Abrasive article and methods of forming

Abstract

An abrasive article can include an abrasive body including abrasive particles and a bond material including an organic material. The body may include a lubricant including an inorganic material. The bond material can include a maximum Tan delta of greater than 0.18.

Description

[0001] ABRASIVE ARTICLE AND METHODS OF FORMING

[0002] TECHNICAL FIELD

[0003] The following is directed to abrasive articles and methods of forming the same, and particularly, to a bonded abrasive article including an abrasive body including an organic bond material and methods of forming the same.

[0004] BACKGROUND ART

[0005] Abrasive articles, such as bonded abrasive wheels, can be used for cutting, grinding, or shaping various materials. Certain materials of work pieces may be difficult to grind and undesirable artifacts are often formed on finished surfaces. For example, grinding of certain metal pieces, such as aluminum, steel, or the like, may utilize resin-bonded grinding wheels having relatively smaller abrasive particles. Various sizes of scratches are typically generated on finished surfaces in those applications. The industry continues to demand improved abrasive articles.

[0006] BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The present disclosure may be better understood, and its numerous features and advantages made apparent to those skilled in the art by referencing the accompanying drawings.

[0008] FIG. 1 includes a flowchart illustrating a process of forming an abrasive article according to an embodiment.

[0009] FIG. 2 includes a side view illustration of an exemplary abrasive article according to an embodiment.

[0010] FIG. 3 includes an illustration of a portion of a cross section of the abrasive article of FIG. 2.

[0011] FIG. 4 includes a plot of Tan Delta vs. Temperature of an exemplary bond material.

[0012] Skilled artisans appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures can be exaggerated relative to other elements to help improve understanding of embodiments of the invention. The use of the same reference symbols in different drawings indicates similar or identical items.

[0013] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

[0014] The following description, in combination with the figures, is provided to assist in understanding the teachings disclosed herein. The following discussion will focus on specific implementations and embodiments of the teachings. This focus is provided to assist in describing the teachings and should not be interpreted as a limitation on the scope or applicability of the teachings.

[0015] As used herein, the terms “comprises”, “comprising”, “includes”, “including”, “has”, “having”, or any other variation thereof are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but can include other features not expressly listed or inherent to such process, method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

[0016] The use of “a” or “an” is employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be read to include one or at least one, and the singular also includes the plural, or vice versa, unless it is clear that it is meant otherwise.

[0017] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The materials, methods, and examples are illustrative only and not intended to be limiting.

[0018] Embodiments herein relate to abrasive articles including a body including an organic bond material and abrasive particles contained within the bond material, wherein the bond material can include improved thermal mechanical properties. For example, the bond material may include improved Tan Delta, storage modulus, glass transition temperatures, loss modulus, or any combination thereof. In embodiments, the body may include a particular content of a lubricant material. The abrasive articles may include improved performance including improved surface finishing, such as significantly reduced formation of scratches compared to convention grinding wheels. Further embodiments relate to a process of forming the abrasive articles. The process may include carefully controlling forming conditions including mixing, heating, pressing, or any combination thereof to facilitate improved formation of the abrasive articles having improved properties and performance.

[0019] The abrasive articles described in embodiments herein can be suitable for conducting material removal operations on various types of workpieces, including for example, but not limited to, metal, glass, superconductive material, or the like, or any combination thereof. In an embodiment, the abrasive articles can include fixed abrasive articles, such as bonded abrasive articles. The bodies of the abrasive articles may be formed into various forms, such as, discs, wheels, cones, stones, cups, cutting saws, or the like, or any combination thereof. A particular example can include grinding wheels, cutting wheels, ultrathin wheels, chop saws, cutoff wheels, or the like.

[0020] FIG. 1 includes a flowchart illustrating a process 100 of forming an abrasive article in accordance with an embodiment. As illustrated, the process 100 may start at block 101, including forming a mixture including a bond precursor material and abrasive particles. The bond precursor material may include precursor materials that can be formed into the bond material of the finally-formed abrasive article after further treatment. The bond precursor material can include an organic material, such as resins, including a thermoset, a thermoplastic, or a combination thereof. Some suitable resins can include phenolics, epoxies, polyesters, cyanate esters, shellacs, polyurethanes, polybenzoxazines, polybismaleimides, polyimides, rubber, or a combination thereof. An exemplary phenolic resin can include phenolic-formaldehyde resins, such as resole and novolac resins, modified phenolic resins, derivatives of phenolic resins, a cross-linking agent or a curing agent, or the like, or any combination thereof. In a further example, modified phenolic resins may include phenolic resins that are modified by rubber, polysiloxane, epoxy, or the like, or any combination thereof. Modifications may be chemical and / or physical. In another example, modified phenolic resins may include phenolic resins modified by a cross-linking agent or a curing agent. Exemplary curing or crosslinking agent may include an epoxy, aldehyde, polyamine, e.g., hexamine, melamine, hydroxyl methylated melamine, or the like, or any combination thereof. In instances, the bond precursor material may include one or more inorganic compounds.

[0021] The bond precursor material may include various forms depending upon the processing pathway. An exemplary bond precursor material may include liquid resins, such as resole, and powder resins, such as novolac resins. The bond precursor material may be formed into a bond material through further processing, such as a thermal treatment, which is described later in this disclosure.

[0022] In an embodiment, the mixture may be formed including a certain content of the bond precursor material, such as at least 4 wt% resin bond precursor material for a total weight of the mixture, at least 6 wt%, at least 11 wt%, at least 13 wt%, or at least 20 wt% of bond precursor material for a total weight of the mixture. Additionally or alternatively, the mixture can include not greater than 40 wt% bond precursor material for the total weight of the mixture, such as not greater than 38 wt%, not greater than 35 wt%, not greater than 33 wt%, not greater than 31 wt%, not greater than 29 wt%, not greater than 27 wt%, not greater than 24 wt%, not greater than 22 wt%, not greater than 20 wt%, not greater than 19 wt%, not greater than 17 wt%, or not greater than 15 wt% bond precursor material for a total weight of the mixture. It is to be appreciated that the content of the bond precursor material can be within a range including any of the minimum and maximum percentages noted above, such as within a range from at least 4 wt% to not greater than 40 wt% or within a range from at least 6 wt% to not greater than 30 wt% for a total weight of the mixture.

[0023] The abrasive particles may include inorganic materials, organic materials, naturally occurring materials (e.g., minerals), synthesized materials (e.g., polycrystalline diamond compacts), or any combination thereof. In an example, the abrasive particles may have a Mohs hardness of at least 7, or at least 8, or at least 9. In a further example, the abrasive particles can include a material that may be selected from the group consisting of oxides, carbides, nitrides, borides, oxycarbides, or any combination thereof. A particular example of abrasive particles can include silicon carbide, such as green silicon carbide, black silicon carbide, or any combination thereof, alumina, such as an alumina-based material, aluminazirconia, alpha alumina, seeded sol gel alumina, nanocrystalline alumina, microcrystalline alumina, fused alumina, sintered alumina, elongated alumina grains, aluminosilicate, alumina-zirconia, bauxite, or any combination thereof. In another example, the abrasive particles may include superabrasive materials, such as diamond, cubic boron nitride, or any combination thereof. In yet another example, the abrasive particles can include agglomerated particles including binder and abrasive particles, non-agglomerated particles, shaped abrasive particles, constant thickness abrasive particles, randomly shaped abrasive particles, nonshaped abrasive particles, such as generally spherical abrasive particles, a blend of different types of abrasive particles having at least one different characteristic, or any combination thereof.

[0024] In an embodiment, the abrasive particles may include a particular average particle size, D50ap, that may facilitate improved formation and / or performance of the abrasive article. In an example, D50 a can be at least 5 microns, at least 10 microns, at least 20 microns, at least 30 microns, at least 40 microns, at least 50 microns, at least 65 microns, at least 70 microns, at least 75 microns, at least 80 microns, at least 90 microns, at least 115 microns, at least 120 microns, at least 140 microns, at least 150 microns, or at least 175 microns. In another instance, D50ap may be at most 300 microns, at most 260 microns, at most 230 microns, at most 205 microns, or at most 180 microns, at most 165 microns, at most 150 microns, at most 135 microns, at most 120 microns, at most 105 microns, at most 90 microns. It will be appreciated that D50ap may be between any of the minimum and maximum values noted herein.

