Polishing wheel, method of manufacturing the same, and method of using the same

Abstract

A bonded abrasive material comprising a body containing abrasive grains contained in a binder, wherein the abrasive grains include a first group of abrasive grains (the first group includes shaped abrasive grains having a first average particle size (PS1)) at a first content (C1), and a second group of abrasive grains (the second group includes non-shaped abrasive grains having a second average particle size (PS2)) at a second content (C2), PS2 < PS1, and the content ratio (C2 / C1) is at least 0.05 to 1.

Description

Technical Field

[0001] Typically, a bonded abrasive article is prepared by blending abrasive grains with a binder and optional additives and shaping the resulting mixture, for example, by using a suitable mold. The mixture is shaped to form a green body, which can be heat-treated, for example, by curing, sintering, etc., to produce an article in which the abrasive grains are held in a three-dimensional bonding matrix. In some cases, the green body can be cold-worked to form a bonded abrasive article. Among bonded abrasive tools, abrasive wheels are often prepared for grinding, cutting, polishing, etc. Such wheels can be reinforced, for example, using disks cut from nylon, carbon, glass, or cotton cloth, or the wheels may not be reinforced.

Summary of the Invention

[0002] The present disclosure generally relates to bonded abrasive articles, and more particularly to abrasive wheels suitable for use as cutoff wheels and methods of manufacturing such abrasive wheels.

[0003] In one aspect, the present disclosure is directed to a bonded abrasive including a body comprising abrasive grains contained within a binder. The abrasive grains include a first group of abrasive grains at a first content (C1). The first group includes shaped abrasive grains having a first average particle size (PS1), and a second group of abrasive grains is included at a second content (C2). The second group includes non-shaped abrasive grains having a second average particle size (PS2), where PS2 < PS1, and the content ratio (C2 / C1) is at least 0.05 to 1.

[0004] The above and other features described herein, including various details and combinations of parts of the configuration, as well as other advantages, are described in more detail with reference to the accompanying drawings and are expressed in the claims. It will be understood that certain methods and articles embody certain features shown as examples rather than limitations, and that the principles and features described herein may be used in various and numerous embodiments. [Brief explanation of the drawing]

[0005] In the attached drawings, reference numerals indicate the same part across different drawings. The drawings are not necessarily to scale. [Figure 1] This is a flowchart illustrating a method for producing a bonded abrasive material according to one embodiment. [Figure 2] This is a side view of a bonded abrasive material according to one embodiment. [Figure 3] This is a cross-sectional view of the bonding abrasive material shown in Figure 2 according to one embodiment. [Figure 4] This is a cross-sectional view of a bonding abrasive material according to an alternative embodiment. [Figure 5] This is a cross-sectional view of a bonding abrasive material according to an alternative embodiment. [Figure 6] This is a perspective view of molded polishing particles according to one embodiment. [Figure 7] This is a perspective view of molded polishing particles according to one embodiment. [Figure 8A] This is an image of 3-PT star-shaped polished particles. [Figure 8B] Figure 8A is a side view of molded polishing particles. [Figure 9] These are photographs of 3-PT star-shaped polished particles and 3-PT star-shaped fragment particles according to one embodiment. [Figure 10] This is an image of 3-PT star-shaped fragment particles. [Modes for carrying out the invention]

[0006] This disclosure relates, in general, to bonded polishing articles, and more particularly to cutting wheels suitable for use as cutoff wheels or chop saws, and to methods for manufacturing the same. Figure 1 is a flowchart of method 100 for manufacturing a bonded polishing article according to one embodiment. In particular, in 102, method 100 includes providing a mixture comprising abrasive particles and a binder. According to one embodiment, the binder may include materials such as glassy, ​​polycrystalline, monocrystalline, organic (e.g., resin), metal, metal alloy, and combinations thereof. The mixture may also include additional components such as processing aids, lubricants (e.g., wetting agents), curing agents, crosslinking agents, antistatic agents, porous inducers, and colorants.

[0007] In one embodiment, the mixture may contain a specific amount of abrasive particles that can facilitate the manufacture and / or improvement of the performance of the bonding abrasive. In a specific embodiment, the mixture may contain abrasive particles in an amount of 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 35% by weight, or at least 40% by weight, or at least 45% by weight, or at least 50% by weight, or at least 55% by weight, or at least 60% by weight, based on the total weight of the mixture. In another embodiment, the mixture may contain abrasive particles in an amount of 95% by weight or less, or 90% by weight or less, or 85% by weight or less, or 80% by weight or less, or 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, based on the total weight of the mixture. It will be understood that the content of abrasive particles in the mixture can be within any of the above values. In a specific embodiment, the mixture may contain abrasive particles in an amount ranging from about 10% by weight to about 95% by weight, based on the total weight of the mixture.

[0008] In one embodiment, the mixture may contain two or more types of abrasive particles, which may differ from each other based on at least one property selected from the group consisting of particle size, two-dimensional shape, three-dimensional shape, composition, hardness, toughness, fragility, density, particle size, aggregation state, or any combination thereof. In one embodiment, the abrasive particles may include a first group of molded abrasive particles having a first content (C1) and a second group of abrasive particles having a second content (C2). In certain embodiments, at least about 50%, or at least 51%, or at least 52%, or at least 53%, or at least 54%, or at least 55%, or at least 56%, or at least 57%, or at least 58%, or at least 59%, or at least 60%, or at least 61%, or at least 62%, or at least 63%, or at least 64%, or at least 65%, or at least 66%, or at least 67%, or at least 68%, or at least 69%, or at least 70% of the total content of abrasive particles comprises a first group of molded abrasive particles (C1). For example, in some cases, 90% or less of the total abrasive particle content, or 89% or less, or 88% or less, or 87% or less, or 86% or less, or 85% or less, or 84% or less, or 83% or less, or 82% or less, or 81% or less, or 80% or less, or 79% or less, or 78% or less, or 77% or less, or 76% or less, or 75% or less, may consist of a first molded abrasive particle group (C1). It will be understood that the content of abrasive particles including the first molded abrasive particle group (C1) may be within any of the above values. In certain exemplary embodiments, the content of abrasive particles including the first molded abrasive particle group (C1) may be in the range of about 50% by weight to about 90% by weight.

[0009] In one embodiment, the abrasive particles may include a second group of abrasive particles having a second content (C2). In a particular embodiment, at least about 10%, or at least 11%, or at least 12%, or at least 13%, or at least 14%, or at least 15%, or at least 16%, or at least 17%, or at least 18%, or at least 19%, or at least 20%, or at least 21%, or at least 22%, or at least 23%, or at least 24%, or at least 25%, or at least 26%, or at least 27%, or at least 28%, or at least 29%, or at least 30% of the total content of abrasive particles is the second group of abrasive particles (C2). For example, in some cases, 50% or less, or 49% or less, or 48% or less, or 47% or less, or 46% or less, or 45% or less, or 44% or less, or 43% or less, or 42% or less, or 41% or less, or 40% or less, or 39% or less, or 38% or less, or 37% or less, or 36% or less, or 35% or less, or 34% or less, or 33% or less, or 32% or less, or 31% or less, or 30% or less of the total abrasive particle content, may include a second group of abrasive particles (C2). It will be understood that the content of abrasive particles including the second group of abrasive particles (C2) may be within any of the above values. In certain exemplary embodiments, the content of abrasive particles including the second group of abrasive particles (C2) may be in the range of about 10% by weight to about 50% by weight.

[0010] In yet another embodiment, the final mixture of bonding abrasives may contain a content ratio (C2 / C1) of the second content (C2) to the first content (C1) that can facilitate the manufacture and / or improvement of the performance of the bonding abrasive. In a particular embodiment, the content ratio (C2 / C1) may be at least 0.11, or at least 0.2, or at least 0.3, or at least 0.4, or at least 0.41, or at least 0.42. In another embodiment, the content ratio (C2 / C1) may be 0.99 or less, or 0.95 or less, or 0.9 or less, or 0.85 or less, or 0.8 or less, or 0.75 or less, or 0.7 or less, or 0.65 or less, or 0.6 or less, or 0.55 or less, or 0.5 or less. The ratio of the content (C2 / C1) may be a value between any of the minimum and maximum values ​​mentioned above, for example, in the range of at least 0.11 to 0.99, such as at least 0.3 to 0.7.

