Abrasive articles and methods of forming

Abstract

The subject application relates to abrasive articles and methods of forming. An abrasive article can include a body including an abrasive portion. The abrasive portion can include abrasive particles and filler contained in a bond material. The filler may include iron disulfide and potassium aluminum fluoride in a volume content ratio of greater than 0.53 and less than 0.71.

Description

[0001] ABRASIVE ARTICLES AND METHODS OF FORMING

[0002] TECHNICAL FIELD

[0003] The disclosure generally relates to abrasive articles and methods for forming the same, and in particular to bonded abrasive articles and methods for forming the same.

[0004] Typically, bonded abrasive articles are prepared by blending abrasive particles with a bond material and additives and shaping the resulting mixture into a green body that may be thermally processed, for example, by curing, sintering, and so forth, to form a bonded abrasive body. Examples of bonded abrasive articles may include abrasive wheels that may be prepared for grinding, cutting, polishing, or the like. Abrasive wheels may be reinforced using, for example, discs cut out of nylon, carbon, glass or cotton cloth; or they may not be reinforced.

[0005] SUMMARY OF THE INVENTION

[0006] The present disclosure relates to an abrasive article, comprising a body comprising an abrasive portion, wherein the abrasive portion comprises: abrasive particles contained in a bond material, wherein the bond material comprises an organic material; and filler including iron disulfide and potassium aluminum fluoride, wherein a ratio of a content of iron disulfide, CpeS2, to a content of potassium aluminum fluoride, CPAF, is greater than 0.53 and less than 0.71, wherein Cpes2 is a volume of iron disulfide relative to a total volume of the filler, and wherein CPAF is a volume of potassium aluminum fluoride relative to a total volume of the filler.

[0007] BRIEF DESCRIPTION OF THE DRAWINGS

[0008] 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.

[0009] FIG. 1 includes a flow diagram of a process for making an abrasive article according to an embodiment.

[0010] FIG. 2 includes a side view of an exemplary abrasive article in accordance with an embodiment.

[0011] FIG. 3 includes cross-sectional view of the abrasive article of FIG. 2.

[0012] FIG. 4 includes a cross-sectional view of an exemplary abrasive article in accordance with another embodiment.

[0013] FIG. 5 includes a cross-sectional view of an exemplary abrasive article in accordance with another embodiment. FIG. 6 includes a cross-sectional view of an exemplary abrasive article in accordance with another embodiment.

[0014] FIGs. 7-10 include cross-sectional views of exemplary abrasive articles having a depressed center configuration in accordance with embodiments.

[0015] 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.

[0016] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

[0017] 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.

[0018] As used herein, the terms “comprises”, “comprising”, “includes”, “including”, “has”, “having,”, or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of features is not necessarily limited 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).

[0019] 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.

[0020] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The materials, methods, and examples are illustrative only and not intended to be limiting.

[0021] The disclosure generally relates to bonded abrasive articles, and in particular, to abrasive wheels suitable for use as a cut-off wheel or a chop saw and to methods for making the same. FIG. 1 includes a flow diagram illustrating an exemplary process 100 for making an abrasive article according to an embodiment. The process 100 may start at block 102, forming a mixture including abrasive particles, filler, and a bond material. The bond material may include a precursor bond material that may be treated to form into the bond material of a finally-formed bonded body. The mixture may also include additional components, such as processing aids, lubricants (e.g., wetting agents), curing agents, crosslinking agents, antistatic agents, a porosity inducer, coloring agents, or the like, or any combination thereof.

[0022] In an embodiment, the mixture may include at least 53 wt% of abrasive particles for a total weight of the mixture, such as at least 59 wt%, or at least 64 wt% of abrasive particles for a total weight of the mixture. In another embodiment, the mixture my includes at most 79 wt% abrasive particles for a total weight of the mixture, such as at most 73 wt%, at most 68 wt%, or at most 66 wt% of abrasive particles for a total weight of the mixture. It will be appreciated that the content of abrasive particles in the mixture may be within a range including any of the minimum and maximum percentages noted above. For example, the mixture may include abrasive particles within a range including at least 53 wt% to at most 79 wt% abrasive particles for a total weight of the mixture.

[0023] An exemplary material of the abrasive particles can include inorganic materials, organic materials, naturally occurring materials (e.g., minerals), superabrasive materials, synthesized materials (e.g., polycrystalline diamond compacts), or a combination thereof. A particular example of abrasive particles can include a material including silica, alumina (e.g., fused or sintered), zirconia, zirconia / alumina oxides, silicon carbide, garnet, diamond, cubic boron nitride, silicon nitride, ceria, titanium dioxide, titanium diboride, boron carbide, tin oxide, tungsten carbide, titanium carbide, iron oxide, chromia, flint, emery, or any combination thereof. A more particular example of the material of the abrasive particles can include alumina, such as seeded or unseeded sintered sol gel alumina, with or without chemical modification by using, for example, rare earth oxides, MgO, or the like, or any combination thereof.

[0024] In particular implementations, the abrasive particles may include alumina. For example, the abrasive particles may include brown fused alumina (also referred to as “BFA” herein), heat-treated brown fused alumina, zirconia-alumina, white fused alumina, seeded sol gel alumina, pink alumina, black alumina, sintered alumina, ceramic coated alumina, nanocrystalline alumina, microcrystalline alumina, or the like, or any combination thereof.

[0025] The abrasive particles may include various shapes, structures, and / or configurations. For example, the abrasive particles can be shaped abrasive particles. Shaped abrasive particles can have a well-defined and regular arrangement (i.e., non-random) of edges and sides, thus defining an identifiable and controlled shape. Moreover, shaped abrasive particles are distinct from traditional crushed or non-shaped abrasive particles as the shaped abrasive particles have substantially the same shape with respect to each other, wherein traditional crushed abrasive particles vary significantly in their shape with respect to each other. For example, a shaped abrasive particle may have a polygonal shape as viewed in a plane defined by any two dimensions of length, width, and height (e.g., viewed in a plane defined by a length and a width). Some exemplary polygonal shapes can be triangular, quadrilateral (e.g., rectangular, square, trapezoidal, parallelogram), a pentagon, a hexagon, a heptagon, an octagon, a nonagon, a decagon, and the like. Additionally, the shaped abrasive particle can have a three-dimensional shape defined by a polyhedral shape, such as a prismatic shape or the like. Further, the shaped abrasive particles may have curved edges and / or surfaces, such that the shaped abrasive particles can have convex, concave, ellipsoidal shapes. Exemplary shaped abrasive particles are disclosed in U.S. Pat. No. 8,758,461, which is incorporated herein in its entirety. In a particular example, the shaped abrasive particles can be in the form of any alphanumeric character, e.g., 1, 2, 3, etc., A, B, C. etc. Further, the shaped abrasive particles can be in the form of a symbol, trademark, a character selected from the Greek alphabet, the modern Latin alphabet, the ancient Latin alphabet, the Russian alphabet, any other alphabet (e.g., Kanji characters), and any combination thereof.