[0025] In some instances, the abrasive particles may include a coating, wherein the coating may include a metal element. In an example, the coating may include a material including a transition metal element, such as iron, titanium, zinc, chromium, manganese, cobalt, or any combination thereof, a rare earth element, or any combination thereof. A particular example of the coating may include an oxide including one or more metal elements noted herein. In a more particular example, the coating may include iron oxide.

[0026] In another embodiment, the abrasive particles may include a blend of abrasive particles including a first type of abrasive particles and a second type of abrasive particles different from the first type, wherein the first type of abrasive particles and the second type of abrasive particles may include any of the abrasive particles noted in embodiments herein. For example, the first type of abrasive particles may include fused alumina, such as white fused alumina, pink fused alumina, brown fused alumina, ruby alumina, grey alumina, black alumina, or any combination there, AhCh-based material including at least 80 wt% of AI2O3 and one or more of SiCh, Fe20s, CaO, TiCh, ZrCh, MgO, or a rare earth oxide (e.g., Y2O3) to make up the remaining content. An example of the second type of abrasive particle may include zirconia, silicon carbide, a composite material including alumina and zirconia, or another material.

[0027] In an embodiment, the mixture can be formed including at least 50 wt% abrasive particles for a total weight of the mixture, such as at least 53 wt%, at least 57 wt%, at least 60 wt%, or at least 64 wt% abrasive particles for a total weight of the mixture. In another embodiment, the mixture can include at most 98 wt% abrasive particles for a total weight of the mixture, such as at most 96 wt%, at most 84 wt%, at most 92 wt%, at most 90 wt%, at most 88 wt%, at most 85 wt%, at most 82 wt%, at most 79 wt%, at most 75 wt%, at most 73 wt%, or at most 68 wt% abrasive particles for a total weight of the mixture. It will be appreciated that the content of abrasive particles in the mixture can be within a range including any of the minimum and maximum percentages noted herein. For example, the mixture can include 50 wt% to 98 wt% abrasive particles for a total weight of the mixture. The mixture may further include an additive including, for example, an antistatic agent, a lubricant, a porosity inducer, coloring agent, a filler, or a combination thereof.

[0028] In an embodiment, the mixture may include a lubricant. In an example, lubricant may include a solid material. Another example of lubricant may include an inorganic material, an organic material, or a combination thereof. A further example of lubricant may include a compound, such as one or more of sulfides, carbonates, fluorides, silicates, or the like, or any combination thereof. Further particular exemplary materials of lubricant may include one or more of molybdenum disulfide, tungsten disulfide, talc, graphite, hexagonal boron nitride, mineral oil, calcium carbonate, mica, carbon, calcium fluoride, magnesium stearate dihydrate, a fluorinated polymer (e.g., polytetrafluoroethylene), graphite, hydrogenated castor oil, lead iodide, wax beads, stearic acid, glycerol monostearate, or the like, or any combination thereof. In a particular application, lubricant may include molybdenum disulfide.

[0029] In an embodiment, lubricant may include a material having a particular average particle size (D50 ib) that may facilitate improved formation and / or performance of the abrasive article. In an example, the average particle size (D50Lub) may be at least 0.5 microns, such as at least 1 micron, at least 1.5 microns, at least 3 microns, at least 5 microns, at least 8 microns, at least 10 microns, at least 12 microns, at least 15 microns, at least 18 microns, at least 20 microns, at least 25 microns, at least 30 microns, at least 35 microns, at least 38 microns, at least 40 microns, at least 45 microns, at least 50 microns, at least 65 microns, at least 75 microns, at least 90 microns, at least 105 microns, at least 130 microns, or at least 150 microns. In another instance, the average particle size (D50 ib) may be at most 210 microns, such as at most 190 microns, at most 180 microns, at most 170 microns, at most 160 microns, at most 150 microns, at most 120 microns, at most 100 microns, at most 80 microns, at most 65 microns, at most 55 microns, at most 45 microns, at most 40 microns, at most 30 microns, or at most 20 microns. Moreover, the average particle size (D50 ib) may be in a range including any of the minimum and maximum percentages disclosed herein. For example, the average particle size (D50 ib) may be at least 0.5 microns and at most 210 microns or in a range including at least 1 microns and at most 190 microns or in a range including at least at least 1.5 microns and at most 30 microns. In a particular embodiment, the lubricant may include an inorganic material including any of the noted average particle sizes (D50 ib). For example, the mixture may include lubricant including a compound having any of the noted average particle sizes (D50mb). In a particular instance, the mixture may include molybdenum disulfide including any of the average particle sizes (D50Lub) noted herein.

[0030] In a particular embodiment, the mixture may include a particular ratio, D50ap / D50Lub, of the average particle size of abrasive particles (D50ap) to the average particle size of a lubricant material (D50Lub). In an example, the ratio, D50ap / D50Lub, may be at least 0.1 : 1, such as at least 0.5: 1, at least 0.8: 1, at least 1 : 1, at least 1.5: 1, at least 2: 1, at least 2.5: 1, at least 3.3: 1, at least 3.7: 1, at least 4: 1, at least 6: 1, at least 8: 1, at least 10:1, at least 14: 1, at least 18: 1, at least 20: 1, or at least 50: 1. In another example, the ratio, D50ap / D50Lub, may be at most 800: 1, such as at most 700:1, at most 550: 1, at most 450: 1, at most 300: 1, at most 200: 1, at most 150: 1, at most 100: 1, at most 90: 1, at most 75: 1, at most 60: 1, at most 50: 1, at most 40: 1, at most 30: 1, at most 20: 1, at most 18:1, at most 15: 1, at most 12: 1, at most 10: 1, at most 9: 1, at most 8: 1, at most 7: 1, at most 6: 1, at most 5: 1, at most 4: 1, at most 3: 1, at most 2: 1, at most 1 : 1, at most 0.8: 1, or at most 0.5:1. Moreover, the ratio, D50ap / D50Lub, may be in a range including any of the minimum and maximum values noted herein. In a particular example, the ratio, D50ap / D50Lub, may be at least 1 or greater than 1.

[0031] The mixture may optionally include another additive. For example, the mixture may optionally include a filler material that may include an inorganic material and / or an organic material in the form including powders, granules, particles, spheres, fibers, or another form, or any combination thereof. As a further example, the filler material may include woven materials, non-woven materials, minerals, nuts, shells, oxides, e.g., alumina, carbides, nitrides, borides, polymeric materials, naturally occurring materials, or any combination thereof. Further particular examples of filler materials can include sand, bubble alumina, chromites, magnesite, dolomites, bubble mullite, borides, titanium dioxide, carbon products (e.g., carbon black, coke or graphite), silicon carbide, wood flour, clay, feldspar, nepheline syenite, glass spheres, glass fibers, CaF2, KBF4, Cryolite (NasAlFe), potassium Cryolite (KsAlFe) , pyrites, ZnS, copper sulfide, carbonates, wollastonite, mullite, steel, iron, copper, brass, bronze, tin, aluminum, kyanite, alusite, garnet, quartz, nepheline syenite, sulfates (e.g., barium sulfate), titanates (e.g., potassium titanate fibers), rock wool, clay, sepiolite, iron sulfide (e.g., Fe2Ss, FeS2, or a combination thereof), potassium fluoroborate (KBF4), zinc borate, borax, boric acid, fine alundum powders, Pl 5 A, cork, glass spheres, silica microspheres (Z-light), silver, Saran™ resin, paradichlorobenzene, oxalic acid, alkali halides, organic halides, attapulgite, lime, potassium sulfate, potassium-manganese chlorides, dechlorane plus, tridecyl alcohol, potassium sulfate, potassium-manganese chloride, dechlorane plus, tridecyl alcohol, cyrolite, fumed silica, or any combination thereof or any combination thereof. In instances wherein the filler is particulate material, it may be distinct from the abrasive particles, e.g., being significantly smaller in average particle size than the abrasive particles. The filler material may have a hardness that is significantly less than the hardness of the abrasive particles and can be completely distinct from the abrasive particles. For example, the filler material can have a Mohs hardness less than 7, such as less than 6, or even less than 5.

[0032] Suitable mixing processes can be utilized as known by those skilled in the art to form a homogeneous mixture of the components contained therein. In an exemplary mixing process, the mixture may be combined in multiple steps. The lubricant material may be combined with the powder bond precursor material and other optional additives if present. The abrasive particles can be mixed with one or more liquid components of the bond precursor material, e.g., resole, in a mixing bowl for the abrasive particles to be wetted before adding to the blend of powder of components, which may facilitate formation of a substantially uniform coating of the powder blend on the abrasive particles.

