Abrasive Articles With Ceramic-Particle Bond Compositions for Material Removal
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Solution Overview
Problem
Existing abrasive articles lack improved performance in material removal operations due to limitations in particle size distribution and composition of abrasive and bond materials.
Innovation Solution
Incorporating ceramic particles with specific size distributions and properties into the bond material of abrasive articles, where the ceramic particles have an average size of at least 2 microns and at most 75 microns, enhancing the performance and properties of the abrasive articles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional abrasive articles are used, then the structure is simple and easy to manufacture, but the material removal efficiency and performance are insufficient
Solution Approach 1:
The patent applies composite materials by combining abrasive particles with ceramic particles (such as alumina, silica, or zirconia) within the bond material matrix. This composite structure enhances the abrasive article's performance by providing both cutting ability from the abrasive particles and structural support/wear resistance from the ceramic particles, thereby improving material removal efficiency while managing the increased compositional complexity through systematic material integration.
2Reliability
If ceramic particles with specific size distribution are added to the bond material, then the wear rate and power draw improve, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies parameter changes by optimizing the ceramic particle size distribution within specific ranges (D10: 1-10 microns, D50: 2-75 microns, D90: 10-200 microns) and controlling the weight percentage (1-50% of total particles). These parameter optimizations enhance wear rate performance and power draw characteristics while managing manufacturing complexity through defined specification ranges that facilitate controlled production processes.
3Strength
If the ceramic particle size is increased, then the bond material strength improves, but the pores surrounded by ceramic particles decrease
Solution Approach 1:
The patent applies local quality by creating different functional zones within the abrasive article structure. Larger ceramic particles (D90: 10-200 microns) are distributed to provide structural strength and support in load-bearing regions, while smaller ceramic particles (D10: 1-10 microns) are present to maintain pore structure and facilitate coolant flow. This spatial differentiation of particle sizes optimizes both bond material strength and pore volume for different functional requirements within the same article.
Data Source
AI summary
An abrasive article can include a body including abrasive particles contained in the body and ceramic particles contained within a bond material. The ceramic particles can have an average particle size D50c of at least 2 microns and at most 75 microns. The abrasive particles can include an average particle size D50a greater than the average particle size D50c.