[0026] The size of abrasive particles can be expressed as a grit size, and charts showing a relation between a grit size and its corresponding average particle size, expressed in microns or inches, are known in the art as correlations to the corresponding United States Standard Sieve (USSS) mesh size.

[0027] In an embodiment, the abrasive particles may include an average particle size that may facilitate improved performance of the abrasive article. For example, the abrasive particles may include an average particle size of at least 63 microns, at least 75 microns, at least 85 microns, at least 90 microns, at least 110 microns, at least 130 microns, at least 160 microns, at last 180 microns, at least 200 microns, at least 300 microns, at least 400 microns, at least 500 microns, at last 600 microns, at least 700 microns, at last 800 microns, at least 900 microns, or at least 1 mm. Alternatively or additionally, the average particle size may be at most 1.5 mm, at most 1.2 mm, at most 1 mm, at most 900 microns, at most 800 microns, at most 600 microns, at most 500 microns, at most 400 microns, at most 300 microns, at most 200 microns, at most 180 microns, at most 150 microns, at most 120 microns, or at most 90 microns. Moreover, the abrasive particles can have an average particle size in a range of any of the minimums and maximums provided herein.

[0028] In an embodiment, the mixture can include more than one type of abrasive particles, wherein different types of abrasive particles can differ from each other based on hardness, toughness, composition, manufacturing process, or any combination thereof. For example, the abrasive particles can include a first type of abrasive particle and a second type of abrasive particles, wherein the first and second types of abrasive particles may include a different material, a different average particle size, or both. In an embodiment, different types of abrasive particles may independently include any of the features described with respect to abrasive particles in embodiments herein. In a particular example, the first abrasive particles may include brown fused alumina. In another particular example, the second abrasive particles may include white fused alumina, heat-treated brown fused alumina, seeded alumina, sintered alumina, or the like. In another example, the first and second type of abrasive particles may independently include any of the average particle sizes noted in embodiments herein. In a particular embodiment, the abrasive particles may include a multi-model particle size distribution.

[0029] In yet another embodiment, the abrasive particles may include 1 wt% to 99 wt% of the first or second type of abrasive particles for a total weight of the abrasive particles. For example, the first or second type of abrasive particles may be at least 5 wt% for a total weight of the abrasive particles, such as at least 10 wt%, at least 15 wt%, at least 25 wt%, at least 32 wt%, at least 40 wt%, at least 45 wt%, at least 52 wt%, at least 56 wt%, or at least 60 wt% of a total weight of the abrasive particles. Additionally or alternatively, the first or second type of abrasive particles may include a content of at most 95 wt% of a total weight of the abrasive particles, such as at most 86 wt%, at most 81 wt%, at most 76 wt%, at most 71 wt%, at most 65 wt%, at most 58 wt%, at most 52 wt%, at most 48 wt%, or at most 44 wt% of a total weight of the abrasive particles. Moreover, the first or second type of abrasive particles may include a content within a range including any of the maximum and minimum percentages noted herein. In another embodiment, the abrasive particles may include more than 2 types of abrasive particles.

[0030] The bond material may include an organic material, such as one or more natural organic materials, synthetic organic materials, or any combination thereof. In particular instances, the organic material can include resins, which may include a thermoset, a thermoplastic, and a combination thereof. For example, some suitable resins can include phenolics, epoxies, polyesters, cyanate esters, shellacs, polyurethanes, polybenzoxazines, polybismaleimides, polyimides, rubber, or any combination thereof. In one particular embodiment, the mixture may include an uncured resin material configured to form a phenolic resin bond material through further processing. In a further embodiment, the uncured resin material may include a liquid resin, a powder resin, or a combination thereof. An exemplary liquid resin may include resole, epoxy, polyester, furan, or any combination thereof. An exemplary powder resin may include novolac, polyurethane, lignin, or any combination thereof.

[0031] The phenolic resin may be modified with a curing or cross-linking agent, such as hexamethylene tetramine. At temperatures in excess of about 90°C, some examples of the hexamethylene tetramine may form crosslinks to form methylene and dimethylene amino bridges that help cure the resin. The hexamethylene tetramine may be uniformly dispersed within the resin. More particularly, hexamethylene tetramine may be uniformly dispersed within resin regions as a cross-linking agent. Even more particularly, the phenolic resin may contain resin regions with cross-linked domains having a sub-micron average size.

[0032] In an embodiment, the mixture can include at least 9 wt% of the bond material for a total weight of the mixture, such as at least 11 wt%, at least 13 wt%, at least 15 wt%, or at least 16 wt% of the bond material for a total weight of the mixture. Additionally or alternatively, the mixture may include at most 23 wt% of the bond material for a total weight of the mixture, at most 21 wt%, at most 19 wt%, or at most 17 wt% of the bond material for a total weight of the mixture. It will be appreciated that the content of the bond material can be within a range including g any of the minimum and maximum percentages noted herein. For example, the mixture can include a content of the bond material within a range of at least 9 wt% to at most 23 wt% for a total weight of the mixture.

[0033] In an embodiment, the mixture can include filler including an inorganic material. In a further embodiment, the filler material can consist of inorganic materials. In a particular embodiment, the filler can include pyrite (FeS?) and potassium aluminum fluoride. Potassium aluminum fluoride is also known as potassium cryolite, potassium tetrafluoraluminate, kalium aluminum fluoride, and KsAlFe / KAIF4. Potassium aluminum fluoride may be also referred to as PAF in this disclosure. In a more particular embodiment, the filler can consist of potassium aluminum fluoride and pyrite (FeS?).