[0033] Referring to FIG. 1, after forming the mixture the process of forming the abrasive article can continue to step 102 to form a green body comprising abrasive particles and lubricant contained in a bond material and / or bond precursor material. A green body is a body that is unfinished and may undergo further processing before a finally-formed abrasive article is formed. Forming of the green body can include techniques such as pressing, molding, casting, printing, spraying, and a combination thereof. In one particular embodiment, forming of the green body can include pressing the mixture into a particular shape, including for example, conducting a pressing operation to form a green body in the form of a grinding wheel. The mixture can be shaped utilizing a shaping device, such as a mold, having the desired shape. The mold can be made of stainless steel, high carbon-steel, high chrome-steel, or another suitable material. In an exemplary application, the mold can be at room temperature (i.e., 15°C to 30°C).

[0034] In an embodiment, pressing the mixture can be conducted in air. In another embodiment, pressing the mixture can be conducted without applying heat to the mixture, such as by using cold pressing. In another example, pressing the mixture can be conducted at room temperature, such as at least 15°C and at most 30°C.

[0035] In at least one embodiment, warm pressing may be utilized. For example, pressing may be applied at a temperature above 40°C to up to 220°C to facilitate improved formation and / or improved properties of the bond material. In a further embodiment, pressing may include isostatic pressing.

[0036] In another embodiment, pressing the mixture can be performed at a certain pressure that can facilitate improved formation of the abrasive article. In an aspect, pressing the mixture can be performed at a pressure of at least 5 MPa, such as at least 10 MPa, 15 MPa, at least 18 MPa, at least 20 MPa, at least 22 MPa, at least 25 MPa, at least 28 MPa, at least 30 MPa, at least 32 MPa, at least 34 MPa, at least 36 MPa, at least 38 MPa, at least 40 MPa, at least 42 MPa, at least 44 MPa, at least 46 MPa, at least 48 MPa, at least 50 MPa, or at least 55 MPa. In another aspect, pressing the mixture can be performed at a pressure of at most 55 MPa, at most 50 MPa, at most 48 MPa, at most 45 MPa, at most 43 MPa, at most 40 MPa, at most 38 MPa, at most 36 MPa, at most 35 MPa, or at most 30 MPa. In still another aspect, the pressure for pressing the mixture can be within a range including any of the minimum and maximum values noted herein. For instance, the pressure can be within a range from 10 MPa to 55 MPa or within a range from 15 MPa to 40 MPa.

[0037] In another embodiment, pressing the mixture can be performed at a certain force that can facilitate improved formation of the abrasive article. In an aspect, the force can be up to 50000 kN, such as at most 40000 kN, at most 30000 kN, at most 20000 kN, at most 10000 kN, at most 9000 kN, at most 8000 kN, at most 7000 kN, at most 6000 kN, or at most 5000 kN. In another aspect, the force can be at least 2 kN, at least 5 kN, at least 10 kN, at least 20 kN, at least 50 kN, at least 100 kN, at least 150 kN, at least 200 kN, at least 400 kN, at least 600 kN, at least 800 kN, at least 1000 kN, at least 1500 kN, at least 2000 kN, at least 3000 kN, at least 5000 kN, at least 7000 kN, at least 8000 kN, at least 9000 kN, at least 10000 kN, at least 12000 kN, at least 13000 kN, at least 15000 kN, at least 17000 kN, at least 18000 kN, at least 20000 kN, at least 30000 kN, or at least 40000 kN. In still another aspect, the force for pressing the mixture can be within a range including any of the minimum and maximum values noted herein.

[0038] In another embodiment, pressing the mixture can be performed for a certain period of time that can facilitate improved formation of the abrasive article. In an aspect, pressing the mixture can be performed for at least 0.5 seconds, at least 2 seconds, at least 10 seconds, at least 30 seconds, at least 1 minute, at least 3 minutes, at least 5 minutes, at least 10 minutes, at least 15 minutes, or at least 30 minutes. In another aspect, pressing the mixture can be performed for at most 50 minutes, at most 40 minutes, at most 30 minutes, at most 20 minutes, or at most 10 minutes. In a further aspect, pressing the mixture can be conducted for a period of time in a range including any of the minimum and maximum values noted herein. A skilled artisan would understand pressing time may vary for forming green bodies with various dimensions and can be adjusted as other pressing parameters change (e.g., pressure). For instance, pressing the mixture for forming a green body of an ultra thin wheel may take seconds, such as from 0.5 to 10 seconds, while the pressing time may be extended to minutes or longer as needed to form green bodies having relatively greater thickness.

[0039] After pressing, the green body can be formed having a porosity, such as at least 2 vol% for the total volume of the green body, such as at least 3 vol%, at least 5 vol%, at least 6 vol%, at least 8 vol%, at least 9 vol%, at least 10 vol%, at least 12 vol%, at least 14 vol%, at least 15 vol%, at least 17 vol%, at least 18 vol%, at least 19 vol%, or at least 20 vol% for the total volume of the green body. In addition, the green body may have a porosity of at most 76 vol% for the total volume of the green body, such as at most 73 vol%, at most 70 vol%, at most 67 vol%, at most 64 vol%, at most 61 vol%, at most 58 vol%, at most 55 vol%, at most 52 vol%, at most 50 vol%, at most 47 vol%, at most 42 vol%, at most 40 vol%, at most 35 vol%, at most 30 vol%, at most 25 vol%, at most 20 vol%, at most 15 vol%, or at most 12 vol%. It is to be understood that the porosity present in the green body can be in a range including any of the minimum and maximum percentages noted herein. For example, the porosity can be in a range from at least 4 vol% to at most 76 vol%.

[0040] In an exemplary implementation, a mounting plate may be attached to the green body. For example, a mounting plate may be placed at the bottom of a mold before the mixture is placed into the mold; or at the top of the mold after the mixture is placed in the mold. In particular instances, pressing may be performed to facilitate formation of the green body and attachment of the mounting plate such that the mounting plate may be molded onto the green body formed from the mixture. In particular embodiments, the mounting plate can be molded to the green body at room temperature (i.e., cold pressing), or can be molded while the green body is heated during molding (i.e., hot pressing). In a further embodiment, the green body can be further treated to form the finally-formed abrasive body that can be attached to the mounting plate. The mounting plate can facilitate the mounting of the abrasive article to a machine, such as a grinder. In examples, the mounting plate may be metal, plastic, or formed from a composite material. In particular, the mounting plate can be rigid, which is different from a substrate used in coated abrasives. In further examples, the mounting plate may include a central opening that may be aligned with the central opening of the abrasive body to facilitate the mounting of the abrasive article. In still another embodiment, after formation, the green body can be free-standing, and may be removed from the mold for further processing.

[0041] The process 100 may continue to step 103 after formation of the green body to form a finally formed abrasive body. In an embodiment, treating the green body may include applying a thermal treatment. In a further embodiment, the process 100 can include heating the green body at a particular temperature that can facilitate improved formation and / or improved property and / or performance of the abrasive article. For example, the heating temperature may be controlled to facilitate improved flowability of the bond precursor material, improved reactions of the bond precursor material, or both.

[0042] In an example, heating may include a particular soak temperature that may facilitate improved formation and / or properties of the abrasive article. In an example, the soak temperature may be at least 105°C, such as at least 110°C, at least 120°C, at least 135°C, at least 140°C, or at least 150°C. In another example, the soak temperature may be at most 220 °C, such as at most 200°C at most 180°C, at most 170°C, at most 160°C, at most 155°C, at most 150°C, at most 145°C, or at most 140°C. Moreover, the soak temperature may be in a range including any of the minimum and maximum values noted herein. In a further example, the soak temperature may be within ±20% of the curing temperature. In a further embodiment, heating the green body may include at least partially or fully curing the bond precursor material. In another embodiment, curing of the green body may be facilitated by applying a pressure to the green body while heating. For example, heated metal plates may be used to apply a pressure to the green body. In another example, heating and clamping the green body may be performed simultaneously.

