive article may include a specific average bond post area (BPA), which may facilitate improved performance and / or manufacturing of the abrasive article. The bond post area may be measured as described in the Examples. Exemplary images used to measure the area and number of bond posts can be found in Figures 4A-4C. The dark spots correspond to bond posts. In one embodiment, the average BPA is 2400 microns. 2 or less than 2300 microns 2 or less than 2200 microns 2 or less than 2100 microns 2 or less than 2000 microns 2 or less than 1900 microns 2 or less than 1875 microns 2 or less than 1850 microns 2 or less than 1825 microns 2 or less than 1800 microns 2 or less than 1775 microns 2 or less than 1750 microns 2 or less than 1730 microns 2 In one embodiment, the BPA may be at least 1000 microns thick. 2 , or at least 1100 microns 2 , or at least 1200 microns 2 , or at least 1300 microns 2 , or at least 1400 microns 2 , or at least 1500 microns 2 , or at least 1600 microns 2 It will be understood that the average BPA can be between any of the minimum and maximum values ​​listed above.

[0103] In one embodiment, the abrasive article may include a specific bond post area (BPA) per bond volume % that may facilitate improved performance and / or manufacturing of the abrasive article. In one embodiment, the BPA per bond volume % is 200 microns per bond volume %. 2 or less than 195 microns 2 or less than 190 microns 2 or less than 185 microns 2 or less than 180 microns 2 or less than 175 microns 2 or less than 170 microns 2 or less than 165 microns 2 or less than 160 microns 2 or less than 155 microns 2 or less than 150 microns 2 or less than 145 microns 2 or less than 140 microns 2 or less than 135 microns 2 or less than 130 microns 2 In one embodiment, the BPA per volume % of bond is at least 60 microns per volume % of bond. 2 , or at least 70 microns 2 , or at least 80 microns 2 , or at least 90 microns 2 , or at least 100 microns 2 , or at least 110 microns 2 , or at least 120 microns 2 , or at least 130 microns 2 It will be understood that the BPA per volume % of the bond can be between any of the minimum and maximum values ​​listed above.

[0104] In one embodiment, the abrasive article may include a specific bond post volume (BPV) per bond volume %, which may facilitate improved performance and / or manufacturing of the abrasive article. In one embodiment, the BPV per bond volume % is 6000 microns per bond volume %. 3 , or 5500 microns3 or less than 5100 microns 3 or less than 5000 microns 3 or less than 4900 microns 3 or less than 4800 microns 3 or less than 4700 microns 3 or less than 4600 microns 3 or less than 4500 microns 3 or less than 4400 microns 3 or less than 4300 microns 3 or less than 4200 microns 3 or less than 4100 microns 3 or less than 4000 microns 3 or less than 3900 microns 3 In one embodiment, the BPV per volume % bond is at least 3100 microns per volume % bond. 3 , or at least 3200 microns 3 , or at least 3300 microns 3 , or at least 3400 microns 3 , or at least 3500 microns 3 , or at least 3600 microns 3 It will be understood that the BPV per bond volume % can be between any of the minimum and maximum values ​​set forth above.

[0105] In one embodiment, the abrasive article has a 1.536 mm diameter, which may facilitate improved performance and / or manufacturing of the abrasive article. 2 The bond post count may include a specific bond post count (BPC) per 1.536 mm. The bond post count may be measured as described in the Examples. Exemplary images used to measure the bond post count can be found in Figures 4A-4C. The dark spots correspond to the bond posts. In one embodiment, 2 The BPC per 1.536 mm may be at least 140, or at least 150, or at least 160, or at least 165, or at least 170, or at least 175, or at least 180, or at least 185. In one embodiment, 2The BPC per unit may be 300 or less, or 275 or less, or 250 or less, or 225 or less. 2 It will be appreciated that the BPC per can be between any of the minimum and maximum values ​​listed above.

[0106] In one embodiment, the abrasive article has a 1.536 mm per volume percent bond, which may facilitate improved performance and / or manufacturing of the abrasive article. 2 In one embodiment, the bond volume percentage may include 1.536 mm 2 BPC bond posts per 1.536 mm per bond volume percent of at least 7.5, or at least 7.6, or at least 7.7, or at least 7.8, or at least 7.9, or at least 8.0, or at least 8.1, or at least 8.2, or at least 8.3, or at least 8.4, or at least 8.5 2 In one embodiment, the bond volume percentage may be 1.536 mm 2 BPC bond posts per 1.536mm per bond volume % of 10 or less, or 9.9 or less, or 9.8 or less, or 9.7 or less, or 9.6 or less, or 9.5 or less 2 1.536mm per bond volume % 2 It will be understood that the BPC bond posts per can be between any of the minimum and maximum values ​​listed above.

[0107] In one embodiment, the abrasive article may have a particular cumulative bond post area distribution. The distribution may include bond post area on the x-axis and the number of bond posts equal to or less than that area on the y-axis. An exemplary cumulative bond post area distribution can be found in Figure 5. In one embodiment, the abrasive article has a cumulative bond post area of ​​at least 115 microns. 2 and 125 microns 2 In one embodiment, the abrasive article may have a 10th percentile bond post area of ​​at least 300 microns. 2 and 310 microns 2In one embodiment, the abrasive article may have a 25th percentile bond post area of ​​at least 715 microns. 2 and 735 microns 2 In one embodiment, the abrasive article may have a 50th percentile bond post area of ​​at least 1800 microns. 2 and 1900 microns 2 In one embodiment, the abrasive article may have a 75th percentile bond post area of ​​at least 3500 microns. 2 and 4000 microns 2 The bond post area may be the following:

[0108] In one embodiment, an abrasive article can have bond posts with a particular average radius of curvature, or bond wetting radius. The radius of curvature of the bond posts indicates the wetting ability of the bond material. Bond materials with high wettability have bond posts with a small radius of curvature, as shown in FIG. 6. Bond materials with low wettability have bond posts with a large radius of curvature, as shown in FIG. 7. The bond post radius of curvature can be measured as described in the Examples from an image such as that shown in FIG. 8. FIG. 8 includes an image of an abrasive article having particles 801, bond material 802, and pores 803.

[0109] In one embodiment, the abrasive article may include bond posts having a particular average bond wetting radius. In one embodiment, the average bond wetting radius may be at least 30 microns, or at least 31 microns, or at least 32 microns, or at least 33 microns, or at least 34 microns, or at least 35 microns, or at least 36 microns, or at least 37 microns, or at least 38 microns, or at least 39 microns, or at least 40 microns. In one embodiment, the average bond wetting radius may be 100 microns or less, or 90 microns or less, or 80 microns or less, or 70 microns or less, or 60 microns or less, or 50 microns or less, or 40 microns or less. It will be understood that the average wetting radius may be between any of the minimum and maximum values ​​listed above.

[0110] The abrasive articles disclosed herein may be used for cutting, chamfering, sharpening, gear power honing, worm gear grinding, CMR, roughing, grinding, weld surface finishing, or precision finishing.

[0111] Many different aspects and embodiments are possible. Some of these aspects and embodiments are described herein. After reading this specification, those skilled in the art will understand that these aspects and embodiments are merely illustrative and do not limit the scope of the invention. An embodiment may follow any one or more of the embodiments listed below.