[0011] In yet another embodiment, the mixture or the final bonded abrasive may include a first group of abrasive particles having a first particle size (PS1) that can facilitate the manufacture and / or improvement of the performance of the bonded abrasive. In a particular embodiment, the first group of abrasive particles may have a size of at least 200 microns, or at least 210 microns, or at least 220 microns, or at least 230 microns, or at least 240 microns, or at least 250 microns, or at least 260 microns, or at least 270 microns, or at least 280 microns, or at least 290 microns, or at least 300 microns, or at least 310 microns, or at least 320 microns, or at least 330 microns, or at least 340 microns, or at least 350 microns, or at least 400 microns, or at least 450 microns, or at least 500 microns. In another embodiment, the first group of abrasive particles may have a first particle size (PS1) of 1,000 microns or less, or 2,000 microns or less, or 1,900 microns or less, or 1,800 microns or less, or 1,700 microns or less, or 1,600 microns or less, or 1,500 microns or less, or 1,400 microns or less. The first group of abrasive particles may have a first particle size (PS1) which can be a value between either the minimum or maximum value described above, and is, for example, in the range of at least 200 microns to 3000 microns, such as at least 300 microns to 1500 microns or less.

[0012] In yet another embodiment, the mixture or the final bonded abrasive may include a second group of abrasive particles having a first particle size (PS2) which can facilitate the manufacture and / or improvement of the performance of the bonded abrasive. In a particular embodiment, the second group of abrasive particles may have a first particle size (PS2) of at least 1 micron, or at least 5 microns, or at least 10 microns, or at least 20 microns, or at least 30 microns, or at least 40 microns, or at least 50 microns, or at least 60 microns, or at least 70 microns, or at least 80 microns, or at least 90 microns, or at least 100 microns, or at least 110 microns, or at least 120 microns, or at least 130 microns, or at least 140 microns, or at least 150 microns, or at least 160 microns, or at least 170 microns, or at least 180 microns, or at least 190 microns. In another embodiment, the second group of abrasive particles may have a first particle size (PS2) of 500 microns or less, or 440 microns or less, or 420 microns or less, or 400 microns or less, or 380 microns or less, or 360 microns or less, or 340 microns or less, or 320 microns or less, or 300 microns or less, or 280 microns or less, or 260 microns or less, or 240 microns or less, or 220 microns or less, or 200 microns or less, or 190 microns or less. The second group of abrasive particles may have a first particle size (PS2) that is between any of the above minimum and maximum values, for example, within a range of at least 1 micron to 500 microns, such as at least within the range of 50 microns to 200 microns or less.

[0013] In yet another embodiment, the mixture or the final bonded abrasive may include a particle size ratio (PS1:PS2) of a first average particle size (PS1) to a second average particle size (PS2) that can facilitate the manufacture and / or improvement of the performance of the bonded abrasive. In a particular embodiment, the particle size ratio (PS1:PS2) of the first average particle size (PS1) to the second average particle size (PS2) 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, or at least 3, or at least 4, or at least 5, or at least 6, or at least 7, or at least 8, or at least 9, or at least 10, or at least 11, or at least 12, or at least 13, or at least 14, or at least 15. In another embodiment, the particle size ratio (PS1:PS2) of the first average particle size (PS1) to the second average particle size (PS2) may be 20 or less, or 19 or less, or 18 or less, or 17 or less, or 16 or less, or 15 or less, or 14 or less, or 13 or less, or 12 or less, or 11 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, or 4 or less, or 3 or less. The particle size ratio (PS1:PS2) may be a value between any of the above minimum and maximum values, for example, within a range of at least 1 to 20, such as at least within a range of 2 to 10 or less.

[0014] The abrasive particles of the embodiments herein may include certain types of abrasive particles. For example, the abrasive particles of the first group may include molded abrasive particles and / or elongated abrasive particles, the elongated abrasive particles may have an aspect ratio of at least 1.1:1 length:width or length:height. Various methods can be used to obtain molded abrasive particles. The particles can be obtained from commercial sources or manufactured. Some preferred processes used to manufacture molded abrasive particles include, but are not limited to, deposition, printing (e.g., screen printing), molding, pressing, casting, sectioning, cutting, dicing, punching, pressing, drying, curing, coating, extrusion, rolling, and combinations thereof. Elongated abrasive particles may be obtained using similar processes. Elongated, unmolded abrasive particles can be formed by grinding and sieving techniques.

[0015] Figure 6 is a perspective view of a molded abrasive particle according to one embodiment. The molded abrasive particle 600 may include a body 601 which includes a main surface 602, a main surface 603, and a side surface 604 extending between the main surfaces 602 and 603. As illustrated in Figure 6, the body 601 of the molded abrasive particle 600 is a thin body, and the main surfaces 602 and 603 are larger than the side surface 604. Furthermore, the body 601 may include a longitudinal axis 610 which extends from a point or corner of the molded abrasive particle 600 to its base (for example, the edge of the molded abrasive particle 600 opposite the point or corner) and extends through a midpoint 650 on the main surface 602. The longitudinal axis 610 can define the longest dimension of the main surface and extends through the midpoint 650 of the main surface. The body 601 may further include a transverse axis 611 that defines the width of the body 601, extending substantially perpendicular to the longitudinal axis 610 on the same main surface 602. Finally, as shown in the illustration, the body 601 may include a vertical axis 612, which can define the height (or thickness) of the body 601 in the context of a thin body. In a thin body, the length of the longitudinal axis 610 is greater than or equal to the length of the vertical axis 612. As shown in the illustration, the thickness 612 may extend perpendicular to the plane defined by the longitudinal axis 610 and the transverse axis 611 along the side surface 604 between the main surfaces 602 and 603. It will be understood that references to the length, width, and height of abrasive particles in this specification may refer to average values ​​taken from a preferred sampling size of abrasive particles in a batch.

[0016] Molded abrasive particles can include any of the features of abrasive particles in the embodiments herein. For example, molded abrasive particles can include crystalline materials, more specifically, polycrystalline materials. In particular, polycrystalline materials can include abrasive grains. In one embodiment, for example, the body of the abrasive particle, including the body of the molded abrasive particle, can essentially not contain organic materials, such as a binder. In at least one embodiment, the abrasive particle can essentially be made of a polycrystalline material.

[0017] Some suitable materials for use as the first and second groups of molded abrasive particles include nitrides, oxides, carbides, borides, oxynitrides, oxyborides, diamonds, carbon-containing materials, and combinations thereof. In certain examples, the abrasive particles may include oxide compounds or composites such as aluminum oxide, zirconium oxide, titanium oxide, yttrium oxide, chromium oxide, strontium oxide, silicon oxide, magnesium oxide, rare earth oxides, and combinations thereof. In one particular embodiment, the abrasive particles may contain at least 95% by weight of alumina relative to the total weight of the body. In at least one embodiment, the abrasive particles may essentially consist of alumina. Furthermore, in certain examples, the abrasive particles may contain 99.5% by weight or less of alumina relative to the total weight of the body. Furthermore, in certain examples, the molded abrasive particles may be formed from seed crystal-added sol-gels. In at least one embodiment, the abrasive particles of the embodiments herein may not essentially contain iron, rare earth oxides, and combinations thereof. In yet another embodiment, the first group of abrasive particles and the second group of abrasive particles may be composed of different materials.

[0018] Figure 6 shows a molded abrasive particle having a two-dimensional shape defined by the plane of a main surface 602 or main surface 603, each of which has a roughly triangular two-dimensional shape. It will be understood that the molded abrasive particles of the embodiments herein are not so limited and may include other two-dimensional shapes. For example, the molded abrasive particles of the embodiments herein may include particles having a body having a two-dimensional shape defined by the main surface of the body from a group of shapes including polygons, irregular polygons, irregular polygons with arcuate or curved edges or parts of edges, ellipses, numerals, Greek letters, Latin letters, Russian letters, Chinese characters, complex shapes with combinations of polygonal shapes, stars, and combinations thereof.

[0019] FIG. 7 is a perspective view of shaped abrasive grains according to an embodiment. Notably, the shaped abrasive grain 700 may include a body 701 including surfaces 702 and 703 that may be referred to as end faces 702 and 703. The body may further include major faces 704, 705, 706, 707 that extend between and are joined to the end faces 702 and 703. The shaped abrasive grain of FIG. 7A is an elongated shaped abrasive grain having a longitudinal axis 710 that extends along major face 705 and through a midpoint 740 between end faces 702 and 703. It will be appreciated that surface 705 has been selected to illustrate the longitudinal axis 710 since the body 701 has a generally square cross-sectional profile defined by end faces 702 and 703. Thus, surfaces 704, 705, 706, and 707 have approximately the same size relative to one another. However, in the context of other elongated abrasive grains where surfaces 702 and 703 define different shapes, such as a rectangle, and one of surfaces 704, 705, 706, and 707 may be larger than the others, the longitudinal axis will extend along the largest of those surfaces since the largest of those surfaces defines the major surface. As further illustrated, the body 701 may include a transverse axis 711 that extends perpendicular to the longitudinal axis 710 within the same plane defined by surface 705. As further illustrated, the body 701 may further include a vertical axis 712 that defines the height of the abrasive grain, and the vertical axis 712 extends in a direction perpendicular to the plane defined by the longitudinal axis 710 and the transverse axis 711 of surface 705.

