Abrasive products and methods for forming them

Abstract

The abrasive product may include a body including abrasive particles contained in the body and ceramic particles contained in a bond material. The ceramic particles may have an average particle size D50c of at least 2 microns and at most 75 microns. The abrasive particles may have an average particle size D50a that is greater than the average particle size D50c.

Description

Technical Field

[0001] The following relates to abrasive articles containing abrasive particles and a bond material, and particularly relates to abrasive articles containing ceramic particles contained in the abrasive particles and the bond material.

Background Art

[0002] Abrasive articles are used in material removal operations such as cutting, grinding, or shaping various materials. Fixed abrasive articles include abrasive particles held in a bond material. The bond material may include organic and / or inorganic materials. The industry continues to demand improved abrasive articles.

Summary of Invention

[0003] In some examples, the present application relates to an abrasive article including a body, wherein the body includes: a bond material extending through at least a portion of the body; abrasive particles contained in the body, the abrasive particles having an average particle size (D50a) of at least 100 microns; and ceramic particles contained in the bond material, the ceramic particles having an average particle size (D50c) of at least 2 microns and at most 75 microns.

[0004] In some examples, the present application also relates to an abrasive article including a body, wherein the body includes: a bond material including a vitreous phase; abrasive particles contained in the body, the abrasive particles having an average abrasive particle size (D50a); and ceramic particles contained in the bond material, the ceramic particles having an average particle size (D50c), wherein the bond material has an average post-bonding size (Sbp), satisfying D50c < Sbp < D50a.

[0005] In some examples, the present application relates to an abrasive article comprising a body, wherein the body comprises a bond material comprising a vitreous phase, abrasive particles contained in the body and having an average abrasive particle size (D50a), and pores surrounded by ceramic particles contained in the bond material, wherein the ceramic particles have an average particle size (D50c), and D50c<D50a.

[0006] The present disclosure may be better understood by reference to the accompanying drawings, and many features and advantages thereof will be apparent to those skilled in the art. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] [Figure 1] FIG. 1 includes a flowchart illustrating a forming process according to an embodiment. [Figure 2] FIG. 2 includes a cross-sectional image of a portion of an abrasive article according to an embodiment. [Figure 3] FIG. 3 includes a flowchart illustrating a forming process according to another embodiment. [Figure 4] FIG. 4 includes an SEM image of a pore former coated with ceramic particles according to an embodiment. [Figure 5] FIG. 5 includes an SEM image of a cross-section of a polishing sample. [Figure 6] FIG. 6 includes a plot of wear rate versus material removal rate for a polishing sample. [Figure 7] FIG. 7 includes a plot of power consumption versus material removal rate for a polishing sample. [Figure 8] FIG. 8 includes a diagram of MOR of a polishing sample. [Figure 9] FIG. 9 includes a cross-sectional image of a portion of an abrasive article according to an embodiment. [Figure 10] FIG. 10 includes a diagram of MOR of a polishing sample. [Figure 11] FIG. 11 includes a diagram of MOR of a polishing sample. [Figure 12] FIG. 12 includes a diagram of MOR of a polishing sample. [Figure 13]Figure 13 includes a diagram of the MOR of the polished sample. [Figure 14] Figure 14 includes a diagram of the MOR of the polished sample. [Figure 15] Figure 15 includes a diagram of the MOR of the polished sample. [Figure 16] Figure 16 includes a diagram of the MOR of the polished sample. [Figure 17] Figure 17 includes a diagram of the MOR of the polished sample. [Figure 18] Figure 18 includes a diagram of the MOR of the polished sample. [Figure 19] Figure 19 includes a diagram of the MOR of the polished sample. [Figure 20] Figure 20 includes a diagram of the MOR of the polished sample. [Figure 21] Figure 21 includes a diagram of the MOR of the polished sample. [Figure 22] Figure 22 includes a diagram of the MOR of the polished sample. [Figure 23] Figure 23 includes a diagram of the MOR of the polished sample. [Figure 24] Figure 24 includes a diagram of the MOR of the polished sample. [Figure 25] Figure 25 includes a plot of power consumption versus material removal rate. [Figure 26] Figure 26 includes a diagram of profile retention of profile ffα throughout the cutting process. [Figure 27] Figure 27 includes a diagram of profile retention of profile fHα over the cutting process. [Modes for carrying out the invention]

[0008] Those skilled in the art will understand that the elements in the drawings are shown for simplification and clarity and are not necessarily drawn to scale. For example, the dimensions of some elements in the drawings may be exaggerated relative to others to help improve the understanding of embodiments of the invention.

[0009] The following description, combined with the drawings, is provided to aid in understanding the teachings provided herein. The following disclosure focuses on specific implementations and embodiments of the teachings. This focus is provided to aid in illustrating 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.

[0010] As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having,” or any other variations thereof are intended to encompass non-exclusive inclusion. For example, a method, article, or apparatus that includes an enumeration of features is not necessarily limited to those features alone, but may include other features not expressly enumerated or inherent to such method, article, or apparatus. Furthermore, unless expressly stated otherwise, “or” means inclusive (or) and not exclusive (or). For example, condition A or B is satisfied by one of the following: A is true (or exists) and B is false (or does not exist); A is false (or does not exist) and B is true (or exists); and both A and B are true (or exist).

[0011] Furthermore, the use of “one (a)” or “one (an)” is used to describe the elements and components described herein. This is done simply for convenience and to give a general sense of the scope of the invention. This description should be read as including one or at least one unless it is clear that otherwise, and the singular includes the plural, and vice versa. For example, where a single item is described herein, two or more items may be used instead of a single item. Similarly, where two or more items are described herein, one item may be replaced by those two or more items.

[0012] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those generally understood by those skilled in the art to which the present invention pertains. Materials, methods, and examples are illustrative and not intended to limit the scope. Unless specific details are described with respect to particular materials and processing activities, such details may include prior art, which can be found in reference books and other sources within the scope of manufacturing technology.

[0013] The embodiment relates to an abrasive product comprising a body containing a bonding material and abrasive particles contained in the body. The body further comprises ceramic particles contained in the bonding material. The ceramic particles are different from the abrasive particles. For example, the ceramic particles may have an average particle size (D50c) smaller than the average particle size (D50a) of the abrasive particles. The abrasive products described in the embodiment of this specification may include fixed abrasive products, such as bonded abrasive products. Compared to conventional abrasive products, the abrasive products may have improved performance and characteristics such as power consumption, wear rate, and G ratio.

[0014] Figure 1 includes a flowchart showing a process 100 for forming an abrasive product according to one embodiment. As shown, the process can be initiated in step 101 by forming a mixture comprising abrasive particles, a bonding agent precursor material, and ceramic particles.

[0015] The bonding precursor material may include a powder material capable of forming the bonding material for the final formed abrasive particles. In one embodiment, the bonding precursor material may include frit. The bonding precursor material may include an inorganic material such as a ceramic material. As used herein, reference to ceramics may include a composition comprising at least one metallic element and at least one nonmetallic element. For example, ceramics may include materials such as oxides, carbides, nitrides, borides, and combinations thereof. More specifically, ceramic materials may have a vitreous phase, a crystalline phase, a polycrystalline phase, and combinations thereof.

[0016] The bonding material precursor material may include oxide-based compositions containing some amounts of silica (i.e., silicon dioxide), boron oxide, alumina (i.e., aluminum oxide), zircon, sodium oxide, potassium oxide, iron oxide, titanium oxide, magnesium oxide, calcium oxide, etc. The composition of the bonding material in the final bonded polished body is disclosed in more detail below. In some cases, the content of components in the bonding material precursor material may differ from the content of components in the final bonded polished body due to losses during ignition. For example, the content of components in the precursor bonding material is given by formula C=C F (100%-P LOI It can be calculated by using the formula, where C is the content of the component in the bonding agent precursor, CF is the content of the component in the final bonded polished body, and P LOI This is the loss on ignition. In further examples, the composition of the bond material precursor and bond material of the final bonded polished body may be substantially the same (i.e., the difference in any one component between the precursor bond material and bond material of the final bonded polished body is 5% or less) or essentially the same (i.e., the difference in any one component between the precursor bond material and bond material of the final bonded polished body is 1% or less).

[0017] In one embodiment, the ceramic particles may include a specific particle size distribution that can facilitate improved performance and properties of the ceramic particles. In one aspect, the ceramic particles may have a specific average particle size D50c that can facilitate improved performance and properties of the abrasive product. In this disclosure, the average particle size (D50), D10, and D90 of the particles can be determined using laser diffraction particle size analysis of at least 1 g of discrete particles. In one example, the ceramic particles may include an average particle size (D50c) of at least 2 microns, at least 4 microns, at least 6 microns, at least 7 microns, at least 8 microns, at least 9 microns, at least 10 microns, at least 11 microns, or at least 12 microns. In further examples, ceramic particles are greater than 12 microns, at least 13 microns, at least 14 microns, at least 15 microns, at least 16 microns, at least 17 microns, at least 18 microns, at least 19 microns, at least 20 microns, at least 21 microns, at least 22 microns, at least 23 microns, at least 24 microns, at least 25 microns, at least 26 microns, at least 37 microns, at least 38 microns, at least 39 microns, at least 40 microns, at least 41 microns, at least 42 microns, at least 43 microns, at least 44 microns, at least 45 microns, and at least 46 microns. This may include an average particle size (D50c) of at least 47 microns, at least 48 microns, at least 49 microns, at least 50 microns, at least 51 microns, at least 52 microns, at least 53 microns, at least 54 microns, at least 55 microns, at least 56 microns, at least 57 microns, at least 58 microns, at least 59 microns, at least 60 microns, at least 61 microns, at least 62 microns, at least 63 microns, at least 64 microns, at least 65 microns, at least 66 microns, at least 67 microns, at least 68 microns, at least 69 microns, or at least 70 microns.In another example, ceramic particles are up to 90 microns, up to 85 microns, up to 80 microns, up to 75 microns, up to 74 microns, up to 73 microns, up to 72 microns, up to 71 microns, up to 70 microns, up to 69 microns, up to 68 microns, up to 67 microns, up to 66 microns, up to 65 microns, up to 64 microns, up to 63 microns, up to 62 microns, up to 61 microns, up to 60 microns, up to 59 microns, up to 58 microns, up to 57 microns, up to 56 microns, up to 55 microns, up to 54 microns, up to 53 microns, up to 52 microns, up to 51 microns, and up to 50 microns. The average particle size (D50c) may include a maximum of 49 microns, 48 ​​microns, 47 microns, 46 microns, 45 microns, 44 microns, 43 microns, 42 microns, 41 microns, 40 microns, 39 microns, 38 microns, 37 microns, 36 microns, 35 microns, 34 microns, 33 microns, 32 microns, 31 microns, 30 microns, 29 microns, 28 microns, 27 microns, 26 microns, 25 microns, 24 microns, 23 microns, or a maximum of 22 microns. The average particle size (D50c) of the ceramic particles D50c may also include a range that includes either the minimum or maximum value mentioned above. For example, the ceramic particles may include an average particle size (D50c) in the range of over 12 microns to 75 microns, 13 microns to 70 microns, 15 microns to 55 microns, 17 microns to 45 microns, 20 microns to 42 microns, or 22 microns to 38 microns.

[0018] In another embodiment, the ceramic particles may have a specific D10 that can define the maximum particle size at least 10% of the distribution (i.e., the particle size of the abrasive particles at the 10th percentile of the distribution). For example, the ceramic particles may include a particle size distribution with a D10 of at least 1 micron, at least 2 microns, at least 3 microns, at least 5 microns, at least 5.5 microns, at least 6 microns, at least 6.5 microns, at least 7 microns, at least 7.5 microns, at least 8 microns, at least 8.3 microns, at least 8.5 microns, at least 8.8 microns, at least 9 microns, at least 9.2 microns, at least 9.4 microns, at least 9.6 microns, at least 9.8 microns, at least 10 microns, at least 10.5 microns, at least 10.8 microns, at least 11 microns, at least 11.3 microns, at least 11.5 microns, at least 11.8 microns, or at least 12 microns. In another example, ceramic particles may contain a D10 of up to 38 microns, 35 microns, 33 microns, 31 microns, 30 microns, 28 microns, 27 microns, 25 microns, 23 microns, 20 microns, 18 microns, 16 microns, 14 microns, or 13 microns. It will be understood that ceramic particles may have a D10 within a range that includes any of the minimum and maximum values ​​above.

[0019] Ceramic particles may also have a specific D90 that can define the minimum particle size of the particles in up to 10% of the distribution (i.e., the particle size of the abrasive particles at the 90th percentile of the distribution). For example, ceramic particles may include a D90 of at least 15 microns, at least 17 microns, at least 19 microns, at least 20 microns, at least 22 microns, at least 23 microns, at least 24 microns, at least 27 microns, at least 29 microns, at least 30 microns, at least 31 microns, at least 33 microns, at least 35 microns, at least 37 microns, at least 38 microns, at least 40 microns, at least 41 microns, or at least 42 microns. In another example, ceramic particles may contain a D90 of up to 120 microns, up to 110 microns, up to 100 microns, up to 90 microns, up to 88 microns, up to 85 microns, up to 83 microns, up to 80 microns, up to 78 microns, up to 76 microns, up to 74 microns, up to 72 microns, up to 70 microns, up to 68 microns, up to 66 microns, up to 64 microns, up to 62 microns, up to 60 microns, up to 58 microns, up to 56 microns, up to 54 microns, up to 52 microns, up to 50 microns, up to 48 microns, up to 46 microns, up to 45 microns, up to 44 microns, or up to 43 microns. It will be understood that ceramic particles can have a D90 within a range that includes either the minimum or maximum value above.

[0020] In further embodiments, the ceramic particles may include crystalline materials, amorphous materials, or combinations thereof. In certain embodiments, the ceramic particles may include polycrystalline materials having a specific average crystallite size that can facilitate improvements in the properties and performance of abrasive products. For example, the average crystallite size may be at least 0.005 microns, at least 0.01 microns, at least 0.02 microns, at least 0.03 microns, at least 0.04 microns, at least 0.05 microns, at least 0.06 microns, at least 0.07 microns, at least 0.08 microns, at least 0.09 microns, at least 0.1 microns, at least 0.11 microns, at least 0.12 microns, at least 0.13 microns, at least 0.14 microns, at least 0.15 microns, at least 0.16, at least 0.17 microns, at least 0.18 microns, at least 0.19 microns, at least 0.2 microns, at least 0.3 microns, at least 0.4 microns, at least 0.5 microns, at least 0.6, at least 0.7 microns, at least 0.8 microns, at least 0.9 microns, at least 1 micron, at least 1.3 microns, at least 1.5 microns, at least 1.8 microns, at least 2 microns, at least 3 microns, at least 4 microns, or at least 5 microns. In another example, ceramic particles may include polycrystalline materials having average crystallite sizes of up to 75 microns, 60 microns, 50 microns, 40 microns, 30 microns, 20 microns, 10 microns, 9 microns, 8 microns, 7 microns, 6 microns, 5 microns, 4 microns, 3 microns, 2 microns, 1.5 microns, 1 micron, 0.9 microns, 0.8 microns, 0.7 microns, 0.6 microns, 0.5 microns, 0.4 microns, 0.3 microns, 0.2 microns, 0.1 microns, 0.09 microns, 0.08 microns, 0.07 microns, 0.06 microns, 0.05 microns, 0.04 microns, 0.03 microns, 0.02 microns, or 0.01 microns.Furthermore, the ceramic particles may include polycrystalline materials having an average crystallite size within a range that includes either the minimum or maximum value described herein.

[0021] In further embodiments, the ceramic particles may include materials comprising oxides, carbides, nitrides, borides, oxycarbides, oxynitrides, silicates, or any combination thereof. In certain examples, the ceramic particles include silicon dioxide, silicon carbide, alumina, zirconia, rare earth-containing materials, cerium oxide, sol-gel derived particles, iron oxide, glass-containing particles, and combinations thereof. In another embodiment, the ceramic particles may include the same material as the abrasive particles. In yet another embodiment, the ceramic particles may include materials different from those of the abrasive particles. In certain examples, the ceramic particles may include alumina, e.g., fused alumina, sol-gel alumina, microcrystalline alumina, nanocrystalline alumina, or any combination thereof. For example, the ceramic particles may include fused alumina. In another example, the ceramic particles may include white alumina, pink alumina, or combinations thereof. In certain embodiments, the ceramic particles may essentially consist of fused alumina particles. In even more specific embodiments, the ceramic particles may essentially consist of white fused alumina. In another specific example, ceramic particles may contain alpha-alumina, or more specifically, may essentially be made from alpha-alumina.

[0022] In one embodiment, the ceramic particles may include a specific Mohs hardness that can facilitate improvements in the performance and properties of the abrasive particles. For example, the ceramic particles may include a Mohs hardness of at least 5.5, at least 6, at least 6.5, at least 7, at least 7.5, at least 8, at least 8.5, or at least 9. In another example, the ceramic particles may include a Mohs hardness of up to 10, up to 9.5, up to 9, up to 8.5, up to 8, up to 7.5, or up to 7. Furthermore, the ceramic particles may include a Mohs hardness within a range that includes any of the minimum and maximum values ​​described herein.