[0034] In an embodiment, the mixture can include a particular total content of filler that may facilitate improved formation and / or performance of the abrasive article. In another embodiment, the mixture may include a total content of filler of at least 15 wt% for a total weight of the mixture, such as at least 17 wt%, or at least 19 wt% for a total weight of the mixture. Additionally or alternatively, the mixture may include a total content of filler of at most 24 wt% for a total weight of the mixture, such as at most 23 wt% or at most 21 wt% for a total weight of the mixture. It will be appreciated that the total content of filler can be within a range including any of the minimum and maximum percentages noted above.

[0035] In an embodiment, the mixture can include a particular content of potassium aluminum fluoride that may facilitate improved formation and / or performance of the abrasive article. In another embodiment, the mixture may include a content of potassium aluminum fluoride of at least 5.3 wt% for a total weight of the mixture, such as at least 6.3 wt%, at least 7.5 wt%, at least 8.2 wt%, at least 8.5 wt%, at least 8.7 wt%, at least 9.0 wt%, or at least 9.3 wt% for a total weight of the mixture. Additionally or alternatively, the mixture may include a content of potassium aluminum fluoride of at most 13.5 wt% for a total weight of the mixture, such as at most 12.5 wt%, at most 11.5 wt%, at most 10.5 wt%, or at most 9.5 wt% for a total weight of the mixture. It will be appreciated that the content of potassium aluminum fluoride can be within a range including any of the minimum and maximum percentages noted above.

[0036] In an embodiment, the mixture can include a particular content of pyrite (FeS?) that may facilitate improved formation and / or performance of the abrasive article. In another embodiment, the mixture may include a content of pyrite (FeS?) of at least 5.5 wt% for a total weight of the mixture, such as at least 6.5 wt%, at least 7.8 wt%, at least 8.3 wt%, at least 8.7 wt%, at least 9.0 wt%, or at least 9.3 wt%, at least 9.7 wt%, or at least 10 wt% for a total weight of the mixture. Additionally or alternatively, the mixture may include a content of pyrite (FeS?) of at most 14.5 wt% for a total weight of the mixture, such as at most 13.5 wt%, at most 12.5 wt%, at most 11.5 wt%, or at most 10.5 wt% for a total weight of the mixture. It will be appreciated that the content of pyrite (FeS?) can be within a range including any of the minimum and maximum percentages noted above.

[0037] In yet another embodiment, the mixture can include a particular content of filler relative to the total weight of filler and the bond material that may facilitate improved formation and performance of the abrasive article. In an embodiment, the mixture can include at least 39 wt% of filler relative to the total weight of filler and the bond material, such as at least 44 wt%, at least 48 wt%, at least 50 wt%, at least 52 wt%, or at least 54 wt% of filler material for a total weight of filler and the bond material. In another embodiment, the mixture may include at most 65 wt% filler material for a total weight of filler and the bond material, such as at most 63 wt%, at most 61 wt%, at most 58 wt%, or at most 56 wt% filler for a total weight of filler and the bond material. It will be appreciated that the content of filler relative to the total weight of filler and bond material can be within a range including any of the minimum and maximum percentages noted herein. For example, the content of filler relative to the total weight of the filler and the bond material can be within a range of at least 44 wt% to at most 58 wt%.

[0038] In an embodiment, the mixture can include a particular total content of filler and the bond material that may facilitate improved formation and performance of the abrasive article. In an embodiment, the total content of filler and the bond material may be at least 21 wt% for a total weight of the mixture, such as at least 23 wt%, at least 26 wt%, at least 31 wt%, at least 33 wt%, or at least 35 wt% for a total weight of the mixture. Additionally or alternatively, the total content of filler and the bond material may be at most 47 wt% for a total weight of the mixture, at most 43 wt%, at most 41 wt%, at most 39 wt%, or at most 37 wt% for a total weight of the mixture. It will be appreciated that the total content of filler and the bond material can be within a range including g any of the minimum and maximum percentages noted herein. For example, the mixture can include a total content of filler and the bond material within a range of at least 30 wt% to at most 43 wt% for a total weight of the mixture.

[0039] In a particular exemplary implementation, the abrasive particles may be wetted by a liquid phenolic resin, such as resole, and then mixed with a powder phenolic resin, such as novolac, to facilitate formation of the mixture with improved homogeneity. In further embodiments, filler particles and additive may be pre-mixed with abrasive particles or powder phenolic resins to facilitate improved formation of a uniform mixture.

[0040] The process 100 can continue to block 104 after the mixture is formed. The mixture may be formed into a green body utilizing a shaping device. For example, the process 100 may include placing the mixture into a mold. The mold can be made of stainless-steel, high carbon-steel, high chrome-steel, another suitable material, or a combination thereof. In some situations, one or more layers of the mixture can be placed into the mold, such as by linear or rotational spreading. In an illustrative embodiment, other components, such as one or more layers of a reinforcement component, can be placed above, below, or both above and below, at least one of the layers of the mixture. The layers of the mixture may be referred to as abrasive layers in this disclosure. In an embodiment, a reinforcement component can include a material including an organic material, an inorganic material, or a combination thereof. A further example of the reinforcement component can include a material selected from the group consisting of a fabric, a fiber, a film, a woven material, a non-woven material, a glass, a fiberglass, a ceramic, a polymer, a resin, a fluorinated polymer, an epoxy resin, a polyester resin, a polyurethane, a polyester, a rubber, a polyimide, a polybenzimidazole, an aromatic polyamide, a modified phenolic resin, or any combination thereof.

[0041] The process 100 may further include applying a pressing process to the mixture while in the mold. In situations when multiple abrasive layers are formed, each of the abrasive layers can be subjected to a respective pressing process. The pressing process can include a cold pressing process, a warm pressing process, or a hot pressing process. In an illustrative embodiment, a warm pressing process can be applied at a temperature within a range of 35°C to 85°C. In another illustrative embodiment, a cold pressing process can be applied at room temperature, i.e., 20°C to 25°C. In an embodiment, a green body may be formed after pressing and removed from the mold for further processes. In another embodiment, the green body may be treated while in the mold.

[0042] The process 100 may continue at block 106 to form a bonded body from the green body. The process 100 may include heating the green body to form the bonded body. 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. In an embodiment, heating may be performed at a suitable temperature to allow the bond material to at least partially cure. For example, heating may be performed at a temperature from 105°C to 240 °C for 2 hours to up to 60 hours to facilitate curing of the bond material.