[0112] Embodiment Embodiment 1. An abrasive article, The main body is a bond material comprising an inorganic material; abrasive particles contained in a bond material; a body comprising a MOR / EMOD ratio of at least 0.92 and a bond volume % of less than 18%; The main body is a) 2400 microns 2 Average Bond Post Area (BPA) of: b) 1.536 mm 2 an average bond post count (BPC) of at least 140 per c) an average bond wetting radius of at least 30 microns; and d) a combination of a) and b).

[0113] Embodiment 2. An abrasive article, The main body is a bond material comprising an inorganic material; abrasive particles contained in a bond material; a body comprising a MOR / EMOD ratio of at least 1.05 and a bond volume percentage of at least 18% and no more than 30%; The main body is a) 2400 microns 2 Average Bond Post Area (BPA) of: b) 1.536 mm 2 an average bond post count (BPC) of at least 140 per c) an average bond wetting radius of at least 30 microns; and d) a combination of a) and b).

[0114] Embodiment 3. The body has a molecular weight of at least 0.91, or at least 0.92, or at least 0.93, or at least 0.94, or at least 0.95, or at least 0.96, or at least 0.97, or at least 0.98, or at least 0.99, or at least 1.00, or at least 1.01, or at least 1.02, or at least 1.03, or at least 1.04, or at least 1.05, or at least 1.06, or at least 1.07, or at least 1.08, or at least 1.09, or at least 1.1, or at least 1.11, or at least 1.12, or at least 1.13, or at least 1.14, or at least 1.15, or at least 1.16, or at least 1.17, or at least 1.18, or at least 1.19, or at least 1.2, or at least 1.21, or at least 1.22, or at least 1.23, or at least 1.24, or at least 1.25, or at least 1.26, or at least 1.27, or at least 1.28, or at least 1.29, or at least 1.3.

[0115] Embodiment 4. The abrasive article of embodiment 1 or embodiment 2, wherein the body comprises a MOR / EMOD ratio of 2 or less, or 1.95 or less, or 1.9 or less, or 1.85 or less, or 1.8 or less, or 1.75 or less, or 1.7 or less, or 1.65 or less, or 1.6 or less, or 1.55 or less, or 1.5 or less, or 1.45 or less, or 1.4 or less, or 1.35 or less, or 1.3 or less, or 1.25 or less, or 1.2 or less, or 1.15 or less, or 1.14 or less, or 1.13 or less, or 1.12 or less, or 1.11 or less, or 1.10 or less, or 1.09 or less, or 1.08 or less.

[0116] Embodiment 5. The abrasive article of embodiment 1 or embodiment 2, wherein the body comprises an MOR of at least 55 MPa, or at least 56 MPa, or at least 57 MPa, or at least 58 MPa, or at least 59 MPa, or at least 60 MPa, or at least 61 MPa, or at least 62 MPa, or at least 63 MPa, or at least 64 MPa, or at least 65 MPa, or at least 66 MPa, or at least 67 MPa, or at least 68 MPa, or at least 69 MPa, or at least 70 MPa, or at least 71 MPa, or at least 72 MPa, or at least 73 MPa, or at least 74 MPa, or at least 75 MPa, or at least 76 MPa, or at least 77 MPa, or at least 78 MPa, or at least 79 MPa, or at least 80 MPa.

[0117] Embodiment 6. The body is 120 MPa or less, or 119 MPa or less, or 118 MPa or less, or 117 MPa or less, or 116 MPa or less, or 115 MPa or less, or 114 MPa or less, or 113 MPa or less, or 112 MPa or less, or 111 MPa or less, or 110 MPa or less, or 109 MPa or less, or 108 MPa or less, or 107 MPa or less, or 106 MPa or less, or 105 MPa or less, or 104 MPa or less, or 103 MPa or less, or 102 MPa or less, or 101 MPa or less, or 100 MPa or less, or 99 MPa or less, or 98 MPa or less, or 97 MPa or less, or 96 MPa or less, or 95 MPa or less, or 94 MPa or less, or 93 MPa or less, or 92 MPa or less, or 91 MPa or less, or 90 MPa or less, or 89 MPa or less, or 88 MPa or less, or 87 MPa or less, or 86 MPa or less, or 85 MPa or less, or 84 MPa or less, or 83 MPa or less, or 82 MPa or less, or 81 MPa or less, or 80 MPa or less, or 79 MPa or less, or 78 MPa or less, or 77 MPa or less, or 76 MPa or less, or 75 MPa or less, or 74 MPa or less, or 73 MPa or less, or 72 MPa or less, or 71 MPa or less, or 70 MPa or less, or 69 MPa or less, or 68 MPa or less.

[0118] Embodiment 7. The abrasive article of embodiment 1 or embodiment 2, wherein the body comprises an EMOD of at least 55 GPa, or at least 56 GPa, or at least 57 GPa, or at least 58 GPa, or at least 59 GPa, or at least 60 GPa, or at least 61 GPa, or at least 62 GPa, or at least 63 GPa, or at least 64 GPa, or at least 65 GPa, or at least 66 GPa, or at least 67 GPa, or at least 68 GPa, or at least 69 GPa, or at least 70 GPa, or at least 71 GPa, or at least 72 GPa, or at least 73 GPa, or at least 74 GPa, or at least 75 GPa, or at least 76 GPa, or at least 77 GPa, or at least 78 GPa, or at least 79 GPa, or at least 80 GPa.

[0119] Embodiment 8. An abrasive article according to embodiment 1 or embodiment 2, wherein the body comprises an EMOD of 90 GPa or less, or 89 GPa or less, or 88 GPa or less, or GPa 87 GPa or less, or 86 GPa or less, or 85 GPa or less, or 84 GPa or less, or 83 GPa or less, or 82 GPa or less, or 81 GPa or less, or 80 GPa or less, or 79 GPa or less, or 78 GPa or less, or 77 GPa or less, or 76 GPa or less, or 75 GPa or less, or 74 GPa or less, or 73 GPa or less, or 72 GPa or less, or 71 GPa or less, or 70 GPa or less, or 69 GPa or less, or 68 GPa or less, or 67 GPa or less, or 66 GPa or less, or 65 GPa or less, or 64 GPa or less, or 63 GPa or less, or 62 GPa or less, or 61 GPa or less, or 60 GPa or less.

[0120] Embodiment 9.2400 microns 2 or less than 2300 microns 2 or less than 2200 microns 2 or less than 2100 microns 2 or less than 2000 microns 2 or less than 1900 microns 2 or less than 1875 microns 2 or less than 1850 microns 2 or less than 1825 microns 2 or less than 1800 microns 2 or less than 1775 microns 2 or less than 1750 microns 2 or less than 1730 microns 2 3. The abrasive article of claim 1 or claim 2, further comprising an average bond post area (BPA) of:

[0121] Embodiment 10. At least 1000 microns 2 , or at least 1100 microns 2 , or at least 1200 microns 2 , or at least 1300 microns 2 , or at least 1400 microns 2, or at least 1500 microns 2 , or at least 1600 microns 2 3. The abrasive article of claim 1 or claim 2, further comprising an average bond post area (BPA) of

[0122] Embodiment 11.200 microns 2 Average bond post area (BPA) per volume % of bond material or 195 microns per volume % of bond 2 Less than or equal to 190 microns 2 Less than or equal to 185 microns 2 Less than or equal to 180 microns 2 Less than or equal to 175 microns 2 Less than or equal to 170 microns 2 Less than or equal to 165 microns 2 Less than or equal to 160 microns 2 Less than or equal to 155 microns 2 Less than or equal to 150 microns 2 Less than or equal to 145 microns 2 Less than or equal to 140 microns 2 Less than or equal to 135 microns 2 Less than or equal to 130 microns 2 3. The abrasive article of claim 1 or claim 2, further comprising an average BPA of:

[0123] Embodiment 12. At least 60 microns 2 Average bond post area (BPA) per volume % of bond material, or at least 70 microns per volume % of bond 2 , or at least 80 microns 2 , or at least 90 microns 2 , or at least 100 microns 2 , or at least 110 microns 2 , or at least 120 microns 2 , or at least 130 microns 2 3. The abrasive article of claim 1 or claim 2, further comprising an average of 100% BPA.