[0023] The mixture may comprise ceramic particles in a specific content that can facilitate improving the performance and characteristics of an abrasive product. In one embodiment, the content of ceramic particles may be in units of volume percentage. As used herein, the volume percentage V of ceramic particles contained in the mixture c / p is obtained by using the formula V c / p =[V cm / (V cm +V bpm )]×100%, wherein in the formula, V cm is the volume of the ceramic particles added to the mixture, and V bpm is the volume of the bond precursor material added to the mixture. In one aspect, the content V of ceramic particles c / p may be at least 1% by volume, for example at least 1.3% by volume, at least 1.5% by volume, at least 1.8% by volume, at least 2% by volume, at least 2.2% by volume, at least 2.5% by volume, at least 2.7% by volume, at least 3% by volume, at least 3.3% by volume, at least 3.5% by volume, at least 3.7% by volume, at least 3.9% by volume, at least 4% by volume, at least 4.1% by volume, at least 4.3% by volume, at least 4.5% by volume, at least 4.7% by volume, at least 4.9% by volume, at least 5% by volume, at least 6% by volume, or at least 7% by volume. In another aspect, the content V of ceramic particles c / p may be at most 15% by volume, for example at most 12% by volume, at most 11% by volume, or at most 10% by volume. In certain aspects, the content V of ceramic particles c / p may be less than 10% by volume, for example, at most 9.7% by volume, at most 9.5% by volume, at most 9.4% by volume, at most 9.2% by volume, at most 9% by volume, at most 8.8% by volume, at most 8.6% by volume, at most 8.3% by volume, at most 8% by volume, at most 7.9% by volume, at most 7.7% by volume, at most 7.5% by volume, at most 7.3% by volume, at most 7% by volume, at most 6.9% by volume, at most 6.7% by volume, at most 6.6% by volume, at most 6.4% by volume, at most 6.2% by volume, at most 6% by volume, at most 5.8% by volume, at most 5.6% by volume, at most 5.4% by volume, at most 5.2% by volume, at most 5% by volume, at most 4.8% by volume, or at most 4.6% by volume. Further, the ceramic particles V c / pThe content may be within the range of either the minimum or maximum percentages specified herein.

[0024] In another embodiment, the content of ceramic particles in the mixture may be in weight percentages. As used herein, W is the weight percentage of ceramic particles in the mixture. c / p is, formula W c / p =[W cm / (W cm +W bpm It can be calculated using ) × 100%, where W cm W is the weight of the ceramic particles added to the mixture. bpm w is the weight of the bonding agent precursor material added to the mixture. In one embodiment, the content of ceramic particles is w c / p This includes at least 0.001% by weight, for example, at least 0.01% by weight, at least 0.05% by weight, at least 0.08% by weight, at least 0.1% by weight, at least 0.2% by weight, at least 0.4% by weight, at least 0.5% by weight, at least 0.7% by weight, at least 0.8% by weight, at least 0.9% by weight, at least 1% by weight, at least 1.2% by weight, at least 1.4% by weight, at least 1.6% by weight, at least 1.8% by weight, at least 2% by weight, at least 2.2% by weight, at least 2.5% by weight, at least 2.7% by weight, at least 3% by weight, and at least It may be 3.3% by weight, at least 3.5% by weight, at least 3.7% by weight, at least 3.9% by weight, at least 4% by weight, at least 4.1% by weight, at least 4.3% by weight, at least 4.5% by weight, at least 4.7% by weight, at least 4.9% by weight, at least 5% by weight, at least 7% by weight, at least 9% by weight, at least 10% by weight, at least 12% by weight, at least 15% by weight, at least 17% by weight, at least 19% by weight, at least 20% by weight, at least 22% by weight, at least 25% by weight, at least 28% by weight, or at least 30% by weight. In another embodiment, the content of ceramic particles W c / pThis includes less than 50% by weight, for example, maximum 45% by weight, maximum 43% by weight, maximum 41% by weight, maximum 39% by weight, maximum 37% by weight, maximum 35% by weight, maximum 33% by weight, maximum 31% by weight, maximum 28% by weight, maximum 26% by weight, maximum 24% by weight, maximum 22% by weight, maximum 20% by weight, maximum 17% by weight, maximum 15% by weight, maximum 13% by weight, maximum 11% by weight, maximum 10% by weight, maximum 9.7% by weight, maximum 9.5% by weight, maximum 9.4% by weight, maximum 9.2% by weight, maximum 9% by weight, maximum 8.8% by weight, maximum 8.6% by weight, maximum 8.3% by weight, maximum 8% by weight, maximum 7.9% by weight, and most The possible amounts are: Large 7.7% by weight, Maximum 7.5% by weight, Maximum 7.3% by weight, Maximum 7% by weight, Maximum 6.9% by weight, Maximum 6.7% by weight, Maximum 6.6% by weight, Maximum 6.4% by weight, Maximum 6.2% by weight, Maximum 6% by weight, Maximum 5.8% by weight, Maximum 5.6% by weight, Maximum 5.4% by weight, Maximum 5.2% by weight, Maximum 5% by weight, Maximum 4.8% by weight, Maximum 4.6% by weight, Maximum 4.1% by weight, Maximum 3.9% by weight, Maximum 3.5% by weight, Maximum 3.3% by weight, Maximum 3% by weight, Maximum 2.7% by weight, Maximum 2.5% by weight, Maximum 2.2% by weight, Maximum 2% by weight, Maximum 1.5% by weight, or Maximum 1% by weight. Furthermore, the ceramic particle content W c / p This may be within a range that includes either the minimum or maximum percentages specified herein.

[0025] Abrasive particles may include naturally occurring materials, synthetic materials, single-crystal materials, polycrystalline materials, amorphous materials, or combinations thereof. In certain examples, abrasive particles may include at least one material selected from oxides, carbides, nitrides, borides, carbon-based materials (e.g., diamond), oxycarbides, oxynitrides, oxyborides, super abrasives, minerals, and any combination thereof. Abrasive particles may have a specific Mohs hardness such as at least 6, at least 6.5, at least 7, at least 8, at least 8.5, at least 9, or at least 9.5.

[0026] In more specific examples, abrasive particles may include materials selected from the group consisting of silicon dioxide, silicon carbide, alumina, zirconia, flint, garnet, emery, rare earth oxides, rare earth-containing materials, cerium oxide, sol-gel derived particles, gypsum, iron oxide, glass-containing particles, and combinations thereof. In more specific examples, abrasive particles may include silicon carbide, brown fused alumina, seeded gel abrasive, sintered alumina with additives, molded and sintered aluminum oxide, pink alumina, ruby ​​alumina, electrofused single-crystal alumina, alumina-zirconia, extruded bauxite, cubic boron nitride, diamond, aluminum oxynitride, sintered alumina, extruded alumina, or any combination thereof.

[0027] In exemplary embodiments, the abrasive particles may include ceramic materials comprising alumina (Al2O3), magnesia (MgO), zirconia (ZrO2), chromium oxide (Cr2O3), or any combination thereof. In particular, the abrasive particles may include at least 50% by weight, for example, at least 60% by weight, at least 80% by weight, or at least 90% by weight of alumina relative to the total weight of the abrasive particles. In more specific examples, the abrasive particles may essentially consist of alumina. In another example, the abrasive particles may include single-crystal alumina. In yet another example, the abrasive particles may include aluminum oxynitride. In yet another example, the abrasive particles may include silicon carbide.

[0028] Other examples of abrasive particles may include aggregates, assemblies, molded abrasive particles, unaggregated particles, unmolded abrasive particles, or any combination thereof. In certain examples, abrasive particles may include aggregated white alumina particles.

[0029] Pre-formed abrasive particles are formed such that, for pre-formed abrasive particles having the same two-dimensional and three-dimensional shapes, each particle has substantially the same surface and edge arrangement relative to one another. Therefore, pre-formed abrasive particles can have high shape fidelity and consistency in surface and edge arrangement compared to other pre-formed abrasive particles of the same two-dimensional and three-dimensional shape. In contrast, unformed abrasive particles are formed by different processes and can have different shape attributes. For example, unformed abrasive particles are typically formed by a grinding process, where a mass of material is formed, and then ground and sieved to obtain abrasive particles of a specific size. However, unformed abrasive particles have a nearly random arrangement of surfaces and edges and generally lack any recognizable two-dimensional or three-dimensional shape in the arrangement of surfaces and edges around the body. Furthermore, unformed abrasive particles of the same group or batch generally lack consistent shape relative to one another, with surfaces and edges arranged randomly relative to one another. Therefore, unformed or crushed particles have significantly lower shape fidelity compared to pre-formed abrasive particles.

[0030] In some embodiments, the abrasive particles may include pre-formed abrasive particles. For example, pre-formed abrasive particles may include those disclosed in U.S. Patents 20150291865, 20150291866, and 20150291867, which are incorporated herein by reference in their entirety. In another example, pre-formed abrasive particles may include two-dimensional shapes selected from the group consisting of regular polygons, irregular polygons, irregular shapes, triangles, partially concave triangles, quadrilaterals, rectangles, trapezoids, pentagons, hexagons, heptagons, octagons, ellipses, Greek letters, Latin letters, Russian letters, and combinations thereof. In another example, the molded abrasive particles may include three-dimensional shapes selected from the group consisting of polyhedra, pyramidal shapes, ellipsoids, spheres, prisms, cylinders, cones, tetrahedra, cubes, cuboids, rhombohedrons, truncated ellipsoids, truncated spheres, truncated cones, pentahedrons, hexahedrons, heptahedrons, octahedrons, non-polyhedra, decahedrons, Greek letters, Latin letters, Russian letters, Chinese characters, compound polygons, irregular shapes, volcanic shapes, monostatic shapes, and combinations thereof, where a monostatic shape is a shape that has a single stable resting position. In yet another example, the molded abrasive particles may include two-dimensional triangular shapes, two-dimensional partially concave triangular shapes, or combinations thereof.

[0031] In further examples, a pre-formed abrasive particle may include a body having a body length (Lb), a body width (Wb), and a body thickness (Tb), where Lb > Wb, Lb > Tb, and Wb > Tb. The body may include a primary aspect ratio (Lb:Wb) of at least about 1:1, at least about 2:1, at least about 3:1, at least about 5:1, or at least about 10:1 and up to 1000:1. The body may also include a secondary aspect ratio (Lb:Tb) of at least about 1:1, at least about 2:1, at least about 3:1, at least about 5:1, or at least about 10:1 and up to 1000:1. The body may also include a tertiary aspect ratio (Wb:Tb) of at least about 1:1, at least about 2:1, at least about 3:1, at least about 5:1, or at least about 10:1 and up to 1000:1. In further examples, at least one of the body length (Lb), body width (Wb), and body thickness (Tb) may have an average dimension of at least 0.1 microns, or at least 1 micron, or at least 10 microns, or at least 50 microns, or at least 100 microns, or at least 150 microns, or at least 200 microns, or at least 400 microns, or at least 600 microns, or at least 800 microns, or at least 1 mm, and a maximum of 20 mm, or a maximum of 18 mm, or a maximum of 16 mm, or a maximum of 14 mm, or a maximum of 12 mm, or a maximum of 10 mm, or a maximum of 8 mm, or a maximum of 6 mm, or a maximum of 4 mm. In further examples, the body has a cross-sectional shape in a plane defined by the body length and body width, selected from the group consisting of triangles, quadrilaterals, rectangles, trapezoids, pentagons, hexagons, heptagons, octagons, ellipses, Greek letters, Latin letters, Russian letters, and combinations thereof.

[0032] In certain embodiments, the mixture may include a blend comprising a first type of abrasive particles and a second type of abrasive particles. The first and second types of abrasive particles may independently comprise any of the abrasive particles referred to in the embodiments herein. For example, the first type of abrasive particles may include a ceramic material, and the second type of abrasive particles may include a single-crystal material. In another example, the first type of abrasive particles may include non-aggregated particles, and the second type of abrasive particles may include aggregated particles.

[0033] The abrasive particles may include a specific particle size distribution. In one embodiment, the abrasive particles may have a specific average particle size D50a that can facilitate improvements in the properties and performance of the abrasive product. In one embodiment, the average particle size D50a may be up to 1.9 mm, up to 1.8 mm, up to 1.6 mm, up to 1.5 mm, up to 1.2 mm, up to 1 mm, up to 900 microns, up to 850 microns, up to 830 microns, up to 800 microns, up to 750 microns, up to 700 microns, up to 650 microns, up to 600 microns, up to 550 microns, up to 500 microns, up to 450 microns, up to 400 microns, up to 380 microns, up to 350 microns, up to 320 microns, up to 300 microns, up to 280 microns, up to 260 microns, or up to 255 microns. In another embodiment, the average particle size D50a may be at least 120 microns, at least 140 microns, at least 150 microns, at least 170 microns, at least 180 microns, at least 200 microns, at least 210 microns, at least 230 microns, at least 250 microns, at least 260 microns, at least 270 microns, at least 290 microns, at least 300 microns, at least 320 microns, at least 340 microns, at least 350 microns, at least 360 microns, at least 380 microns, at least 400 microns, at least 420 microns, at least 430 microns, at least 440 microns, at least 450 microns, at least 460 microns, at least 470 microns, at least 490 microns, or at least 500 microns. Furthermore, the particle size D50a may be within a range that includes any of the minimum and maximum values ​​described herein.

[0034] In further embodiments, the abrasive particles may have a specific D10 that can promote improved properties and performance of the abrasive product. In one embodiment, the abrasive particles may include a D10 of at least 60 microns, at least 65 microns, at least 70 microns, at least 75 microns, at least 80 microns, at least 85 microns, at least 90 microns, at least 95 microns, at least 100 microns, at least 110 microns, at least 120 microns, at least 130 microns, at least 135 microns, at least 140 microns, at least 145 microns, at least 150 microns, at least 155 microns, at least 160 microns, or at least 165 microns. In further embodiments, the abrasive particles may include D10 with dimensions of up to 1 mm, up to 900 microns, up to 850 microns, up to 830 microns, up to 800 microns, up to 750 microns, up to 700 microns, up to 650 microns, up to 600 microns, up to 550 microns, up to 500 microns, up to 450 microns, up to 400 microns, up to 380 microns, up to 350 microns, up to 320 microns, up to 300 microns, up to 280 microns, up to 260 microns, up to 250 microns, up to 240 microns, up to 220 microns, up to 210 microns, up to 200 microns, or up to 170 microns. Furthermore, the abrasive particles may include D10 within a range that includes any of the minimum and maximum values ​​described herein.

[0035] In further embodiments, abrasive particles may have a specific D90 which can promote improved properties and performance of the abrasive product. In one embodiment, abrasive particles may include a D90 of at least 150 microns, at least 170 microns, at least 190 microns, at least 200 microns, at least 220 microns, at least 240 microns, at least 250 microns, at least 260 microns, at least 270 microns, at least 280 microns, at least 300 microns, at least 310 microns, at least 320 microns, at least 340 microns, at least 350 microns, at least 360 microns, or at least 370 microns. In a further embodiment, the abrasive particles may include a particle size distribution with D90 of up to 2.2 mm, up to 2 mm, up to 1 mm, up to 900 microns, up to 870 microns, up to 850 microns, up to 820 microns, up to 780 microns, up to 750 microns, up to 730 microns, up to 700 microns, up to 670 microns, up to 640 microns, up to 610 microns, up to 580 microns, up to 530 microns, up to 500 microns, up to 470 microns, up to 450 microns, up to 330 microns, up to 410 microns, up to 390 microns, or up to 370 microns. Furthermore, the abrasive particles may include a range of D90 that includes either the minimum or maximum values ​​described herein.

[0036] In further embodiments, the abrasive particles may have an average length-to-width aspect ratio. In one embodiment, the average aspect ratio may be at least 1, at least 1.2, at least 1.5, at least 2, at least 2.3, at least 2.5, at least 2.8, at least 3, at least 4, at least 5, or at least 6. In another embodiment, the average aspect ratio may be up to 30, up to 25, up to 22, up to 20, up to 15, up to 12, up to 10, up to 8, up to 6, up to 5, up to 4, or up to 3. Furthermore, the abrasive particles may have an aspect ratio within a range that includes any of the minimum and maximum values ​​described herein.

[0037] The mixture may optionally contain one or more filler materials. The filler materials may provide improved mechanical properties and facilitate the formation of abrasive products. The filler materials may differ from abrasive particles and may differ from ceramic particles. For example, the filler materials may have a hardness lower than that of abrasive particles and lower than that of ceramic particles. The filler materials may also differ from the composition contained in the bond material precursor material. In at least one embodiment, the filler materials may include a variety of materials such as fibers, woven materials, nonwoven materials, particles, minerals, nuts, shells, oxides, alumina, carbides, nitrides, borides, organic materials, polymer materials, naturally occurring materials, and combinations thereof. In certain examples, the filler material may be wollastonite, mullite, steel, iron, copper, brass, bronze, tin, aluminum, kyanite, alcite, garnet, quartz, fluoride, mica, nepheline siehnite, sulfates (e.g., barium sulfate), carbonates (e.g., calcium carbonate), cryolite, glass, glass fibers, titanates (e.g., potassium titanate fibers), zircon, rock wool, clay, sepiolite, iron sulfide (e.g., Fe2S3, FeS2, or combinations thereof). This material may include materials such as fluorospar (CaF2), potassium sulfate (K2SO4), graphite, potassium fluoroborate (KBF4), potassium aluminum fluoride (KAlF4), zinc sulfide (ZnS), zinc borate, borax, boric acid, fine alundum powder, P15A, alumina, cork, glass spheres, silver, Saran® resin, paradichlorobenzene, oxalic acid, alkali halides, organic halides, and attapulgite.