[0020] Similar to the thin-shaped abrasive grains of FIG. 6, it will be appreciated that the elongated shaped abrasive grains of FIG. 7A can have various two-dimensional shapes such as those defined with respect to the shaped abrasive grains of FIG. 6. The two-dimensional shape of the body 701 can be defined by the shape of the outer periphery of the end faces 702 and 703. The elongated shaped abrasive grain 700 can have any of the attributes of the shaped abrasive grains of the embodiments herein.

[0021] Formed abrasive particles can be formed through specific processes including molding, printing, casting, extrusion, etc. The formed abrasive particles are formed such that each particle has a surface and edges with a substantially the same arrangement relative to each other. For example, a group of formed abrasive particles generally has the same arrangement and orientation relative to each other and / or a surface and edges of a two-dimensional shape. Thus, the formed abrasive particles have high shape fidelity and consistency in the arrangement and orientation of the surfaces and edges relative to each other. In contrast, non-formed abrasive particles can be formed through different processes and can have different shape attributes. For example, crushed grains are typically formed by a crushing process that forms a mass of material and then crushes and sieves it to obtain abrasive particles of a certain size. However, non-formed abrasive particles have surfaces and edges with a substantially random arrangement and generally lack any recognizable two-dimensional or three-dimensional shape in the arrangement of the surfaces and edges. Further, non-formed abrasive particles do not necessarily have a consistent shape relative to each other, and thus have a significantly lower shape fidelity compared to formed abrasive particles. Non-formed abrasive particles are generally defined by a random arrangement of surfaces and edges relative to each other.

[0022] In certain embodiments, the plurality of formed abrasive particles can include a plurality of formed abrasive particles having a 3-PT star two-dimensional shape when viewed in the plane of the length and width of the body. The body can include at least three outer corners and at least four side sections, or at least five side sections, or at least six side sections. In certain embodiments, the plurality of formed abrasive particles can include a body having at least three outer corners, and the sum of the angles of the outer corners is less than 180 degrees. In certain embodiments, the plurality of formed abrasive particles can include a body having at least three outer corners, and each of the outer corners defines a corner of less than 60 degrees or less than 59 degrees or less than 58 degrees or less than 57 degrees or less than 56 degrees or less than 55 degrees. In one embodiment, the plurality of formed abrasive particles can include a body having at least three outer corners and at least three inner corners, and each of the inner corners has an inner corner angle value that exceeds any of the outer corner angle values of any of the at least three outer corners.

[0023] The outer corners can be identified using the "rubber band test." When a rubber band is stretched around the body of the abrasive particles, the corners that come into contact with the rubber band and cause it to bend are the outer corners.

[0024] Figure 8A includes a top view image of a 3-PT star-shaped abrasive particle according to a particular embodiment. As shown, the molded abrasive particle 800 can define a star-shaped body when viewed in two dimensions. Specifically, the molded abrasive particle 800 may include a body 801 having a central portion 802 and a first arm 803, a second arm 804, and a third arm 805 extending from the central portion 802. The body 801 may have a length (l) measured as the longest dimension along the side of the particle and a width (w) measured as the longest dimension of the particle from the midpoint 853 of the side through the midpoint 890 of the body 801 to the first tip 806 of the first arm 803. The width may extend in a direction perpendicular to the length dimension. As shown in Figure 8B, which is a side view of the particle image in Figure 8A, the main body 801 may have a thickness (t) that extends in a direction perpendicular to the top surface or the first main surface 810 of the main body 801 and defines a third side surface 856 between the top surface or the first main surface 810 and the base surface 811.

[0025] The molded abrasive particle 800 may have a body 801 in the shape of a 3-PT star, defined by a first arm 803, a second arm 804, and a third arm 805 extending from a central portion 802. According to a particular embodiment, for example, at least one of the arms, including the first arm 803, may have a midpoint width 813 less than the central portion width 812. The central portion 802 may be defined as the region between the midpoints 851, 852, and 853 of the first side surface 854, the second side surface 855, and the third side surface 856, respectively. The central portion width 812 of the first arm 803 may be the width of the dimension between the midpoints 851 and 852. The midpoint width 813 may be the width of the line at the midpoint between the line of the central portion width 812 and the tip 806 of the first arm 803 along the first axis 860. In a particular example, the midpoint width 813 may be about 90% or less of the central portion width 812, for example, about 80% or less, or about 70% or less, or about 5% or less, or even about 60% or less. Furthermore, the midpoint width 813 may be at least about 10% of the central portion width 812, for example, at least about 20%, at least about 30%, or even at least about 40%. It will be understood that the midpoint width 813 may have a width within the range between any of the above minimum and maximum percentages of the central portion width 812.

[0026] Furthermore, the body 801 may have at least one arm, such as the first arm 803, having a tip width at the tip 806 of the first arm 803 which is less than the midpoint width 813. In such an example where the tip 806 is sharply formed, the tip width may be considered to be 0. In an example where the tip 806 has a radius of curvature, the tip width may be considered to be the diameter of the circle defined by the radius of curvature. According to one embodiment, the tip width 814 may be about 90% or less of the midpoint width 813, for example, about 80% or less, or about 70% or less, or about 60% or less, or about 50% or less, or about 40% or less, or about 30% or less, or about 20% or less, or even about 10% or less. Furthermore, in certain non-limiting embodiments, the tip width 814 may be at least about 1% of the midpoint width 813, for example, at least about 2%, at least about 3%, at least about 5%, or even at least about 10%. It will be understood that the tip width 814 can have a width within the range between the minimum and maximum ratios mentioned above, relative to the midpoint width 813.

[0027] As further illustrated, the body 801 may have a first arm 803 including a first tip 806 that defines a first tip angle 821 between a first side 854 and a second side 855. According to one embodiment, the first tip angle may be less than about 60 degrees, for example, about 55 degrees or less, about 50 degrees or less, about 45 degrees or less, or even more about 40 degrees or less. Furthermore, the first tip angle may be at least about 5 degrees, for example, at least about 8 degrees, at least about 10 degrees, at least about 15 degrees, at least about 20 degrees, at least about 25 degrees, or even more than 30 degrees. The first tip angle may be within a range between any of the minimum and maximum values ​​described above.

[0028] The main body 801 may include a second arm 804 having a second tip 807 that defines a second tip angle 822 between a second side 855 and a third side 856. The second tip angle may be substantially the same as the first tip angle, such as within 5% of the angle value. Alternatively, the second tip angle may be substantially different from the first tip angle.

[0029] The main body 801 may include a third arm 805 having a third tip 808 that defines a third tip angle 823 between a first side 854 and a third side 856. The third tip angle may be substantially the same as the first or second tip angle, such as within 5% of the angle value. Alternatively, the third tip angle may be substantially different from the first or second tip angle.

[0030] The body 801 may have a total angle which is the sum of the values ​​of the first tip angle, the second tip angle, and the third tip angle, which may be less than about 180 degrees. In other embodiments, the total angle may be about 175 degrees or less, for example, about 170 degrees or less, or about 160 degrees or less, or about 150 degrees or less, for example, about 140 degrees or less, or about 130 degrees or less, or about 125 degrees or less, or even about 120 degrees or less. Furthermore, in one non-limiting embodiment, the body 801 may have a total angle of at least about 60 degrees, for example, at least about 70 degrees, or at least about 80 degrees, or at least about 90 degrees, for example, at least about 95 degrees, or at least about 100 degrees, or even at least about 105 degrees. It will be understood that the total angle may be within the range of any of the minimum and maximum values ​​described above.

[0031] As described herein, the body 801 may have a first side surface 854 extending between the first arm 806 and the third arm 808. In certain examples, the first side surface 854 may have an arched contour.

[0032] Referring again to Figure 8A, the body 801 may have a first side 854 having a first side section 858 and a second side section 859. The first side section 858 may extend between the first tip 806 and the midpoint 851, and the second side section 859 may extend between the third tip 808 and the midpoint 851. The first side section 858 and the second side section 859 may define an interior angle 862 which may be obtuse. For example, the interior angle 862 may be greater than about 90 degrees, e.g., greater than about 95 degrees, or greater than about 100 degrees, or greater than about 110 degrees, or even greater than about 120 degrees. Furthermore, in one non-limiting embodiment, the interior angle 862 may be less than or equal to about 320 degrees, e.g., less than or equal to about 300 degrees, or even less than or equal to about 270 degrees. It will be understood that the interior angle may be within a range between any of the minimum and maximum values ​​described above.