[0043] In a further embodiment, heating may include keeping the green body at the soak temperature for a particular period of time that may facilitate improved formation and / or properties of the abrasive article. For example, the green body may be heated at the soak temperature to facilitate curing and formation of abrasive articles having improved properties. In at least one embodiment, heating the green body can include at least partially curing the bond precursor material contained in the green body. In an example, heating the green body can be performed for at least 2 hours, at least 5 hours, at least 6 hours, at least 10 hours, at least 12 hours, at least 15 hours, at least 18 hours, at least 20 hours, or at least 24 hours. In another instance, heating the green body may be performed for at most 50 hours, at most 48 hours, at most 36 hours, at most 30 hours, at most 26 hours, at most 24 hours, at most 20 hours, at most 18 hours, at most 15 hours, at most 13 hours, at most 12 hours, or at most 10 hours. It is to be understood that heating the green body can be performed for a time in a range including any of the minimum and maximum values noted herein. After reading the present disclosure, a skilled artisan would understand that heating time can be adjusted based on the composition and dimension of the green body, the heating apparatus, or heating temperature. For instance, a shorter heating time may be used when using a microwave to heat the green body, as compared to when an oven is used.

[0044] In exemplary implementations, heating may be performed outside of the pressing apparatus. For example, heating can be performed utilizing a heating device separate from the pressing apparatus. An exemplary heating tool can include an oven, a microwave, a lamp, a heater, a radiation source (e.g., infrared radiation), or any combination thereof. An exemplary lamp can include a heating lamp, an infrared lamp, or the like. Other conventional heating means can also be used to transfer heat to the green body by conduction, convection, radiation, or any combination thereof. In another embodiment, heating the green body can be performed at an atmospheric condition. In at least one particular embodiment, heating the green body can be performed without applying a pressure to the green body.

[0045] After heating at a suitable temperature and time, the green body may be cured to form a finally formed abrasive body.

[0046] FIG. 2 includes an illustration of a side view of an exemplary abrasive article 200 formed by the methods noted in embodiments herein. The abrasive article 200 is illustrated in the shape of a wheel, but a skilled artisan appreciates that the abrasive articles of embodiments herein can have different shapes and that features described with respect to the wheel 200 can be applied to abrasive articles shaped differently.

[0047] The abrasive article 200 can include a finally-formed body 202 and a central hole 204 that extends through the axial thickness of the body 202. The central hole 204 may be a mounting hole or an arbor hole for mounting the abrasive article 200 to a tool. A diameter 206 of the central hole 204 can be an inner diameter of the body 202, and the body 202 can have an outer diameter 208. In an embodiment, the outer diameter 208 may be at least 10mm, such as at least 12mm, at least 20mm, at least 30mm, at least 60mm, 75mm, at least 80mm, at least 90mm, at least 100mm, at least 200mm, at least 220mm, at least 250mm, at least 300mm, at least 350mm, at least 400mm, at least 500mm, at least 600mm, at least 700mm, at least 800mm, at least 900mm, at least 1000mm, at least 1200mm, at least 1400mm, at least 1600mm, or at least 1700mm. Additionally or alternatively, the outer diameter 208 may be at most 5000mm, such as at most 4000mm, at most 3000mm, at most 2000mm, at most 1800mm, at most 1500mm, at most 1200mm, at most 1000mm, at most 900mm, at most 800mm, at most 700mm, at most 620mm, at most 550mm, at most 535mm, at most 457mm, or at most 430mm. Moreover, the outer diameter 208 may be in a range including any of the minimum and maximum values noted herein.

[0048] In certain aspects, the inner diameter 206 can be at least 5mm, such as at least 10mm, at least 20mm, at least 50mm, at least 85mm, at least 120mm, at least 250mm, at least 420mm, at least 650mm, or at least 750mm. In other instances, the inner diameter 206 can be at most 800mm, such as at most 710mm, at most 590mm, at most 470mm, at most 310mm, at most 220mm, at most 105mm, at most 70mm, at most 50mm, at most 35mm, or at most 20mm. It will be appreciated that the inner diameter 206 of the abrasive portion 202 can be within a range between any of the values noted above.

[0049] FIG. 3 includes an illustration of a cross-sectional view of the abrasive article 200 of FIG. 2. The body 202 can include a first major surface 306, a second major surface 307 opposite the first major surface 206, and a peripheral surface 308. In an embodiment, the peripheral surface 308 may form the work surface that may come into contact with a workpiece. In another embodiment, one or both the major surfaces 306 or 307 may serve as the work surface.

[0050] The body 202 can include an average axial thickness 304. In an embodiment, the thickness 304 can be at least 0.7mm, such as at least 1.5mm, at least 3mm, at least 5mm, at least 6mm, at least 10mm, at least 15mm, at least 25mm, at least 45mm, at least 60mm, at least 70mm, at least 85mm, at least 100mm, at least 130mm, at least 150mm, at least 170mm, or at least 190mm. In some cases, the thickness 304 may be an average axial thickness of, such as at most 200mm, at most 180mm, at most 150mm, at most 130mm, at most 110mm, at most 90mm, at most 70mm, at most 55mm, at most 40mm, at most 30mm, at most 20mm, at most 10mm, at most 8mm, at most 5mm, or at most 2mm. It is to be appreciated that the average axial thickness of the body 202 may be within a range including any of the minimum and maximum values noted above.

[0051] The body 202 can include abrasive particles contained in the bond material, wherein the bond material may include a particular thermomechanical property including Tan Delta, storage modulus (G'), loss modulus (G”), glass transition temperature (Tg), or any combination thereof. As used herein, Tan Delta, storage modulus (G'), loss modulus (G”), and glass transition temperature (Tg) can be determined by dynamic mechanical analysis (DMA) on a DMA Q-800 (TA instruments) or an equivalent as follows. Test specimens having the dimension, lengthxwidthxthickness, of 35mmx7mmx4mm may be cut from the abrasive body of an abrasive article (e.g., a wheel). Measurements can be made at a frequency of 1 Hz, linear displacement amplitude of 20 pm and a heating rate of 5°C / min from 40°C to 300°C with a single cantilever clamp. It is to be appreciated values of thermomechanical properties noted in embodiments herein are average values of at least 3 specimens taken from the wheel sample.

[0052] In an embodiment, the bond material may include a particular maximum Tan Delta that may facilitate improved performance of the abrasive article. As used herein, maximum Tan Delta is in reference to the highest peak value of Tan Delta in the glass transition region over the tested temperature range (i.e., 40-300°C). Briefly turning to FIG. 4, a plot of Tan Delta vs. Temperature including the peak 302 is illustrated. The values of Tan Delta may change with increases of the temperature and the value of the highest peak 402 can be taken as maximum Tan Delta. In an embodiment, the bond material may include a maximum Tan Delta of greater than 0.18, at least 0.19, at least 0.20, at least 0.21, at least 0.22, at least 0.23, at least 0.24, or at least 0.25. Additionally or alternatively, the maximum Tan Delta may be at most 0.49, at least 0.45, at least 0.42, at least 0.40, at most 0.35, at most 0.32. In a particular example, the maximum Tan Delta may be less than 0.32, such as at most 0.31, at most 0.30, at most 0.28, at most 0.27, at most 0.26, or at most 0.25. Moreover, the bond material may include a maximum Tan Delta in a range including any of the minimum and maximum values noted herein. It is to be appreciated values of thermomechanical properties noted in embodiments herein are average values of at least 3 specimens taken from the bodies of abrasive articles made in the same batch.

[0053] In an embodiment, the bond material may include a particular storage modulus, loss modulus, or both that may facilitate improved performance of the abrasive article. It is worth noting by carefully controlling the soak temperature, soak time, or both, in combination with other parameters in the forming process, e.g., pressing, the bond material can have improved storage modulus, loss modulus, or both compared to a conventional product formed differently. In particular applications, soak may be performed at a temperature that is relatively low but sufficient to allow proper curing of the green body and at the same time formation of the bond material that may have increased loss modulus, decreased storage modulus, or both compared to a conventional product formed at a higher soak temperature. Not wishing to be bound to any theory, it appears to the inventors that improved thermomechanical properties of the bond material noted herein may facilitate improved performance of the abrasive articles.