[0038] The formation of the mixture may include the formation of a dry or wet mixture. It may be appropriate to prepare a wet mixture to facilitate the uniform dispersion of components within the mixture. In some embodiments, a premixture of the bond material and ceramic particles can be prepared so that a uniform bond material precursor composition can be prepared for mixing with other components of the mixture. In other examples, ceramic particles, abrasive particles, and / or other components can be mixed with the bond material precursor without forming a premixture. Those skilled in the art will understand that the mixture may include, for example, fillers, additives, binders, pore-forming agents, other materials including hollow particles, or any other materials known in the art for facilitating the formation of the mixture before the formation of an abrasive product to produce a green product. In at least one embodiment, the mixture may not inherently contain a pore-forming agent.

[0039] After reading this disclosure, those skilled in the art will understand that the ceramic particles and the bonding agent precursor material constitute the binding components in the mixture, and that the ceramic particles are not intended to replace any of the abrasive particles.

[0040] Referring again to Figure 1, after the mixture has formed, the process can proceed to step 102 to form the mixture into a green body. The process of forming the mixture into a green body may include pressing, molding, casting, cutting, printing, curing, depositing, drying, heating, cooling, or any combination thereof.

[0041] Referring again to Figure 1, after forming the green body in step 102, the process can be continued in step 103 by forming the green body into the final formed abrasive product. In certain examples, the process of forming the green body and the process of forming the final formed abrasive product can be combined so that the mixture is directly converted into the final formed abrasive product. Suitable processes for forming the final formed abrasive product may include pressing, molding, casting, cutting, printing, curing, deposition, drying, heating, cooling, or any combination thereof.

[0042] In a particular embodiment, the method for forming the final abrasive product may include heat-treating the mixture. According to one embodiment, the heat-treating process may include heating the mixture to a temperature sufficient to form a vitreous bond material from a bond material precursor material. According to one embodiment, the heat-treating may include heating the mixture to a forming temperature of 1250°C or less, for example, 1200°C or less, 1150°C or less, 1100°C or less, 1050°C or less, or 950°C or less. Furthermore, in at least one non-limiting embodiment, the heat-treating process may include heating the mixture, comprising abrasive particles, ceramic particles, and bond material, to a forming temperature of at least 850°C, for example, at least 875°C, at least 900°C, at least 920°C, or even further at least 950°C. It will be understood that the forming temperature may be within a range including any of the above minimum and maximum values. The forming temperature may be above the melting temperature of the bond material precursor material.

[0043] The bonding precursor material may have viscosity and a specific fluidity when heated to the formation temperature. It should be noted that ceramic particles may affect the viscosity and / or bond flow to facilitate improved formation of the bonded abrasive. For example, ceramic particles may help reduce bond flow. In a further example, a mixture containing ceramic particles may have bond flow that facilitates improved formation of the number and / or size of bond bridges between abrasive particles compared to a similar mixture without ceramic particles.

[0044] The heat treatment may further include heating the mixture in a non-oxidizing atmosphere. In at least another embodiment, the heat treatment process may include heating the mixture in a nitrogen-rich atmosphere, more specifically an atmosphere essentially consisting of nitrogen. Furthermore, it will be understood that the non-oxidizing atmosphere may include one or more noble gases. In yet another embodiment, the heat treatment process may be carried out in an ambient atmosphere (i.e., air).

[0045] After heat treatment to form a bonded abrasive body, the bonded abrasive body may be incorporated into an abrasive product. The bonded abrasive body can have any suitable size and shape as known in the art and can be incorporated into various types of abrasive products to form a bonded abrasive product suitable for material removal operations, including but not limited to abrasive wheels, cones, horns, cups, flanged wheels, tapered cups, segments, mounted grinding tools, discs, thin wheels, large diameter cutting wheels, etc.

[0046] As described above, the abrasive product may have a body in the form of a bonded abrasive, comprising a bond material 201 in the form of bond bridges (also referred to in this disclosure as “bond posts”) that bond abrasive particles 205, ceramic particles 202 contained in the bond material 201, and pores 203 extending between the bond material 202 and the abrasive particles 205. In certain embodiments, the bond material 201 may form a bond matrix that extends continuously through the volume of the body.

[0047] In one embodiment, the body may include bond posts having a specific average size that facilitates the formation of abrasive products and the improvement of their properties and performance. In one embodiment, the bond posts may have an average size Sbp greater than the average ceramic particle size D50c. In another embodiment, the average post-bonding size (Sbp) may be greater than 12 microns, for example, at least 13 microns, at least 15 microns, at least 17 microns, at least 19 microns, at least 20 microns, at least 22 microns, at least 24 microns, at least 25 microns, at least 26 microns, at least 37 microns, at least 38 microns, at least 39 microns, at least 40 microns, at least 42 microns, at least 45 microns, at least 47 microns, at least 49 microns, at least 51 microns, at least 53 microns, at least 55 microns, at least 57 microns, and less The diameter may be at least 59 microns, at least 62 microns, at least 65 microns, at least 67 microns, at least 70 microns, at least 74 microns, at least 76 microns, at least 78 microns, at least 80 microns, at least 82 microns, at least 84 microns, at least 87 microns, at least 90 microns, at least 93 microns, at least 95 microns, at least 98 microns, at least 100 microns, at least 110 microns, at least 120 microns, at least 140 microns, at least 160 microns, at least 180 microns, or at least 200 microns. In further embodiments, the body may include an average post-bonding size (Sbp) less than the average particle size (D50a) of the abrasive particles.In further embodiments, the average post-bonding size (Sbp) may be up to 1.8 mm, up to 1.5 mm, up to 1.2 mm, up to 900 microns, up to 850 microns, up to 830 microns, up to 800 microns, up to 750 microns, up to 700 microns, up to 650 microns, up to 600 microns, up to 550 microns, up to 500 microns, up to 450 microns, up to 400 microns, up to 380 microns, up to 350 microns, up to 320 microns, up to 300 microns, up to 280 microns, up to 260 microns, up to 255 microns, up to 220 microns, or up to 200 microns. It should be understood that the average post-bonding size may be within a range that includes any of the minimum and maximum values ​​described herein.

[0048] The average size of bond posts can be determined as follows: The cross-section of the bonded abrasive can be polished, and high-contrast scanning electron microscope images of the entire cross-section can be taken. Typically, at least six images are required for the entire cross-section. Image J is used to analyze the size of all bond posts in the cross-section, and the average of the sizes of all bond posts is used as the average post-bonded size within the body.

[0049] In further embodiments, the bonding material may have a specific Vickers hardness that can facilitate improvements in the properties and performance of abrasive products. In one embodiment, the bonding material may include an average Vickers hardness of at least 5.70 GPa, at least 5.75 GPa, or at least 5.80 GPa. In another embodiment, the bonding material may include an average Vickers hardness of up to 6.50 GPa, up to 6.45 GPa, or up to 6.40 GPa. It should be understood that the bonding material may include a Vickers hardness within a range that includes any of the minimum and maximum values ​​described herein. The Vickers hardness is determined according to the standard test method for Vickers Indentation Hardness, ASTM C 1327-2015.

[0050] In one embodiment, ceramic particles can be dispersed substantially uniformly in the bonding material. For example, the majority of the bond bridge may contain dispersed ceramic particles. In another example, at least 51% of the bond bridge may contain dispersed ceramic particles, for example, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or at least 95% of the bond bridge may contain dispersed ceramic particles. In one embodiment, all bond bridges may contain dispersed ceramic particles.

[0051] In one embodiment, the body may contain a specific content of bonding material that can facilitate improvements in the performance of abrasive products. In one aspect, the body may contain at least 2 volume%, e.g., at least 4 volume%, at least 5 volume%, or at least 6 volume%, or at least 7 volume%, or at least 8 volume%, or at least 9 volume%, or at least 10 volume%, or at least 11 volume%, or at least 12 volume%, or at least 13 volume%, or at least 14 volume%, or at least 15 volume%, or at least 16 volume%, or at least 17 volume%, or at least 18 volume%, or at least 19 volume%, or at least 20 volume%, relative to the total volume of the body. In another aspect, the body may contain up to 35 volume%, e.g., up to 30 volume%, or up to 25 volume%, or up to 20 volume%, relative to the total volume of the body. Furthermore, the body may contain bonding material in a content range that includes either the minimum or maximum percentages described herein.

[0052] In one embodiment, the bonding material may include a ceramic material, an amorphous material, or a combination thereof. The ceramic material is a composition comprising at least one metal or metalloid element, including but not limited to alkali metal elements, alkaline earth metal elements, lanthanides, transition metal elements, and combinations thereof. The ceramic material may also include oxides, carbides, nitrides, borides, and combinations thereof. Furthermore, the ceramic material may include a single-crystal phase, a polycrystalline phase, an amorphous phase, or a combination thereof. It will be understood that the ceramic material may essentially consist of a single-crystal phase, a polycrystalline phase, an amorphous phase, or a combination thereof.

[0053] In one embodiment, the bonding material may include a vitreous material. The vitreous material may comprise an amorphous phase. For example, the bonding material may essentially consist of a vitreous material having an amorphous phase. In another embodiment, the bonding material may include a non-vitreous material. The non-vitreous material may include a polycrystalline phase. In yet another embodiment, the bonding material may include a mixture of a polyclearin material and a vitreous material.

[0054] In one embodiment, the bonding material may contain boron oxide (B2O3) in a specific content that can promote improved formation and / or performance of the abrasive product. The boron oxide may be present in a specific weight percentage relative to the total weight of the bonding material. For example, the boron oxide may be up to 30% by weight, up to 28% by weight, up to 26% by weight, up to 24% by weight, or up to 22% by weight of the total weight of the bonding material. In another example, the bonding material may contain at least 2% by weight, e.g., at least 3% by weight, at least 4% by weight, or at least 5% by weight of boron oxide relative to the total weight of the bonding material. In a particular example, the boron oxide content may be greater than 5% by weight, e.g., at least 6% by weight, at least 7% by weight, at least 8% by weight, at least 10% by weight, at least 12% by weight, or even further at least 15% by weight. It will be understood that the boron oxide content in the bonding material may range from any minimum to maximum percentage described herein. For example, the bonding material may contain boron oxide in the range of 2% to 30% by weight, 5% to 30% by weight, or 8% to 22% by weight.

[0055] In one embodiment, the bonding material may contain silicon dioxide (SiO2) in a specific amount that can promote improved formation and / or performance of the abrasive product. The silicon dioxide content relative to the total weight of the bonding material may be, for example, up to 80% by weight, up to 75% by weight, up to 70% by weight, up to 66% by weight, up to 65% by weight, up to 63% by weight, up to 60% by weight, up to 55% by weight, up to 52% by weight, or up to 50% by weight. In certain examples, the bonding material may contain less than 66% by weight of silicon dioxide. In other examples, the bonding material may contain at least 25% by weight of silicon dioxide, for example, at least 30% by weight, at least 35% by weight, at least 38% by weight, at least 40% by weight, at least 42% by weight, at least 45% by weight, at least 47% by weight, at least 48% by weight, and even at least 49% by weight. It will be understood that the silicon dioxide content may be within the range of the minimum to maximum percentages listed above. For example, the silicon dioxide content may be in the range of 35% to 80% by weight, or in the range of 40% to 65% by weight.

[0056] In further embodiments, the bonding material may contain boron oxide and silicon oxide in specific amounts that can promote improved formation and / or performance of the abrasive product. For example, the total content of boron oxide and silicon oxide may be up to 80% by weight, e.g., up to 77% by weight, up to 75% by weight, up to 73% by weight, up to 70% by weight, up to 70% by weight, or up to 65% by weight. In another example, the total content of boron oxide and silicon oxide may be at least 40% by weight, at least 42% by weight, at least 46% by weight, at least 48% by weight, or even further at least 50% by weight, relative to the total weight of the bonding material. It will be understood that the total content of boron oxide and silicon oxide may be within a range that includes either the minimum and maximum percentages disclosed herein. For example, the total content of boron oxide and silicon oxide may be in the range of 40% to 80% by weight, or in the range of 42% to 77% by weight, or in the range of 46% to 65% by weight.

[0057] In one embodiment, the bonding material may include a specific ratio of weight percent silicon dioxide (SiO2) to weight percent boron oxide (B2O3) that can promote improved formation and / or performance of abrasive products. For example, the ratio may be up to 22:1, up to 21:1, up to 20:1, or up to 19:1. In certain examples, the ratio may be less than 19:1, for example, up to 18:1, up to 16:1, up to 15:1, up to 12:1, up to 10:1, up to 9:1, up to 8:1, up to 7:1, up to 6.5:1, up to 6:1, up to 5.5:1, up to 5.2:1, up to 5:1, or up to 4.8:1. In another example, the ratio of weight percent silicon dioxide (SiO2) to weight percent boron oxide (B2O3) may be at least 1.3:1, at least 1.5:1, at least 1.7:1, at least 2:1, at least 2.2:1, at least 2.4:1, at least 2.6:1, at least 2.8:1, or at least 3:1. The ratio of weight percent silicon dioxide (SiO2) to weight percent boron oxide (B2O3) may be within a range that includes any of the minimum and maximum values ​​above, and it will be understood that, for example, the ratio may be in the range of 1:3 to 22:1 or 1:3 to 7:1.

[0058] In one embodiment, the bonding material may contain aluminum oxide (Al2O3) in a content that can promote improved formation and / or performance of the abrasive product. In one example, the bonding material may contain at least 5% by weight, at least 8% by weight, at least 9% by weight, at least 10% by weight, at least 12% by weight, or at least 14% by weight of aluminum oxide (Al2O3) relative to the total weight of the bonding material. In another example, the bonding material may contain up to 30% by weight, up to 28% by weight, up to 25% by weight, up to 23% by weight, or up to 20% by weight of aluminum oxide (Al2O3) relative to the total weight of the bonding material. In a particular example, the bonding material may contain up to or less than 20% by weight of aluminum oxide relative to the total weight of the bonding material, for example, up to 19% by weight or up to 18% by weight. It will be understood that the aluminum oxide content may be within either of the minimum and maximum percentages above, for example, within the range of 5% to 31% by weight or within the range of 10% to 25% by weight.

[0059] In one embodiment, the bonding material may contain aluminum and alumina in amounts that can promote improved formation and / or improved performance of the abrasive product. For example, the bonding material may contain at least 15% by weight of alumina and aluminum metal (Al2O3 / Al) relative to the total weight of the bonding material, for example, at least 18% by weight, for example, at least 20% by weight, at least 22% by weight, or even more than 24% by weight of alumina and aluminum metal (Al2O3 / Al) relative to the total weight of the bonding material. In another example, the bonding material may contain up to 45% by weight, for example, up to 42% by weight, up to 40% by weight, up to 38% by weight, up to 35% by weight, or even more than 32% by weight of alumina and aluminum metal relative to the total weight of the bonding material. It will be understood that the bonding material may contain alumina and aluminum metal in amounts within a range that includes any of the minimum and maximum percentages described herein. For example, the content of alumina and aluminum metal may be in the range of 5% to 45% by weight, 10% to 40% by weight, or 22% to 35% by weight, relative to the total weight of the bonding material.

[0060] In one embodiment, the bonding material may contain aluminum oxide and silicon oxide. For example, the total content of aluminum oxide and silicon oxide relative to the total weight of the bonding material may be at least 50% by weight, e.g., at least 52% by weight, at least 56% by weight, at least 58% by weight, or at least 60% by weight. In another example, the total content of aluminum oxide and silicon oxide may be up to 80% by weight, or up to 79% by weight, relative to the total weight of the bonding material. In a particular example, the total content of aluminum oxide and silicon oxide may be less than 79% by weight, e.g., up to 78% by weight, up to 77% by weight, up to 76% by weight, up to 75% by weight, up to 74% by weight, or up to 73% by weight. The total content of aluminum oxide and silicon oxide may be within any of the minimum to maximum percentages described herein, for example, the total content may be in the range of 50% to 79% by weight, 56% to 75% by weight, or even 60% to 73% by weight.

[0061] In one embodiment, the bonding material may include a specific ratio of weight percent silicon dioxide (SiO2) to weight percent aluminum oxide (Al2O3) that can facilitate improved formation and / or improved performance of abrasive products. For example, the ratio may be up to 5.5:1, up to 5:1, up to 4.5:1, up to 4:1, up to 3.5:1, up to 3:1, up to 2.5:1, up to 2.2:1, or up to 2:1. In another example, the weight percent silicon dioxide (SiO2) to weight percent aluminum oxide (Al2O3) ratio may be at least 1.3:1, at least 1.5:1, at least 1.7:1, or at least 2:1. The ratio of weight percent silicon dioxide to weight percent aluminum oxide may be within a range that includes any of the minimum and maximum ratios above, and it will be understood that, for example, the ratio may be in the range of 1:1 to 2.5:1 or 1.3:1 to 2.2:1.