[0043] In an embodiment, the finally formed bonded body may include one or more abrasive portions formed from one or more abrasive layers of the mixture. In another embodiment, an abrasive portion may be coupled to one or more non-abrasive portions. In an example, a nonabrasive portion may include one or more layers of reinforcement components.

[0044] FIG. 2 includes a view of an exemplary abrasive article 200 in the form of a cutting wheel in accordance with an embodiment. The abrasive article 200 includes a body 202 and a mounting hole 204 for mounting the abrasive article 200 to a cutting tool. A diameter 206 of the mounting 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 can be at least 220 mm, at least 270 mm, at least 310 mm, or at least 360 mm. In another embodiment, the outer diameter 208 can be at most 535 mm, at most about 457 mm, at most 415 mm, or at most 355 mm. It will be appreciated that the outer diameter 208 of the body 202 can be within a range including any of the minimum and maximum values noted herein.

[0045] In a further embodiment, the inner diameter 206 can be at least 22 mm, at least 30 mm, at least 35 mm, at least 46 mm, or at least 54 mm. Alternatively or additionally, the inner diameter 206 can be at most 90 mm, at most 77 mm, or at most 62 mm. It will be appreciated that the inner diameter 206 of the body 202 can be within a range including any of the values noted herein.

[0046] FIG. 3 includes a cross-sectional view of the abrasive article 200 of FIG. 2 according to an embodiment. The body 202 may include an abrasive portion 302. The abrasive portion 302 can include abrasive particles and filler contained within the bond material.

[0047] The abrasive portion 302 can also have a thickness 304. In certain embodiment, the body 202 may include one abrasive portion, i.e., abrasive portion 302. In a particular example, the thickness 304 may constitute the thickness of the body 202. In another example, the body 202 may include a thickness of at least about 2.0 mm, at least about 2.2 mm, at least about 2.5 mm, at least 2.7 mm, at least about 2.9 mm, or at least about 3.2 mm. In some cases, the body can have a thickness of at most about 6.5 mm, at most about 5.7 mm, at most about 4.8 mm, at most about 3.5 mm, or at most about 2.2 mm. It will be appreciated that the thickness of the body 202 can be within a range between any of the values noted above. Furthermore, the body 202 can have an aspect ratio of the outer diameter 208 to the thickness of the body within a range including any of the minimum and maximum values noted herein, such as in a range from 125: 1 to 15: 1.

[0048] In another embodiment, the abrasive portion 302 can include filler including pyrite and potassium aluminum fluoride. In a particular embodiment, the abrasive portion 302 can include filler consisting of pyrite and potassium aluminum fluoride. In a particular embodiment, the abrasive portion 302 can include a particular ratio of a content of iron disulfide, Cpes2, to a content of potassium aluminum fluoride, CPAF, that may facilitate improved performance of the abrasive article, wherein Cpes2 may be a volume of iron disulfide relative to a total volume of the filler, and wherein CPAF may be a volume of potassium aluminum fluoride relative to a total volume of the filler in the abrasive portion 302. In an example, the ratio of Cpes2 to CPAF may be greater than 0.53, such as at least 0.55, at least 0.57, at least 0.59, at least 0.61, or at least 0.63. In a further example, the ratio of CpeS2 to CPAF may be at most 0.70, at most 0.68, at most 0.66, or at most 0.64. It will be appreciated that the ratio of Cpes2 to CPAF may be within a range including any of the minimum and maximum values noted herein. In a particular embodiment, the abrasive portion 302 may include a ratio of Cpes2 to CPAF in a range of greater than 0.53 and less than 0.71, such as in a range of at least 0.55 to at most 0.66.

[0049] In an embodiment, the abrasive portion 302 can include a particular content of pyrite that may facilitate improved performance of the abrasive article. In another embodiment, the abrasive portion 302 may include a content of pyrite, Cpes2, of at least 3.5 vol% for a total volume of the abrasive particles, the filler, and the bond material, such as at least 3.8 vol%, at least 4.1 vol%, at least 4.4 vol%, at least 4.7 vol%, at least 5.2 vol%, at least 5.5 vol%, at least 5.7 vol%, at least 6.0 vol%, or at least 6.1 vol% for the total volume of the abrasive particles, the filler, and the bond material. Alternatively or additionally, the abrasive portion 302 may include Cpes2 of at most 10.2 vol% for the total volume of the abrasive particles, the filler, and the bond material, at most 9.7 vol%, at most 9.3 vol%, at most 8.8 vol%, at most 8.4 vol%, at most 8.1 vol%, at most 7.8 vol%, at most 7.4 vol%, at most 7.1 vol%, at most 6.6 vol%, at most 6.3 vol%, or at most 6.1 vol% for the total volume of the abrasive particles, the filler, and the bond material. It will be appreciated that the content of pyrite can be within a range including any of the minimum and maximum percentages noted herein. For example, the abrasive portion 302 can include the content of pyrite, Cpes2, within a range of at least 3.8 vol% to at most 9.7 vol% or within a range of at least 4.7 vol% and at most 7.8 vol%.

[0050] In an embodiment, the abrasive portion 302 can include a particular content of potassium aluminum fluoride (also referred to as “PAF” in this disclosure) that may facilitate improved performance of the abrasive article. In another embodiment, the abrasive portion 302 may include a content of PAF, CPAF, of at least 4.7 vol% for a total volume of the abrasive particles, the filler, and the bond material, at least 5.2 vol%, at least 5.6 vol%, at least 5.9 vol%, at least 6.4 vol%, at least 6.8 vol%, at least 7.3 vol%, at least 7.8 vol%, at least 8.2 vol%, at least 8.5 vol%, at least 8.8 vol%, at least 9.1 vol%, at least 9.3 vol%, or at least 9.5 vol% for the total volume of the abrasive particles, the filler, and the bond material. Alternatively or additionally, the content of PAF, CPAF, may be at most 14.3 vol% for the total volume of the abrasive particles, the filler, and the bond material, at most 13.7 vol%, at most 13.3 vol%, at most 12.8 vol%, at most 12.4 vol%, at most 12.1 vol%, at most 11.8 vol%, at most 11.5 vol%, at most 11.2 vol%, at most 10.9 vol%, at most 10.6 vol%, at most 10.3 vol%, at most 10.1 vol%, at most 9.8 vol%, or at most 9.6 vol% for the total volume of the abrasive particles, the filler, and the bond material. It will be appreciated that the content of PAF of the abrasive portion 302 can be within a range between any of the minimum and maximum percentages noted herein. In an example, the content of PAF, CPAF, of the abrasive portion 302 can be within a range of at least 4.7 vol% to at most 14.3 vol% or within a range of at least 7.3 vol% and at most 11.8 vol% for a total volume of the bond material, abrasive particles, and filler.