[0033] Referring again to Figure 8A, the body 801 may have a second side 855 having a third side section 870 and a fourth side section 871. The third side section 870 may extend between the first tip 806 and the midpoint 852, and the fourth side section 871 may extend between the second tip 807 and the midpoint 852. The third side section 870 and the fourth side section 871 may define an interior angle 880 which may be obtuse. For example, the interior angle 880 may be greater than about 90 degrees, for example, greater than about 95 degrees, or greater than about 100 degrees, or greater than about 110 degrees, or even greater than about 120 degrees. Furthermore, in one non-limiting embodiment, the interior angle 880 may be less than or equal to about 320 degrees, for example, less than or equal to about 300 degrees, or even less than or equal to about 270 degrees. It will be understood that the interior angle can be within the range of either the minimum or maximum value mentioned above.

[0034] Referring again to Figure 8A, the body 801 may have a third side 856 having a fifth side section 873 and a sixth side section 874. The fifth side section 873 may extend between the second tip 807 and the midpoint 853, and the sixth side section 874 may extend between the third tip 808 and the midpoint 853. The fifth side section 873 and the sixth side section 874 may define an interior angle 881 which may be obtuse. For example, the interior angle 881 may be greater than about 90 degrees, for example, greater than about 95 degrees, or greater than about 100 degrees, or greater than about 110 degrees, or even greater than about 120 degrees. Furthermore, in one non-limiting embodiment, the interior angle 881 may be less than or equal to about 320 degrees, for example, less than or equal to about 300 degrees, or even less than or equal to about 270 degrees. It will be understood that the interior angle can be within the range of either the minimum or maximum value mentioned above.

[0035] In yet another embodiment, the body 801 may have a recess depth 883 formed by a fifth side section 873 and a sixth side section 874. In one embodiment, the recess depth 883 may be measured along a first axis 860 between a midpoint 853 and a length endpoint 885, where the length endpoint 885 represents the length of the molded abrasive particles measured beyond the midpoint 853 along the first axis 860. In a particular embodiment, the recess depth 883 may be at least 1 micron, for example, 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 75 microns, or at least 80 microns, or at least 85 microns, or at least 90 microns, or at least 95 microns, or at least 100 microns. Furthermore, in a non-limiting embodiment, the recess depth 883 can be 500 microns or less, or 400 microns or less, or 300 microns or less, or 200 microns or less, or 150 microns or less, or 120 microns or less, or 110 microns or less, or 100 microns or less. It will be understood that the recess depth 883 can be within a range between any of the above minimum and maximum values, such as at least 1 micron to 1000 microns, or at least 10 microns to 500 microns. It will also be understood that the first side portion 858 and the second side portion 859 can form a recess depth having any of the above values ​​with respect to the recess depth 883. It will also be understood that the third side portion 870 and the fourth side portion 871 can form a recess depth having any of the above values ​​with respect to the recess depth 883.

[0036] The first side section 858 can extend over a substantial portion of the length of the first side 854. For example, the first side section 858 can extend over at least about 20% of the total length of the first side 854, e.g., at least about 25%, or at least about 30%, or at least about 35%, or even at least about 40%. Furthermore, in one non-limiting embodiment, the first side section 858 can have a length (ls1) between the midpoint 851 and the first tip 806 of the total length of the side 854, e.g., at least about 75%, at least about 70%, or even at least about 5%. It will be understood that the length of the first side section 858 can be within the range between any of the above minimum and maximum percentages.

[0037] The second side section 859 can extend over a substantial portion of the length of the first side section 854. For example, the second side section 859 can extend over at least about 20% of the total length of the first side section 854, e.g., at least about 25%, or at least about 30%, or at least about 35%, or even at least about 40%. Furthermore, in one non-limiting embodiment, the second side section 859 can have a length (ls2) between the midpoint 851 and the third tip 808 that is no more than about 80% of the total length of the side section 854 as a straight line between the first tip 806 and the third tip 808, e.g., no more than about 75%, no more than about 70%, or even no more than about 5%. It will be understood that the length of the second side section 859 can be within the range of either the minimum or maximum percentage described above.

[0038] The main body 801 may include a first mean side angle 831 between the sides 854, 855, and 856 and the top surface or first main surface 810. The main body may also include a second side angle 832 between the sides 854, 855, and 856 and the second main surface or base surface 812.

[0039] In one embodiment, the abrasive particles may include a specific first side angle that facilitates improvements in the performance and / or manufacture of the abrasive particles. In one embodiment, the first side angle may be at least 45 degrees, or at least 50 degrees, or at least 55 degrees, or at least 60 degrees, or at least 65 degrees, or at least 70 degrees. In yet another embodiment, the first side angle may be 95 degrees or less, or 90 degrees or less, or 85 degrees or less, or 80 degrees or less. The first side angle may be within any of the above minimum and maximum percentages, and will be understood to be, for example, within the range of at least 45 degrees to 95 degrees or less, or within the range of at least 50 degrees to 90 degrees or less, or within the range of at least 55 degrees to 85 degrees or less.

[0040] In one embodiment, the abrasive particles may include a specific second side angle that facilitates improvements in the performance and / or manufacture of the abrasive particles. In one embodiment, the second side angle may be at least 45 degrees, or at least 50 degrees, or at least 55 degrees, or at least 60 degrees, or at least 65 degrees, or at least 70 degrees. In yet another embodiment, the second side angle may be 95 degrees or less, or 90 degrees or less, or 85 degrees or less, or 80 degrees or less. The second side angle may be within either of the minimum and maximum percentages described above, and will be understood to be, for example, within the range of at least 45 degrees to 95 degrees, or within the range of at least 50 degrees to 90 degrees, or within the range of at least 55 degrees to 85 degrees.

[0041] The aforementioned 3-PT star-shaped body 801 is shown to have a top surface 810 having a two-dimensional shape that, when viewed in a plane of length and width of the body, is substantially the same as the two-dimensional shape of the base surface or second principal surface 811 of the body 801, but other shapes are also contemplated. For example, in one embodiment, the cross-sectional shape of the body at the base surface can define base surface shapes from a group consisting of 3-PT star shapes, 4-PT star shapes, cross shapes, polygons, ellipses, numerals, Greek letters, Latin letters, Russian letters, combinations of polygonal shapes, and combinations thereof. Furthermore, the cross-sectional shape of the body may include a two-dimensional shape when viewed in a plane of length and width of the body having an odd number of external points. For example, the body may have at least three external points, or at least five external points, or at least seven external points. Furthermore, the cross-sectional shape of the main body on the top surface differs from the base surface shape and can be defined by selecting from a group of complex shapes having combinations of 3-PT star shapes, 4-PT star shapes, cross shapes, polygons, ellipses, numbers, Greek letters, Latin letters, Russian letters, and polygonal shapes, as well as combinations thereof.

[0042] In certain cases, the top surface shape may have an arched form similar to the base surface shape. For example, the top surface shape may define an arched 3-PT two-dimensional shape, which defines an arm with a rounded end. Specifically, an arm defined on the base surface may have a smaller radius of curvature at its tip compared to the corresponding radius of curvature at its tip on the top surface.

[0043] As described in other embodiments of this specification, it will be understood that at least one of the arms of the body 801 may be formed to have a twist such that the arm twists around a central axis. For example, the first arm 803 may twist around axis 860. Furthermore, the body 801 may be formed such that at least one arm extends from a central region in an arc-shaped path.

[0044] In one embodiment, a plurality of molded abrasive particles may include a plurality of 3-PT star-shaped fragment particles when viewed in a plane of the length and width of the body. Figure 9 includes photographs of 3-PT star-shaped abrasive particles 901 and 3-PT star-shaped fragment particles 902. As seen in Figure 9, 3-PT star-shaped fragment particles 902 are abrasive fragments formed from 3-PT star-shaped abrasive particles 901. In one embodiment, 3-PT star-shaped fragment particles 902 can be obtained from a manufacturing process of 3-PT star-shaped abrasive particles 901 such as extrusion, molding, screen printing, rolling, melting, pressing, casting, segmentation, sectioning, or a combination thereof. In one embodiment, 3-PT star-shaped fragment particles 902 can be obtained from a manufacturing process of 3-PT star-shaped abrasive particles 901 in which case precursor abrasive particles are crushed in a mold or during a demolding process, and the final 3-PT star-shaped abrasive particles are crushed or destroyed or otherwise become imperfect 3-PT star-shaped abrasive particle shapes. An exemplary forming process is shown in U.S. Patent No. 5,009,676. In yet another embodiment, the 3-PT star-shaped fragment particles 902 may be obtained from a different manufacturing process of the 3-PT star-shaped abrasive particles 901, such as a screen printing process, in which case the precursor abrasive particles may be crushed or destroyed during the forming process, or during the post-forming process when the precursor abrasive particles are removed from the belt, during drying, heating, or at any step of the forming process in which the 3-PT star-shaped abrasive particles 901 are crushed or destroyed. An exemplary screen printing process is shown in U.S. Patent No. 8,753,742.