[0062] In one embodiment, the bonding material may contain a specific content of zircon (ZrSiO4) that can facilitate the formation of abrasive products and improve their performance. For example, the bonding material may contain at least 1% by weight, for example, at least 2% by weight, 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, or at least 21% by weight, or at least 22% by weight, or at least 23% by weight, or at least 24% by weight, or at least 25% by weight, or at least 26% by weight, or at least 27% by weight, or at least 28% by weight, or at least 29% by weight of zircon, based on the total weight of the bonding material. In another example, the bonding material may contain up to 44% by weight, up to 42% by weight, up to 40% by weight, up to 38% by weight, up to 36% by weight, up to 35% by weight, up to 34% by weight, up to 33% by weight, or up to 32% by weight of zircon relative to the total weight of the bonding material. It will be understood that the bonding material may contain zircon within a range that includes any of the minimum and maximum percentages above. In at least one embodiment, the bonding material may not contain zircon (ZrSiO4) in any way.

[0063] In one embodiment, the bonding material may contain at least one alkaline earth oxide compound (RO) in a content that can promote improved formation and / or performance of the abrasive product. The total content of the alkaline earth oxide compound relative to the total weight of the bonding material may be up to 6% by weight, up to 5% by weight, up to 4% by weight, up to 3.0% by weight, up to 2.5% by weight, or up to 2% by weight. In another embodiment, the total content of the alkaline earth oxide compound (RO) may be at least 0.5% by weight or at least 0.8% by weight. The total content of the alkaline earth oxide compound may be within a range that includes either the minimum and maximum percentages described herein, for example, the total content may be in the range of 0.5% by weight to 5.0% by weight.

[0064] In some embodiments, the bonding material may include up to three different alkaline earth oxide compounds (ROs) selected from the group consisting of calcium oxide (CaO), magnesium oxide (MgO), barium oxide (BaO), and strontium oxide (SrO).

[0065] For example, the bonding material may contain at least 0.5% by weight, at least 0.8% by weight, or at least 1% by weight of calcium oxide (CaO) relative to the total weight of the bonding material. Alternatively or additionally, the bonding material may contain 3% by weight or less, 2.8% by weight or less, or 2.5% by weight or less, 2% by weight or less, or 1.7% by weight or less of calcium oxide (CaO) relative to the total weight of the bonding material. Furthermore, the calcium oxide content may be within the range of any of the minimum and maximum percentages described herein. In at least one embodiment, the bonding material may not contain calcium oxide (CaO) in any way.

[0066] In one embodiment, the bonding material may include an alkali oxide compound (R2O). Exemplary alkali oxide compounds may include lithium oxide (Li2O), sodium oxide (Na2O), potassium oxide (K2O), cesium oxide (Cs2O), etc. In further embodiments, the bonding material may include at least one alkali oxide compound. In particular, the bonding material may include an alkali oxide compound (R2O) selected from the group consisting of compounds comprising lithium oxide (Li2O), sodium oxide (Na2O), potassium oxide (K2O), and cesium oxide (Cs2O), as well as combinations thereof.

[0067] In one embodiment, the total content of the alkali oxide compound relative to the total weight of the bond material may be up to 25% by weight, or up to 22% by weight, or up to 20% by weight. Alternatively or additionally, the total content of the alkali oxide compound may be at least 3% by weight, at least 5% by weight, at least 7% by weight, or at least 9% by weight. It will be understood that the total content of the alkali oxide compound may be within any of the minimum to maximum percentages described herein. For example, the total content of the alkali oxide compound may be in the range of 3% to 25% by weight, or in the range of 7% to 22% by weight.

[0068] In one embodiment, the bonding material may contain lithium oxide (Li2O) in a content that can promote improved formation and / or performance of the abrasive product. For example, the bonding material may contain at least 1% by weight, at least 1.5% by weight, or at least 2% by weight of lithium oxide (Li2O) based on the total weight of the bonding material. In another example, the bonding material may contain up to 7% by weight, up to 6.5% by weight, up to 6% by weight, up to 5.5% by weight, or up to 5% by weight of lithium oxide (Li2O) based on the total weight of the bonding material. It will be understood that the lithium oxide content may be within any of the above minimum to maximum percentages, for example, within the range of 1% to 7% by weight or 1.5% to 6% by weight. In at least one embodiment, the bonding material is essentially free of lithium oxide (Li2O).

[0069] In one embodiment, the bonding material may contain sodium oxide (Na2O) in a content that can promote improved formation and / or performance of the abrasive product. The sodium oxide content relative to the total weight of the bonding material may be, for example, at least 3% by weight, at least 4% by weight, or at least 5% by weight. In another example, the sodium oxide content may be up to 15% by weight, up to 14% by weight, up to 13% by weight, up to 12% by weight, up to 11% by weight, or up to 10% by weight of sodium oxide (Na2O) relative to the total weight of the bonding material. It will be understood that the sodium oxide content may be within any of the above minimum to maximum percentages, for example, in the range of 3% to 14% by weight, or in the range of 4% to 11% by weight.

[0070] In one embodiment, the bonding material may contain potassium oxide (K2O) in a content that can promote improved formation and / or performance of the abrasive product. For example, the content of potassium oxide relative to the total weight of the bonding material may be at least 1% by weight, at least 1.5% by weight, or at least 2% by weight. In another example, the content of potassium oxide (K2O) may be up to 15% by weight, for example, up to 13% by weight, up to 11% by weight, up to 10% by weight, up to 8% by weight, up to 7% by weight, up to 6.5% by weight, up to 6% by weight, or up to 5.5% by weight, or up to 5% by weight, relative to the total weight of the bonding material. It will be understood that the content of potassium oxide may be within any of the minimum to maximum percentages described herein, including, for example, a range of 1% to 15% by weight.

[0071] In one embodiment, the bonding material may contain phosphorus oxide (P2O5) in a content that can promote improved formation and / or performance of the abrasive product. For example, the bonding material may contain up to 3.0% by weight, e.g., up to 2% by weight or up to 1% by weight of phosphorus oxide (P2O5). In at least one embodiment, the bonding material may not contain phosphorus oxide (P2O5) in any way.

[0072] In one embodiment, the bonding material may contain certain components in specific amounts that promote proper formation and / or performance of the abrasive product. Such components may include manganese dioxide (MnO2), iron oxide (Fe2O3), ZrSiO2, CoAl2O4, titanium dioxide (TiO2), or any combination thereof. For example, in one example, the bonding material may contain up to 2% by weight, e.g., up to 1% by weight or up to 0.5% by weight of one of manganese dioxide (MnO2), iron oxide (Fe2O3), ZrSiO2, CoAl2O4, or titanium dioxide (TiO2) based on the total weight of the bonding material. In at least one embodiment, the bonding material may not essentially contain any one or a combination of manganese dioxide (MnO2), iron oxide (Fe2O3), ZrSiO2, CoAl2O4, or titanium dioxide (TiO2).

[0073] In one embodiment, the body may contain a specific content of abrasive particles that can facilitate improvement in the performance of the abrasive product. In one embodiment, the body may contain at least 20 volume%, at least 25 volume%, at least 30 volume%, at least 33 volume%, or at least 35 volume% of the total volume of the body of abrasive particles. In another embodiment, the body may contain up to 65 volume%, up to 64 volume%, or up to 62 volume%, or up to 60 volume%, or up to 58 volume%, or up to 56 volume%, or up to 55 volume%, or up to 54 volume%, or up to 52 volume%, or up to 50 volume% of the total volume of the body of abrasive particles. Furthermore, the body may contain abrasive particles in a range that includes either the minimum or maximum percentages described herein.

[0074] In another embodiment, the body may include a specific ratio D50a / D50c between the average particle size D50a of abrasive particles and the average particle size D50a of ceramic particles, which can facilitate improvements in the properties and performance of the abrasive product. In some embodiments, the ratio D50a / D50c may be up to 35, up to 34.8, up to 34.5, up to 34.2, up to 34, up to 33.8, up to 33.5, up to 33.2, up to 33, up to 32.7, up to 32.5, up to 32.1, up to 31.8, up to 31.5, up to 31, up to 30.5, up to 30, up to 29.6, up to 29.3, up to 29 , max 28.6, max 28.3, max 28, max 27.6, max 27.3, max 27, max 26.6, max 26.3, max 26, max 25.7, max 25.3, max Large 25, Max 24.8, Max 24.5, Max 24.2, Max 24, Max 23.7, Max 23.4 Max 23, Max 22.8, Max 22.5, Max 22.1, Max 21. 8, maximum 21.5, maximum 21, maximum 20.5, maximum 20, maximum 19.6, maximum 19.3, maximum 19, maximum 18.8, maximum 18.6, maximum 18.3, maximum 18, maximum 17.6, maximum 17.2, maximum 17, maximum 16.6, maximum 16.3, maximum 16, maximum 15.7, maximum 15.3, maximum 15, maximum 14.8, maximum 14.5, maximum 14.2, maximum 14, maximum 13.7, maximum 13.5, maximum 13.3, maximum 13, maximum 12.5, maximum 12.3, maximum 12, maximum 11.8, maximum 11.5, maximum 11.3, maximum 11, maximum 10.9, maximum 10.7, maximum 10.6, maximum 10.3, maximum 10, maximum 9.8, maximum 9.6, maximum 9.5, maximum 9.2, or maximum 9. In another example, the ratio D50a / D50c is at least 4, at least 4.2, at least 4.5, at least 4.8, at least 5, at least 5.2, at least 5.4, at least 5.6, at least 5.9, at least 6.2, at least 6.5, at least 6.8, at least 7, at least 7.2, at least 7.6, at least 8, at least 8.2, at least 8.5, at least 8.8, at least 9, at least 9.2, at least 9.5, at least 9.7, at least 9.9, at least 10.1, at least 10.5, at least 10.8, at least 10.9, at least 11, at least 11.1, at least 11.2, at least 11.5, at least 11.7, at least 11.9, at least 12.1, at least 12.3, at least 12.7, at least 13, at least 13.2, at least 13.4, at least 13.6, at least 13.9, at least 14, at least 14.2, at least 14.3, at least 14.5, at least 14.7, at least (at last) 14.9, at least 15, at least 15.2, at least 15.3, at least 15.5, at least 15.7, at least 16, at least 16.2, at least 16.4, at least 16.6, at least 16.9, at least 17, at least 17.2, at least 17.3, at least 17.5, at least 17.7, at least (at last) 17.9, at least 18, at least 18.2, at least 18.3, at least 18.5, at least 18.7, at least 19, at least 19.2, at least 19.4, at least 19.6, at least 19.9, at least 20, at least 20.2, at least 20.4, at least 20.5, at least 20.7, at least (at (at) 21, at least 21.5, at least 21.7, at least 21.9, at least 22, at least 22.3, at least 22.5, at least 22.8, at least 23, at least 23.2, at least 23.6, at least 24, at least 24.2, at least 24.5, at least 24.7, at least 25, at least 25.3, at least 25.5, at least 25.7, at least 26, at least 26.2, at least 26.4, at least 26.6, at least 26.9, at least 27, at least 27.2, at least 27.3, at least 27.5, at least 27.7, at least (at (last) 27.9, at least 28.1, at least 28.2, at least 28.5, at least 28.7, at least 29, at least 29.1, at least 29.4, at least 29.6, at least 29.8, at least 30, at least 30.2, at least 30.4, at least 30.5, at least 30.7, at least (at last) 30.9, at least 31, at least 31.2, at least 31.3, at least 31.5, at least 31.7, at least 31.9, at least 32, at least 32.2, at least 32.4, at least 32.7, at least 33, at least 33.4, at least 33.6, at least 33.9, at least 34, at least 34.2, at least 34.5, at least 34.7, at least (at last) 34.9, at least 35, at least 35.2, at least 35.5, at least 35.8, at least 36, at least 36.2, at least 36.5, at least 36.7, at least 37, at least 37.2, at least 37.4, at least 37.6, at least 37.9, at least 38, at least 38.3, at least 38.5, at least 38.7, at least (at (at last) 39, at least 39.3, at least 39.5, at least 39.7, at least 40, at least 40.2, at least 40.5, at least 40.7, at least 41, at least 41.2, at least 41.4, at least 41.6, at least 41.9, at least 42, at least 42.3, at least 42.5, at least 42.7, at least (at last) 42.9, at least 43, at least 43.2, at least 42.3, at least 42.5, at least 42.7, at least 43, at least 43.2, at least 43.4, at least 43.6, at least 43.9, at least 44, at least 44.2, at least 44.3, at least 44.5, at least 44.7, at least (at last) 44.9, or at least 45. Furthermore, the ratio D50a / D50c may be within a range that includes either the maximum or minimum values ​​described herein.

[0075] In one embodiment, the body may contain a certain degree of porosity that can facilitate improvements in the performance of abrasive products. In one embodiment, the body may contain porosity of at least 20 volume%, for example, at least 22 volume%, at least 24 volume%, at least 26 volume%, at least 28 volume%, at least 30 volume%, at least 32 volume%, or at least 35 volume% relative to the total volume of the body. In another embodiment, the body may contain porosity of up to 75 volume%, up to 70 volume%, up to 65 volume%, up to 62 volume%, up to 60 volume%, up to 55 volume%, up to 50 volume%, up to 45 volume%, or up to 40 volume% relative to the total volume of the body. It will be understood that the porosity of the body may be within a range that includes any of the above minimum to maximum percentages.

[0076] The porosity of the material can take various forms. For example, the porosity can be closed porosity, open porosity, or may include both closed and open porosity. In one embodiment, the porosity can be of a type selected from the group consisting of closed porosity, open porosity, and combinations thereof. In another embodiment, the majority of the porosity may include open porosity. In a particular embodiment, all of the porosity may be essentially open porosity. Furthermore, in yet another embodiment, the majority of the porosity may include closed porosity. For example, all of the porosity may be essentially closed porosity.

[0077] The body may include pores having a specific average pore diameter. In one embodiment, the average pore diameter may be up to 3 mm, up to 2.5 mm, up to 2 mm, up to 1.9 mm, up to 1.5 mm, up to 1 mm, up to 900 microns, up to 800 microns, up to 700 microns, up to 600 microns, up to 500 microns, up to 450 microns, up to 400 microns, up to 350 microns, up to 300 microns, up to 250 microns, up to 200 microns, up to 150 microns, or up to 100 microns. In another embodiment, the average pore diameter may be at least 0.01 microns, at least 0.1 microns, at least 1 micron, at least 5 microns, at least 8 microns, at least 10 microns, at least 14 microns, at least 16 microns, at least 25 microns, at least 50 microns, at least 100 microns, at least 150 microns, or at least 200 microns. It will be understood that the body may have an average pore diameter within a range that includes any of the above minimum to maximum values. In this disclosure, the average pore size can be measured using ASTM standard E112 Standard Test Methods for Determining Average Grain Size. Cross-sectional images of the main body were viewed at 60x magnification with a Hitachi microscope. The macro for determining the pore length follows a method of measuring crystal size based on drawing six equally spaced lines on the image and determining the region of the lines that intersect the pores. The region of the lines that intersect the pores is measured. This process was repeated for seven different images of a portion of the bonded polished body. After analyzing all images, the average pore size was calculated by averaging the values. Furthermore, it should be understood that a reference to the average pore size may also refer to the mean pore size.

[0078] The abrasive product may have significantly improved performance compared to the corresponding conventional abrasive product. The corresponding conventional abrasive product is intended to refer to a similar abrasive product that does not contain the ceramic particles described in the embodiments herein. In at least one embodiment, the abrasive product representative of the embodiments herein may have improved performance, including power consumption, G ratio, wear rate, and / or material removal rate, compared to the corresponding conventional abrasive product, while simultaneously having a similar modulus of rupture (MOR). In certain examples, the abrasive product representative of the embodiments herein may have an improved modulus of rupture (MOR) compared to the corresponding conventional abrasive product.

[0079] For certain applications, abrasive products may have a MOR of at least 38 MPa, at least 39 MPa, at least 40 MPa, at least 41 MPa, at least 43 MPa, at least 45 MPa, at least 46 MPa, at least 47 MPa, or at least 48 MPa. For other applications, abrasive products may include an average MOR of up to 60 MPa, up to 58 MPa, up to 56 MPa, up to 55 MPa, up to 53 MPa, up to 52 MPa, up to 50 MPa, or up to 49 MPa. Furthermore, abrasive products may include a range of MORs that include any of the minimum and maximum values ​​described herein.