[0051] In another embodiment, the abrasive portion 302 can include a particular total content of the filler (i.e., a total content of pyrite and PAF) that may facilitate improved performance and / or formation of the abrasive article. In an embodiment, the abrasive portion 302 may include for a total volume of the abrasive particles, the filler, and the bond material, a total content of the filler, CF, of at least 8.2 vol%, at least 8.6 vol%, at least 9.1 vol%, at least 9.6 vol%, at least 10.1 vol%, at least 10.5 vol%, at least 10.9 vol%, at least 11.3 vol%, at least

[0052] 11.7 vol%, at least 12.3 vol%, at least 12.8 vol%, at least 13.2 vol%, at least 13.8 vol%, at least 14.3 vol%, at least 14.7 vol%, at least 15.3 vol%, or at least 15.6 vol% for the total volume of the abrasive particles, the filler, and the bond material. Additionally or optionally, the abrasive portion 302 may include a total content of the filler, CF, of at most 20.3 vol% for the total volume of the abrasive particles, the filler, and the bond material, such as at most

[0053] 19.7 vol%, at most 19.3 vol%, at most 18.8 vol%, at most 18.4 vol%, at most 18.1 vol%, at most 17.8 vol%, at most 17.5 vol%, at most 17.2 vol%, at most 16.9 vol%, at most 16.6 vol%, at most 16.3 vol%, at most 16.1 vol%, at most 15.9 vol%, or at most 15.7 vol% for the total volume of the abrasive particles, the filler, and the bond material. It will be appreciated that the content of the filler of the abrasive portion 302 can be within a range including any of the minimum and maximum percentages noted herein. In a particular illustrative embodiment, the total content of filler in the abrasive portion 302 can be within a range of 8.2 vol% to 20.3 vol% for the total volume of the abrasive particles, filler, and the bond material of the abrasive portion 302.

[0054] In an embodiment, the abrasive portion 302 can include a particular content of abrasive particles that may facilitate improved performance and / or formation of the abrasive article. In an embodiment, the abrasive portion 302 may include a content of the abrasive particles for a total volume of the abrasive particles, the filler, and the bond material. In an example, the content of the abrasive particles maybe at least 43.2 vol%, at least 43.7 vol%, at least 44.1 vol%, at least 44.6 vol%, at least 44.9 vol%, at least 45.3 vol%, at least 45.9 vol%, at least 46.3 vol%, at least 46.6 vol%, at least 46.9 vol%, or at least 47.2 vol% for the total volume of the abrasive particles, the filler, and the bond material. In another example, the content of the abrasive particles may be at most 57.5 vol% for the total volume of the abrasive particles, the filler, and the bond material, such as at most 56.3 vol%, at most 55.5 vol%, at most 54.6 vol%, at most 53.5 vol%, at most 52.9 vol%, at most 52.2 vol%, at most 51.5 vol%, at most 50.5 vol%, at most 49.5 vol%, at most 48.8 vol%, at most 48.3 vol%, at most 48.0 vol%, at most 47.6 vol%, or at most 47.3 vol% for the total volume of the abrasive particles, the filler, and the bond material. Moreover, the abrasive particles may be in a content including any of the minimum and maximum percentages noted herein.

[0055] In an embodiment, the abrasive portion 302 can include a particular content of the bond material that may facilitate improved performance and / or formation of the abrasive article. In an embodiment, the abrasive portion 302 may include a content of the bond material for a total volume of the abrasive particles, the filler, and the bond material, of at most 44.1 vol%, at most 43.5 vol%, or at most 42.5 vol% for the total volume of the abrasive particles, the filler, and the bond material. In a particular example, the content of the bond material may be at most 41.5 vol% for the total volume of the abrasive particles, the filler, and the bond material, at most 41.2 vol%, at most 40.9 vol%, at most 40.5 vol%, at most 40.2 vol%, at most 39.9 vol%, at most 39.5 vol%, at most 39.2 vol%, at most 38.9 vol%, at most

[0056] 38.5 vol%, at most 38.2 vol%, at most 37.9 vol%, at most 37.5 vol%, or at most 37.2 vol% for the total volume of the abrasive particles, the filler, and the bond material. Alternatively or additionally, the content of the bond material may be at least 30.1 vol% for the total volume of the abrasive particles, the filler, and the bond material, such as at least 31.5 vol%,

[0057] 32.5 vol%, at least 33.3 vol%, at least 34.5 vol%, at least 35 vol%, at least 35.3 vol%, at least

[0058] 35.6 vol%, at least 35.9 vol%, at least 36.2 vol%, at least 36.4 vol%, at least 36.6 vol%, at least 36.9 vol%, or at least 37.1 vol% for the total volume of the abrasive particles, the filler, and the bond material. It will be appreciated that of the abrasive portion 302 may include a content of the bond material within a range including any of the minimum and maximum percentages noted above. For an example, the content of the bond material may be within a range of 30.1 vol% to 41.5 vol% for a total volume of the bond material.