[0054] In an embodiment, the bond material may include a storage modulus at the glass transition temperature of the bond material of at least 300 MPa, such as at least 500 MPa, at least 600 MPa, at least 800 MPa, at least 900 MPa, at least 1000 MPa, at least 1100 MPa, or at least 1200 MPa. In a particular example, the storage modulus at the glass transition temperature may be at least 1210 MPa, at least 1230 MPa, at least 1235 MPa, at least 1250 MPa, at least 1270 MPa, at least 1280 MPa, at least 1300 MPa, at least 1320 MPa, at least 1350 MPa, 1340 MPa, at least 1360 MPa, 1380 MPa, at least 1400 MPa, or at least 1410 MPa. In another example, the storage modulus at the glass transition temperature may be at least 1430 MPa, at least 1450 MPa, at least 1470 MPa, at least 1500 MPa, at least 1550 MPa, at least 1570 MPa, or at least 1580 MPa. In another example, the storage modulus at the glass transition temperature may be at least 1700 MPa, at least 1900 MPa, at least 2000 MPa, or at least 2200 MPa. In a further embodiment, the bond material may include a storage modulus at the glass transition temperature of the bond material of at most 2200 MPa, such as at most 2000 MPa, at most 1900 MPa, at most 1800 MPa, at most 1600 MPa, or less than 1580 MPa. In a particular example, the bond material may include a storage modulus at the glass transition temperature of at most 1570 MPa, at most 1550 MPa, at most 1530 MPa, at most 1510 MPa, at most 1500 MPa, at most 1480 MPa, at most 1460 MPa, at most 1450 MPa, at most 1430 MPa, at most 1420 MPa, at most 1400 MPa, at most 1200 MPa, at most 950 MPa, at most 600 MPa, or at most 400 MPa. Moreover, the bond material may have a storage modulus at the glass transition temperature in a range including any of the minimum and maximum values noted herein. In a particular example, storage modulus at the glass transition temperature may be in a range including at least 1235 MPa and less than 1580 MPa or in a range including at least 1250 MPa and at most 1530 MPa.

[0055] In an embodiment, the bond material may include a particular loss modulus that may facilitate improved performance of the abrasive article. In an embodiment, the bond material may include a loss modulus at the glass transition temperature of the bond material of at least 100 MPa, such as at least 140 MPa, at least 200 MPa, at least 250 MPa, or higher. In a particular embodiment, the loss modulus may be at least 282 MPa, such as at least 285 MPa, at least 290 MPa, at least 295 MPa, 300 MPa, at least 305 MPa, 310 MPa, at least 320 MPa, at least 330 MPa, 335 MPa, at least 340 MPa, at least 345 MPa, at least 350 MPa, or at least 355 MPa. In a further embodiment, the bond material may include a loss modulus at the glass transition temperature of the bond material of less than 580 MPa, such as at most 550 MPa, at most 530 MPa, at most 500 MPa, at most 450 MPa, at most 420 MPa, at most 410 MPa, or less than 395 MPa. In a particular example, the loss modulus at the glass transition temperature may be at most 390 MPa, at most 385 MPa, at most 380 MPa, at most 375 MPa, at most 370 MPa, at most 365 MPa, or at most 360 MPa. In a further embodiment, the loss modulus at the glass transition temperature of the bond material may be in a range including any of the minimum and maximum values noted herein.

[0056] In an embodiment, the bond material may include a particular glass transition temperature that may facilitate improved performance of the abrasive article. In an embodiment, the bond material may include a glass transition temperature in a range from 100°C to 350°C. In a particular example, the glass transition temperature may be in a range including at least 230°C and at most 290°C. After reading this disclosure, a skilled artisan appreciates that the glass transition temperatures may vary depending on the resins used to form the bond materials. For example, the bond material may be formed from a precursor of phenolic resins according to embodiments herein and may include a glass transition temperature from 230°C to 290°C.

[0057] In an embodiment, the body 202 can include a particular content of the abrasive particles that may facilitate improved performance of the abrasive article. For instance, the content of the abrasive particles may be at least 20 vol% relative to the total volume of the body 202, such as at least 25 vol%, at least 30 vol%, at least 35 vol%, at least 38 vol%, at least 40 vol%, at least 43 vol%, or at least 45 vol% for the total volume of the body 202. In another example, the content of the abrasive particles may be at most 75 vol% for a total volume of the body 202, such as at most 70 vol%, at most 68 vol%, at most 65 vol%, at most 60 vol%, at most 57 vol%, at most 53 vol%, at most 50 vol%, at most 48 vol%, or at most 45 vol% for the total volume of the body 202. It is to be understood that the content of the abrasive particles may be in a range including any of the minimum and maximum percentages disclosed herein. For instance, the body 202 may include a content of the abrasive particles in a range of at least 20 vol% to at most 70 vol% for the total volume of the body.

[0058] In an embodiment, the abrasive particles may have a weight content (wt%) relative to the total weight of the abrasive body. For example, the abrasive particles may be at least 50 wt% relative to the total weight of the abrasive body, such as at least 52 wt%, at least 55 wt%, at least 58 wt%, at least 63 wt%, at least 66 wt%, at least 70 wt%, at least 75 wt%, at least 78 wt%, at least 80 wt%, at least 82 wt%, at least 85 wt%, at least 87 wt%, or at least 90 wt% relative to the total weight of the abrasive body. In another example, the abrasive particles may be at most 94 wt% relative to the total weight of the abrasive body, such as at most 93 wt%, at most 92 wt%, at most 90 wt%, at most 87 wt%, at most 84 wt%, at most 82 wt%, at most 80 wt%, at most 75 wt%, at most 70 wt%, at most 60 wt%, or at most 55 wt% relative to the total weight of the abrasive body. Moreover, the abrasive particles may be in a weight content including any of the minimum and maximum percentages noted herein.

[0059] In an embodiment, the body 202 can include a particular content of the bond material that may facilitate improved performance of the abrasive article. For instance, the content of the bond material may be at least 3 vol% for a total volume of the body, such as at least 5 vol%, at least 7 vol%, at least 9 vol%, at least 10 vol%, at least 13 vol%, at least 16 vol%, at least 18 vol%, at least 20 vol%, at least 22 vol%, at least 25 vol%, at least 28 vol%, at least 30 vol%, at least 33 vol%, or at least 36 vol% of the total volume of the abrasive body. In another example, the content of the bond material may be at most 60 vol% of a total volume of the abrasive body, such as at most 50 vol%, at most 47 vol%, at most 45 vol%, or at most 42 vol%, at most 40 vol%, at most 37 vol%, at most 34 vol%, at most 33 vol%, at most 30 vol%, at most 27 vol%, or at most 25 vol% of the total volume of the abrasive body. It is to be understood that the content of the bond material may be in a range including any of the minimum and maximum percentages disclosed herein.

[0060] In an embodiment, the bond material may be quantified in wt% relative to the total weight of the abrasive body. For example, the bond material may be at least 2 wt% relative to the total weight of the abrasive body, such as at least 5 wt%, at least 8 wt%, at least 9 wt%, at least 10 wt%, at least 12 wt%, at least 15 wt%, at least 18 wt%, at least 20 wt%, or at least 23 wt% relative to the total weight of the abrasive body. In another example, the bond material may be at most 38 wt% relative to the total weight of the abrasive body, such as at most 34 wt%, at most 31 wt%, at most 29 wt%, at most 27 wt%, at most 25 wt%, at most 23 wt%, or at most 21 wt% relative to the total weight of the abrasive body. Moreover, the bond material may be in a weight content including any of the minimum and maximum percentages noted herein.

[0061] In an embodiment, the body 202 can include a particular porosity that may facilitate improved performance of the abrasive article. For instance, the body 202 may include porosity of at most 62 vol% for the total volume of the abrasive body 202, such as at most 58 vol%, at most 55 vol%, at most 52 vol%, at most 50 vol%, at most 47 vol%, at most 45 vol%, at most 43 vol%, at most 40 vol%, or at most 38 vol% for the total volume of the body 202. In another instance, the body 202 may include porosity of at least 10 vol% for the total volume of the abrasive body 202, such as at least 15 vol%, at least 20 vol%, at least 25 vol%, at least 28 vol%, at least 30 vol%, at least 32 vol%, at least 34 vol% or at least 36 vol% for the total volume of the body. It is to be understood that the porosity may be in a range including any of the minimum and maximum percentages disclosed herein.