[0124] Embodiment 13.6000 microns 3 Average bond post volume (BPV) per volume % of bond material or 5500 microns per volume % of bond 3 Less than or equal to 5100 microns 3 Less than or equal to 5000 microns 3 Less than or equal to 4900 microns 3 or less than 4800 microns 3 Less than or equal to 4700 microns 3 Less than or equal to 4600 microns 3 Less than or equal to 4500 microns 3 Less than or equal to 4400 microns 3 Less than or equal to 4300 microns 3 or less than 4200 microns 3 Less than or equal to 4100 microns 3 Less than or equal to 4000 microns 3 Less than or equal to 3900 microns 3 3. The abrasive article of claim 1 or claim 2, further comprising an average BPV of:

[0125] Embodiment 14. At least 3100 microns 3 Average bond post volume (BPV) per vol % of bond material, or at least 3200 microns per vol % of bond 3 , or at least 3300 microns 3 , or at least 3400 microns 3 , or at least 3500 microns 3 , or at least 3600 microns 3 3. The abrasive article of claim 1 or claim 2, further comprising an average BPV of:

[0126] Embodiment 15.1.536 mm 2 3. The abrasive article of claim 1 or claim 2, further comprising an average bond post count (BPC) of at least 140, or at least 150, or at least 160, or at least 165, or at least 170, or at least 175, or at least 180, or at least 185 bond posts per BPC.

[0127] Embodiment 16.1.536 mm 2 3. The abrasive article of claim 1 or claim 2, further comprising an average bond post count (BPC) of 300 or less, or 275 or less, or 250 or less, or 225 or less bond posts per BPC.

[0128] Embodiment 17. 1.536 mm per volume percent of bond 2 3. The abrasive article of claim 1 or claim 2, further comprising an average bond post per volume percent bond material (BPC) of at least 7.5, or at least 7.6, or at least 7.7, or at least 7.8, or at least 7.9, or at least 8.0, or at least 8.1, or at least 8.2, or at least 8.3, or at least 8.4, or at least 8.5 bond posts per volume percent bond material (BPC).

[0129] Embodiment 18. 1.536 mm per volume percent of bond 2 3. The abrasive article of claim 1 or claim 2, further comprising an average bond post per volume percent bond material (BPC) of 10 or less, or 9.9 or less, or 9.8 or less, or 9.7 or less, or 9.6 or less, or 9.5 or less bond posts per BPC.

[0130] Embodiment 19. At least 1300 microns 2 And 2400 microns 2 Further includes an average bond post area (BPA) of 1.536mm 2 At least 40 bond posts per 1.536mm 2 3. The abrasive article of claim 1 or claim 2, further comprising an average bond post count (BPC) of 300 or less bond posts per abrasive.

[0131] Embodiment 20. The abrasive article of embodiment 1 or embodiment 2, further comprising an average bond wetting radius of at least 30 microns, or at least 31 microns, or at least 32 microns, or at least 33 microns, or at least 34 microns, or at least 35 microns, or at least 36 microns, or at least 37 microns, or at least 38 microns, or at least 39 microns, or at least 40 microns.

[0132] Embodiment 21. The abrasive article of embodiment 1 or embodiment 2, further comprising an average bond wetting radius of 100 microns or less, or 90 microns or less, or 80 microns or less, or 70 microns or less, or 60 microns or less, or 50 microns or less, or 40 microns or less.

[0133] Embodiment 22. The 10th percentile bond post area is at least 115 microns 2 and 125 microns 2 3. An abrasive article according to embodiment 1 or embodiment 2, wherein:

[0134] Embodiment 23. The 25th percentile bond post area is at least 300 microns 2 and 310 microns 2 3. An abrasive article according to embodiment 1 or embodiment 2, wherein:

[0135] Embodiment 24. The 50th percentile bond post area is at least 715 microns 2 and 735 microns 2 3. An abrasive article according to embodiment 1 or embodiment 2, wherein:

[0136] Embodiment 2: The 5.75th percentile bond post area is at least 1800 microns. 2 and 1900 microns 2 3. An abrasive article according to embodiment 1 or embodiment 2, wherein:

[0137] Embodiment 26. The 90th percentile bond post area is at least 3500 microns 2and 4000 microns 2 3. An abrasive article according to embodiment 1 or embodiment 2, wherein:

[0138] Embodiment 27. An abrasive article according to embodiment 1 or embodiment 2, wherein the body contains a bond content of at least 1% by volume relative to the total volume of the body, or at least 2% by volume, or at least 3% by volume, or at least 4% by volume, or at least 5% by volume, or at least 6% by volume, or at least 7% by volume, or at least 8% by volume, or at least 9% by volume, or at least 10% by volume, or at least 11% by volume, or at least 12% by volume, or at least 13% by volume, or at least 14% by volume, or at least 15% by volume, or at least 16% by volume, or at least 17% by volume, or at least 18% by volume, or at least 19% by volume, or at least 20% by volume.

[0139] Embodiment 28. An abrasive article as described in embodiment 1 or embodiment 2, wherein the body contains a bond content of 50% by volume or less, or 48% by volume or less, or 46% by volume or less, or 44% by volume or less, or 42% by volume or less, or 40% by volume or less, or 38% by volume or less, or 36% by volume or less, or 34% by volume or less, or 32% by volume or less, or 30% by volume or less, or 28% by volume or less, or 26% by volume or less, or 24% by volume or less, or 22% by volume or less, or 20% by volume or less, relative to the total volume of the body.

[0140] Embodiment 29. An abrasive article according to embodiment 1 or embodiment 2, wherein the bond material comprises an Al2O3 content of at least 18 wt%, or at least 20 wt%, or at least 22 wt%.

[0141] Embodiment 30. An abrasive article according to embodiment 1 or embodiment 2, wherein the bond material comprises an Al2O3 content of 36 wt. % or less, or 33 wt. % or less, or 30 wt. % or less, or 27 wt. % or less, based on the total content of the bond material.

[0142] Embodiment 31. An abrasive article according to embodiment 1 or embodiment 2, wherein the bond material comprises an SiO2 content of at least 38 wt.%, or at least 40 wt.%, or at least 42 wt.%, or at least 45 wt.%.

[0143] Embodiment 32. An abrasive article according to embodiment 1 or embodiment 2, wherein the bond material contains at least 10% by weight, or not more than 18% by weight, or not more than 15% by weight of B2O3, based on the total content of the bond material.

[0144] Embodiment 33. An abrasive article according to embodiment 1 or embodiment 2, wherein the bond material contains BaO in an amount of 0.6 wt. % or less, or 0.4 wt. % or less, or 0.2 wt. % or less, or 0.1 wt. % or less, or 0.05 wt. % or less, or 0.03 wt. % or less, based on the total content of the bond material.