[0059] In an embodiment, the abrasive portion 302 can include a particular total content of filler, CF / B+F, relative to the total volume of filler and the bond material that may facilitate improved performance and / or formation of the abrasive article. In an embodiment, the total content of filler, CF / B+F, may be at least 22.0 vol% relative to the total volume of the filler and the bond material, such as at least 22.3 vol%, at least 22.9 vol%, at least 23.5 vol%, at least 24.4 vol%, at least 25.0 vol%, at least 25.6 vol%, at least 26.1 vol%, at least 26.7 vol%, at least 27.3 vol%, at least 27.9 vol%, at least 28.1 vol%, at least 28.5 vol%, at least 28.9 vol%, at least 29.3 vol%, or at least 29.6 vol% relative to the total volume of the filler and the bond material. Alternatively or additionally, the total content of filler, CF / B+F, may be at most 37.0 vol%, at most 36.8 vol%, at most 36.5 vol%, at most 34.5 vol%, at most 33.5 vol%, or at most 32.5 vol% relative to the total volume of the filler and the bond material. In a particular embodiment, the total content of filler, CF / B+F, may be less than 31.3 vol% relative to the total volume of the filler and the bond material, at most 31.0 vol%, at most 30.8 vol%, at most 30.6 vol%, at most 30.5 vol%, at most 30.3 vol%, at most 30.1 vol%, at most 29.9 vol%, or at most 29.7 vol% relative to the total volume of the filler and the bond material. Moreover, the total content of filler, CF / B+F, in the abrasive portion 302 may be in a range including any of the minimum and maximum percentages noted herein. For example, the total content of filler, CF / B+F, in the abrasive portion 302 may be in a range of at least 22.0 vol% and at most 37.0 vol% or in a range of at least 25.0 vol% and less than 31.3 vol% relative to the total volume of the filler and the bond material.

[0060] In an embodiment, the abrasive portion 302 can include a particular total content of filler and the bond material, CF+B, relative to a total volume of the abrasive particles, the filler, and the bond material that may facilitate improved performance and / or formation of the abrasive article. In an embodiment, the abrasive portion 302 may include a total content of filler and the bond material, CF+B, of at least 43.0 vol% relative to a total volume of the abrasive particles, the filler, and the bond material, such as at least 44.5 vol%, at least 45.6 vol%, at least 47.0 vol%, at least 48.5 vol%, at least 49.5 vol%, at least 50.3 vol%, at least 50.8 vol%, at least 51.5 vol%, at least 51.8 vol%, at least 52.1 vol%, or at least 52.5 vol% for the total volume of the abrasive particles, the filler, and the bond material. Alternatively or additionally, the total content of the filler and the bond material, CF+B, in the abrasive portion 302 may be at most 56.4 vol% for the total volume of the abrasive particles, the filler, and the bond material., at most 55.8 vol%, at most 55.2 vol%, at most 54.7 vol%, at most 54.2 vol%, at most 53.6 vol%, at most 53.2 vol%, or at most 52.8 vol% for the total volume of the abrasive particles, the filler, and the bond material. Moreover, the abrasive portion 302 may include the total content of filler and the bond material, CF+B, in a range including any of the minimum and maximum percentages noted herein. For example, the total content of filler and the bond material, CF+B, may be in a range of at least 43.0 vol% and at most 56.4 vol% for the total volume of the abrasive particles, the filler, and the bond material.

[0061] In an embodiments, the abrasive portion 302 can include a content of porosity, such as at least 6 vol% of porosity for a total volume of the abrasive portion 302, at least 11 vol%, or at least 14 vol% porosity for a total volume of the abrasive portion 302. Alternatively or additionally, the abrasive portion 302 may include at most 25 vol% of porosity for a total volume of the abrasive portion 302, at most 21 vol%, or at most 18 vol% of porosity for a total volume of the abrasive portion 302. It will be appreciated that the porosity of the abrasive portion 302 can be within a range including any of the minimum and maximum percentages noted herein.

[0062] Referring to FIG. 4, a side view of an exemplary abrasive article 400 is illustrated, including a body 410. The body 410 can include a first abrasive portion 402, a second abrasive portion 404, and a non-abrasive portion 406 between the first and second abrasive portions 402 and 404. In an example, the non-abrasive portion 406 can include a reinforcement component. The first abrasive portion 402 and the second abrasive portion 404 can include any of the features described in embodiments with respect to the abrasive portion 302 illustrated in FIG. 3. In certain exemplary implementations, the content of abrasive particles, filler, and / or the bond material may be substantially the same between the first abrasive portion 402 and the second abrasive portion 404. In some other instances, one or more of the content of the abrasive particles, the content of the filler, and / or the content of the bond material may be different between the first abrasive portion 402 and the second abrasive portion 404.

[0063] The first abrasive portion 402 can have a thickness 408, and the second abrasive portion 404 can have a thickness 410. As illustrated, the non-abrasive portion 406 can have a thickness 412. The thickness 408 can be substantially the same as or different from the thickness 410. The thickness 412 can be substantially the same or different with respect to the thickness 408, the thickness 410, or both. In an embodiment, the total of the thickness 408, 410, and 402 may make up the thickness of the body 410, which may include any of the features described with respect to the thickness 304 illustrated in FIG. 3.

[0064] FIG. 5 includes a cross-sectional view of an exemplary abrasive article 500 in the shape of a cutting wheel in accordance with another embodiment. The abrasive article 500 can include a body 510 including a mounting hole 501and an abrasive portion 506 coupled to a first non-abrasive portion 502 and a second non-abrasive portion 504. The first non- abrasive portion 502 and the second non-abrasive portion 504 may include a reinforcement component including a same or different material including any of the reinforcement materials noted in embodiments herein. In a particular example, the first non-abrasive portion 502 and a second non-abrasive portion 504 may include glass cloth.

[0065] FIG. 6 includes a cross-sectional view of an exemplary abrasive article 600 having a body 610 in accordance with an embodiment. The body 610 can include a mounting hole 601, an outer abrasive portion 606, and a central non-abrasive portion 603. The abrasive portion 606 can be coupled or bonded to the non-abrasive portion 603. The abrasive portion 606 can include any of the features described in embodiments with respect to the abrasive portion 302 illustrated in FIG. 3. In an embodiment, the non-abrasive portion 603 may include a reinforcement component. In another embodiment, the non-abrasive portion 603 may include abrasive particles and / or filler particles contained in an organic bond material, wherein the central non-abrasive portion 603 may not be used as a work surface or contact a workpiece. The bond material of the central non-abrasive portion 603 may include any of the bond materials described in embodiments herein. The bond material of the non-abrasive portion 603 may be substantially the same as or different from the bond material of the abrasive portion 606. In an embodiment, the central non-abrasive portion 603 may include abrasive particles including one or more types of the abrasive particles noted in this disclosure. In another embodiment, the central non-abrasive portion may include filler particles including one or more of conventional filler materials.