[0062] In an embodiment, a lubricant material may be uniformly dispersed within the bond material. In another embodiment, the body 202 may include pores, wherein the pores may be essentially free of a lubricant material. In an embodiment, the body 202 can include a particular content of lubricant that may facilitate improved performance of the abrasive article. For instance, the body 202 may include a content of lubricant of less than 5 wt% for a total weight of the body 202, such as at most 4.50 wt% for the total weight of the body, at most 3. 05 wt%, or less than 2.66 wt%. In a particular example, the content of lubricant may be at most 2.65 wt%, at most 2.56, at most 2.45 wt%, at most 2.30 wt%, at most 2.25 wt%, at most 2.20 wt%, at most 2.16 wt%, at most 2.13 wt%, at most 2.10 wt%, at most 2.05 wt%, at most 1.98 wt%, at most 1.93 wt%, at most 1.90 wt%, at most 1.85 wt%, at most 1.80 wt%, at most 1.77 wt%, at most 1.75 wt%, at most 1.72 wt%, at most 1.70 wt%, at most 1.68 wt%, at most 1.65 wt%, at most 1.62 wt%, at most 1.60 wt%, at most 1.57 wt%, at most 1.55 wt%, at most 1.53 wt%, at most 1.50 wt%, at most 1.48 wt%, at most 1.45 wt%, at most 1.43 wt%, at most 1.41 wt%, at most 1.39 wt%, at most 1.38 wt%, or at most 1.35 wt% for the total weight of the body 202. In another instance, the abrasive body 202 may include the content of lubricant of at least 0.27 wt% for the total weight of the body, at least 0.30 wt%, at least 0.32 wt%, at least 0.34 wt%, at least 0.37 wt%, at least 0.40 wt%, at least 0.44 wt%, at least 0.47 wt%, at least 0.50 wt%, at least 0.53 wt%, at least 0.55 wt%, at least 0.58 wt%, at least 0.60 wt%, at least 0.63 wt%, at least 0.66 wt%, at least 0.68 wt%, at least 0.71 wt%, at least 0.74 wt%, at least 0.77 wt%, at least 0.80 wt%, at least 0.83 wt%, at least 0.86 wt%, at least 0.88 wt%, at least 0.90 wt%, at least 0.92 wt%, at least 0.95 wt%, at least 0.98 wt%, at least 1.00 wt%, at least 1.07 wt%, at least 1.22 wt%, or at least 1.35 wt% for the total weight of the body. It is to be understood that the content lubricant may be in a range including any of the minimum and maximum percentages disclosed herein. In a particular embodiment, the abrasive body 202 may include lubricant including an inorganic compound in any of the contents noted herein. For example, the abrasive body 202 may include molybdenum disulfide in any of the contents noted herein. In an embodiment, the abrasive body 202 may include a content of filler material from 0 wt% to 50 wt% for the total weight of the abrasive body. In an embodiment, the abrasive body may include at least 0.5 wt% of filler, such as at least 2 wt%, at least 5 wt%, at least 8 wt%, at least 14 wt%, or at least 20 wt% for the total weight of the body. In another embodiment, the abrasive body may include at most 50 wt% for the total weight of the body, such as at most 40 wt%, at most 30 wt%, at most 22 wt%, at most 11 wt%, or at most 6 wt% for the total weight of the body. Moreover, the content of filler may be in a range including any of the minimum and maximum percentages noted herein. In a particular example, the abrasive body may be essentially free of a filler material. In another example, the body may include a total content of filler and lubricant material, wherein the total content may include any contents noted with respect to the lubricant.

[0063] In an embodiment, the abrasive body 202 may include a particular content of molybdenum that may facilitate improved performance of the abrasive article. The content of molybdenum may be determined by using inductively coupled plasma (ICP) analysis. ICP may be performed using ICP-OES Agilent 5110 or a functional equivalent instrument following the manufacturer’s instructions. Sample preparation may be performed as follows. A wheel sample may be crushed into powder, and 0.5000 ± 0.0100 grams of the powder may be transferred into a Pt / Au crucible, heated at 600°C for 5 hours in a furnace, and cooled down to room temperature. Lithium tetraborate of 3.0000 ± 0.0100 g and 200pl of lithium bromide solution may be added and well mixed with the heated sample. The mixture may be melted at 1300±30°C and cooled down to form a fused sample. The fused sample, approximately 125 mL of deionized H2O, and 25mL of HC1 may be transferred into a beaker, which may be heated and then cooled down to obtain a solution. The ICP analysis may be performed on the solution.

[0064] In an embodiment, the abrasive body 202 may include a particular content of molybdenum that may facilitate improved performance of the abrasive article. In an example, the abrasive body 202 may include at least 0.2 wt% of molybdenum for a total weight of the abrasive body, such as at least 0.3 wt%, at least 0.5 wt%, at least 0.6 wt%, at least 0.8 wt%, at least 0.9 wt%, at least 1.0 wt%, at least 1.1 wt%, at least 1.2 wt%, at least 1.3 wt%, at least 1.4 wt%, at least 1.5 wt%, or at least 1.6 wt% for a total weight of the abrasive body. In another example, the abrasive body may include at most 3.5 wt% molybdenum, such as at most 3.1 wt%, at most 2.7 wt%, at most 2.5 wt%, at most 2.5 wt%, at most 2.1 wt%, at most 1.9 wt%, at most 1.7 wt%, at most 1.6 wt%, at most 1.5 wt%, at most 1.4 wt%, at most 1.3 wt%, at most 1.1 wt%, at most 0.9 wt%, or at most 0.7 wt%. Moreover, the abrasive body 202 may include molybdenum in a content including any of the minimum and maximum percentages noted herein.

[0065] After reading this disclosure, a skilled artisan appreciates that the content of molybdenum disulfide may be determined based on the content of molybdenum determined by the ICP analysis using the formula, M0S2 wt% = 1 ,667*(Mo wt%), wherein Mo wt% is the content of molybdenum detected by the ICP analysis, and M0S2 wt%. .% is the content of molybdenum disulfide relative to the total weight of the abrasive body.

[0066] In an embodiment, the abrasive body 202 may include a particular content of sulfur for a total weight of the abrasive body that may facilitate improved performance of the abrasive article. The content of sulfur may be determined by ICP analysis using ICP-OES Agilent 5110 or a functional equivalent instrument following the manufacturer’s instructions. Sample preparation may be performed as follows. A wheel sample may be crushed into powder, and 1.0000± 0.0100 g of may be added into a PTFE digestion tank. After adding 10ml of HC1 having the concentration of 37% and 3ml of HNO3 having the concentration of 68%, the digestion tank can be sealed, placed in an oven, and heated at 105°C for 1 hour. After cooling to room temperature, the sample in the digestion tank can be filtered and the solution can be transferred into a 250ml volumetric flask. The solution can be diluted by adjusting the volume to 250ml using deionized water. The ICP test can be performed on the solution. In an embodiment, the abrasive body 202 may include at least 0.05 wt% of sulfur. In another embodiment, the abrasive body may include at most 3.1 wt% of sulfur. Moreover, the abrasive body 202 may include sulfur in a content including any of the minimum and maximum percentages noted herein.

[0067] In another embodiment, the abrasive body comprises a particular ratio, Wb / WLub, that may facilitate improved performance of the abrasive article, wherein Wb is a weight content of the bond material (wt%) relative to the total weight of the body and Wi.ub is the weight content of the lubricant (wt%) relative to a total weight of the body. In an example, the ratio, Wb / WLub, may be at least 3.7, at least 5.5, at least 6, at least 7, at least 8, at least 9, at least 10, at least 12, at least 13, or at least 14. In another example, the ratio, Wb / WLub, may be at most 46, at most 41, at most 36, at most 30, at most 25, at most 20, at most 16, at most 14, at most 13, at most 12, at most 10, at most 9, at most 8, or at most 7.2. Moreover, the ratio, Wb / WLub, may be in a range including any of the minimum and maximum values noted herein. It has been noted through empirical studies that the combination of features provided herein may facilitate formation of improved abrasive articles. For example, in the context of embodiments related to utilizing particular additives, such as lubricant, and contents thereof, and controlling parameters of the forming process, in combination with one or more of average particle sizes of the abrasive particles and lubricant material and / or ratios thereof, the finally formed abrasive articles have improved performance, in particular, as noted in Examples, reduced formation of scratches on finished workpieces. The carefully-controlled forming process may facilitate formation of the bond material having improved thermomechanical properties, such as storage modulus, Tan delta, glass transition temperatures, loss modulus, or any combination thereof. Not wishing to be bound to any theory, it is noted improved thermomechanical properties of the bond material may contribute to improved performance of abrasive wheels.

[0068] Many different aspects and embodiments are possible. Some of those aspects and embodiments are described herein. After reading this specification, skilled artisans will appreciate that those aspects and embodiments are only illustrative and do not limit the scope of the present invention. Embodiments may be in accordance with any one or more of the embodiments as listed below.