[0080] Figure 3 includes a flowchart showing the process 300 for forming an abrasive product. The process begins at block 301, and a pore-forming agent coated with ceramic particles can be formed. In one embodiment, the pore-forming agent may include a material with a low volatilization temperature such that, during the high-temperature treatment required to form the bonded abrasive, such pore-forming material volatilizes to form a gas, thereby leaving pores in the bonded abrasive that is ultimately formed. Suitable pore-forming agents may include inorganic or organic materials. Suitable inorganic materials may include oxides or carbon-containing materials such as graphite. Suitable oxide-containing materials may include glass, glass-ceramics, ceramics, or combinations thereof. Some suitable organic pore-forming materials may include waxes, seeds and shells, sulfosuccinates, naphthalenes, polyvinyl, ketones, polystyrene, polyethylene, polypropylene, acrylics, benzene-containing polymers, alkyds, polyalkyds, epoxy, phenols, acetals, and combinations thereof. Suitable inorganic pore-forming agents may include hollow particles such as beads and spheres made from materials such as glass, ceramics, glass-ceramics, hollow glass beads, crushed walnut shells, plastic materials or organic compound beads, foamed glass particles and bubble alumina, elongated particles, fibers, or combinations thereof. Other inorganic pore-forming materials may include salts such as sodium chloride, potassium chloride, magnesium chloride, calcium chloride, sodium silicate, sodium carbonate, sodium sulfate, potassium sulfate, magnesium sulfate, and combinations thereof.

[0081] The pore-forming agent may have a particle size suitable for forming a desired degree of porosity within the bonded abrasive. For example, the pore-forming agent may include an average particle size similar to the pore diameter described in the embodiments herein.

[0082] In exemplary embodiments, a binder material can be used to facilitate the formation of a pore-forming agent coated with ceramic particles. The exemplary binder material may include glycols, dextrins, resins, adhesives, or alcohols, or combinations thereof.

[0083] In another embodiment, the ceramic particles may be mixed with a pore-forming agent in a specific ratio that facilitates improved formation of abrasive products. For example, the ratio of the volume of ceramic particles Vc to the volume of pore-forming agent Vpf (Vc:Vpf) may be at least 0.01:1, at least 0.1:1, at least 0.2:1, at least 0.5:1, at least 1:1, at least 2:1, at least 3:1, at least 5:1, or at least 10:1. In another example, the ratio of the volume of ceramic particles Vc to the volume of pore-forming agent Vpf (Vc:Vpf) may be up to 100:1, up to 80:1, up to 50:1, up to 30:1, up to 20:1, or up to 10:1. It will be understood that the ratio of the volume of ceramic particles Vc to the volume of pore-forming agent Vpf (Vc:Vpf) may be within a range that includes any of the minimum and maximum values ​​described herein. Figure 4 includes an image of a coated pore-forming agent 401 containing a pore-forming agent 400 coated with ceramic particles 402.

[0084] The process proceeds to block 302, where a mixture comprising abrasive particles, a bonding agent precursor material, and a pore-forming agent coated with ceramic particles can be formed. The mixture may contain a specific amount of the coated pore-forming agent that facilitates the formation of improved properties and performance of the abrasive product. For example, the mixture may contain small amounts of such pore-forming agent, such as up to 40 vol%, up to 30 vol%, up to 25 vol%, up to 20 vol%, or up to 10 vol% of the total volume of the mixture. In another example, the mixture may contain at least 1 vol% of the total volume of the mixture, for example, at least 2 vol%, or at least 5 vol% of the coated pore-forming agent. It will be understood that the content of the coated pore-forming agent may range from any of the minimum and maximum percentages described herein.

[0085] The mixture may include a bonding agent precursor material, abrasive particles, and optionally fillers and / or additives, as described in the embodiments herein with respect to process 100.

[0086] Process 300 can proceed to blocks 303 and 304 in the same manner as described with respect to process 100 in this disclosure.

[0087] In one embodiment, the bonded abrasive can include a specific distribution of ceramic particles. For example, a bonded abrasive formed according to process 300 may have a different distribution of ceramic particles compared to a bonded abrasive formed according to process 100. In one embodiment, the bonded abrasive can include pores that are at least partially defined by ceramic particles. For example, at least 50% of the pores can be at least partially defined by ceramic particles, and for example, at least 55%, at least 60%, at least 70%, at least 80%, at least 90%, or at least 95% of the pores of the body can be at least partially defined by ceramic particles.

[0088] In another embodiment, the ceramic particles may have a concentrated distribution adjacent to the pores. For example, at least the majority of the ceramic particles may be distributed around the pores of the body. In another example, at least 55% of the total volume of the ceramic particles, for example, at least 50%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or at least 95%, may be distributed adjacent to the pores. In yet another example, a small number of the ceramic particles may have a dispersed distribution within the bond bridge, such that less than 50%, up to 40%, up to 30%, up to 20%, up to 10%, or up to 5% of the total volume of the ceramic particles may be dispersed within the bond bridge.

[0089] In further embodiments, the ceramic particles may form a continuous or discontinuous layer adjacent to or around the edges of the pores. In certain embodiments, the abrasive may include a specific average thickness of such a layer of ceramic particles that can help retain the pores in the abrasive. As an example, the average thickness of the layer of ceramic particles may be at least 50 microns, at least 100 microns, at least 200 microns, at least 300 microns, at least 400 microns, or at least 500 microns. In another example, the layer of ceramic particles may have an average thickness of up to 500 microns, up to 400 microns, up to 300 microns, up to 200 microns, up to 100 microns, or up to 50 microns. In certain examples, the average thickness may be within a range including any of the minimum and maximum values ​​described herein.

[0090] Referring briefly to Figure 9, a scanning electron microscope image of a cross-section of an exemplary bonded polished body 900 is shown. The body 900 comprises polishing particles 902 contained in the bonding material 904 and pores 906. The pores 906 are at least partially defined by a layer 910 containing ceramic particles 908.

[0091] In one embodiment, the content W of ceramic particles in the bonded polished body c / b is, formula W c / b =[W cb / (W cb +W b It can be calculated using ) × 100%, where W c / b This is the weight percentage of ceramic particles in the bonded polished body, and W cb is the weight of the ceramic particles in the bonded polished body, W b This is the weight of the bonding material in the bonded polished body.

[0092] In a further embodiment, the body has a specific content W of ceramic particles c / bIt may include. In one embodiment, the body may contain at least 0.0005% by weight, for example, at least 0.0008% by weight, at least 0.001% by weight, at least 0.002% by weight, at least 0.004% by weight, at least 0.006% by weight, at least 0.008% by weight, at least 0.01% by weight, at least 0.02% by weight, at least 0.05% by weight, at least 0.08% by weight, at least 0.1% by weight, at least 0.2% by weight, at least 0.4% by weight, at least 0.5% by weight, at least 0.7% by weight, at least 0.8% by weight, at least 0.9% by weight, at least 1% by weight, at least 1.2% by weight, at least 1.4% by weight, at least 1.6% by weight, at least 1.8% by weight, at least 2% by weight, and less Content W of at least 2.2% by weight, at least 2.5% by weight, at least 2.7% by weight, at least 3% by weight, at least 3.3% by weight, at least 3.5% by weight, at least 3.7% by weight, at least 3.9% by weight, at least 4% by weight, at least 4.1% by weight, at least 4.3% by weight, at least 4.5% by weight, at least 4.7% by weight, at least 4.9% by weight, at least 5% by weight, at least 6% by weight, at least 7% by weight, at least 9% by weight, at least 10% by weight, at least 12% by weight, at least 15% by weight, at least 17% by weight, at least 19% by weight, at least 20% by weight, at least 22% by weight, at least 25% by weight, at least 28% by weight, or at least 30% by weight c / b It may include the content of ceramic particles W. c / bThis refers to less than 50% by weight, for example, maximum 45% by weight, maximum 43% by weight, maximum 41% by weight, maximum 39% by weight, maximum 37% by weight, maximum 35% by weight, maximum 33% by weight, maximum 31% by weight, maximum 28% by weight, maximum 26% by weight, maximum 24% by weight, maximum 22% by weight, maximum 20% by weight, maximum 18% by weight, maximum 17% by weight, maximum 15% by weight, maximum 13% by weight, maximum 11% by weight, maximum 10% by weight, maximum 9.7% by weight, maximum 9.5% by weight, maximum 9.4% by weight, maximum 9.2% by weight, maximum 9% by weight, maximum 8.8% by weight, maximum 8.6% by weight, maximum 8.3% by weight, maximum 8% by weight, maximum 7.9% by weight The possible amounts are: 1% by weight, up to 7.7% by weight, up to 7.5% by weight, up to 7.3% by weight, up to 7% by weight, up to 6.9% by weight, up to 6.7% by weight, up to 6.6% by weight, up to 6.4% by weight, up to 6.2% by weight, up to 6% by weight, up to 5.8% by weight, up to 5.6% by weight, up to 5.4% by weight, up to 5.2% by weight, up to 5% by weight, up to 4.8% by weight, up to 4.6% by weight, up to 4.1% by weight, up to 3.9% by weight, up to 3.5% by weight, up to 3.3% by weight, up to 3% by weight, up to 2.7% by weight, up to 2.5% by weight, up to 2.2% by weight, up to 2% by weight, up to 1.5% by weight, or up to 1% by weight. Furthermore, the ceramic particle content W c / b This may be within a range that includes either the minimum or maximum percentages specified herein.

[0093] In a further embodiment, the body has a specific content V of ceramic particles c / b It may include, when used herein, the volume percentage V of ceramic particles contained in the bonding material. c / b is, equation V c / b =[V cm / (V cm +V bm It can be calculated using ) × 100%, where V cm V is the volume of the ceramic particles. bm V is the volume of the bonding material in the polished body. In one embodiment, the content of ceramic particles is V. c / bThis can be at least 1 volume%, for example, at least 1.3 volume%, at least 1.5 volume%, at least 1.8 volume%, at least 2 volume%, at least 2.2%, at least 2.5 volume%, at least 2.7 volume%, at least 3 volume%, at least 3.3 volume%, at least 3.5 volume%, at least 3.7 volume%, at least 3.9 volume%, at least 4 volume%, at least 4.1 volume%, at least 4.3 volume%, at least 4.5 volume%, at least 4.7 volume%, at least 4.9 volume%, at least 5 volume%, at least 6 volume%, or at least 7 volume%. In another embodiment, the content of ceramic particles V c / b This can be up to 15 volume%, for example, up to 12 volume%, up to 11 volume%, or up to 10 volume%. In certain embodiments, the content of ceramic particles V c / b This can be less than 10 volume%, for example, a maximum of 9.7 volume%, 9.5 volume%, 9.4 volume%, 9.2 volume%, 9 volume%, 8.8 volume%, 8.6 volume%, 8.3 volume%, 8 volume%, 7.9 volume%, 7.7 volume%, 7.5 volume%, 7.3 volume%, 7 volume%, 6.9 volume%, 6.7 volume%, 6.6 volume%, 6.4 volume%, 6.2 volume%, 6 volume%, 5.8 volume%, 5.6 volume%, 5.4 volume%, 5.2 volume%, 5 volume%, 4.8 volume%, 4.6 volume%, 4.3 volume%, or a maximum of 4 volume%. Furthermore, ceramic particles V c / b The content may be within the range of either the minimum or maximum percentages specified herein.

[0094] As used herein, particle size is intended to refer to the principal dimension (i.e., length) of a particle. For example, an abrasive may include ceramic particles having an average length having the values ​​described with respect to the ceramic particle sizes described herein. Length may be understood to be the diameter of the particle if the particle is spherical. In this disclosure, the particle sizes (e.g., D50, D10, and D90) of abrasive and ceramic particles in an abrasive can be determined by measuring the size of all particles in at least seven images of the cross-section of the abrasive to a statistically significant extent. To determine the particle size, Image Pro Plus version 6.2 from Media Cybernetics or other software with equivalent functionality can be used.

[0095] 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 illustrative and do not limit the scope of the invention. Embodiments may follow one or more of the embodiments listed below.

[0096] Embodiment Embodiment 1. An abrasive product comprising a main body, The aforementioned main body, A bonding material extending through at least a portion of the main body, The abrasive particles contained in the main body, having an average particle size (D50a) of at least 100 microns, The ceramic particles contained in the bonding material, having an average particle size (D50c) exceeding 12 microns and a maximum of 75 microns, Abrasive products, including those containing abrasive materials.

[0097] Embodiment 2. An abrasive product comprising a main body, The aforementioned main body, A bonding material having a vitreous phase, The abrasive particles contained in the main body include abrasive particles having an average abrasive particle size (D50a), ceramic particles contained in the bond material, the ceramic particles having an average particle size (D50c); and comprising: the abrasive product, wherein the bond material has an average size after bonding (Sbp), and D50c ≤ Sbp < D50a.

[0098] Embodiment 3. An abrasive product comprising a body, wherein: the body comprises: a bond material comprising a vitreous phase; abrasive particles contained in the body, the abrasive particles having an average abrasive particle size (D50a); and ceramic particles contained in the bond material, the ceramic particles having an average particle size (D50c); and comprising: wherein D50c < D50a, and the abrasive product, wherein the bond material has an average Vickers hardness of at least 5.70 GPa.

[0099] Embodiment 4. An abrasive product comprising a body, wherein: the body comprises: a bond material comprising a vitreous phase; abrasive particles contained in the body, the abrasive particles having an average abrasive particle size (D50a); and ceramic particles contained in the bond material, the ceramic particles having an average particle size (D50c); and comprising: wherein D50c < D50a, and the abrasive product, wherein the body has an average MOR of at least 38 MPa.

[0100] Embodiment 5. An abrasive product comprising a body, wherein: the body comprises: a bond material comprising a vitreous phase; abrasive particles contained in the body and having an average abrasive particle size (D50a); and pores surrounded by ceramic particles contained in the bond material; and comprising: An abrasive product, wherein the ceramic particles have an average particle diameter (D50c), and D50c < D50a.

[0101] Embodiment 6. The abrasive product according to Embodiment 1, wherein the bond material comprises a vitreous phase.

[0102] Embodiment 7. The abrasive product according to any one of Embodiments 1 to 6, wherein the bond material is essentially free of organic materials.

[0103] Embodiment 8. The abrasive product according to any one of Embodiments 1 to 7, wherein the ceramic particles have an average particle diameter (D50c) of greater than 12 microns, at least 13 microns, at least 14 microns, at least 15 microns, at least 16 microns, at least 17 microns, at least 18 microns, at least 19 microns, at least 20 microns, at least 21 microns, at least 22 microns, at least 23 microns, at least 24 microns, at least 25 microns, at least 26 microns, at least 37 microns, at least 38 microns, at least 39 microns, at least 40 microns, at least 41 microns, at least 42 microns, at least 43 microns, at least 44 microns, at least 45 microns, at least 46 microns, at least 47 microns, at least 48 microns, at least 49 microns, at least 50 microns, at least 51 microns, at least 52 microns, at least 53 microns, at least 54 microns, at least 55 microns, at least 56 microns, at least 57 microns, at least 58 microns, at least 59 microns, at least 60 microns, at least 61 microns, at least 62 microns, at least 63 microns, at least 64 microns, at least 65 microns, at least 66 microns, at least 67 microns, at least 68 microns, at least 69 microns, or at least 70 microns.

[0104] Embodiment 9. The ceramic particles are up to 75 microns, up to 74 microns, up to 73 microns, up to 72 microns, up to 71 microns, up to 70 microns, up to 69 microns, up to 68 microns, up to 67 microns, up to 66 microns, up to 65 microns, up to 64 microns, up to 63 microns, up to 62 microns, up to 61 microns, up to 60 microns, up to 59 microns, up to 58 microns, up to 57 microns, up to 56 microns, up to 55 microns, up to 54 microns, up to 53 microns, up to 52 microns, up to 51 microns, up to 50 microns, up to 49 microns, up to 48 microns, up to 4 An abrasive product according to any one of Embodiments 1 to 8, having an average particle size (D50c) of 7 microns, up to 46 microns, up to 45 microns, up to 44 microns, up to 43 microns, up to 42 microns, up to 41 microns, up to 40 microns, up to 39 microns, up to 38 microns, up to 37 microns, up to 36 microns, up to 35 microns, up to 34 microns, up to 33 microns, up to 32 microns, up to 31 microns, up to 30 microns, up to 29 microns, up to 28 microns, up to 27 microns, up to 26 microns, up to 25 microns, up to 24 microns, up to 23 microns, or up to 22 microns.

[0105] Embodiment 10. An abrasive product according to any one of Embodiments 1 to 9, wherein the ceramic particles have an average particle size (D50c) in the range of at least 6 to 80 microns, 6 to 69 microns, greater than 12 microns to 75 microns, 13 to 70 microns, 15 to 55 microns, 17 to 45 microns, 20 to 42 microns, or 22 to 38 microns.