[0045] Figure 10 includes a top view image of an exemplary 3-PT star-shaped fragment particle according to a particular embodiment. As shown, the molded abrasive particle 1000 can define a partial star-shaped body when viewed in two dimensions. In particular, the 3-PT star-shaped fragment particle 1000 may include a body 1001 having a central portion 1002, first arms 1003 and second arms 1004 extending from the central portion 1002, and a crushing surface 1073, where a portion of the molded abrasive particle is broken or crushed. The body 1001 may have a length (l) measured as the longest dimension along the side of the particle, and a width (w) measured as the longest dimension of the particle between the midpoint 1053 of the side passing through the central portion 1002 of the body 1001 and the midpoint 1063 of the crushing surface 1073. The width may extend in a direction perpendicular to the length dimension. In yet another embodiment, the crushing surface 1073 may extend into the central portion 1002. This embodiment represents a configuration in which a larger portion of the main body 1001 is destroyed or shattered.

[0046] In one embodiment, the 3-PT star-shaped fragment particle 1000 may include a first side surface 1006 extending between a first tip 1014 and a first fracture endpoint 1020. In one embodiment, the 3-PT star-shaped fragment particle 1000 may include a second side surface 1008 extending between a first corner 1014 and a midpoint 1053. In one embodiment, the 3-PT star-shaped fragment particle 1000 may include a third side surface 1010 extending between a midpoint 1053 and a second corner 1016. In one embodiment, the 3-PT star-shaped fragment particle 1000 may include a fourth side surface 1012 extending between a second corner 1016 and a second fracture endpoint 1022. In yet another embodiment, the first side surface 1006 may have a length longer than the length of the fourth side surface 1012. In another embodiment, the first side surface 1006 may have a length shorter than the length of the fourth side surface 1012. In another embodiment, the first side surface 1006 may have a length equal to the length of the fourth side surface 1012. In one embodiment, the crushing surface 1073 may have a length shorter than the length of the first side surface 1006. In one embodiment, the crushing surface 1073 may have a length shorter than the length of the fourth side surface 1012. In one embodiment, the crushing surface 1073 may have a length shorter than any of the lengths of the first side surface 1006, the second side surface 1008, the third side surface 1010, or the fourth side surface 1012.

[0047] In one embodiment, the mixture may contain a specific amount of binder that can facilitate the manufacture and / or improvement of the performance of the bonded abrasive. In a particular embodiment, the mixture may contain at least about 5% by weight, or at least 10% by weight, or at least 15% by weight, or at least 20% by weight of the binder, relative to the total weight of the mixture. In another embodiment, the mixture may contain about 60% by weight or less, or 50% by weight or less, or 40% by weight or less, or 30% by weight or less, or 20% by weight or less of the binder, relative to the total weight of the mixture. It will be understood that the binder content in the mixture can be within any of the above values. In a particular embodiment, the mixture may contain binder in the range of about 10% by weight to about 95% by weight, relative to the total weight of the mixture.

[0048] In yet another embodiment, the mixture may also contain one or more fillers. In a particular embodiment, the mixture may contain fillers in an amount of at least about 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 35% by weight, or at least 40% by weight, relative to the total weight of the mixture. In another embodiment, the fillers may contain fillers in an amount of about 60% by weight or less relative to the total weight of the mixture, or fillers in an amount of about 57% by weight or less relative to the total weight of the mixture, or fillers in an amount of about 52% by weight or less relative to the total weight of the mixture. It will be understood that the filler content may be within a range between any of the above values. In a particular exemplary embodiment, the filler content may be in the range of about 5% by weight to about 60% by weight relative to the total weight of the mixture. It will be understood that the fillers may contain essentially zero fillers.

[0049] The filler may include materials selected from the group consisting of powders, granules, spheres, fibers, and combinations thereof. In one embodiment, the filler may include materials selected from the group consisting of inorganic materials, organic materials, and combinations thereof. In further embodiments, the filler may include materials selected from the group consisting of sand, bubble alumina, bauxite, chromite, magnesite, dolomite, bubble mullite, borides, titanium dioxide, carbon products (e.g., carbon black, coke, or graphite), wood flour, clay, talc, hexagonal boron nitride, molybdenum disulfide, feldspar, nepheline syenite, glass spheres, glass fibers, CaF2, KBF4, cryolite (Na3AlF6), potassium aluminum fluoride, for example, potassium cryolite (K3AlF6), pyrite, ZnS, copper sulfide, Fe2S, for example, Pyrox, mineral oil, fluoride, carbonate, calcium carbonate, and combinations thereof.

[0050] In 104, method 100 includes placing the mixture into a mold. The mold can be made from stainless steel, high carbon steel, high chromium steel, another suitable material, or a combination thereof. In some situations, one or more layers of the mixture can be placed in the mold by spreading them, for example, linearly or rotationally. In exemplary embodiments, other components, such as one or more reinforcing layers, can be placed above, below, or both above and below at least one of the layers of the mixture. In certain embodiments, the reinforcing layer can include a material selected from the group consisting of organic materials, inorganic materials, and combinations thereof. Furthermore, the reinforcing layer can include a material selected from the group consisting of fabrics, fibers, films, woven materials, nonwoven materials, glass, glass fibers, ceramics, polymers, resins, polymers, fluorinated polymers, epoxy resins, polyester resins, polyurethanes, polyesters, rubber, polyimides, polybenzimidazoles, aromatic polyamides, modified phenolic resins, and combinations thereof.

[0051] In 106, method 100 includes applying a pressing process to the mixture while it is in a mold. In situations where multiple polishing layers are formed, each of the polishing layers can be subjected to its own pressing process. Examples of pressing processes include cold pressing, warm pressing, or hot pressing. In exemplary embodiments, the warm pressing process can be applied at a temperature in the range of about 35°C to about 75°C.

[0052] In 108, method 100 includes heating the mixture to produce a bonding abrasive. In some embodiments, heating the mixture to produce the bonding abrasive may be optional.

[0053] Figure 2 includes a diagram of a bonded abrasive 200 according to one embodiment. The bonded abrasive 200 includes a body 202 and a mounting hole 204 for attaching the bonded abrasive 200 to a cutting tool. The diameter 206 of the mounting hole 204 may be the inner diameter of the body 202, and the body 202 may have an outer diameter 208. In one embodiment, the outer diameter 208 may be at least about 220 mm, at least about 270 mm, at least about 310 mm, or at least about 360 mm. In another embodiment, the outer diameter 208 may be about 535 mm or less, about 457 mm or less, about 415 mm or less, or about 355 mm or less. It will be understood that the outer diameter 208 of the body 202 may be within a range between any of the above values.

[0054] In certain embodiments, the inner diameter 206 can be at least about 35 mm, at least about 46 mm, or at least about 54 mm. In other examples, the inner diameter 206 can be about 90 mm or less, about 77 mm or less, or about 62 mm or less. It will be understood that the inner diameter 206 of the body 202 can be within any of the above values.

[0055] The body 202 may also have a thickness of at least about 0.7 mm, at least about 1.5 mm, or at least about 1.9 mm. In some cases, the body may have a thickness of about 6.5 mm or less, about 5.7 mm or less, about 4.8 mm or less, about 3.5 mm or less, or about 2.2 mm or less. It will be understood that the thickness of the body 202 may be within the range of any of the above values. Furthermore, the body 202 may have an outer diameter to thickness ratio in the range of about 125:1 to about 15:1.

[0056] The body 202 may include materials contained in the mixture used to form the bonded abrasive 200, as described above with respect to Figure 1. For example, the body 202 may include abrasive particles provided in the mixture, a binder provided in the mixture, and any other components provided in the mixture. Furthermore, the body 202 may also include one or more abrasive layers containing abrasive particles contained within the binder. In certain examples, one or more reinforcing layers may be located adjacent to one or more abrasive layers. In certain structures, one or more of the reinforcing layers may be upper or lower materials for the abrasive layers. In at least one embodiment, the reinforcing layer may be in direct contact with the abrasive layer. In certain embodiments, the reinforcing layer may be directly bonded to a portion of the abrasive layer and may be at least partially impregnated to the abrasive layer. In other designs of embodiments herein, at least one abrasive layer (or more abrasive layers) may be arranged between a first reinforcing layer and a second reinforcing layer. According to one configuration, multiple abrasive layers can be used as separate intervening layers separating at least the first and second reinforcing layers. It will be understood that in this specification, any combination of reinforcing and polishing layers is intended.

[0057] In certain embodiments, the body 202 may include a first group of abrasive particles. In one embodiment, the first group of abrasive particles may include molded abrasive particles. In yet another embodiment, the first group of abrasive particles may include molded abrasive particles having a body having a 3-pt star-shaped two-dimensional form when viewed in a plane of the length and width of the body. Furthermore, the first group of abrasive particles may have a first average particle size as described above with respect to the first average particle size of the first group of abrasive particles of the mixture used to form the bonding abrasive 200.