[0145] Embodiment 34. An abrasive article according to embodiment 1 or embodiment 2, wherein the bond material contains at least 0.3 wt. %, or not more than 2 wt. %, or not more than 1.5 wt. %, or not more than 1 wt. %, or not more than 0.5 wt. % CaO, based on the total content of the bond material.

[0146] Embodiment 35. An abrasive article according to embodiment 1 or embodiment 2, wherein the bond material contains 0.7 wt. % or less CoO relative to the total content of the bond material.

[0147] Embodiment 36. An abrasive article according to embodiment 1 or embodiment 2, wherein the bond material contains 0.01 wt. % or less of Cr2O3 relative to the total content of the bond material.

[0148] Embodiment 37. An abrasive article according to embodiment 1 or embodiment 2, wherein the bond material contains 0.01 wt % or less CuO relative to the total content of the bond material.

[0149] Embodiment 38. An abrasive article according to embodiment 1 or embodiment 2, wherein the bond material contains at least 0.8 wt. % or less, or 0.7 wt. % or less, of Fe2O3 relative to the total content of the bond material.

[0150] Embodiment 39. An abrasive article according to embodiment 1 or embodiment 2, wherein the bond material contains 0.02 wt. % or less HfO2 relative to the total content of the bond material.

[0151] Embodiment 40. An abrasive article according to embodiment 1 or embodiment 2, wherein the bond material comprises a content of K2O of at least 0.5 wt. %, or not more than 2 wt. %, or not more than 1 wt. %, based on the total content of the bond material.

[0152] Embodiment 41. An abrasive article according to embodiment 1 or embodiment 2, wherein the bond material contains at least 1.3 wt. %, or not more than 2.0 wt. %, or not more than 1.5 wt. % of La2O2, based on the total content of the bond material.

[0153] Embodiment 42. An abrasive article according to embodiment 1 or embodiment 2, wherein the bond material contains at least 0.2 wt. %, or at least 0.5 wt. %, or at least 0.7 wt. %, or at least 0.9 wt. %, or 3 wt. % or less, or 2.5 wt. % or less, or 2.0 wt. % or less, or 1.5 wt. % or less, or 1.1 wt. % or less of Li2O, based on the total content of the bond material.

[0154] Embodiment 43. An abrasive article according to embodiment 1 or embodiment 2, wherein the bond material contains an MgO content of at least 0.5 wt.%, or at least 0.7 wt.%, or not more than 1.5 wt.%, or not more than 1.0 wt.%, relative to the total content of the bond material.

[0155] Embodiment 44. An abrasive article according to embodiment 1 or embodiment 2, wherein the bond material contains 0.05 wt. % or less MnO2 relative to the total content of the bond material.

[0156] Embodiment 45. An abrasive article according to embodiment 1 or embodiment 2, wherein the bond material contains at least 4% by weight, or not more than 12% by weight, or not more than 9% by weight, or not more than 6% by weight of Na2O, based on the total content of the bond material.

[0157] Embodiment 46. An abrasive article according to embodiment 1 or embodiment 2, wherein the bond material contains 0.01 wt % or less NiO relative to the total content of the bond material.

[0158] Embodiment 47. An abrasive article according to embodiment 1 or embodiment 2, wherein the bond material contains 0.02 wt. % or less SrO relative to the total content of the bond material.

[0159] Embodiment 48. An abrasive article according to embodiment 1 or embodiment 2, wherein the bond material contains at least 0.2 wt % and not more than 0.8 wt % TiO2 relative to the total content of the bond material.

[0160] Embodiment 49. An abrasive article according to embodiment 1 or embodiment 2, wherein the bond material contains 0.02 wt. % or less V2O5 relative to the total content of the bond material.

[0161] Embodiment 50. An abrasive article according to embodiment 1 or embodiment 2, wherein the bond material contains at least 0.4 wt. % and not more than 1.0 wt. % Y2O3 relative to the total content of the bond material.

[0162] Embodiment 51. An abrasive article according to embodiment 1 or embodiment 2, wherein the bond material contains 0.2 wt. % or less ZnO based on the total content of the bond material.

[0163] Embodiment 52. An abrasive article according to embodiment 1 or embodiment 2, wherein the bond material contains 0.01 wt. % or less ZrO2 relative to the total content of the bond material.

[0164] Embodiment 53. An abrasive article according to embodiment 1 or embodiment 2, wherein the body contains an abrasive particle content of at least 1 vol%, or at least 5 vol%, or at least 10 vol%, or at least 15 vol%, or at least 20 vol%, or at least 25 vol%, or at least 30 vol%, or at least 32 vol%, or at least 34 vol%, or at least 36 vol%, or at least 38 vol%, or at least 40 vol%, or at least 42 vol%, or at least 44 vol%, or at least 46 vol%, or at least 48 vol%, or at least 50 vol%, relative to the total volume of the body.

[0165] Embodiment 54. An abrasive article according to embodiment 1 or embodiment 2, wherein the body contains an abrasive particle content of 80% by volume or less, or 78% by volume or less, or 76% by volume or less, or 74% by volume or less, or 72% by volume or less, or 70% by volume or less, or 68% by volume or less, or 66% by volume or less, or 64% by volume or less, or 62% by volume or less, or 60% by volume or less, or 58% by volume or less, or 56% by volume or less, or 54% by volume or less, or 52% by volume or less, or 50% by volume or less, relative to the total volume of the body.

[0166] Embodiment 55. An abrasive article according to embodiment 1 or embodiment 2, wherein the body comprises a ratio of abrasive particle volume % / bond volume % (APv / ABv) of at least 1, or at least 1.1, or at least 1.2, or at least 1.3, or at least 1.4, or at least 1.5, or at least 1.6, or at least 1.7, or at least 1.8, or at least 1.9, or at least 2.0, or at least 2.1, or at least 2.2, or at least 2.3, or at least 2.4, or at least 2.5, or at least 2.6.

[0167] Embodiment 56. An abrasive article according to embodiment 1 or embodiment 2, wherein the body comprises a ratio of abrasive particle volume % / bond volume % (APv / ABv) of 10 or less, or 9 or less, or 8 or less, or 7 or less, or 6 or less, or 5 or less, or 4.5 or less, or 4.0 or less, or 3.9 or less, or 3.8 or less, or 3.7 or less, or 3.6 or less, or 3.5 or less, or 3.4 or less, or 3.3 or less, or 3.2 or less, or 3.1 or less, or 3.0 or less.

[0168] Embodiment 57. An abrasive article according to embodiment 1 or embodiment 2, wherein the body comprises a porosity content of at least 1 vol%, or at least 2 vol%, or at least 3 vol%, or at least 4 vol%, or at least 5 vol%, or at least 6 vol%, or at least 7 vol%, or at least 8 vol%, or at least 9 vol%, or at least 10 vol%, or at least 11 vol%, or at least 12 vol%, or at least 13 vol%, or at least 14 vol%, or at least 15 vol%, or at least 16 vol%, or at least 17 vol%, or at least 18 vol%, or at least 19 vol%, or at least 20 vol%, or at least 21 vol%, or at least 22 vol%, or at least 23 vol%, or at least 24 vol%, or at least 25 vol%, or at least 26 vol%, or at least 27 vol%, or at least 28 vol%, or at least 29 vol%, or at least 30 vol%.