[0106] Embodiment 11. The body comprises at least 4, at least 4.2, at least 4.5, at least 4.8, at least 5, at least 5.2, at least 5.4, at least 5.6, at least 5.9, at least 6.2, at least 6.5, at least 6.8, at least 7, at least 7.2, at least 7.6, at least 8, at least 8.2, at least 8.5, at least 8.8, at least 9, at least 9.2, at least 9.5, at least 9.7, at least 9.9, and at least 10.1, at least 10.5, at least 10.8, at least 10.9, at least 11, at least 11.1, at least 11.2, at least 11.5, at least 11.7, at least 11.9, at least 12.1, at least 12.3, at least 12.7, at least 13, at least 13.2, at least 13.4, at least 13.6, at least 13.9, at least 14, at least 14.2, at least 14.3, at least 14.5, at least 14.7, at least (at (at last) 14.9, at least 15, at least 15.2, at least 15.3, at least 15.5, at least 15.7, at least 16, at least 16.2, at least 16.4, at least 16.6, at least 16.9, at least 17, at least 17.2, at least 17.3, at least 17.5, at least 17.7, at least (at last) 17.9, at least 18, at least 18.2, at least 18.3, at least 18.5, at least 18.7, at least 19, at least 19.2, at least 19.4, at least 19.6, at least 19.9, at least 20, at least 20.2, at least 20.4, at least 20.5, at least 20.7, at least (at (p) 21, at least 21.5, at least 21.7, at least 21.9, at least 22, at least 22.3, at least 22.5, at least 22.8, at least 23, at least 23.2, at least 23.6, at least 24, at least 24.2, at least 24.5, at least 24.7, at least 25, at least 25.3, at least 25.5, at least 25.7, at least 26, at least 26.2, at least 26.4, at least 26.6, at least 26.9, at least 27, at least 27.2, at least 27.3, at least 27.5, at least 27.7, at least (at last) 27.9, at least 28.1, at least 28.2, at least 28.5, at least 28.7, at least 29, at least 29.1, at least 29.4, at least 29.6, at least 29.8, at least 30, at least 30.2, at least 30.4, at least 30.5, at least 30.7, at least (at last) 30.9, at least 31, at least 31.2, at least 31.3, at least 31.5, at least 31.7, at least 31.9, at least 32, at least 32.2, at least 32.4, at least 32.7, at least 33, at least 33.4, at least 33.6, at least 33.9, at least 34, at least 34.2, at least 34.5, at least 34.7, at least (at last) 34.9, at least 35, at least 35.2, at least 35.5, at least 35.8, at least 36, at least 36.2, at least 36.5, at least 36.7, at least 37, at least 37.2, at least 37.4, at least 37.6, at least 37.9, at least 38, at least 38.3, at least 38.5, at least 38.7, at least (at last) 39, at least 39.3, at least 39.5, at least 39.7, at least 40, at least 40.2, at least 40.5, at least 40.7, at least 41, at least 41.2, at least 41.4, at least 41.6, at least 41.9, at least 42, at least 42.3, at least 42.5, at least 42.7, at least (at (at last) 42.9, at least 43, at least 43.2, at least 42.3, at least 42.5, at least 42.7, at least 43, at least 43.2, at least 43.4, at least 43.6, at least 43.9, at least 44, at least 44.2, at least 44.3, at least 44.5, at least 44.7, at least (at last) 44.An abrasive product according to any one of Embodiments 1 to 10, comprising a ratio D50a / D50c of the average particle size (D50a) of the abrasive particles to the average particle size (D50c) of the ceramic particles, of 9 or at least 45.

[0107] Embodiment 12. The main body has a maximum length of 35, 34.8, 34.5, 34.2, 34, 33.8, 33.5, 33.2, 33, 32.7, 32.5, 32.1, 31.8, 31.5, 31, 30.5, 30, 29.6, 29.3, 29, 28.6, 28.3, 28, and 27. .6, max 27.3, max 27, max 26.6, max 26.3, max 26, max 25.7, max 25.3, max 25, max 24.8, max 24.5, max 24.2, max 24, max 2 3.7, max 23.4 max 23, max 22.8, max 22.5, max 22.1, max 21.8, max 21.5, max 21, max 20.5, max 20, max 19.6, max 19.3, max Large 19, Max 18.8, Max 18.6, Max 18.3, Max 18, Max 17.6, Max 17.2, Max 17, Max 16.6, Max 16.3, Max 16, Max 15.7, Max 15.3, Max 15, Max 14.8, Max 14.5, Max 14.2, Max 14, Max 13.7, Max 13.5, Max 13.3, Max 13, Max 12.5, Max 12.3, Max 12, Max 11.8 An abrasive product according to any one of Embodiments 1 to 11, comprising a ratio D50a / D50c of the average particle size (D50a) of the abrasive particles to the average particle size (D50c) of the ceramic particles, up to 11.5, up to 11.3, up to 11, up to 10.9, up to 10.7, up to 10.6, up to 10.3, up to 10, up to 9.8, up to 9.6, up to 9.5, up to 9.2, or up to 9.

[0108] Embodiment 13: The abrasive product according to any one of Embodiments 1 to 12, wherein the ceramic particles include a crystalline material, an amorphous material, or a combination thereof.

[0109] Embodiment 14. The ceramic particles are at least 0.005 microns, at least 0.01 microns, at least 0.02 microns, at least 0.03 microns, at least 0.04 microns, at least 0.05 microns, at least 0.06 microns, at least 0.07 microns, at least 0.08 microns, at least 0.09 microns, at least 0.1 microns, at least 0.11 microns, at least 0.12 microns, at least 0.13 microns, at least 0.14 microns, at least 0.15 microns, at least 0.16, at least 0.17 microns, and less Abrasive product according to any one of Embodiments 1 to 13, comprising a polycrystalline material having an average crystallite size of at least 0.18 microns, at least 0.19 microns, at least 0.2 microns, at least 0.3 microns, at least 0.4 microns, at least 0.5 microns, at least 0.6, at least 0.7 microns, at least 0.8 microns, at least 0.9 microns, at least 1 micron, at least 1.3 microns, at least 1.5 microns, at least 1.8 microns, at least 2 microns, at least 3 microns, at least 4 microns, or at least 5 microns.

[0110] Embodiment 15. An abrasive product according to any one of Embodiments 1 to 14, wherein the ceramic particles include a polycrystalline material having an average crystallite size of up to 75 microns, up to 60 microns, up to 50 microns, up to 40 microns, up to 30 microns, up to 20 microns, up to 10 microns, up to 9 microns, up to 8 microns, up to 7 microns, up to 6 microns, up to 5 microns, up to 4 microns, up to 3 microns, up to 2 microns, up to 1.5 microns, up to 1 micron, up to 0.9 microns, up to 0.8 microns, up to 0.7 microns, up to 0.6 microns, up to 0.5 microns, up to 0.4 microns, up to 0.3 microns, up to 0.2 microns, up to 0.1 microns, up to 0.09 microns, up to 0.08 microns, up to 0.07 microns, up to 0.06 microns, up to 0.05 microns, up to 0.04 microns, up to 0.03 microns, up to 0.02 microns, or up to 0.01 microns.

[0111] Embodiment 16. An abrasive product according to any one of Embodiments 1 to 15, wherein the ceramic particles include oxides, carbides, nitrides, borides, oxycarbides, oxynitrides, silicates, or any combination thereof.

[0112] Embodiment 17. An abrasive product according to any one of Embodiments 1 to 16, wherein the ceramic particles include silicon dioxide, silicon carbide, alumina, zirconia, rare earth-containing materials, cerium oxide, sol-gel derived particles, iron oxide, glass-containing particles, and combinations thereof.

[0113] Embodiment 18. The abrasive product according to any one of Embodiments 1 to 17, wherein the ceramic particles contain alumina.

[0114] Embodiment 19. The abrasive product according to any one of Embodiments 1 to 18, wherein the ceramic particles include fused alumina, sol-gel alumina, microcrystalline alumina, nanocrystalline alumina, or any combination thereof.

[0115] Embodiment 20. The abrasive product according to any one of Embodiments 1 to 19, wherein the ceramic particles contain fused alumina.

[0116] Embodiment 21. An abrasive product according to any one of Embodiments 1 to 20, wherein the ceramic particles are essentially made from fused alumina.

[0117] Embodiment 22. An abrasive product according to any one of Embodiments 1 to 21, wherein the ceramic particles essentially consist of white fused alumina.

[0118] Embodiment 23. An abrasive product according to any one of Embodiments 1 to 22, wherein the ceramic particles are essentially made of alpha alumina.

[0119] Embodiment 24. An abrasive product according to any one of Embodiments 1 to 23, wherein the ceramic particles have a Mohs hardness of at least 5.5, at least 6, at least 6.5, at least 7, at least 7.5, at least 8, at least 8.5, or at least 9.

[0120] Embodiment 25. An abrasive product according to any one of Embodiments 1 to 24, wherein the ceramic particles have a Mohs hardness of up to 10, up to 9.5, up to 9, up to 8.5, up to 8, up to 7.5, or up to 7.

[0121] Embodiment 26. An abrasive product according to any one of Embodiments 1 to 25, wherein the ceramic particles have a particle size distribution including D10 of at least 3 microns, at least 5 microns, at least 5.5 microns, at least 6 microns, at least 6.5 microns, at least 7 microns, at least 7.5 microns, at least 8 microns, at least 8 microns, at least 8.3 microns, at least 8.5 microns, at least 8.8 microns, at least 9 microns, at least 9.2 microns, at least 9.4 microns, at least 9.6 microns, at least 9.8 microns, at least 10 microns, at least 10.5 microns, at least 10.8 microns, at least 11 microns, at least 11.3 microns, at least 11.5 microns, at least 11.8 microns, or at least 12 microns.

[0122] Embodiment 27. An abrasive product according to any one of Embodiments 1 to 26, wherein the ceramic particles have a particle size distribution including D10 of up to 38 microns, up to 35 microns, up to 33 microns, up to 31 microns, up to 30 microns, up to 28 microns, up to 27 microns, up to 25 microns, up to 23 microns, up to 20 microns, up to 18 microns, up to 16 microns, up to 14 microns, or up to 13 microns.

[0123] Embodiment 28. An abrasive product according to any one of Embodiments 1 to 27, wherein the ceramic particles have a particle size distribution including D90 of at least 15 microns, at least 17 microns, at least 19 microns, at least 20 microns, at least 22 microns, at least 23 microns, at least 24 microns, at least 27 microns, at least 29 microns, at least 30 microns, at least 31 microns, at least 33 microns, at least 35 microns, at least 37 microns, at least 38 microns, at least 40 microns, at least 41 microns, or at least 42 microns.

[0124] Embodiment 29. An abrasive product according to any one of Embodiments 1 to 28, wherein the ceramic particles have a particle size distribution including D90 of up to 120 microns, up to 110 microns, up to 100 microns, up to 90 microns, up to 88 microns, up to 85 microns, up to 83 microns, up to 80 microns, up to 78 microns, up to 76 microns, up to 74 microns, up to 72 microns, up to 70 microns, up to 68 microns, up to 66 microns, up to 64 microns, up to 62 microns, up to 60 microns, up to 58 microns, up to 56 microns, up to 54 microns, up to 52 microns, up to 50 microns, up to 48 microns, up to 46 microns, up to 45 microns, up to 44 microns, or up to 43 microns.

[0125] Embodiment 30. An abrasive product according to any one of Embodiments 1 to 29, wherein the abrasive particles have an average particle size (D50a) of at least 120 microns, at least 140 microns, at least 150 microns, at least 170 microns, at least 180 microns, at least 200 microns, at least 210 microns, at least 230 microns, at least 250 microns, at least 260 microns, at least 270 microns, at least 290 microns, at least 300 microns, at least 320 microns, at least 340 microns, at least 350 microns, at least 360 microns, at least 380 microns, at least 400 microns, at least 420 microns, at least 430 microns, at least 440 microns, at least 450 microns, at least 460 microns, at least 470 microns, at least 490 microns, or at least 500 microns.

[0126] Embodiment 31. An abrasive product according to any one of Embodiments 1 to 30, wherein the abrasive particles have an average particle size (D50a) of a maximum of 1.9 mm, a maximum of 1.8 mm, a maximum of 1.6 mm, a maximum of 1.5 mm, a maximum of 1.2 mm, a maximum of 1 mm, a maximum of 900 microns, a maximum of 850 microns, a maximum of 830 microns, a maximum of 800 microns, a maximum of 750 microns, a maximum of 700 microns, a maximum of 650 microns, a maximum of 600 microns, a maximum of 550 microns, a maximum of 500 microns, a maximum of 450 microns, a maximum of 400 microns, a maximum of 380 microns, a maximum of 350 microns, a maximum of 320 microns, a maximum of 300 microns, a maximum of 280 microns, a maximum of 260 microns, or a maximum of 255 microns.

[0127] Embodiment 32. An abrasive product according to any one of Embodiments 1 to 31, wherein the abrasive particles have a particle size distribution including D10 of at least 60 microns, at least 65 microns, at least 70 microns, at least 75 microns, at least 80 microns, at least 85 microns, at least 90 microns, at least 95 microns, at least 100 microns, at least 110 microns, at least 120 microns, at least 130 microns, at least 135 microns, at least 140 microns, at least 145 microns, at least 150 microns, at least 155 microns, at least 160 microns, or at least 165 microns.

[0128] Embodiment 33. An abrasive product according to any one of Embodiments 1 to 32, wherein the embodiment of the abrasive particles has a particle size distribution including D10 of up to 1 mm, up to 900 microns, up to 850 microns, up to 830 microns, up to 800 microns, up to 750 microns, up to 700 microns, up to 650 microns, up to 600 microns, up to 550 microns, up to 500 microns, up to 450 microns, up to 400 microns, up to 380 microns, up to 350 microns, up to 320 microns, up to 300 microns, up to 280 microns, up to 260 microns, up to 250 microns, up to 240 microns, up to 220 microns, up to 210 microns, up to 200 microns, or up to 170 microns.

[0129] Embodiment 34. An abrasive product according to any one of Embodiments 1 to 33, wherein the abrasive particles have a particle size distribution including D90 of at least 150 microns, at least 170 microns, at least 190 microns, at least 200 microns, at least 220 microns, at least 240 microns, at least 250 microns, at least 260 microns, at least 270 microns, at least 280 microns, at least 300 microns, at least 310 microns, at least 320 microns, at least 340 microns, at least 350 microns, at least 360 microns, or at least 370 microns.

[0130] Embodiment 35. An abrasive product according to any one of Embodiments 1 to 34, wherein the abrasive particles have a particle size distribution including D90 of up to 2.2 mm, up to 2 mm, up to 1 mm, up to 900 microns, up to 870 microns, up to 850 microns, up to 820 microns, up to 780 microns, up to 750 microns, up to 730 microns, up to 700 microns, up to 670 microns, up to 640 microns, up to 610 microns, up to 580 microns, up to 530 microns, up to 500 microns, up to 470 microns, up to 450 microns, up to 330 microns, up to 410 microns, up to 390 microns, or up to 370 microns.

[0131] Embodiment 36. An abrasive product according to any one of Embodiments 1 to 35, wherein the bonding material includes a ceramic material, an amorphous material, or a combination thereof.

[0132] Embodiment 37. An abrasive product according to any one of Embodiments 1 to 36, wherein the bonding material contains up to 30% by weight, up to 28% by weight, up to 26% by weight, up to 24% by weight, or up to 22% by weight of boron oxide (B2O3) relative to the total weight of the bonding material.

[0133] Embodiment 38. An abrasive product according to any one of Embodiments 1 to 37, wherein the bonding material contains at least 5% by weight, at least 8% by weight, at least 10% by weight, at least 12% by weight, or at least 15% by weight of boron oxide (B2O3) based on the total weight of the bonding material.

[0134] Embodiment 39. An abrasive product according to any one of Embodiments 1 to 38, wherein the bonding material contains up to 80% by weight, up to 75% by weight, up to 70% by weight, up to 69% by weight, up to 66% by weight, up to 65% by weight, up to 60% by weight, up to 55% by weight, up to 52% by weight, or up to 50% by weight of silicon dioxide (SiO2) based on the total weight of the bonding material.

[0135] Embodiment 40. An abrasive product according to any one of Embodiments 1 to 39, wherein the bonding material contains at least 25% by weight, at least 35% by weight, at least 38% by weight, or at least 40% by weight of silicon dioxide (SiO2) relative to the total weight of the bonding material.

[0136] Embodiment 41. An abrasive product according to any one of Embodiments 1 to 40, wherein the bond comprises boron oxide (B2O3) and silicon oxide (SiO2), and the total content of boron oxide and silicon oxide is up to 80% by weight, up to 77% by weight, up to 75% by weight, up to 73% by weight, up to 70% by weight, up to 70% by weight, or up to 65% by weight.

[0137] Embodiment 42. An abrasive product according to any one of Embodiments 1 to 41, wherein the bond comprises boron oxide (B2O3) and silicon dioxide (SiO2), and the total content of boron oxide and silicon dioxide is at least 40% by weight, at least 42% by weight, at least 46% by weight, at least 48% by weight, or at least 50% by weight.

[0138] Embodiment 43. An abrasive product according to any one of Embodiments 1 to 42, wherein the bonding material has a weight percent silicon dioxide (SiO2):weight percent boron oxide (B2O3) ratio of up to 7:1, up to 6.5:1, up to 6:1, up to 5.5:1, up to 5.2:1, up to 5:1, or up to 4.8:1.

