Fixed Abrasive Articles with Agglomerated Particles
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Solution Overview
Problem
Existing abrasive articles lack optimal comfort of use and performance while maintaining good handfeel, particularly in material removal operations such as grinding and polishing, due to limitations in the distribution of porosity and composition of abrasive particles.
Innovation Solution
The development of fixed abrasive articles with a specific distribution of agglomerated abrasive particles and a binder system, including a mixture of primary abrasive particles like brown fused alumina and a vitrified bond composition, which enhances the manufacturing and performance of the abrasive articles by optimizing the volume percentage of agglomerated primary abrasive particles and binder content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the volume percentage of agglomerated primary abrasive particles is increased to improve material removal efficiency, then productivity is improved, but the handfeel and comfort of use deteriorate
Solution Approach 1:
The patent applies local quality by creating different porosity zones within the abrasive article. The body contains a first porosity and a second porosity that is different from the first, with the porous structure strategically distributed to balance cutting performance and handfeel. This allows high abrasive particle concentration in cutting zones while maintaining comfort in contact zones.
Solution Approach 2:
The patent utilizes porous materials by incorporating a controlled porous structure throughout the abrasive article body. The porosity ranges from 5-40% and is distributed to optimize both performance and comfort. The porous network allows for better particle distribution and reduces density, improving handfeel while maintaining cutting efficiency.
2Productivity
If the abrasive particle concentration is increased to enhance performance, then material removal efficiency is improved, but the comfort of use deteriorates
Solution Approach 1:
The patent implements local quality by varying the abrasive particle concentration and porosity in different regions of the article. Agglomerated abrasive particles are concentrated in specific zones for enhanced cutting, while other zones maintain lower concentration and higher porosity for comfort, resolving the contradiction between performance and usability.
Solution Approach 2:
The patent employs composite materials by combining agglomerated abrasive particles with a binder system in a porous matrix. This composite structure allows optimization of different properties in different phases - the abrasive agglomerates provide cutting power while the porous binder matrix provides comfort and structural integrity.
3Ease of operation
If the porosity distribution is optimized to improve comfort of use, then ease of operation is improved, but manufacturing precision becomes more difficult to control
Solution Approach 1:
The patent applies preliminary action by pre-forming abrasive particle agglomerates with controlled size and composition before incorporating them into the article body. This pre-agglomeration allows better control over the final porosity distribution and reduces variability in the manufacturing process, making it easier to achieve consistent comfort and performance.
Data Source
AI summary
An abrasive article with a bonded abrasive body having a ratio of diameter to thickness of at least 10:1. The abrasive article can include secondary abrasive particles contained in a bond material, wherein the secondary abrasive particles include agglomerated primary abrasive particles.