[0169] Embodiment 58. An abrasive article as described in embodiment 1 or embodiment 2, wherein the body contains a porosity content of 65% by volume or less, relative to the total volume of the body, or 60% by volume or less, or 55% by volume or less, or 50% by volume or less, or 48% by volume or less, or 46% by volume or less, or 44% by volume or less, or 42% by volume or less, or 40% by volume or less, or 38% by volume or less, or 36% by volume or less, or 34% by volume or less, or 32% by volume or less, or 30% by volume or less.

[0170] Embodiment 59. An abrasive article according to embodiment 1 or embodiment 2, wherein the abrasive particles define a multimodal particle size distribution.

[0171] Embodiment 60. An abrasive article according to embodiment 59, wherein the multimodal particle size distribution comprises a fine mode and a coarse mode, and the coarse mode is at least 5 microns, or at least 10 microns, or at least 15 microns, or at least 20 microns, or at least 25 microns, or at least 30 microns, or at least 35 microns, or at least 40 microns, or at least 45 microns, or at least 50 microns, or at least 55 microns, or at least 60 microns, or at least 65 microns, or at least 70 microns, or at least 75 microns, or at least 80 microns.

[0172] Embodiment 61. The multimodal particle size distribution comprises a fine mode and a coarse mode, wherein the coarse mode is 1000 microns or less, or 800 microns or less, or 600 microns or less, or 500 microns or less, or 400 microns or less, or 300 microns or less, or 200 microns or less, or 190 microns or less, or 185 microns or less, or 180 microns or less, or 175 microns or less, or 170 microns or less, or 165 microns or less, or 160 microns or less, or 155 microns or less. 60. The abrasive article of embodiment 59, wherein the thickness is 150 microns or less, or 145 microns or less, or 140 microns or less, or 135 microns or less, or 130 microns or less, or 125 microns or less, or 120 microns or less, or 115 microns or less, or 110 microns or less, or 105 microns or less, or 100 microns or less, or 95 microns or less, or 90 microns or less, or 85 microns or less, or 80 microns or less, or 75 microns or less, or 70 microns or less.

[0173] Embodiment 62. An abrasive article according to embodiment 59, wherein the multimodal particle size distribution comprises a fine mode and a coarse mode, and the fine mode is at least 1 micron, or at least 2 microns, or at least 3 microns, or at least 4 microns, or at least 5 microns, or at least 6 microns, or at least 7 microns, or at least 8 microns, or at least 9 microns, or at least 10 microns, or at least 11 microns, or at least 12 microns, or at least 13 microns, or at least 14 microns, or at least 15 microns, or at least 16 microns, or at least 17 microns, or at least 18 microns, or at least 19 microns, or at least 20 microns, or at least 21 microns, or at least 22 microns, or at least 23 microns, or at least 24 microns, or at least 25 microns, or at least 26 microns, or at least 27 microns, or at least 28 microns.

[0174] Embodiment 63. An abrasive article according to embodiment 59, wherein the multimodal particle size distribution comprises a fine mode and a coarse mode, and the fine mode is 80 microns or less, or 78 microns or less, or 76 microns or less, or 74 microns or less, or 72 microns or less, or 70 microns or less, or 68 microns or less, or 66 microns or less, or 64 microns or less, or 62 microns or less, or 60 microns or less, or 58 microns or less, or 56 microns or less, or 54 microns or less, or 52 microns or less, or 50 microns or less, or 48 microns or less, or 46 microns or less, or 44 microns or less, or 42 microns or less, or 40 microns or less, or 38 microns or less, or 36 microns or less, or 34 microns or less, or 32 microns or less, or 30 microns or less.

[0175] Embodiment 64. An abrasive article according to embodiment 59, wherein the multimodal particle size distribution comprises a fine mode and a coarse mode, and further comprises a particle size difference between the fine mode and the coarse mode of at least 5 microns, or at least 10 microns, or at least 15 microns, or at least 20 microns, or at least 25 microns, or at least 30 microns, or at least 35 microns, or at least 40 microns, or at least 45 microns, or at least 50 microns, or at least 55 microns, or at least 60 microns, or at least 65 microns, or at least 70 microns, or at least 75 microns, or at least 80 microns.

[0176] Embodiment 65. The multimodal particle size distribution includes a fine mode and a coarse mode and is 1000 microns or less, or 800 microns or less, or 600 microns or less, or 500 microns or less, or 400 microns or less, or 300 microns or less, or 200 microns or less, or 190 microns or less, or 185 microns or less, or 180 microns or less, or 175 microns or less, or 170 microns or less, or 165 microns or less, or 160 microns or less, or 155 microns or less, or 150 microns or less. 60. The abrasive article of embodiment 59, further comprising a grain size difference between a fine mode and a coarse mode of 100 microns or less, or 145 microns or less, or 140 microns or less, or 135 microns or less, or 130 microns or less, or 125 microns or less, or 120 microns or less, or 115 microns or less, or 110 microns or less, or 105 microns or less, or 100 microns or less, or 95 microns or less, or 90 microns or less, or 85 microns or less, or 80 microns or less, or 75 microns or less, or 70 microns or less.

[0177] Embodiment 66. The abrasive article of embodiment 59, wherein the multimodal particle size distribution comprises a fine mode and a coarse mode and further comprises a volume percent ratio [Vc / Vf] of at least 0.5, where Vc represents the volume percent of coarse abrasive particles having a particle size greater than the average of the fine mode and the coarse mode, and Vf represents the volume percent of abrasive particles having a particle size less than the average of the fine mode and the coarse mode, or further wherein the volume percent ratio [Vc / Vf] is at least 0.6, or at least 0.7, or at least 0.8, or at least 0.9, or at least 1, or at least 1.1, or at least 1.2, or at least 1.3, or at least 1.4, or at least 1.5, or at least 2, or at least 3, or at least 4, or at least 5, or at least 6, or at least 7, or at least 8.

[0178] Embodiment 67. An abrasive article according to embodiment 59, wherein the multimodal particle size distribution comprises a fine mode and a coarse mode, and further comprises a volume percent ratio [Vc / Vf] of 100 or less, or 75 or less, or 50 or less, or 40 or less, or 30 or less, or 20 or less, or 15 or less, or 12 or less, or 10 or less, or 9 or less, or 8 or less, or 7 or less, or 6 or less, or 5 or less.

[0179] Embodiment 68. An abrasive article according to embodiment 1, wherein the abrasive particles comprise a material comprising at least one of an oxide, a carbide, a nitride, a boride, a diamond, or any combination thereof.

[0180] Embodiment 69. An abrasive article according to embodiment 68, wherein the abrasive particles comprise at least one material from the group consisting of alumina, silica, zirconia, or any combination thereof.

[0181] Embodiment 70. The abrasive article of embodiment 69, wherein the abrasive particles comprise at least one of fused alumina, unseeded alumina, seeded sol-gel alumina, and alumina having one or more magnetoplumbite-containing phases.

[0182] Embodiment 71. An abrasive article according to embodiment 69, wherein the abrasive particles comprise La or MgO, or a combination thereof.