[0058] The main body 202 may also include a second group of abrasive particles. In one embodiment, the second group of abrasive particles may have a second average particle size as described above with respect to the second average particle size of the second group of abrasive particles of the mixture.

[0059] In one embodiment, the body 202 may contain a certain amount of abrasive particles that can facilitate the manufacture and / or improvement of the performance of the bonding abrasive. In a particular embodiment, the body may have abrasive particles in an amount of at least about 20 vol% or at least 25 vol% or at least 30 vol% or at least 35 vol% or at least 40 vol% of the total volume of the body 202. In another embodiment, the body may contain abrasive particles in an amount of about 60 vol% or less, or 55 vol% or less, or 50 vol% or less, or 45 vol% or less, or 40 vol% or less, or 35 vol% or less of the total volume of the body 202. It will be understood that the abrasive particle content of the body 202 can be within any of the above values. In a particular exemplary embodiment, the body 202 may contain abrasive particles in an amount ranging from about 20 vol% to about 60 vol% of the total volume of the body 202.

[0060] In one embodiment, the body 202 may contain a certain volume of binder that can facilitate the manufacture and / or improvement of the performance of the bonded abrasive. In a particular embodiment, the body may have a binder in an amount of at least about 10 vol%, or at least 20 vol%, or at least 30 vol%, or at least 40 vol%, or at least 50 vol% relative to the total volume of the body 202. Furthermore, the body may contain a binder in an amount of about 70 vol% or less relative to the total volume of the body 202, a binder in an amount of about 60 vol% or less relative to the total volume of the body 202, or a binder in an amount of about 50 vol% or less relative to the total volume of the body 202. It will be understood that the binder content of the body 202 may be within a range of any of the above values. In a particular embodiment, the binder content of the body 202 may be in the range of about 10 vol% to about 70 vol% relative to the total volume of the body 202.

[0061] In another embodiment, the body 202 may contain at least about 2 volume% of filler relative to the total volume of the body 202, at least about 5 volume% of filler relative to the total volume of the body 202, or at least about 7 volume% of filler relative to the total volume of the body 202. Furthermore, the body 202 may contain filler of about 16 volume% or less relative to the total volume of the body 202, about 12 volume% or less relative to the total volume of the body 202, or about 9 volume% or less relative to the total volume of the body 202. It will be understood that the filler content may be within any of the above values. In a particular exemplary embodiment, the body 202 may contain filler in the range of about 6 volume% to about 10 volume% relative to the total volume of the body 202.

[0062] In certain embodiments, the body 202 may include a porosity of at least about 6 volume% relative to the total volume of the body 202, at least about 11 volume% relative to the total volume of the body 202, or at least about 14 volume% relative to the total volume of the body 202, or at least 16 volume%, or at least 18 volume%, or at least 20 volume%, or at least 22 volume%, or at least 24 volume%, or at least 26 volume%, or at least 28 volume% relative to the total volume of the body 202. In additional cases, the body 202 may include a porosity of about 30 volume% or less relative to the total volume of the body 202, a porosity of about 25 volume% or less relative to the total volume of the body 202, or a porosity of about 20 volume% or less relative to the total volume of the body 202. It will be understood that the porosity of the body 202 may be within any of the above values. In certain exemplary embodiments, the porosity of the body 202 may be in the range of about 6 volume% to about 25 volume% relative to the total volume of the body 202.

[0063] Figure 3 includes a cross-sectional view of the bonded abrasive 200 of Figure 2 according to one embodiment. In the exemplary embodiment of Figure 3, the bonded abrasive has a mounting hole 204 and an abrasive layer 302. The abrasive layer 302 may contain abrasive particles contained within the bonded material. The abrasive layer 302 may also have a thickness of 304.

[0064] FIG. 4 includes a cross-sectional view of the bonded abrasive 200 of FIG. 2 according to another embodiment. In the exemplary embodiment of FIG. 4, the bonded abrasive has a mounting hole 204, a first abrasive layer 402, and a second abrasive layer 404. The bonded abrasive 200 can also include a reinforcing layer 406. The first abrasive layer 402 and the second abrasive layer 404 can include abrasive particles contained in the binder. In some cases, the content of the abrasive particles and the content of the binder in the first abrasive layer 402 and the second abrasive layer 404 can be substantially the same, and in other situations, the content of the abrasive particles and the content of the binder in the first abrasive layer 40 and the second abrasive layer 404 can be different.

[0065] The first abrasive layer 402 can have a thickness 408, and the second abrasive layer 404 can have a thickness 410. Further, the reinforcing layer 406 can have a thickness 412. In some scenarios, the thickness 408 can be substantially the same as the thickness 410, but in other embodiments, the thickness 408 can be different from the thickness 410. Further, the thickness 412 can be substantially the same as or different from the thickness 408, the thickness 410, or both.

[0066] FIG. 5 includes a cross-sectional view of the bonded abrasive 200 of FIG. 2 according to an additional embodiment. In the exemplary embodiment of FIG. 2, the bonded abrasive 200 includes a mounting hole 204, a first reinforcing layer 502, and a second reinforcing layer 504. The bonded abrasive 200 also includes an abrasive layer 506.

[0067] Embodiment Embodiment 1. A bonded abrasive comprising a body including abrasive particles contained in a binder, wherein the abrasive particles are a first group of abrasive particles (the first group includes shaped abrasive particles having a first average particle size (PS1)) at a first content (C1), and a second group of abrasive particles (the second group includes non-shaped abrasive particles having a second average particle size (PS2)) at a second content (C2), with PS2 < PS1 and a content ratio (C2 / C1) of at least 0.05 to 1.

[0068] Embodiment 2. The first average particle size (PS1) is at least 200 microns, or at least 210 microns, or at least 220 microns, or at least 230 microns, or at least 240 microns, or at least 250 microns, or at least 260 microns, or at least 270 microns, or at least 280 microns, or at least 290 microns, or at least 300 microns, or at least 310 microns, or at least 320 microns, or at least 330 microns, or at least 340 microns, or at least 350 microns, or at least 400 microns, or at least 450 microns, or at least 50 A bonding abrasive material of Embodiment 1, having a thickness of 0 microns, or at least 550 microns, or at least 600 microns, or at least 650 microns, or at least 700 microns, or at least 750 microns, or at least 800 microns, or at least 850 microns, or at least 900 microns, or at least 950 microns, or at least 1000 microns, or at least 1050 microns, or at least 1100 microns, or at least 1150 microns, or at least 1200 microns, or at least 1250 microns, or at least 1300 microns, or at least 1350 microns, or at least 1400 microns.

[0069] Embodiment 3. The bonding abrasive of Embodiment 1, wherein the first average particle size (PS1) is 3000 microns or less, or 2500 microns or less, or 2000 microns or less, or 1900 microns or less, or 1800 microns or less, or 1700 microns or less, or 1600 microns or less, or 1500 microns or less, or 1400 microns or less.

[0070] Embodiment 4. The bonding abrasive of Embodiment 1, wherein the second average particle size (PS2) is at least 1 micron, or at least 5 microns, or at least 10 microns, or at least 20 microns, or at least 30 microns, or at least 40 microns, or at least 50 microns, or at least 60 microns, or at least 70 microns, or at least 80 microns, or at least 90 microns, or at least 100 microns, or at least 110 microns, or at least 120 microns, or at least 130 microns, or at least 140 microns, or at least 150 microns, or at least 160 microns, or at least 170 microns, or at least 180 microns, or at least 190 microns.

[0071] Embodiment 5. The bonding abrasive material of Embodiment 1, wherein the second average particle size (PS2) is 500 microns or less, or 440 microns or less, or 420 microns or less, or 400 microns or less, or 380 microns or less, or 360 microns or less, or 340 microns or less, or 320 microns or less, or 300 microns or less, or 280 microns or less, or 260 microns or less, or 240 microns or less, or 220 microns or less, or 200 microns or less, or 190 microns or less.

[0072] Embodiment 6. The bonding abrasive of Embodiment 1, wherein the body has a particle size ratio (PS1:PS2) of a first average particle size (PS1) to a second average particle size (PS2) 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, or at least 3, or at least 4, or at least 5, or at least 6, or at least 7, or at least 8, or at least 9, or at least 10, or at least 11, or at least 12, or at least 13, or at least 14, or at least 15.

[0073] Embodiment 7. The bonding abrasive of Embodiment 1, wherein the main body has a particle size ratio (PS1:PS2) of a first average particle size (PS1) to a second average particle size (PS2) of 20 or less, or 19 or less, or 18 or less, or 17 or less, or 16 or less, or 15 or less, or 14 or less, or 13 or less, or 12 or less, or 11 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, or 4 or less, or 3 or less.