[0066] Turning to FIG. 10, a cross-sectional view of an exemplary abrasive article 1000 is illustrated, including a body 1001 including a depressed center configuration, in accordance with an embodiment. The body 100 lean include a mounting hole 1004 having a diameter 1010 and an abrasive portion 1020 having a thickness 1040. The diameter 1010 may include any of the features described in embodiments with respect to the diameter 206 illustrated in FIG. 2. The thickness 1040 can include any of the features described with respect to the thickness 304 illustrated in FIG. 3. The body 1001 may also include an outer diameter 1080, which may include any of the features described in embodiments with respect to the outer diameter 208 illustrated in FIG. 2. The abrasive portion 1020 can include any of the features described in embodiments with respect to the abrasive portion 302 illustrated in FIG. 3.

[0067] Referring to FIG. 7, a cross-sectional view of an exemplary abrasive article 700 is illustrated, including a body 730 having a depressed center configuration in accordance with an embodiment. The body 730 may include a mounting hole 701, a first abrasive portion 702, and a second abrasive portion 704. The first abrasive portion 702 and the second abrasive portion 704may include any of the features described in embodiments with respect to the abrasive portion 302 illustrated in FIG. 3. Additionally, the body 730 may include a first non-abrasive portion 706 and a second non-abrasive portion 708. Further, the first abrasive portion 702 and the second abrasive portion 704 can each have a respective thickness, such as thickness 710. The first non-abrasive portion 706 and the second non- abrasive portion 708 can each have a respective thickness, such as thickness 712. In an embodiment, the total thickness of the abrasive portions 702 and 704 and the non-abrasive portions 706 and 708 may make up the thickness of the body 730. The thickness of the body 730 may include any of the features described with respect to the thickness 304 illustrated in FIG. 3. In a further embodiment, the first non-abrasive portion 706 and the second non- abrasive portion 708 may include a same or different reinforcement component.

[0068] FIG. 8 includes a cross-sectional view of an exemplary abrasive article 800 including a body 810 having a depressed center configuration in accordance with an additional embodiment. The body 800 can include a mounting hole 801, a first abrasive portion 802, and a second abrasive portion 804. The first abrasive portion 802 and the second abrasive portion 804 may include any of the features described in embodiments with respect to the abrasive portion 302 illustrated in FIG. 3. The body 810 may further include a first nonabrasive portion 806, a second non-abrasive portion 808, and a third non-abrasive portion 810. In an embodiment, the first non-abrasive portion 806, the second non-abrasive portion 808, and the third non-abrasive portion 810 may include a same or different reinforcement component between one another. In the illustrative embodiment of FIG. 8, the third non- abrasive portion 810 may extend for a portion of the outer diameter 820. In another embodiment, more than one non-abrasive portion may extend from the center of the body 810 for a distance less than the outer diameter 820. In still another embodiment, at least one or all of the non-abrasive portions may extend from the center for the full length of the outer diameter.

[0069] FIG. 9 includes a cross-sectional view of an exemplary article including a body 901 having a depressed center configuration in accordance with a further embodiment. The body 901 may include a mounting hole 920, a first abrasive portion 902, a second abrasive portion 904, and a third abrasive portion 906. The first abrasive portion 902, the second abrasive portion 904, and the third abrasive portion 906 may include any of the features described in embodiments with respect to the abrasive portion 302 illustrated in FIG. 3. The body 901 may further include a first non-abrasive portion 908 and a second non-abrasive portion 910. In an embodiment, the first non-abrasive portion 908 and the second non-abrasive portion 910 may include a same or different reinforcement component between one another.

[0070] 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 items as listed below.

[0071] EXAMPLES

[0072] Example 1

[0073] Sample abrasive wheels in the form of chop saws are formed according to embodiments described herein. Novolac and resole resins are used as bond precursors. All the wheel samples have a body having the outer diameter of 405-408 mm and the thickness of 3.5 mm. Sample SI includes the composition of Table 1. types of workpieces as summarized in Table 4. A grinding machine of 7.5kW (3000 rpm) is used to operate the wheel samples. A group of 2-3 wheels are tested for each of Samples SI, CS2, and CS3 using the same workpiece. Each wheel is consumed to the point that it can no longer be used. The number of cuts is counted and the average of the group of wheels is taken as the cut number for the Sample the group represents. Table 4

[0074] Sample SI demonstrates improved cutting compared to Sample CS2 and CS3 on all the tested workpieces, which suggests improved service life of SI over CS2 and CS3 on a diversity of workpieces. For example, Sample SI demonstrates at least 40% of increased cut numbers compared to Sample CS2, and at least 15% of increased cut numbers compared to Sample CS3.

[0075] Example 2

[0076] Additional wheel samples in the form of chop saws having the diameter of 16 inches are formed according to embodiments herein, having the compositions summarized in Table 5 below. The resin bond and abrasive particles are the same for all the samples. The content of the noted ingredient is the volume of the ingredient relative to the total volume of the grains (abrasive particles), the bond material, and the filler (pyrite and PAF). CF+B is the total content of the filler and the bond material relative to the total volume of the grains, the bond material, and the filler. CF / B+F is the total content of the filler relative to the total volume of the filler and the bond material. The samples have similar porosity, approximately 18 vol% for the total volume of the abrasive portion. Table 5

[0077] 'he wheels samples are tested on cutting SS304 workpieces having the casting riser with the cross-sectional area of 2400 mm2. A grinding machine of 7.5kW (3000 rpm) is used to operate the wheel samples. A group of 2-3 wheels are tested for each of Samples SI and CS4 to CS6 using the same workpiece. Each wheel is consumed to the point that it can no longer be used. The number of cuts is counted and the average of the group of wheels is taken as the cut number for the Sample the group represents. The results are included in Table 5.

[0078] Sample SI demonstrates significantly improved cutting numbers over Samples CS4, CS5, and CS6.

[0079] Example 3

[0080] Additional wheel samples in the form of ultra thin wheels are formed according to embodiments herein, having the compositions summarized in Table 6 below. The samples have the same resin bond and fused alumina abrasive particles. The content of each noted ingredient is the volume of the ingredient relative to the total volume of the grains (abrasive particles), the bond material, and the filler (pyrite and PAF). CF+B is the total content of the filler and the bond material relative to the total volume of the grains, the bond material, and the filler. CF / B+F is the total content of the filler relative to the total volume of the filler and the bond material. The samples have similar porosity, approximately 18 vol% for the total volume of the abrasive portion.