[0183] Embodiment 72. An abrasive article according to embodiment 69, wherein the abrasive particles may have a polycrystalline phase having crystalline domains, the crystalline domains having an average domain size of 8 microns or less, or 7 microns or less, or 6 microns or less, or 5 microns or less, or 4 microns or less, or 3 microns or less, or 2 microns or less, or 1 micron or less, or 0.5 microns or less, or 0.3 microns or less, by uncorrected sectioning.

[0184] Embodiment 73. An abrasive article according to embodiment 1 or embodiment 2, wherein the abrasive particles comprise at least one of non-shaped particles (e.g., crushed particles), shaped particles, agglomerated particles, and non-agglomerated particles.

[0185] Embodiment 74. The body has a density of at least 2.10 g / cm 3 , or at least 2.15 g / cm 3 , or at least 2.20 g / cm 3 , or at least 2.25 g / cm 3 , or at least 2.3 g / cm 3 , or at least 2.35 g / cm 3 3. The abrasive article of claim 1 or claim 2, comprising an average density of

[0186] Embodiment 75. The body has a density of 2.60 g / cm 3 Less than or equal to 2.55g / cm 3 3. The abrasive article of claim 1 or claim 2, comprising an average density of:

[0187] Embodiment 76. The body has a density of 0.040 g / cm 3 or less, or 0.035 g / cm 3 or less, or 0.030 g / cm 3 or less, or 0.025g / cm 3 or less, or 0.022 g / cm 3 or less, or 0.020 g / cm 3 or less, or 0.019 g / cm 3or less, or 0.018 g / cm 3 or less, or 0.017 g / cm 3 or less, or 0.016 g / cm 3 or less, or 0.015g / cm 3 or less than 0.014 g / cm 3 or less, or 0.013 g / cm 3 or less, or 0.012 g / cm 3 or less, or 0.011 g / cm 3 or less than 0.010g / cm 3 3. The abrasive article of claim 1 or claim 2, comprising the following density variation of the body:

[0188] Embodiment 77. The body has a density of at least 0.0001 g / cm 3 , or at least 0.0005 g / cm 3 , or at least 0.001 g / cm 3 , or at least 0.005 g / cm 3 , or at least 0.01 g / cm 3 3. The abrasive article of claim 1 or claim 2, comprising a density variation in the body of:

[0189] Embodiment 78. An abrasive article according to embodiment 1 or embodiment 2, wherein the main body is in the shape of a wheel.

[0190] Embodiment 79. An abrasive article according to embodiment 78, wherein the body has an outer diameter of at least 255 mm, or at least 256 mm, or at least 257 mm, or at least 258 mm, or at least 259 mm, or at least 260 mm, or at least 261 mm, or at least 262 mm, or at least 263 mm, or at least 264 mm, or at least 265 mm.

[0191] Embodiment 80. An abrasive article according to embodiment 78, wherein the body has an outer diameter of 500 mm or less, or 475 mm or less, or 450 mm or less, or 425 mm or less, or 400 mm or less, or 380 mm or less, or 360 mm or less, or 340 mm or less, or 320 mm or less, or 300 mm or less, or 280 mm or less.

[0192] Embodiment 81. An abrasive article according to embodiment 78, wherein the body has an inner diameter of at least 100 mm, or at least 110 mm, or at least 120 mm, or at least 130 mm, or at least 140 mm, or at least 150 mm, or at least 155 mm, or at least 160 mm, or at least 165 mm, or at least 170 mm, or at least 175 mm, or at least 180 mm, or at least 190 mm, or at least 210 mm, or at least 220 mm, or at least 230 mm, or at least 240 mm, or at least 250 mm, or at least 260 mm.

[0193] Embodiment 82. An abrasive article according to embodiment 78, wherein the body has an inner diameter of 350 mm or less, or 340 mm or less, or 330 mm or less, or 320 mm or less, or 310 mm or less, or 300 mm or less, or 290 mm or less, or 280 mm or less, or 270 mm or less, or 260 mm or less, or 250 mm or less, or 240 mm or less, or 230 mm or less, or 220 mm or less, or 210 mm or less, or 200 mm or less, or 190 mm or less, or 180 mm or less.

[0194] Embodiment 83. An abrasive article according to embodiment 78, wherein the body has a thickness of at least 10 mm, or at least 11 mm, or at least 12 mm, or at least 13 mm, or at least 14 mm, or at least 15 mm, or at least 16 mm, or at least 17 mm, or at least 18 mm, or at least 19 mm, or at least 20 mm.

[0195] Embodiment 84. An abrasive article according to embodiment 78, wherein the body has a thickness of 100 mm or less, or 95 mm or less, or 90 mm or less, or 85 mm or less, or 80 mm or less, or 75 mm or less, or 70 mm or less, or 65 mm or less, or 60 mm or less, or 55 mm or less, or 50 mm or less, or 45 mm or less, or 40 mm or less, or 35 mm or less, or 30 mm or less.

[0196] Embodiment 85. A method for producing an abrasive article according to any one of embodiments 1 to 84, comprising: providing a mixture of abrasive particles and a bond material precursor; pressing the mixture into a green body; and firing the green body into a fully formed abrasive article.

[0197] Embodiment 86. The method of embodiment 85, wherein the pressing is performed at a pressing force of at least 300 tons, or at least 310 tons, or at least 320 tons, or at least 330 tons, or at least 340 tons, or at least 350 tons, or at least 360 tons, or at least 370 tons, or at least 380 tons, or at least 390 tons, or at least 400 tons, or at least 410 tons, or at least 420 tons, or at least 430 tons, or at least 440 tons, or at least 450 tons, or at least 460 tons, or at least 470 tons, or at least 480 tons, or at least 490 tons, or at least 500 tons.

[0198] Embodiment 87. The method of embodiment 85, wherein the pressing is performed at a press force of 500 tons or less, or 490 tons or less, or 480 tons or less, or 470 tons or less, or 460 tons or less, or 450 tons or less, or 440 tons or less, or 430 tons or less, or 420 tons or less, or 410 tons or less, or 400 tons or less, or 390 tons or less, or 380 tons or less, or 370 tons or less, or 360 tons or less, or 350 tons or less.

[0199] Embodiment 88. The method of embodiment 85, further comprising drying the green body before firing the green body.

[0200] Embodiment 89. The method of embodiment 88, wherein the drying is carried out at a humidity of at least 30%, or at least 32%, or at least 34%, or at least 36%, or at least 38%, or at least 40%, or at least 42%, or at least 44%, or at least 46%, or at least 48%, or at least 50%, or at least 52%, or at least 54%, or at least 56%, or at least 58%, or at least 60%.

[0201] Embodiment 90. The method of embodiment 88, wherein drying is carried out at a humidity of 60% or less, or 58% or less, or 56% or less, or 54% or less, or 52% or less, or 50% or less, or 48% or less, or 46% or less, or 44% or less, or 42% or less, or 40% or less, or 38% or less, or 36% or less, or 34% or less, or 32% or less, or 30% or less.

[0202] Embodiment 91. The method of embodiment 88, wherein the drying is carried out at a temperature of at least 45°C, or at least 46°C, or at least 47°C, or at least 48°C, or at least 49°C, or at least 50°C, or at least 51°C, or at least 52°C, or at least 53°C, or at least 54°C, or at least 55°C, or at least 56°C, or at least 57°C, or at least 58°C, or at least 59°C, or at least 60°C.