[0139] Embodiment 44. An abrasive product according to any one of Embodiments 1 to 43, wherein the bonding material has a weight percent silicon dioxide (SiO2):weight percent boron oxide (B2O3) ratio of at least 1.3:1, at least 1.5:1, at least 1.7:1, at least 2.0:1, at least 2.2:1, at least 2.4:1, at least 2.6:1, at least 2.8:1, or at least 3:1.

[0140] Embodiment 45. The abrasive product according to any one of Embodiments 1 to 44, wherein the bond comprises at least 8% by weight, at least 9% by weight, at least 10% by weight, at least 12% by weight, or at least 14% by weight of aluminum oxide (Al2O3) based on the total weight of the bond material.

[0141] Embodiment 46. An abrasive product according to any one of Embodiments 1 to 45, wherein the bond contains up to 30% by weight, up to 28% by weight, up to 25% by weight, up to 23% by weight, or up to 20% by weight of aluminum oxide (Al2O3) relative to the total weight of the bond material.

[0142] Embodiment 47. An abrasive product according to any one of Embodiments 1 to 46, wherein the bond comprises aluminum oxide (Al2O3) and silicon oxide (SiO2), and the total content of aluminum oxide and silicon oxide is at least 50% by weight, at least 52% by weight, at least 56% by weight, at least 58% by weight, or at least 60% by weight relative to the total weight of the bond material.

[0143] Embodiment 48. An abrasive product according to any one of Embodiments 1 to 47, wherein the bond comprises aluminum oxide (Al2O3) and silicon dioxide (SiO2), and the total content of aluminum oxide and silicon dioxide is up to 80% by weight, up to 77% by weight, up to 75% by weight, or up to 73% by weight relative to the total weight of the bond material.

[0144] Embodiment 49. An abrasive product according to any one of Embodiments 1 to 48, wherein the bonding material has a weight percent silicon dioxide (SiO2):weight percent aluminum oxide (Al2O3) ratio of up to 5.5:1, up to 5:1, up to 4.5:1, up to 4.1, up to 3.5:1, up to 3.1, up to 2.5:1, up to 2.2:1, or up to 2:1.

[0145] Embodiment 50. An abrasive product according to any one of Embodiments 1 to 49, wherein the bonding material comprises a weight percent silicon dioxide (SiO2) to weight percent aluminum oxide (Al2O3) ratio of at least 1.3:1, at least 1.5:1, at least 1.7:1, or at least 2:1.

[0146] Embodiment 51. An abrasive product according to any one of Embodiments 1 to 50, wherein the bonding material comprises a polycrystalline phase containing zircon (ZrSiO4).

[0147] Embodiment 52. An abrasive product according to any one of Embodiments 1 to 51, wherein the bonding material contains at least 15% by weight, at least 17% by weight, at least 19% by weight, at least 20% by weight, at least 21% by weight, at least 22% by weight, at least 23% by weight, or at least 24% by weight of zircon relative to the total weight of the bonding material.

[0148] Embodiment 53. An abrasive product according to any one of Embodiments 1 to 52, wherein the bonding material contains up to 44% by weight, up to 42% by weight, up to 40% by weight, up to 38% by weight, up to 36% by weight, up to 35% by weight, up to 34% by weight, up to 33% by weight, or up to 32% by weight of zircon.

[0149] Embodiment 54. An abrasive product according to any one of Embodiments 1 to 53, wherein the bond does not essentially contain zircon (ZrSiO4).

[0150] Embodiment 55. An abrasive product according to any one of Embodiments 1 to 54, wherein the bonding material comprises at least one alkaline earth oxide compound (RO), and the total content of the alkaline earth oxide compound (RO) is up to 6% by weight, up to 5% by weight, up to 4% by weight, up to 3.0% by weight, up to 2.5% by weight, or up to 2% by weight relative to the total weight of the bonding material.

[0151] Embodiment 56. The abrasive product according to any one of Embodiments 1 to 55, wherein the bonding material comprises at least one alkaline earth oxide compound (RO), and the total content of the alkaline earth oxide compound (RO) is at least 0.5% by weight or at least 0.8% by weight.

[0152] Embodiment 57. An abrasive product according to any one of Embodiments 1 to 56, wherein the bonding material comprises up to three different alkaline earth oxide compounds (RO) selected from the group consisting of calcium oxide (CaO), magnesium oxide (MgO), barium oxide (BaO), and strontium oxide (SrO).

[0153] Embodiment 58. An abrasive product according to any one of Embodiments 1 to 57, wherein the bonding material contains at least 0.5% by weight, at least 0.8% by weight, or at least 1% by weight of calcium oxide (CaO) relative to the total weight of the bonding material.

[0154] Embodiment 59. An abrasive product according to any one of Embodiments 1 to 58, wherein the bonding material is essentially free of calcium oxide (CaO).

[0155] Embodiment 60. An abrasive product according to any one of Embodiments 1 to 59, wherein the bonding material contains 3% by weight or less, 2.8% by weight or less, or 2.5% by weight or less, 2% by weight or less, or 1.7% by weight or less of calcium oxide (CaO) relative to the total weight of the bonding material.

[0156] Embodiment 61. An abrasive product according to any one of Embodiments 1 to 60, wherein the bonding material comprises an alkali oxide compound (R2O) selected from the group consisting of lithium oxide (Li2O), sodium oxide (Na2O), potassium oxide (K2O), and cesium oxide (Cs2O), and combinations thereof.

[0157] Embodiment 62. The abrasive product according to any one of Embodiments 1 to 61, wherein the bonding material comprises at least one alkali oxide compound (R2O), and the total content of the alkali oxide compound (RO) is up to 25% by weight, or up to 22% by weight, or up to 20% by weight.

[0158] Embodiment 63. The abrasive product according to any one of Embodiments 1 to 62, wherein the bonding material comprises at least one alkali oxide compound (R2O), and the total content of the alkali oxide compound (R2O) is at least 3% by weight, at least 5% by weight, at least 7% by weight, or at least 9% by weight.

[0159] Embodiment 64. An abrasive product according to any one of Embodiments 1 to 63, wherein the bonding material contains at least 1% by weight, at least 1.5% by weight, or at least 2% by weight of lithium oxide (Li2O) relative to the total weight of the bonding material.

[0160] Embodiment 65. An abrasive product according to any one of Embodiments 1 to 64, wherein the bonding material is essentially free of lithium oxide (Li2O).

[0161] Embodiment 66. An abrasive product according to any one of Embodiments 1 to 65, wherein the bonding material contains up to 7% by weight, up to 6.5% by weight, up to 6% by weight, up to 5.5% by weight, or up to 5% by weight of lithium oxide (Li2O) relative to the total weight of the bonding material.

[0162] Embodiment 67. An abrasive product according to any one of Embodiments 1 to 66, wherein the bonding material contains at least 3% by weight, at least 4% by weight, or at least 5% by weight of sodium oxide (Na2O) relative to the total weight of the bonding material.

[0163] Embodiment 68. An abrasive product according to any one of Embodiments 1 to 67, wherein the bonding material contains up to 15% by weight, up to 14% by weight, up to 13% by weight, up to 12% by weight, up to 11% by weight, or up to 10% by weight of sodium oxide (Na2O) relative to the total weight of the bonding material.

[0164] Embodiment 69. An abrasive product according to any one of Embodiments 1 to 68, wherein the bonding material contains at least 1% by weight, at least 1.5% by weight, or at least 2% by weight of potassium oxide (K2O) relative to the total weight of the bonding material.

[0165] Embodiment 70. The bonding material is an abrasive product according to any one of Embodiments 1 to 69, wherein the bonding material is at least 15% by weight, up to 13% by weight, up to 11% by weight, up to 10% by weight, up to 8% by weight, up to 7% by weight, up to 6.5% by weight, up to 6% by weight, or up to 5.5% by weight, or up to 5% by weight of potassium oxide (K2O) relative to the total weight of the bonding material.

[0166] Embodiment 71. An abrasive product according to any one of Embodiments 1 to 70, wherein the bonding material contains up to 3.0% by weight of phosphorus oxide (P2O5), or the bonding material is essentially free of phosphorus oxide (P2O5).

[0167] Embodiment 72. An abrasive product according to any one of Embodiments 1 to 71, wherein the bonding material comprises a composition that essentially does not contain an oxide compound selected from the group consisting of TiO2, Fe2O3, MnO2, ZrSiO2, and CoAl2O4.

[0168] Embodiment 73. An abrasive product according to any one of Embodiments 1 to 72, wherein the bonding material has a forming temperature of up to 1250°C, up to 1200°C, or up to 1175°C, or up to 1150°C, or up to 1125°C, or up to 1100°C.

[0169] Embodiment 74. The abrasive product according to any one of Embodiments 1 to 73, wherein the bonding material has a forming temperature of at least 800°C, at least 850°C, at least about 900°C, 920°C, or at least about 950°C, or at least about 975°C.

[0170] Embodiment 75. The abrasive product according to any one of Embodiments 1 to 74, wherein the abrasive product comprises a fixed abrasive product.

[0171] Embodiment 76. An abrasive product according to any one of Embodiments 1 to 75, wherein the bonding material is an embodiment m of a matrix that extends continuously through the volume of the main body.

[0172] Embodiment 77. An abrasive product according to any one of Embodiments 1 to 76, wherein the body contains, with respect to the total volume of the bond material, at least 1 volume%, at least 1.3 volume%, at least 1.5 volume%, at least 1.8 volume%, at least 2 volume%, at least 2.2%, at least 2.5 volume%, at least 2.7 volume%, at least 3 volume%, at least 3.3 volume%, at least 3.5 volume%, at least 3.7 volume%, at least 3.9 volume%, at least 4 volume%, at least 4.1 volume%, at least 4.3 volume%, at least 4.5 volume%, at least 4.7 volume%, at least 4.9 volume%, or at least 5 volume% of ceramic particles.

[0173] Embodiment 78. An abrasive product according to any one of Embodiments 1 to 77, wherein the main body contains ceramic particles in an amount of less than 10 vol%, up to 9.7 vol%, up to 9.5 vol%, up to 9.4 vol%, up to 9.2 vol%, up to 9 vol%, up to 8.8 vol%, up to 8.6 vol%, up to 8.3 vol%, up to 8 vol%, up to 7.9 vol%, up to 7.7 vol%, up to 7.5 vol%, up to 7.3 vol%, up to 7 vol%, up to 6.9 vol%, up to 6.7 vol%, up to 6.6 vol%, up to 6.4 vol%, up to 6.2 vol%, up to 6 vol%, up to 5.8 vol%, up to 5.6 vol%, up to 5.4 vol%, up to 5.2 vol%, up to 5 vol%, up to 4.8 vol%, or up to 4.6 vol%.

[0174] Embodiment 79. The abrasive product according to any one of Embodiments 1 to 78, wherein the body contains abrasive particles in an amount of at least 20 volume%, at least 25 volume%, at least 30 volume%, or at least 35 volume%, relative to the total volume of the body.

[0175] Embodiment 80. An abrasive product according to any one of Embodiments 1 to 79, wherein the body contains abrasive particles in an amount of up to 65 volume%, up to 64 volume%, or up to 62 volume%, or up to 60 volume%, or up to 58 volume%, or up to 56 volume%, or up to 54 volume%, or up to 52 volume%, or up to 50 volume%, relative to the total volume of the body.

[0176] Embodiment 81. The abrasive product according to any one of Embodiments 1 to 80, wherein the body contains at least 2 volume%, at least 4 volume%, at least 5 volume%, at least 10 volume%, and at least 20 volume% of a bonding material relative to the total volume of the body.

[0177] Embodiment 82. The abrasive product according to any one of Embodiments 1 to 81, wherein the main body contains up to 35 volume%, or up to 30 volume%, or up to 25 volume%, or up to 20 volume%.

[0178] Embodiment 83. The abrasive product according to any one of Embodiments 1 to 82, wherein the body has a porosity of at least 20 volume%, which is at least 22 volume%, at least 24 volume%, at least 26 volume%, at least 28 volume%, at least 30 volume%, at least 32 volume%, or at least 35 volume%, relative to the total volume of the body.

[0179] Embodiment 84. An abrasive product according to any one of Embodiments 1 to 83, wherein the body has a porosity of up to 75 volume%, up to 70 volume%, up to 65 volume%, up to 60 volume%, up to 55 volume%, up to 50 volume%, up to 45 volume%, or up to 40 volume% relative to the total volume of the body.

[0180] Embodiment 85. An abrasive product according to any one of Embodiments 1 to 84, wherein the main body includes a porosity of a type selected from the group consisting of closed porosity, open porosity, and combinations thereof.

[0181] Embodiment 86. An abrasive product according to any one of Embodiments 1 to 85, wherein the body has porosity, and the majority of the porosity is closed porosity, or the porosity is essentially all closed porosity.

[0182] Embodiment 87. An abrasive product according to any one of Embodiments 1 to 86, wherein the body has porosity, the majority of the porosity is closed porosity, and essentially all of the porosity is closed porosity.

[0183] Embodiment 88. An abrasive product according to any one of Embodiments 1 to 350, wherein the main body has a porosity having an average pore diameter of up to 1.9 mm, up to 1.5 mm, up to 1 mm, up to 900 microns, up to 800 microns, up to 700 microns, up to 600 microns, up to 500 microns, up to 450 microns, up to 400 microns, up to 87 microns, up to 300 microns, up to 250 microns, up to 200 microns, up to 150 microns, or up to 100 microns.

[0184] Embodiment 89. An abrasive product according to any one of Embodiments 1 to 88, wherein the body has a porosity having an average pore diameter of at least 0.1 microns, at least 1 micron, at least 5 microns, at least 8 microns, at least 10 microns, at least 14 microns, at least 16 microns, at least 25 microns, at least 50 microns, at least 100 microns, at least 150 microns, or at least 200 microns.

[0185] Embodiment 90. An abrasive product according to any one of Embodiments 1 to 89, wherein the abrasive particles comprise a blend comprising a first type of abrasive particles and a second type of abrasive particles, and the first type and the second type comprise at least one material selected from the group consisting of oxides, carbides, nitrides, borides, oxycarbides, oxynitrides, superabrasives, and carbon-based materials.

[0186] Embodiment 91. An abrasive product according to any one of Embodiments 1 to 90, wherein the abrasive particles include non-aggregated particles, aggregated particles, molded abrasive particles, unmolded abrasive particles, or any combination thereof.

[0187] Embodiment 92. The abrasive product according to Embodiment 91, wherein the molded abrasive particles have a two-dimensional shape selected from the group consisting of regular polygons, irregular polygons, irregular shapes, triangles, partially concave triangles, quadrilaterals, rectangles, trapezoids, pentagons, hexagons, heptagons, octagons, ellipses, Greek letters, Latin letters, Russian letters, and combinations thereof.

[0188] Embodiment 93. The abrasive product according to Embodiment 91, wherein the molded abrasive particles have a three-dimensional shape selected from the group consisting of polyhedra, pyramidal bodies, ellipsoids, spheres, prisms, cylinders, cones, tetrahedra, cubes, rectangular prisms, rhombohedrons, truncated ellipsoids, truncated spheres, truncated cones, pentahedrons, hexahedrons, heptahedrons, octahedrons, non-polyhedra, decahedrons, Greek letters, Latin letters, Russian letters, Chinese characters, compound polygons, irregular shapes, volcanic shapes, monostatic shapes, and combinations thereof, and the monostatic shape is a shape having a single stable resting position.

[0189] Embodiment 94. The abrasive product of Embodiment 93, wherein the molded abrasive particles have a triangular two-dimensional shape.

[0190] Embodiment 95. The abrasive product of Embodiment 91, wherein the molded abrasive particles have a partially concave triangular two-dimensional shape.

[0191] Embodiment 96. An abrasive product according to any one of Embodiments 91 to 95, wherein the molded abrasive particles include a body having a body length (Lb), a body width (Wb), and a body thickness (Tb), and Lb > Wb, Lb > Tb, and Wb > Tb.

[0192] Embodiment 97. The abrasive product of Embodiment 96, wherein the body has a primary aspect ratio (Lb:Wb) of at least about 1:1, at least about 2:1, at least about 3:1, at least about 5:1, at least about 10:1 and up to 1000:1.

[0193] Embodiment 98. The abrasive product according to Embodiment 96 or 97, wherein the body has a secondary aspect ratio (Lb:Tb) of at least about 1:1, at least about 2:1, at least about 3:1, at least about 5:1, at least about 10:1 and up to 1000:1.

[0194] Embodiment 99. An abrasive product according to any one of Embodiments 96 to 98, wherein the body has a tertiary aspect ratio (Wb:Tb) of at least about 1:1, at least about 2:1, at least about 3:1, at least about 5:1, at least about 10:1 and up to 1000:1.

[0195] Embodiment 100. An abrasive product according to any one of Embodiments 96 to 99, wherein at least one of the body length (Lb), body width (Wb), and body thickness (Tb) has an average dimension of at least 0.1 microns, or at least 1 micron, or at least 10 microns, or at least 50 microns, or at least 100 microns, or at least 150 microns, or at least 200 microns, or at least 400 microns, or at least 600 microns, or at least 800 microns, or at least 1 mm, and a maximum of 20 mm, or at least 18 mm, or at least 16 mm, or at least 14 mm, or at least 12 mm, or at least 10 mm, or at least 8 mm, or at least 6 mm, or at least 4 mm.