[0081] Table 6 The wheel samples are tested on cutting stainless steel workpieces. A group of 2-3 wheels are used for the testing of Samples SI and CS8 on the same workpiece. The test is manually conducted on SS304 plates of 100* 1.8 mm, using an angle grinder (Hitachi; 705W; 12000 rpm). Each wheel made 30 cuts on the workpiece, and G ratio was calculated based on the wheel consumptions, wherein G Ratio=(total area of the cross sections of work pieces being generated) / (total area of wheel consumption). The results are included in Table 6. Sample S7 demonstrates significantly improved cutting performance over Sample CS8.

[0082] Example 4

[0083] Additional wheel samples in the form of chop saws are formed according to embodiments herein, having the compositions summarized in Table 7 below. The samples have the same resin bond and fused alumina abrasive particles. The content of each noted ingredient is the volume of the ingredient relative to the total volume of the grains (abrasive particles), the bond material, and the filler (pyrite and PAF). CF+B is the total content of the filler and the bond material relative to the total volume of the grains, the bond material, and the filler. CF / B+F is the total content of the filler relative to the total volume of the filler and the bond material. The samples have similar porosity, approximately 18 vol% for the total volume of the abrasive portion.

[0084] Table 7

[0085] The wheel samples are tested on cutting bars of stainless steel 304. The bars have a diameter of 20 mm and 6 bars are lined up for the cutting test. 25 cuts are made. Grinding ratio (G ratio) is evaluated and included in Table 7. Sample CS4 is representative of the state of art. Samples 10-12 demonstrate improved grinding ratios over CS4. Increases in G ratio are 23%, 26%, and 56%, respectively, for Samples 10-12 compared to CS4. G ratios of Samples 13-14 increased 30%, 26%, and 15% over CS4, respectively.

[0086] The foregoing embodiments are directed to bonded abrasive articles, and particularly cutting wheels, such as chop saws, ultra thin wheels, and the like, which represent a departure from the state-of-the-art. The cutting wheels of the embodiments herein utilize a combination of features that facilitate unexpected improvement in performance over conventional cutting wheels. Not wishing to be bound to any theory, improvement in performance may be facilitated by utilizing a particular combination of filler materials in particular content ratios, in combination with one or more of the content of filler relative to the content of the bond material, the total content of filler and the bond material, and the content of the abrasive particles.

[0087] Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims. Reference herein to a material including one or more components may be interpreted to include at least one embodiment wherein the material consists essentially of the one or more components identified. The term “consisting essentially” will be interpreted to include a composition including those materials identified and excluding all other materials except in minority contents (e.g., impurity contents), which do not significantly alter the properties of the material. Additionally, or in the alternative, in certain non-limiting embodiments, any of the compositions identified herein may be essentially free of materials that are not expressly disclosed. The embodiments herein include a range of contents for certain components within a material, and it will be appreciated that the contents of the components within a given material total 100%.

[0088] 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 of 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 subcombination. 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 IS:

1. An abrasive article, comprising a body comprising an abrasive portion, wherein the abrasive portion comprises: abrasive particles contained in a bond material, wherein the bond material comprises an organic material; and filler including iron disulfide and potassium aluminum fluoride, wherein a ratio of a content of iron disulfide, Cpes2, to a content of potassium aluminum fluoride, CPAF, is greater than 0.53 and less than 0.71, wherein Cpes2 is a volume of iron disulfide relative to a total volume of the filler, and wherein CPAF is a volume of potassium aluminum fluoride relative to the total volume of the filler.

2. The abrasive article of claim 1, wherein the ratio of Cpes2 to CPAF is at least 0.55 and at most 0.70.

3. The abrasive article of claim 1 or 2, wherein the content of iron disulfide, Cpes2, is at least 3.5 vol% and at most 10.2 vol% for a total volume of the abrasive particles, the filler, and the bond material.

4. The abrasive article of claim 1 or 2, wherein the content of potassium aluminum fluoride, CPAF, is at least 4.7 vol% and at most 14.3 vol% for the total volume of the abrasive particles, the filler, and the bond material.

5. The abrasive article of claim 1 or 2, wherein the abrasive portion comprises a total content of filler, CF / (B+F), of at least 22.0 vol% and less than 38 vol% relative to a total volume of the filler and the bond material.

6. The abrasive article of claim 1 or 2, wherein the abrasive portion comprises for the total volume of the abrasive particles, the filler, and the bond material: a total content of the filler, CF, of at least 8.2 vol% and at most 20.3 vol%; a content of the bond material of at least 32.0 vol% and at most 41.0 vol%; a content of the abrasive particles of at least 43.2 vol% and at most 57.5 vol%; or any combination thereof.

7. The abrasive article of claim 6, wherein the filler consists essentially of iron disulfide (FeS2) and potassium aluminum fluoride.

8. The abrasive article of claim 1 or 2, wherein the abrasive portion comprises a total content of the filler and the bond material, C(F+B), of at least 43.0 vol% and at most 56.4 vol% relative to the total volume of the abrasive particles, the filler, and the bond material.

9. The abrasive article of claim 1 or 2, wherein the ratio of Cpes2 to CPAF is at least 0.58 and at most 0.68.

10. The abrasive article of claim 1 or 2, wherein the filler consists essentially of iron disulfide (FeS?) and potassium aluminum fluoride.

11. The abrasive article of claim 10, wherein the ratio of Cpes2 to CPAF is at least 0.58 and at most 0.68.

12. The abrasive article of claim 1 or 2, wherein the body comprises a non-abrasive portion coupled to the abrasive portion.

13. The abrasive article of claim 12, wherein the non-abrasive portion comprises one or more reinforcement layers comprising a material including a fabric, a fiber, a film, a woven material, a non-woven material, a glass, a fiberglass, a ceramic, a polymer, a resin, a fluorinated polymer, an epoxy resin, a polyester resin, a polyurethane, a polyester, a rubber, a polyimide, a polybenzimidazole, an aromatic polyamide, a modified phenolic resin, or any combination thereof.

14. The abrasive article of claim 13, wherein the abrasive portion comprises a total content of filler, CF / (B+F), of at least 26 vol% and at most 34 vol% relative to a total volume of the filler and the bond material.

15. The abrasive article of claim 1 or 2, comprising a fixed abrasive article comprising grinding wheels, chop saws, cut-off wheels, or any combination thereof.

Images