[0203] Embodiment 92. The method of embodiment 88, wherein drying is carried out at a temperature of 80°C or less, or 79°C or less, or 78°C or less, or 77°C or less, or 76°C or less, or 75°C or less, or 74°C or less, or 73°C or less, or 72°C or less, or 71°C or less, or 70°C or less, or 69°C or less, or 68°C or less, or 67°C or less, or 66°C or less, or 65°C or less, or 64°C or less, or 63°C or less, or 62°C or less, or 61°C or less, or 60°C or less, or 59°C or less, or 58°C or less, or 57°C or less, or 56°C or less, or 55°C or less, or 54°C or less, or 53°C or less, or 52°C or less, or 51°C or less, or 50°C or less.

[0204] Embodiment 93. The method of embodiment 85, wherein the calcining is carried out at a temperature of at least 900°C, or at least 905°C, or at least 910°C, or at least 915°C, or at least 920°C, or at least 925°C, or at least 930°C, or at least 935°C, or at least 940°C, or at least 945°C, or at least 950°C, or at least 955°C, or at least 960°C, or at least 965°C, or at least 970°C, or at least 975°C, or at least 980°C, or at least 995°C, or at least 1000°C.

[0205] Embodiment 94. The firing may be performed at a temperature of 1300°C or less, or 1290°C or less, or 1280°C or less, or 1270°C or less, or 1260°C or less, or 1250°C or less, or 1240°C or less, or 1230°C or less, or 1220°C or less, or 1210°C or less, or 1200°C or less, or 1190°C or less, or 1180°C or less, or 1170°C or less, or 1160°C or less, or 1150°C or less, or 1140°C or less, or 1130°C or less, or 1120°C or less, or 1110°C or less, or 1100°C or less, or 1090°C or less, or 1080°C or less, or 1070°C or less, or 1060°C or less, or 1050°C or less, or 1040°C or less, or 1030°C or less, or 1020°C or less, 86. The method of embodiment 85, conducted at a temperature of 1010°C or less, or 1000°C or less, or 995°C or less, or 990°C or less, or 985°C or less, or 980°C or less, or 75°C or less, or 970°C or less, or 965°C or less, or 960°C or less, or 955°C or less, or 950°C or less, or 945°C or less, or 940°C or less, or 935°C or less, or 930°C or less, or 925°C or less, or 920°C or less, or 915°C or less, or 910°C or less, or 905°C or less, or 900°C, or 890°C or less, or 880°C or less, or 870°C or less, or 860°C or less, or 850°C or less, or 840°C or less, or 830°C or less, or 820°C or less, or 810°C or less, or 800°C or less.

[0206] Embodiment 95. A method for polishing a workpiece using an abrasive article described in any one of embodiments 1 to 94, the method including cutting, chamfering, sharpening, gear power honing, worm gear grinding, CMR, roughing, grinding, weld surface finishing, or high-precision finishing.

[0207] Embodiment 96. An abrasive article according to embodiment 1 or embodiment 2, wherein the body comprises a bond content of at least 1% by weight relative to the total weight of the body, or at least 2% by weight relative to the total weight of the body, or at least 3% by weight, or at least 4% by weight, or at least 5% by weight, or at least 6% by weight, or at least 7% by weight, or at least 8% by weight, or at least 9% by weight, or at least 10% by weight, or at least 11% by weight, or at least 12% by weight, or at least 13% by weight, or at least 14% by weight, or at least 15% by weight, or at least 16% by weight, or at least 17% by weight, or at least 18% by weight, or at least 19% by weight, or at least 20% by weight.

[0208] Embodiment 97. An abrasive article according to embodiment 1 or embodiment 2, wherein the body comprises a bond content of 50% by weight or less, based on the total weight of the body, or 48% by weight or less, or 46% by weight or less, or 44% by weight or less, or 42% by weight or less, or 40% by weight or less, or 38% by weight or less, or 36% by weight or less, or 34% by weight or less, or 32% by weight or less, or 30% by weight or less, or 28% by weight or less, or 26% by weight or less, or 24% by weight or less, or 22% by weight or less, or 20% by weight or less, based on the total weight of the body.

[0209] Embodiment 98. An abrasive article according to embodiment 1 or embodiment 2, wherein the bond material contains 55% by weight or less of SiO2 relative to the total content of the bond material.

[0210] Embodiment 99. An abrasive article according to embodiment 1 or embodiment 2, wherein the body contains an abrasive particle content of at least 1% by weight, or at least 5% by weight, or at least 10% by weight, or at least 15% by weight, or at least 20% by weight, or at least 25% by weight, or at least 30% by weight, or at least 32% by weight, or at least 34% by weight, or at least 36% by weight, or at least 38% by weight, or at least 40% by weight, or at least 42% by weight, or at least 44% by weight, or at least 46% by weight, or at least 48% by weight, or at least 50% by weight, relative to the total weight of the body.

[0211] Embodiment 100. An abrasive article according to embodiment 1 or embodiment 2, wherein the body is 80% by weight or less, or 78% by weight or less, or 76% by weight or less, or 74% by weight or less, or 72% by weight or less, or 70% by weight or less, or 68% by weight or less, or 66% by weight or less, or 64% by weight or less, or 62% by weight or less, or 60% by weight or less, or 58% by weight or less, or 56% by weight or less, or 54% by weight or less, or 52% by weight or less, or 50% by weight or less, based on the total weight of the body.

[0212] Embodiment 101. An abrasive article according to embodiment 69, wherein the abrasive particles have a polycrystalline phase with crystalline domains, and the crystalline domains have an average domain size of at least 0.1 microns, or at least 0.2 microns, or at least 0.3 microns, or at least 0.4 microns, or at least 0.5 microns, or at least 0.75 microns, or at least 1 micron, or at least 1.5 microns, or at least 2 microns, or at least 2.5 microns, or at least 3 microns, or at least 3.5 microns, or at least 4 microns, or at least 4.5 microns, or at least 5 microns.

[0213] Embodiment 102. The method of embodiment 85, wherein the pressing is carried out at a pressing force of at least 90 MPa, or at least 95 MPa, or at least 100 MPa, or at least 105 MPa, or at least 110 MPa.

[0214] Embodiment 103. The method of embodiment 85, wherein the pressing is performed at a pressing force of 195 MPa or less, or 190 MPa or less, or 185 MPa or less, or 180 MPa or less. [Example]

[0215] Fixed abrasive samples were made according to the following process: Mixtures were prepared according to Table 1 and the following procedure: Commercially available samples CMS1, CMS2, and CMS3 were purchased.

[0216] [Table 1]

[0217] The mixture was pressed into a green body. The green body was dried under controlled humidity. The dried green body was then fired into a fully formed abrasive body. The abrasive body was then finished and contoured to the appropriate dimensions. Where relevant, the dimensions are set forth below.

[0218] Sintered Binder Composition The commercial samples and fired abrasive samples were subjected to ICP testing to determine the composition of the bond material, and the results, in weight percent, can be found in Table 2 below.

[0219] [Table 2]

[0220] MOR, MOE, density and porosity Specimen bars were prepared according to the process described above, resulting in bars measuring 101 mm x 25 mm x 13 mm. The specimens had MORs assessed according to test standard ASTM D6272. Testing was performed on a three-point indicator fixture with a support spacing of 50.8 mm and a test speed of 1.27 mm / min. A comparative specimen measuring 90 mm x 24 mm x 16 mm was calibrated according to the cross-sectional area of ​​the specimen.