[0196] Embodiment 101. An abrasive product according to any one of Embodiments 96 to 100, wherein the body has a cross-sectional shape in a plane defined by the length and width of the body, selected from the group consisting of triangles, quadrilaterals, rectangles, trapezoids, pentagons, hexagons, heptagons, octagons, ellipses, Greek letters, Latin letters, Russian letters, and combinations thereof.

[0197] Embodiment 102. An abrasive product according to any one of Embodiments 96 to 101, wherein the body has a cross-sectional shape in a plane defined by the length and thickness of the body, selected from the group consisting of triangles, quadrilaterals, rectangles, trapezoids, pentagons, hexagons, heptagons, octagons, ellipses, Greek letters, Latin letters, Russian letters, and combinations thereof.

[0198] Embodiment 103. An abrasive product according to any one of Embodiments 1 to 102, wherein the main body comprises a filler selected from the group consisting of powder, granules, spheres, fibers, pore-forming agents, hollow particles, and combinations thereof.

[0199] Embodiment 104. An abrasive product according to any one of Embodiments 1 to 103, wherein the main body has a shape selected from the group consisting of a wheel, horn, cone, cup, flanged wheel, tapered cup, disc, segment, mounted grinding wheel, and combinations thereof.

[0200] Embodiment 105. The bonding material has an average post-bonding size (Sbp) greater than the average particle size (D50c) of the ceramic particles, and the average post-bonding size (Sbp) is greater than 12 microns, at least 13 microns, at least 15 microns, at least 17 microns, at least 19 microns, at least 20 microns, at least 22 microns, at least 24 microns, at least 25 microns, at least 26 microns, at least 37 microns, at least 38 microns, at least 39 microns, at least 40 microns, at least 42 microns, at least 45 microns, at least 47 microns, at least 49 microns, at least 51 microns, at least 53 microns, at least 55 microns, and less than An abrasive product according to any one of Embodiments 1 to 104, wherein the diameter is at least 57 microns, at least 59 microns, at least 62 microns, at least 65 microns, at least 67 microns, at least 70 microns, at least 74 microns, at least 76 microns, at least 78 microns, at least 80 microns, at least 82 microns, at least 84 microns, at least 87 microns, at least 90 microns, at least 93 microns, at least 95 microns, at least 98 microns, at least 100 microns, at least 110 microns, at least 120 microns, at least 140 microns, at least 160 microns, at least 180 microns, or at least 200 microns.

[0201] Embodiment 106. An abrasive product according to any one of Embodiments 1 to 280, wherein the bonding material has an average post-bonding size (Sbp) less than the average abrasive particle size (D50a) of the abrasive particles, and the average post-bonding size (Sbp) is a maximum of 1.8 mm, a maximum of 1.5 mm, a maximum of 1.2 mm, a maximum of 900 microns, a maximum of 850 microns, a maximum of 830 microns, a maximum of 800 microns, a maximum of 750 microns, a maximum of 700 microns, a maximum of 105 microns, a maximum of 600 microns, a maximum of 550 microns, a maximum of 500 microns, a maximum of 450 microns, a maximum of 400 microns, a maximum of 380 microns, a maximum of 350 microns, a maximum of 320 microns, a maximum of 300 microns, a maximum of 650 microns, a maximum of 260 microns, a maximum of 255 microns, a maximum of 220 microns, or a maximum of 200 microns.

[0202] Embodiment 107. An abrasive product according to any one of Embodiments 1 to 106, wherein the bonding material has an average Vickers hardness of at least 5.70 GPa, at least 5.75 GPa, or at least 5.80 GPa.

[0203] Embodiment 108. An abrasive product according to any one of Embodiments 1 to 107, wherein the bonding material has an average Vickers hardness of up to 6.50 GPa, up to 6.45 GPa, or up to 6.40 GPa.

[0204] Embodiment 109. The abrasive product according to any one of Embodiments 1 to 108, wherein the main body has an average MOR of at least 38 MPa, at least 39 MPa, at least 40 MPa, at least 41 MPa, at least 43 MPa, at least 45 MPa, at least 46 MPa, at least 47 MPa, or at least 48 MPa.

[0205] Embodiment 110. An abrasive product according to any one of Embodiments 1 to 109, wherein the main body has an average MOR of up to 60 MPa, up to 58 MPa, up to 56 MPa, up to 55 MPa, up to 53 MPa, up to 52 MPa, up to 50 MPa, or up to 49 MPa.

[0206] Embodiment 111. The main body is such that, relative to the total volume of the main body, Abrasive particles in a concentration of 33% to 55% by volume, Bonding material in 4% to 20% by volume, Porosity of 26% to 62% by volume and Abrasive product according to embodiments 109 to 110, comprising the above.

[0207] example Example 1 As described in the embodiments herein, polished bar samples were prepared and the Vickers hardness of the bonding material was tested. Samples were prepared according to the forming process described in the embodiments herein, except that the samples of Sample Group 1 were formed without ceramic particles. First, bonding material precursors were prepared to form the bonding compositions included in Table 1. It should be understood that the total content of all components is 100% by weight, even though some contents are provided as ranges. All samples were formed using the bonding material precursors, except that the samples of Sample Group 2 were formed by substituting 3-6 volume% of the bonding material precursor with 3-6 volume% of fused alumina particles having an average particle size D50c of 22.996 microns. To form the samples of Sample Group 3, 3-6 volume% of the bonding material precursor was substituted with 3-6 volume% of fused alumina ceramic particles having an average particle size D50c of 6.827 microns. All samples had 44 volume% of polishing particles and 46.88 volume% of porosity relative to the total volume of the bonded polished body. Sample group 1 contained 9.12 volume% of the bonding material. Sample groups 2 and 3 had a total content of 9.12 volume% of the bonding material and ceramic particles. [Table 1]

[0208] All samples were tested for Vickers hardness. Figure 5 includes an image of a bar sample with a depression 505 in the bond bridge 501 between abrasive particles 503. The depression was caused by the Vickers hardness test. The length of the depression, as shown in Figure 4, was measured using Image J. Table 2 includes the average length and average Vickers hardness of at least 10 depressions in each test sample group. [Table 2]

[0209] Example 2 Polishing bar samples were prepared using the same method as described in Example 1, but with the bonding material compositions listed in Table 3. In particular, sample group 4 did not contain ceramic particles, while sample groups 5 and 6 were formed with ceramic particles, similar to sample groups 2 and 3, respectively. Sample group 7 was prepared in the same manner as sample group 2, except that 9-12 volume% of the bonding material precursor was replaced with ceramic particles. Table 4 shows the content of ceramic particles D50 and each sample group.

[0210] All samples contained 44 volume% abrasive particles and 46.88 volume% porosity relative to the total weight of the bonded structure. Sample group 1 had 9.12 volume% bond material relative to the total volume of the main body. The total content of bond material and ceramic particles in the bonded structures of sample groups 5 and 6 was the same, at 9.12 volume% relative to the total volume of the main body. The abrasive particles were fused alumina, measuring 247 microns for D50, 157 microns for D10, and 388 microns for D90. [Table 3] [Table 4]

[0211] All samples were tested by cutting 20CrMnTi steel to evaluate power consumption vs. MRR, WWR vs. MRR, and MOR. The test data are shown in Figures 6-8. As shown in Figure 6, sample group 5 showed an improved wear rate (WWR) compared to sample groups 4, 6, and 7 when tested at the same material removal rate (MRR). As shown in Figure 7, sample group 5 showed improved power consumption compared to sample groups 4, 6, and 7 when operated at the same material removal rate (MRR). As shown in Figure 8, sample group 5 showed a similar MOR compared to sample group 4. Sample groups 6 and 7 showed a decrease in MOR compared to sample group 4.

[0212] Example 3 As described in the embodiments herein, wheel samples were formed containing the bonding material, abrasive particles, and porosity described in Tables 3 and 5-6. The mixture for forming the bonded polished body of each group of wheel samples contained 5 volume% white fused alumina ceramic particles V c / p It contained the following: The ceramic particles had a D50c size of 22.996 microns.

[0213] Table 5 shows the properties of different abrasive particles. [Table 5]

[0214] Table 6 includes the composition of the wheel sample group. [Table 6]

[0215] Sample groups 8-23 will be tested for MOR (Motor Load), wear rate, material removal rate, and power consumption, and are expected to perform better than the corresponding conventional wheels.

[0216] Example 4 Polishing bar samples were prepared using the same method as described in Example 1. The bonding agent compositions of the samples are shown in Table 7. All bar samples contain pink alumina abrasive grains with a D50a of 247 microns, with a content of 44 volume% and a porosity of 46.88 volume% relative to the total volume of the bar. Polishing bar samples were formed by adding white alumina ceramic particles with different D50c values ​​to the bonding agent composition in different amounts. Samples without ceramic particles have a bonding content of 9.12 volume% relative to the total volume of the bar. Samples with ceramic particles have a total bonding and ceramic particle content of 9.12 volume% relative to the total volume of the bar. Table 8 shows the ceramic particle content and D50c of the polishing bar samples.

[0217] Samples S24-0 to S24-9 have bond material composition S24. Similarly, samples S25-0 to S25-9 have bond material composition S25, and samples S26-0 to S26-9 have bond material composition S26. All bar samples were tested for MOR by three-point bending using a Vernier Caliper MEA-PHY-013 with a load cell of 30 kN, a speed of 1.27 mm / min, and a support span of 50.8 mm, based on ASTM C1161-02c (2008) (Standard test method for bending strength of advanced ceramics at ambient temperature). MOR can be determined by the formula S = 3PL / 2bd² (wherein S represents MOR, P is the peak breaking load in N, L is the support span in mm, b is the specimen width in mm, and d is the specimen thickness in mm). [Table 7] [Table 8]

[0218] Figures 10-14 include examples of MOR of samples having the bonding agent composition S24. As shown, samples S24-1 and S24-3-S24-9 had similar MOR, while sample S24-2 showed a significant improvement in MOR compared to sample S24-0, which did not contain ceramic particles.

[0219] Figures 15-19 include examples of MOR of samples having the bonding agent composition S25. As shown, samples S25-1 to S25-3 had similar MOR compared to sample S25-0, and showed improved MOR compared to samples S25-4 to S25-9.

[0220] Figures 20-24 include examples of MOR of samples having the bonding agent composition S26. As shown, samples S26-1 to S26-9 had similar MOR compared to sample S26-0, which did not contain ceramic particles.

[0221] Example 5 Cut wheel samples S29 and CS30 were formed according to the embodiments herein, except that sample CS30 does not contain ceramic particles. Both samples S29 and CS30 contain the bonding material described in Table 9, 44 volume% of pink alumina abrasive particles having a D50c of 247 microns, and 46.88 volume% of porosity relative to the total volume of the abrasive. Sample CS30 contains 9.12 volume% of bonding material relative to the total volume of the abrasive. Sample S29 contains a total content of 9.12 volume% of bonding material and ceramic particles relative to the total volume of the abrasive. Sample S29 is formed of white alumina ceramic particles having a D50c of 23 microns in a content of 4 volume% relative to the total volume of bonding material and ceramic particles. [Table 9]

[0222] Samples S29 and CS30 were tested on cut 20CrMnTi steel workpieces to evaluate material removal rate versus power consumption, as well as profile retention including ffα and fHα. The test results are shown in Figures 25-26. As shown, sample S29 did not show any improvement over CS30.

[0223] Benefits, other benefits, and solutions to problems are described above with respect to specific embodiments. However, any benefit, benefit, solution to a problem, and any feature(s) that may give rise to or make more prominent any benefit, benefit, or solution should not be construed as an important, necessary, or essential feature of any or all of the claims. References in this specification to materials comprising one or more components may be construed as including at least one embodiment in which the material is essentially composed of one or more identified components. The term “essentially” is construed as including a composition that includes the identified materials and excludes all other materials except for small amounts (e.g., impurity content) that do not significantly alter the properties of the material. Furthermore, or alternatively, in certain non-limiting embodiments, none of the compositions identified herein may essentially contain materials not expressly disclosed. Embodiments herein include a range of content of specific components in a material, and it will be understood that the total content of components in a given material is 100%.

[0224] The description and examples of embodiments described herein are intended to provide a general understanding of the structures of various embodiments. This specification and examples are not intended to serve as a comprehensive and exhaustive description of all elements and features of apparatus and systems using the structures or methods described herein. Different embodiments may also be provided in combination in a single embodiment, and conversely, various features described in the context of a single embodiment for the sake of 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 so that structural substitutions, logical substitutions, or other modifications can be made without departing from the scope of this disclosure. Therefore, this disclosure should be considered illustrative rather than restrictive.

Claims

1. Abrasive product comprising a main body, The aforementioned main body, A bonding material extending through at least a portion of the main body, Abrasive particles contained in the main body, wherein the abrasive particles have an average particle size (D50a), The ceramic particles contained in the bonding material have an average particle size (D50c) of at least 2 microns and a maximum of 75 microns, Includes, D50c < D50a, The ratio of D50a / D50c is at least 4 and 35 or less. The ceramic particles are silicon dioxide, silicon carbide, alumina, zirconia, rare earth-containing materials, cerium oxide, sol-gel derived particles, iron oxide, glass-containing particles, or a combination thereof. An abrasive product wherein the abrasive particles are non-aggregated particles.

2. Abrasive product comprising a main body, The aforementioned main body, A bonding material having a vitreous phase, The abrasive particles contained in the main body include abrasive particles having an average abrasive particle size (D50a), The ceramic particles contained in the bonding material, having an average particle size (D50c), Includes, D50c < D50a, The ceramic particles have an average particle size (D50c) of at least 2 microns and a maximum of 75 microns, and the ratio of D50a / D50c is at least 4 and 35 or less. The aforementioned bonding material is Al ２ O ３ and SiO ２ Includes, Al ２ O ３ and SiO ２ The total content of is a maximum of 79% by weight relative to the total weight of the bond material. The ceramic particles are silicon dioxide, silicon carbide, alumina, zirconia, rare earth-containing materials, cerium oxide, sol-gel derived particles, iron oxide, glass-containing particles, or a combination thereof. An abrasive product wherein the abrasive particles are non-aggregated particles.

3. Abrasive product comprising a main body, The aforementioned main body, A bonding material having a vitreous phase, The main body contains abrasive particles having an average abrasive particle size (D50a), Pores that are at least partially defined by the ceramic particles contained in the bonding material, Includes, The ceramic particles have an average particle size (D50c), and D50c < D50a. The ceramic particles have an average particle size (D50c) of at least 2 microns and a maximum of 75 microns, and the ratio of D50a / D50c is at least 4 and 35 or less. The ceramic particles are silicon dioxide, silicon carbide, alumina, zirconia, rare earth-containing materials, cerium oxide, sol-gel derived particles, iron oxide, glass-containing particles, or a combination thereof. An abrasive product wherein the abrasive particles are non-aggregated particles.

4. The abrasive product according to claim 1, wherein the bonding material comprises a vitreous phase.

5. The abrasive product according to any one of claims 1 to 4, wherein the bonding material has an average post-bonding size (Sbp) and D50c ≤ Sbp < D50a.

6. The abrasive product according to any one of claims 1 to 4, wherein the ceramic particles have an average particle size (D50c) of at least 6 microns and a maximum of 69 microns.

7. The abrasive product according to any one of claims 1 to 4, wherein the ceramic particles have an average particle size (D50c) of more than 12 microns.

8. The abrasive product according to any one of claims 1 to 4, wherein the main body contains ceramic particles in a maximum volume of 12% relative to the total volume of ceramic particles and bonding material.

9. The aforementioned bonding material is SiO ２ Includes SiO ２ The abrasive product according to any one of claims 1 to 4, wherein the content of is less than 66% by weight relative to the total weight of the bond material.

10. The binder material comprises SiO in an amount of at least 25% by weight and at most 63% by weight based on the total weight of the binder material ２ The abrasive product according to any one of claims 1 to 4, which comprises

11. The aforementioned bonding material is B ２ O ３ Includes B ２ O ３ The abrasive product according to any one of claims 1 to 4, wherein the content of is at least 5% by weight relative to the total weight of the bond material.

12. The bonding material contains at least 5% by weight and a maximum of 18% by weight of Al ２ O ３ An abrasive product according to any one of claims 1 to 4, including the abrasive product described in any one of claims 1 to 4.

13. The aforementioned bonding material is SiO ２ and B ２ O ３ It contains silicon dioxide (SiO ２ Weight percentage of ): Boron oxide (B ２ O ３ The abrasive product according to any one of claims 1 to 4, wherein the weight percentage of ) is up to 19:

1.

14. The aforementioned bonding material is SiO ２ and Al ２ O ３ Includes SiO ２ and Al ２ O ３ The abrasive product according to any one of claims 1 to 4, wherein the total content of is at least 50% by weight and at most 77% by weight relative to the total weight of the bond material.

15. The abrasive product according to any one of claims 1 to 4, wherein the ceramic particles contain alumina.

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