Composite Abrasive Body with Ceramic Bond and Pores

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Solution Overview

Problem

Conventional bonded abrasives with vitrified bonds have limited performance properties due to the nature of the bond material, abrasive grains, and the presence and composition of pores within the bond, which affect the microstructure and effectiveness of grinding or polishing processes.

Innovation Solution

A composite body is developed with a ceramic bond material that includes pores, where the pore-defining composition has a distinct melting point and hardness from the ceramic material, and is formed using a process involving a mixture of glass powder and a pore former to create a three-dimensional matrix with embedded abrasive particles, enhancing porosity and structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional vitrified bond materials are used in bonded abrasives, then the bond material provides structural integrity, but the performance properties are limited due to the uniform composition and lack of controlled pore structure

Engineering Contradiction:

Improveperformance propertiesVSAvoidbond material composition

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies local quality by creating distinct regions within the bond material: a first region with a first composition containing pores, and a second region with a second composition. This allows different local properties - the first region provides controlled porosity for chip evacuation and reduced clogging, while the second region provides structural support and bonding strength, thereby improving overall performance without excessive complexity

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent uses composite materials by combining multiple compositions within the bond material. The bond material comprises a first composition with pores formed from a pore-forming agent, and a second composition that is different from the first. This composite structure enables the bond material to simultaneously achieve porosity for improved grinding performance and structural integrity, resolving the limitation of conventional uniform vitrified bonds

Inventive Principle:

Principle #40Composite materials

2Productivity

If pores are introduced into the bond material to improve chip evacuation and reduce clogging, then grinding performance is enhanced, but the structural integrity and strength of the bond material may be compromised

Engineering Contradiction:

Improvegrinding performanceVSAvoidbond material strength

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent uses porous materials by incorporating pores into the first composition of the bond material. These pores are formed using a pore-forming agent and provide channels for chip evacuation and coolant flow, reducing clogging and improving grinding performance. The porous structure is localized to the first region, allowing the second region to maintain structural integrity

Inventive Principle:

Principle #31Porous materials

3Temperature

If the pore defining composition has a melting point not less than the ceramic material, then thermal stability is improved during grinding operations, but the manufacturing process complexity increases

Engineering Contradiction:

Improvethermal stabilityVSAvoidmanufacturing process

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The patent applies parameter changes by specifying that the pore defining composition has a melting point not less than the melting point of the ceramic material. This parameter control ensures thermal stability during grinding operations, as the pore structure remains intact at operating temperatures. The composition is designed to maintain its physical properties under thermal stress, improving reliability without requiring complex manufacturing processes

Inventive Principle:

Principle #35Parameter changes

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 composite body exhibits improved grinding performance, wear resistance, and reduced power consumption, with clear demarcation of the pore former within the bond material, leading to enhanced grinding behavior and performance characteristics.

Implementation Method 1

a pore former comprising a first pore former composition... forming the composite body mixture into a composite body comprising a bond material including a ceramic material and a region surrounding a pore in the bond material... The first pore defining composition has a melting point not less than a melting point of a composition of the ceramic material

Methodology Applied

Scientific EffectPhase change: Phase Change

Data Source

PatentEP3089850B1Composite bodies and methods of forming the same

Publication Date: 2021.12.08 SAINT GOBAIN ABRASIVES INC

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AI summary

A composite body is provided that can include abrasive grains and at least one pore within a bond matrix, the abrasive grains including cubic boron nitride (cBN) and the bond matrix including a polycrystalline ceramic phase. The bonded abrasive may have a Modulus of Rupture (MOR) of not less than about 40 MPa. Certain embodiments may have porosity, such as, greater than about 5.0 vol%.