[0221] The samples also had their MOE evaluated according to ASTM E1876-01. The porosity (volume %) of the articles was also measured. The MOE, MOR and porosity data can be found in Table 3 below.

[0222] [Table 3]

[0223] The variation in sample density was measured by taking eight samples with dimensions of 20 mm × 15 mm × 5 mm from each wheel. Samples were taken from four layers at two different locations on each wheel, as shown in Figure 9.

[0224] The samples were sealed with wax and then their Archimedes density was measured. The density variation measurements can be seen in Figure 10.

[0225] Bonded microstructure Various aspects of the bond microstructure were measured according to the following procedure. Ten SEM-EDS images of each sample were taken. ImageJ software was used to identify and highlight the bond structure of each sample. Exemplary images of the bond structure can be seen in Figures 4A-4C. ImageJ software was used to calculate the number of bond posts as well as the bond post area. Bond wettability was evaluated by measuring the radius of curvature of the bond posts at the bond interface. Bond post characterization data can be found in the table below. Figure 5 contains the cumulative bond post size distribution.

[0226] [Table 4]

[0227] [Table 5]

[0228] Percentile can be understood as the X percentile bond post area being the area where X% of the specified bond posts in the sample have an area less than or equal to the specified area.

[0229] The wettability of each bond system was measured by calculating the bond post radius according to the following procedure. An image, such as that shown in Figure 11A, was taken. The bond area was manually identified, and then the contour of the bond area was identified using the binarization and smoothing functions in ImageJ, as shown in Figure 11B. The contour radius of curvature was then calculated by fitting the contour to the following equation:

[0230]

number

[0231] The curvature of the bond area curve should be 180°±10%. x,y are the pixel coordinates of the image. x',y' are the first derivatives, and x”,y” are the second derivatives.

[0232] A bond post having the aforementioned area was identified for each sample, and the radius of curvature of the bond post between the abrasive particles was measured. Bonds with poor wetting properties have a larger radius.

[0233] [Table 6]

[0234] The specification and illustrations of the embodiments described herein are intended to provide a general understanding of the structure of various embodiments. The specification and illustrations are not intended to serve as an exhaustive and comprehensive description of all elements and features of apparatus and systems that utilize the structures or methods described herein. Separate embodiments may be provided in combination in a single embodiment, and conversely, various features that are described for brevity in the context of a single embodiment may also be provided separately or in any subcombination. Furthermore, references to values ​​recited in ranges include any and all values ​​within that range. Many other embodiments may become apparent to those skilled in the art only after reading this specification. Other embodiments may be utilized and derived from the present disclosure, such that structural substitutions, logical substitutions, or other changes may be made without departing from the scope of the present disclosure. Accordingly, the present disclosure should be considered illustrative, not restrictive. Benefits, other advantages, and solutions to problems have been described above with respect to specific embodiments. However, benefits, advantages, solutions to problems, and any features that may bring about or make more pronounced any benefit, advantage, or solution are not to be construed as critical, necessary, or essential features of any or all claims.

[0235] The description in combination with the drawings is provided to aid in understanding the teachings disclosed herein. The following discussion focuses on specific implementations and embodiments of the teachings. This focus is provided to help explain the teachings and should not be construed as a limitation on the scope or applicability of the teachings. However, other teachings can certainly be used in this application.

[0236] As used herein, the terms "comprises," "comprising," "includes," "including," "has," "having," or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a method, article, or apparatus that includes a list of features is not necessarily limited to only those features, but may include other features not expressly listed or inherent to such method, article, or apparatus. Further, unless expressly stated to the contrary, "or" refers to an inclusive "or" and not an exclusive "or." For example, condition A or B can be satisfied by any one of the following: A is true (or present) and B is false (or absent); A is false (or absent) and B is true (or present); and both A and B are true (or present).

[0237] Additionally, the use of "a" or "an" is employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This specification should be read as including one, or at least one, and the singular as including the plural, and vice versa, unless it is clear that this is meant to be otherwise. For example, where a single item is described herein, two or more items can be used in place of the single item. Similarly, where two or more items are described herein, the two or more items may be replaced with a single item.

[0238] 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 are not intended to be limiting. To the extent not described herein, many details regarding specific materials and processing operations are conventional and can be found in reference literature and other sources within the technical fields of construction and corresponding manufacturing arts.

[0239] The subject matter disclosed above should be considered illustrative rather than limiting, and the appended claims are intended to encompass all such modifications, enhancements, and other embodiments that fall within the true scope of the invention. Accordingly, to the maximum extent permitted by law, the scope of the invention should be determined by the broadest permissible interpretation of the following claims and their equivalents, and should not be restricted or limited by the foregoing detailed description.

Claims

1. An abrasive article, The main body is a bond material comprising an inorganic material; abrasive particles contained in a bond material; a body comprising a MOR / EMOD ratio of at least 0.92 and a bond volume percent of less than 18%; The body includes: a) 2400 microns ２ The following average bond post area (BPA): b) 1.536 mm ２ an average bond post count (BPC) of at least 140 per c) an average bond wetting radius of at least 30 microns; and d) a combination of a) and b).

2. An abrasive article, The main body is a bond material comprising an inorganic material; abrasive particles contained in a bond material; a body comprising a MOR / EMOD ratio of at least 1.05 and a bond volume percentage of at least 18% and no more than 30%; The body includes: a) 2400 microns ２ The following average bond post area (BPA): b) 1.536 mm ２ an average bond post count (BPC) of at least 140 per c) an average bond wetting radius of at least 30 microns; and d) a combination of a) and b).

3. 2400 microns ２ 3. The abrasive article of claim 1 or claim 2, further comprising an average bond post area (BPA) of:

4. 1.536 mm ２ At least 140 bond posts per 1.536 mm ２ 3. The abrasive article of claim 1 or claim 2, further comprising an average bond post per (BPC) number.

5. At least 400 microns ２ and 925 microns ２ and further comprising an average bond post area (BPA) of 1.536 mm ２ At least 40 and no more than 300 bond posts per 1.536 mm ２ 3. The abrasive article of claim 1 or claim 2, further comprising an average bond post count per bond (BPC).

6. 3. The abrasive article of claim 1 or claim 2, further comprising an average bond wetting radius of at least 30 microns.

7. 25th percentile bond post area at least 770 microns ２ 3. The abrasive article according to claim 1 or 2, wherein:

8. 25th percentile bond post area is 795 microns ２ 3. The abrasive article according to claim 1 or claim 2, wherein:

9. 50th percentile bond post area is 1880 microns ２ 3. The abrasive article according to claim 1 or claim 2, wherein:

10. 50th percentile bond post area of ​​at least 1830 microns ２ 3. The abrasive article according to claim 1 or 2, wherein:

11. 75th percentile bond post area of ​​at least 4600 microns ２ 3. The abrasive article according to claim 1 or 2, wherein:

12. 75th percentile bond post area is 4850 microns ２ 3. The abrasive article according to claim 1 or claim 2, wherein:

13. 6000 microns per volume percent of bond material ３ 3. The abrasive article of claim 1 or claim 2, comprising an average bond post volume (BPV) of:

14. 3. The abrasive article of claim 1 or claim 2, comprising an average bond post volume (BPV) of at least 3100 microns per volume percent of bond material.

15. 3. The abrasive article of claim 1 or claim 2, wherein the abrasive particles define a multimodal particle size distribution.

Images