Abrasive Article Binder via Melt-Flowable Composition
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Solution Overview
Problem
There is a need for bonded abrasives with improved abrading properties and reduced costs while maintaining performance levels, as existing bonded abrasives face limitations in efficiency and cost-effectiveness.
Innovation Solution
A method of making abrasive articles by providing a porous abrasive member with openings, urging a malleable thermosetting melt-flowable composition comprising novolac phenolic resin and furfuryl alcohol through the openings, and heating to form a cross-linked reaction product, which can be reinforced with scrims to create a durable bonded abrasive article.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional bonded abrasives are used, then manufacturing cost is reduced, but abrading performance and cutting efficiency deteriorate
Solution Approach 1:
The invention changes the chemical composition parameters of the binder system by using a two-component thermosetting system (epoxy resin combined with phenolic resin or polyamide resin) instead of conventional single-component binders. This parameter change enables superior adhesion between abrasive particles and the substrate, resulting in enhanced abrading performance and cutting efficiency while maintaining manufacturing cost-effectiveness through the use of commercially available resin systems.
Solution Approach 2:
The invention employs a composite binder system combining epoxy resin with either phenolic resin or polyamide resin. This composite material approach creates a synergistic effect where the epoxy provides strong adhesion and the phenolic/polyamide component contributes to thermal stability and cross-linking density, delivering improved abrading performance without proportionally increasing manufacturing cost.
2Strength
If binder material is increased to improve adhesion, then strength increases, but porosity and cooling efficiency deteriorate
Solution Approach 1:
The invention optimizes the binder composition parameters by using a thermosetting system with controlled cross-linking density. The epoxy-phenolic or epoxy-polyamide combination allows achieving high adhesion strength through chemical cross-linking rather than increasing binder quantity, thereby maintaining porosity and allowing coolant penetration while securing abrasive particles effectively.
Solution Approach 2:
The invention replaces mechanical adhesion (relying on binder quantity and physical bonding) with chemical adhesion through thermosetting cross-linking reactions. The epoxy resin forms strong covalent bonds with abrasive particles and the substrate, achieving high strength with minimal binder content, thus preserving porosity for coolant flow.
3Productivity
If wheel speed is increased to improve productivity, then cutting speed increases, but wheel integrity and safety deteriorate
Solution Approach 1:
The invention changes the thermal and mechanical property parameters of the binder system by using a thermosetting cross-linked network. This network provides exceptional thermal stability and mechanical strength, enabling the abrasive wheel to withstand high rotational speeds and the thermal stresses generated during cutting operations, thereby maintaining wheel integrity and safety at high cutting speeds.
Solution Approach 2:
The composite thermosetting binder system (epoxy with phenolic or polyamide) provides a balanced combination of properties: epoxy contributes to mechanical strength and adhesion, while phenolic/polyamide components enhance thermal stability and resistance to thermal shock. This composite structure enables safe operation at high wheel speeds by withstanding the combined mechanical and thermal stresses.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method results in abrasive articles with enhanced abrading performance and reduced costs, offering improved cutting and grinding efficiency while maintaining durability and performance.
Implementation Method 1
urging a malleable thermosetting melt-flowable composition through the openings in the porous abrasive member
Implementation Method 2
both of the first and second major surfaces comprise a cross-linked reaction product of the malleable thermosetting melt-flowable composition
Implementation Method 3
the malleable thermosetting melt-flowable composition comprises novolac phenolic resin and furfuryl alcohol
Implementation Method 4
heating the abrasive article precursor to form the abrasive article
Data Source
Figure 1~2
Figure 3~4A
Figure 4B
AI summary
A method of making an abrasive article comprises urging a malleable thermosetting melt-flowable composition through openings extending through a porous abrasive member to form an abrasive article precursor; which is heated to form the abrasive article. Multiple abrasive articles may be stacked prior to heating. Methods can be used to fabricate abrasive articles such as grinding wheels and cut-off wheels.