[0074] Embodiment 8. The bonding abrasive of Embodiment 1, wherein the first group of abrasive particles contains a first content (C1) of at least about 50%, or at least 51%, or at least 52%, or at least 53%, or at least 54%, or at least 55%, or at least 56%, or at least 57%, or at least 58%, or at least 59%, or at least 60%, or at least 61%, or at least 62%, or at least 63%, or at least 64%, or at least 65%, or at least 66%, or at least 67%, or at least 68%, or at least 69%, or at least 70% of the total content of abrasive particles.

[0075] Embodiment 9. The bonding abrasive material of Embodiment 1, wherein the first group of abrasive particles contains a first content (C1) of about 90% or less, or 89% or less, or 88% or less, or 87% or less, or 86% or less, or 85% or less, or 84% or less, or 83% or less, or 82% or less, or 81% or less, or 80% or less, or 79% or less, or 78% or less, or 77% or less, or 76% or less, or 75% or less, relative to the total content of abrasive particles.

[0076] Embodiment 10. The bonding abrasive of Embodiment 1, wherein the second group of abrasive particles contains a second content (C2) of at least about 10%, or at least 11%, or at least 12%, or at least 13%, or at least 14%, or at least 15%, or at least 16%, or at least 17%, or at least 18%, or at least 19%, or at least 20%, or at least 21%, or at least 22%, or at least 23%, or at least 24%, or at least 25%, or at least 26%, or at least 27%, or at least 28%, or at least 29%, or at least 30% of the total content of abrasive particles.

[0077] Embodiment 11. The bonding abrasive material of Embodiment 1, wherein the second group of abrasive particles contains a second content (C2) of about 50% or less, or 49% or less, or 48% or less, or 47% or less, or 46% or less, or 45% or less, or 44% or less, or 43% or less, or 42% or less, or 41% or less, or 40% or less, or 39% or less, or 38% or less, or 37% or less, or 36% or less, or 35% or less, or 34% or less, or 33% or less, or 32% or less, or 31% or less, or 30% or less, relative to the total content of abrasive particles.

[0078] Embodiment 12. The bonding abrasive of Embodiment 1, wherein the main body contains a content ratio (C2 / C1) of a second content (C2) to a first content (C1) of at least 0.11, or at least 0.2, or at least 0.3, or at least 0.4, or at least 0.41, or at least 0.42.

[0079] Embodiment 13. The bonding abrasive of Embodiment 1, wherein the main body contains a content ratio (C2 / C1) of the second content (C2) to the first content (C1) of 0.99 or less, or 0.95 or less, or 0.9 or less, or 0.85 or less, or 0.8 or less, or 0.75 or less, or 0.7 or less, or 0.65 or less, or 0.6 or less, or 0.55 or less, or 0.5 or less.

[0080] Embodiment 14. The bonded abrasive material of Embodiment 1, wherein the molded abrasive particles of the first group of abrasive particles have a body, and each body includes a length (l), a width (w), and a height (h), where l>w>h.

[0081] Embodiment 15. The combined abrasive material of Embodiment 14, wherein the molded abrasive particles of the first group of abrasive particles have a body, and each body includes a 3-pt star-shaped two-dimensional form when viewed in a plane of the length and width of the body.

[0082] Embodiment 16. The bonding abrasive material of Embodiment 15, wherein the body of each molded abrasive particle in the first group of abrasive particles has at least three outer corners, and the sum of the angles of the outer corners is less than 180 degrees.

[0083] Embodiment 17. The bonding abrasive material of Embodiment 15, wherein the body of each molded abrasive particle of the first abrasive particle group comprises at least three outer corners and at least three inner corners, and each of the inner corners has an inner corner angle value that exceeds any of the outer corner angle values ​​of the at least three outer corners.

[0084] Embodiment 18. The combined abrasive material of Embodiment 15, wherein the body of each molded abrasive particle in the first group of abrasive particles comprises a first arm, a second arm, and a third arm extending from a central portion.

[0085] Embodiment 19. The bonding abrasive material of Embodiment 1, wherein the body of each molded abrasive particle in the first group of abrasive particles contains a ceramic material.

[0086] Embodiment 20. The bonding abrasive of Embodiment 19, wherein the body of each molded abrasive particle in the first group of abrasive particles comprises at least one of nitrides, oxides, carbides, borides, oxynitrides, oxyborides, diamonds, carbon-containing materials, or any combination thereof.

[0087] Embodiment 21. The bonding abrasive of Embodiment 20, wherein the body of each molded abrasive particle of the first group of abrasive particles comprises an oxide compound or composite such as aluminum oxide, zirconium oxide, titanium oxide, yttrium oxide, chromium oxide, strontium oxide, silicon oxide, magnesium oxide, rare earth oxides, or any combination thereof.

[0088] Embodiment 22. A bonding abrasive comprising a body containing abrasive particles contained within a binder, wherein the abrasive particles are The first group of abrasive particles with a first content (C1), The second content (C2) includes a second group of abrasive particles, The content ratio (C2 / C1) is at least 0.05 to 1. The second group of abrasive particles is a bonding abrasive containing 3-PT star-shaped fragment particles.

[0089] Embodiment 23. The first group of abrasive particles constitutes at least about 10%, or at least 11%, or at least 12%, or at least 13%, or at least 14%, or at least 15%, or at least 16%, or at least 17%, or at least 18%, or at least 19%, or at least 20%, or at least 21%, or at least 22%, or at least 23%, or at least 24%, or at least 25%, or at least 26%, or at least 27%, or at least 28%, or at least 29%, or less than 20% of the total abrasive particle content. A bonding abrasive of Embodiment 22 comprising a first content (C1) of at least 30%, or at least 31%, or at least 32%, or at least 33%, or at least 34%, or at least 35%, or at least 36%, or at least 37%, or at least 38%, or at least 39%, or at least 40%, or at least 41%, or at least 42%, or at least 43%, or at least 44%, or at least 45%, or at least 46%, or at least 47%, or at least 48%, or at least 49%, or at least 50%.

[0090] Embodiment 24. The first group of abrasive particles constitutes approximately 90% or less, or 89% or less, or 88% or less, or 87% or less, or 86% or less, or 85% or less, or 84% or less, or 83% or less, or 82% or less, or 81% or less, or 80% or less, or 79% or less, or 78% or less, or 77% or less, or 76% or less, or 75% or less, or 74% or less, or 73% or less, or 72% or less, or 71% or less, relative to the total content of abrasive particles. A bonding abrasive of Embodiment 22, comprising a first content (C1) of 70% or less, or 69% or less, or 68% or less, or 67% or less, or 66% or less, or 65% or less, or 64% or less, or 63% or less, or 62% or less, or 61% or less, or 60% or less, or 59% or less, or 58% or less, or 57% or less, or 56% or less, or 55% or less, or 54% or less, or 53% or less, or 52% or less, or 51% or less, or 50% or less.

[0091] Embodiment 25. The second group of abrasive particles makes up at least about 10%, or at least 11%, or at least 12%, or at least 13%, or at least 14%, or at least 15%, or at least 16%, or at least 17%, or at least 18%, or at least 19%, or at least 20%, or at least 21%, or at least 22%, or at least 23%, or at least 24%, or at least 25%, or at least 26%, or at least 27%, or at least 28%, or at least 29%, or less than 20% of the total abrasive particle content. A bonding abrasive of Embodiment 22, comprising a second content (C2) of at least 30%, or at least 31%, or at least 32%, or at least 33%, or at least 34%, or at least 35%, or at least 36%, or at least 37%, or at least 38%, or at least 39%, or at least 40%, or at least 41%, or at least 42%, or at least 43%, or at least 44%, or at least 45%, or at least 46%, or at least 47%, or at least 48%, or at least 49%, or at least 50%.

[0092] Embodiment 26. The second group of abrasive particles constitutes approximately 90% or less, or 89% or less, or 88% or less, or 87% or less, or 86% or less, or 85% or less, or 84% or less, or 83% or less, or 82% or less, or 81% or less, or 80% or less, or 79% or less, or 78% or less, or 77% or less, or 76% or less, or 75% or less, or 74% or less, or 73% or less, or 72% or less, or 71% or less, relative to the total content of abrasive particles. A bonding abrasive of Embodiment 22, comprising a second content (C2) of 70% or less, or 69% or less, or 68% or less, or 67% or less, or 66% or less, or 65% or less, or 64% or less, or 63% or less, or 62% or less, or 61% or less, or 60% or less, or 59% or less, or 58% or less, or 57% or less, or 56% or less, or 55% or less, or 54% or less, or 53% or less, or 52% or less, or 51% or less, or 50% or less.

[0093] Embodiment 27. The bonding abrasive of Embodiment 22, wherein the body contains a content ratio (C2 / C1) of a second content (C2) to a first content (C1) of at least 0.11, or at least 0.2, or at least 0.3, or at least 0.4, or at least 0.41, or at least 0.42, or at least 0.43, or at least 0.44, or at least 0.45, or at least 0.46, or at least 0.47, or at least 0.48, or at least 0.49, or at least 0.50.