[0069] EMBODIMENTS

[0070] Embodiment 1. An abrasive article, comprising an abrasive body comprising: abrasive particles contained in a bond material, wherein the bond material comprises an organic material and a maximum Tan delta of greater than 0.18; a porosity of at least 10 vol% for a total volume of the body; and a lubricant in a content of less than 5 wt% for a total weight of the body, wherein the lubricant comprises an inorganic material.

[0071] Embodiment 2. The abrasive article of embodiment 1, wherein the bond material comprises a maximum Tan delta of at least 0.19, at least 0.20, at least 0.21, at least 0.22, at least 0.23, at least 0.24, or at least 0.25; and / or wherein the maximum Tan delta is at most 0.49, at least 0.45, at least 0.42, at least 0.40, at most 0.35, at most 0.32, at most 0.30, at most 0.28, at most 0.27, at most 0.26, or at most 0.25.

[0072] Embodiment 3. The abrasive article of embodiment 1 or 2, wherein the content of the lubricant is at least 0.27 wt% for the total weight of the body, at least 0.30 wt%, at least 0.32 wt%, at least 0.34 wt%, at least 0.37 wt%, at least 0.40 wt%, at least 0.44 wt%, at least 0.47 wt%, at least 0.50 wt%, at least 0.53 wt%, at least 0.55 wt%, at least 0.58 wt%, at least 0.60 wt%, at least 0.63 wt%, at least 0.66 wt%, at least 0.68 wt%, at least 0.71 wt%, at least 0.74 wt%, at least 0.77 wt%, at least 0.80 wt%, at least 0.83 wt%, at least 0.86 wt%, at least 0.88 wt%, at least 0.90 wt%, at least 0.92 wt%, at least 0.95 wt%, at least 0.98 wt%, at least 1.00 wt%, at least 1.07 wt%, at least 1.22 wt%, or at least 1.35 wt% for the total weight of the body; and / or wherein the content of the lubricant is at most 4.50 wt% for the total weight of the body, at most 3. 05 wt%, at most 2.65 wt%, at most 2.45 wt%, at most 2.30 wt%, at most 2.25 wt%, at most 2.20 wt%, at most 2.16 wt%, at most 2.13 wt%, at most 2.10 wt%, at most

[0073] 2.05 wt%, at most 1.98 wt%, at most 1.93 wt%, at most 1.90 wt%, at most 1.85 wt%, at most

[0074] 1.80 wt%, at most 1.77 wt%, at most 1.75 wt%, at most 1.72 wt%, at most 1.70 wt%, at most

[0075] 1.68 wt%, at most 1.65 wt%, at most 1.62 wt%, at most 1.60 wt%, at most 1.57 wt%, at most

[0076] 1.55 wt%, at most 1.53 wt%, at most 1.50 wt%, at most 1.48 wt%, at most 1.45 wt%, at most

[0077] 1.43 wt%, at most 1.41 wt%, at most 1.39 wt%, at most 1.38 wt%, or at most 1.35 wt%.

[0078] Embodiment 4. The abrasive article of embodiment 1 or 2, wherein the solid lubricant comprises a compound including sulfides, nitrides, silicates, or any combination thereof.

[0079] Embodiment 5. The abrasive article of embodiment 1 or 2, wherein the solid lubricant comprises molybdenum disulfide, tungsten disulfide, or any combination thereof.

[0080] Embodiment 6. The abrasive article of embodiment 1 or 2, wherein the abrasive particles comprise an average particle size (D50ap) of at least 5 microns, at least 10 microns, at least 30 microns, at least 50 microns, at least 75 microns, at least 80 microns, at least 120 microns, or at least 150 microns; and / or wherein the average particle size (D50ap) is at most 300 microns, at most 260 microns, at most 230 microns, at most 205 microns, or at most 180 microns, at most 165 microns, at most 150 microns, at most 135 microns, at most 120 microns, at most 105 microns, at most 90 microns.

[0081] Embodiment 7. The abrasive article of embodiment 1 or 2, wherein the lubricant comprises an average particle size (D50Lub) of at least 0.5 microns, at least 1 micron, at least 1.5 microns, at least 3 microns, at least 5 microns, at least 8 microns, at least 10 microns, at least 12 microns, at least 15 microns, at least 18 microns, at least 20 microns, at least 25 microns, at least 30 microns, at least 35 microns, at least 38 microns, at least 40 microns, at least 45 microns, at least 50 microns, at least 65 microns, at least 75 microns, at least 90 microns, at least 105 microns, at least 130 microns, or at least 150 microns; and / or the an average particle size (D50Lub) is at most 210 microns, such as at most 190 microns, at most 180 microns, at most 170 microns, at most 160 microns, at most 150 microns, at most 120 microns, at most 100 microns, at most 80 microns, at most 65 microns, at most 55 microns, at most 45 microns, at most 40 microns, at most 30 microns, or at most 20 microns.

[0082] Embodiment 8. The abrasive article of embodiment 1 or 2, wherein the abrasive body comprises a ratio of D50ap / D50Lub, wherein D50Lub is an average particle size of the lubricant, and D50ap is an average particle size of the abrasive particles, wherein the ratio is at least 0.1 : 1, at least 0.5: 1, at least 0.8: 1, at least 1 : 1, at least 1.5: 1, at least 2:1, at least 2.5: 1, at least 3.3: 1, at least 3.7: 1, at least 4: 1, at least 6: 1, at least 8: 1, at least 10: 1, at least 14: 1, at least 18: 1, at least 20: 1, or at least 50: 1; and / or wherein the ratio, D50ap / D50Lub, is at most 800: 1, such as at most 700: 1, at most 550: 1, at most 450: 1, at most 300: 1, at most 200: 1, at most 150: 1, at most 100: 1, at most 90: 1, at most 75: 1, at most 60: 1, at most 50: 1, at most 40: 1, at most 30: 1, at most 20: 1, at most 18: 1, at most 15: 1, at most 12: 1, at most 10: 1, at most 9: 1, at most 8: 1, at most 7: 1, at most 6: 1, at most 5: 1, at most 4: 1, at most 3: 1, at most 2: 1, at most 1 : 1, at most 0.8: 1, or at most 0.5: 1.

[0083] Embodiment 9. The abrasive article of embodiment 1 or 2, wherein the abrasive body comprises at least 25 vol% of the abrasive particles for a total volume of the body, at least 30 vol%, at least 35 vol%, at least 38 vol%, at least 40 vol%, or at least 43 vol% of the abrasive particles for the total volume of the body; and / or wherein the abrasive particles are at most 68 vol% for the total volume of the body, at most 65 vol%, at most 60 vol%, at most 57 vol%, at most 53 vol%, at most 50 vol%, or at most 45 vol% for the total volume of the body.

[0084] Embodiment 10. The abrasive article of embodiment 1 or 2, wherein the abrasive body comprises at least 3 vol% of the bond material for a total volume of the body, at least 5 vol%, at least 7 vol%, at least 9 vol%, at least 10 vol%, at least 13 vol%, at least 16 vol%, at least 18 vol%, at least 20 vol%, at least 22 vol%, at least 25 vol%, at least 28 vol%, at least 30 vol%, or at least 33 vol% of the bond material for the total volume of the body; and / or wherein the bond material is at most 42 vol% for the total volume of the body, at most 40 vol%, at most 37 vol%, at most 34 vol%, at most 33 vol%, at most 30 vol%, at most 27 vol%, or at most 25 vol% for the total volume of the body.

[0085] Embodiment 11. The abrasive article of embodiment 1 or 2, wherein the abrasive body comprises a ratio, Wb / WLub, of the bond material to the lubricant, wherein Wb is a weight content of the bond material (wt%) relative to a total weight of the body and WLub is a weight content of the lubricant (wt%) relative to a total weight of the body, wherein the ratio, Wb / WLub, is at least 3.7, at least 5.5, at least 6, at least 7, at least 8, at least 9, at least 10, at least 12, at least 13, or at least 14; and / or wherein the ratio, Wb / WLub, is at most 46, at most 41, at most 36, at most 30, at most 25, at most 20, at most 16, at most 14, at most 13, at most 12, at most 10, at most 9, at most 8, or at most 7.2.

[0086] Embodiment 12. The abrasive article of embodiment 1 or 2, wherein the abrasive body comprises porosity of at least 25 vol%, at least 28 vol%, at least 30 vol%, at least 32 vol%, at least 34 vol% or at least 36 vol% for a total volume of the body; and / or wherein the body comprises porosity of at most 58 vol%, at most 55 vol%, at most 52 vol%, at most 50 vol%, at most 47 vol%, at most 45 vol%, at most 43 vol%, at most 40 vol%, or at most 38 vol% for the total volume of the body.