[0094] Embodiment 28. The bonding abrasive of Embodiment 22, wherein the main body contains a content ratio (C2 / C1) of the second content (C2) to the first content (C1) of 0.99 or less, or 0.95 or less, or 0.9 or less, or 0.85 or less, or 0.8 or less, or 0.75 or less, or 0.7 or less, or 0.65 or less, or 0.6 or less, or 0.55 or less, or 0.5 or less.

[0095] Embodiment 29. The bonded abrasive material of Embodiment 22, wherein the molded abrasive particles of the first group of abrasive particles have a body, and each body includes a length (l), a width (w), and a height (h), where l>w>h.

[0096] Embodiment 30. The combined abrasive material of Embodiment 29, wherein the molded abrasive particles of the first group of abrasive particles have a body, and each body includes a 3-pt star-shaped two-dimensional form when viewed in a plane of the length and width of the body.

[0097] Embodiment 31. The bonding abrasive material of Embodiment 30, wherein the body of each molded abrasive particle in the first group of abrasive particles has at least three outer corners, and the sum of the angles of the outer corners is less than 180 degrees.

[0098] Embodiment 32. The bonding abrasive material of Embodiment 30, wherein the body of each molded abrasive particle of the first abrasive particle group comprises at least three outer corners and at least three inner corners, and each of the inner corners has an inner corner angle value that exceeds any of the outer corner angle values ​​of the at least three outer corners.

[0099] Embodiment 33. The combined abrasive material of Embodiment 30, wherein the body of each molded abrasive particle in the first group of abrasive particles comprises a first arm, a second arm, and a third arm extending from a central portion. [Examples]

[0100] Example 1 A combined polishing wheel was formed from samples containing a first group of molded polishing particles and a second group of polishing particles in specific concentrations. The first group of polishing particles contained molded polishing particles with a 3-pt star shape, as shown in Figure 8A, with an average particle size of approximately 1400 microns. The second group of polishing particles contained brown fused alumina particles of 80 grit size, with an average particle size of 180 microns. Using 0.22 wt% cedarwood oil as a wetting solution additive, two mixtures, namely mixtures A and B, with the compositions shown in Table 1 were prepared.

[0101] [Table 1]

[0102] Mixture A and a portion of Mixture B were combined in various ratios and pressed into wheels. Sample 1 had a 100:0 ratio of Mixture A to Mixture B, Sample 2 had a 10:90 ratio of Mixture A to Mixture B, Sample 3 had a 40:60 ratio of Mixture A to Mixture B, Sample 4 had a 70:30 ratio of Mixture A to Mixture B, Sample 5 had an 80:20 ratio of Mixture A to Mixture B, and Sample 6 had a 100:0 ratio of Mixture B to Mixture A. The six wheel samples had the abrasive particle content shown in Table 2.

[0103] [Table 2]

[0104] Using samples 1-6, a MetaboW 12 cutting tool was used to cut a 4-inch wide x 0.25-inch thick (101.6mm x 6.35mm) carbon steel workpiece. All sample wheels had a diameter of 125mm and a thickness of 1.7mm. The cutting tool operated at a speed of approximately 9,000 revolutions per minute when free-rotating and at a speed of approximately 6,000 revolutions per minute when cutting with an operating current of approximately 9-11 amperes. The total number of cuts before the wheel failed is shown in Table 2.

[0105] Example 2 A combined polishing wheel was formed from a sample containing a first group of molded polishing particles and a second group of polishing particles in specific concentrations. The first group of polishing particles contained molded polishing particles with a 3-pt star shape, as shown in Figure 8A, having an average particle size of approximately 1400 microns. The second group of polishing particles contained 3-pt star-shaped fragment particles 902, as shown in Figure 9. Using 0.22 wt% Cedarwood Oil as a wetting solution additive, two mixtures, namely mixtures B and C, with the compositions shown in Tables 1 and 2, were prepared.

[0106] [Table 3]

[0107] Mixture B and parts of Mixture C were combined in various ratios and pressed into wheels. Sample 7 had a Mixture B to Mixture C ratio of 100:0, Sample 8 had a Mixture B to Mixture C ratio of 100:0, and Sample 9 had a Mixture B to Mixture C ratio of 50:50. The three wheel samples had the abrasive particle content shown in Table 4.

[0108] [Table 4]

[0109] Using samples 7–9, a MetaboW 12 cutting tool was used to cut a 4-inch wide x 1.25-inch thick (101.6mm x 32mm) carbon steel workpiece. All sample wheels had a diameter of 76mm and a thickness of 1.7mm. The cutting tool operated at a speed of approximately 9,000 revolutions per minute when free-rotating and at a speed of approximately 6,000 revolutions per minute when cutting with an operating current of approximately 9–11 amperes. The total number of cuts before the wheel failed is shown in Table 4.

[0110] Benefits, other advantages, and solutions to problems are described above in relation to specific embodiments. However, benefits, advantages, solutions to problems, and any features that may result in or enhance any benefit, advantage, or solution should not be construed as essential, necessary, or intrinsic features of any or all of the claims.

[0111] The description and illustrative drawings of the embodiments described herein are intended to provide a general understanding of the structures of various embodiments. The description and illustrative drawings are not intended to serve as a comprehensive and exhaustive description of all elements and features of apparatuses and systems using the structures or methods described herein. Different embodiments may be combined within a single embodiment, and conversely, various features described in the context of a single embodiment for brevity may also be provided separately or in any partial combination. Furthermore, references to values ​​within a range include 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 used and derived from this disclosure, in such a way that structural substitutions, logical substitutions, or other modifications may be made without departing from the scope of this disclosure. Therefore, this disclosure should be considered illustrative, not restrictive.

Claims

1. A bonding abrasive comprising a body containing abrasive particles contained within a binder, The aforementioned abrasive particles A first group of abrasive particles with a first content (C1) (the first group includes molded abrasive particles having a first average particle size (PS1)), A second abrasive particle group (the second group includes unformed abrasive particles having a second average particle size (PS2)) with a second content (C2), wherein PS2 < PS1, A bonding abrasive having a content ratio of at least 0.05 to 1 (C2 / C1).

2. The bonding abrasive material according to claim 1, wherein the first average particle size (PS1) is at least 200 microns and 3000 microns or less.

3. The bonding abrasive material according to claim 1, wherein the second average particle size (PS2) is at least 1 micron and 500 microns or less.

4. The bonding abrasive material according to claim 1, wherein the main body includes at least one particle size ratio (PS1:PS2) of the first average particle size (PS1) to the second average particle size (PS2).

5. The bonding abrasive material according to claim 1, wherein the main body includes a particle size ratio (PS1:PS2) of the first average particle size (PS1) to the second average particle size (PS2) of 20 or less.

6. The bonding abrasive material according to claim 1, wherein the first group of abrasive particles contains a first content (C1) of at least about 50% and 90% or less relative to the total content of abrasive particles.

7. The bonding abrasive material according to claim 1, wherein the second group of abrasive particles contains a second content (C2) of at least about 10% and 50% or less relative to the total content of abrasive particles.

8. The bonding abrasive material according to claim 1, wherein the main body contains a content ratio (C2 / C1) of the second content (C2) to the first content (C1) of at least 0.11 and 0.99 or less.

9. The bonded abrasive material according to claim 1, wherein the molded abrasive particles of the first group of abrasive particles have a body, and each body includes a length (l), a width (w), and a height (h), where l > w > h.

10. The bonded abrasive material according to claim 9, wherein the molded abrasive particles of the first group of abrasive particles have a body, and each body includes a 3-pt star-shaped two-dimensional form when viewed in a plane of the length and width of the body.

11. The bonding abrasive material according to claim 10, wherein the body of each molded abrasive particle in the first group of abrasive particles has at least three outer corners, and the sum of the angles of the outer corners is less than 180 degrees.

12. The bonding abrasive material according to claim 10, wherein the body of each molded abrasive particle of the first group of abrasive particles comprises at least three outer corners and at least three inner corners, and each of the inner corners has an inner corner angle value that exceeds any of the outer corner angle values ​​of the at least three outer corners.

13. The bonding abrasive material according to claim 10, wherein the body of each molded abrasive particle in the first group of abrasive particles comprises a first arm, a second arm, and a third arm extending from a central portion.

14. A bonding abrasive comprising a body containing abrasive particles contained within a binder, The aforementioned abrasive particles The first group of abrasive particles with a first content (C1), The second content (C2) includes a second group of abrasive particles, The content ratio is at least 0.05 to 1 (C2 / C1), The second group of abrasive particles is a bonding abrasive containing 3-PT star-shaped fragment particles.

15. The bonding abrasive material according to claim 14, wherein the content ratio (C2 / C1) is 1.

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