[0087] Embodiment 13. The abrasive article of embodiment 1 or 2, wherein the bond material comprises a storage modulus at the glass transition temperature of at least 300 MPa, at least 500 MPa, at least 800 MPa, at least 900 MPa, at least 1000 MPa, at least 1100 MPa, at least 1200 MPa, 1230 MPa, at least 1250 MPa, 1270 MPa, at least 1300 MPa, at least 1320 MPa, at least 1340 MPa, at least 1360 MPa, 1380 MPa, at least 1400 MPa, or at least 1410 MPa; and / or wherein the storage modulus at the glass transition temperature is at most 2200 MPa, at most 1850 MPa, at most 1630 MPa, at most 1510 MPa, at most 1500 MPa, at most 1480 MPa, at most 1460 MPa, at most 1450 MPa, at most 1430 MPa, or at most 1420 MPa.

[0088] Embodiment 14. The abrasive article of embodiment 1 or 2, wherein the bond material comprises a loss modulus at a glass transition temperature of the bond material of at least 100 MPa, at least 150 MPa, at least 200 MPa, at least 282 MPa, at least 285 MPa, at least 290 MPa, at least 295 MPa, 300 MPa, at least 305 MPa, 310 MPa, at least 320 MPa, at least 330 MPa, 335 MPa, at least 340 MPa, at least 345 MPa, at least 350 MPa, or at least 355 MPa; and / or wherein the loss modulus at the glass transition temperature is less than 580 MPa, at most 550 MPa, at most 530 MPa, at most 500 MPa, at most 450 MPa, at most 420 MPa, at most 410 MPa, at most 390 MPa, at most 380 MPa, or at most 360 MPa.

[0089] Embodiment 15. The abrasive article of embodiment 1 or 2, comprising a fixed abrasive article.

[0090] Embodiment 16. The abrasive article of embodiment 1 or 2, wherein the abrasive body is in a shape including a disc, a wheel, a cone, a stone, a cup, or a cutting saw.

[0091] EXAMPLES

[0092] Example 1

[0093] Grinding wheel samples were formed according to embodiments herein using the components noted Tables 1 to 8 below. The compositions of the Wheel samples are disclosed in the tables as well. The abrasive particles were first mixed with liquid resole in a mixing bowl for 2 to 7 minutes or until all the grains were wet and coated by the liquid resole resin. The wet abrasive grains were then combined with the rest of the bond material. The mixture of each sample was poured into a mold, and cold pressed to form a corresponding green body. The green bodies were then removed from the molds and heat treated in the oven at the soak temperature of 160°C for 15h for the bond material to cure. It was noted that the green bodies of Sample S4 had low green strength and were difficult to handle, resulting in defects.

[0094] Table 1 Composition of Samples SO and SI

[0095] Table 2 Composition of Sample S2 Table 3 Composition of Sample S3

[0096] Table 4 Composition of Sample S4 Table 5 Composition of Sample S5 Table 6 Composition of Sample S6

[0097] Table 7 Composition of Sample S7 Table 8 Composition of Sample S8

[0098] All of Samples SO-S8 were tested for grinding M2 high-speed steel rolls on cylindrical grinding machine (an OD grinding machine) under the same conditions using the wheel speed of 25 m / s, work piece speed of 70 rpm, traverse speed of 400 mm / min, and total feed in diameter of 0.48mm.

[0099] Tables 9-10 include surface evaluation results (number of scratches) of the workpieces after grinding. The numbers of scratches are determined by examining images taken by a Line scan camera with 8K resolution under circular blue light with dark field illumination. Big scratches have a length from greater than 400 microns to 600 microns, middle scratches have a length from greater than 240 microns to 400 microns, and small scratches have a length of 60 to 240 microns. Each of Samples S1-S8 is a group of at least 3 samples. Test data for each sample is an average of the respective group. Table 9 Performance Evaluation of Samples S1-S4

[0100] Table 10 Performance Evaluation of Samples S5-S8 It can be observed that Samples S6 to S8 demonstrated improved performance over Sample S5.

[0101] Example 2

[0102] Abrasive wheels samples S9 to S12 were formed using the same process noted in Example 1 except different soaking temperatures were used as noted in Table 13. Samples S9-S10 have the same composition disclosed in Table 11 below. Sample SI 1 and S12 have the composition disclosed in Table 12 below. DMA analysis was performed on Samples S9- S11 and test data is included in Table 13. The glass transition temperature (Tg) of the bond material for all the Samples is 230-290 °C. Each of Samples S9-S12 is a group of at least 3 samples. Test data for each sample is an average of the respective group.

[0103] Table 11 Composition of Samples S9 and S10

[0104] Table 12 Composition of Samples Si l and S12 Table 13. DMA Analysis of Samples

[0105] It can be observed that wheel samples S9 outperformed over S10 and SI 1.

[0106] The specification and illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The specification and illustrations are not intended to serve as an exhaustive and comprehensive description of all the elements and features of apparatus and systems that use the structures or methods described herein. Separate embodiments may also be provided in combination in a single embodiment, and conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any sub combination. Further, reference to values stated in ranges includes each and every value within that range. Many other embodiments may be apparent to skilled artisans only after reading this specification. Other embodiments may be used and derived from the disclosure, such that a structural substitution, logical substitution, or another change may be made without departing from the scope of the disclosure. Accordingly, the disclosure is to be regarded as illustrative rather than restrictive.

Claims

WHAT IS CLAIMED IS1. An abrasive article, comprising an abrasive body comprising: abrasive particles contained in a bond material, wherein the bond material comprises an organic material and a maximum Tan delta of greater than 0.18; a porosity of at least 10 vol% for a total volume of the body; and a lubricant material in a content of less than 5 wt% for a total weight of the body, wherein the lubricant material comprises an inorganic material.

2. The abrasive article of claim 1, wherein the bond material comprises a maximum Tan delta of less than 0.32.

3. The abrasive article of claim 1 or 2, wherein the content of the lubricant material is at least 0.27 wt% and less than 2.66 wt% for the total weight of the body.

4. The abrasive article of claim 1 or 2, wherein the solid lubricant material comprises a compound including sulfides, nitrides, silicates, or any combination thereof.

5. The abrasive article of claim 1 or 2, wherein the solid lubricant material comprises molybdenum disulfide, tungsten disulfide, or any combination thereof.

6. The abrasive article of claim 5, wherein the solid lubricant material is in the content of at least 0.27 wt% and at most 2.56 wt%.

7. The abrasive article of claim 1 or 2, wherein the lubricant comprises an average particle size (D50 ib) of at least 0.5 microns and at most 210 microns.

8. The abrasive article of claim 1 or 2, wherein the abrasive body comprises a ratio of D50ap / D50Lub, wherein D50mb is an average particle size of the lubricant, and D50ap is an average particle size of the abrasive particles, wherein the ratio is at least 0.1 : 1 and at most 800: 19.

9. The abrasive article of claim 1 or 2, wherein the abrasive body comprises at least 3 vol% and at most 42 vol% of the bond material, at least 25 vol% and at most 68 vol% of the abrasive particles, and porosity of at least 25 vol% and at most 58 vol% for a total volume of the body.

10. The abrasive article of claim 1 or 2, wherein the abrasive body comprises a ratio, Wb / WLub, of the bond material to the lubricant, wherein Wb is a weight content of the bond material (wt%) relative to a total weight of the body and Wi.ub is a weight content of the lubricant (wt%) relative to a total weight of the body, wherein the ratio, Wb / WLub, is at least 3.7 and at most 46.

11. The abrasive article of claim 1 or 2, wherein the bond material comprises a storage modulus at the glass transition temperature of at least 1230 MPa and less than 1580 MPa.

12. The abrasive article of claim 1 or 2, wherein the bond material comprises a loss modulus at a glass transition temperature of the bond material of at least 285 MPa and less than 395 MPa.

13. The abrasive article of claim 1 or 2, comprising a fixed abrasive article.

14. The abrasive article of claim 13, wherein the abrasive body is in a shape including a disc, a wheel, a cone, a stone, a cup, or a cutting saw.

15. The abrasive article of claim 14, wherein the solid lubricant material comprises particles including molybdenum disulfide, tungsten disulfide, or any combination thereof, wherein an average particle size (D50Lub) of the solid lubricant material is at least 1.5 to 30 microns.

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