U.S. patent application number 17/646174 was filed with the patent office on 2022-06-30 for abrasive article and method of use.
The applicant listed for this patent is SAINT-GOBAIN ABRASIFS, SAINT-GOBAIN ABRASIVES, INC.. Invention is credited to Taewook HWANG, Cecile O. MEJEAN, Samuel H. ODEH.
Application Number | 20220203502 17/646174 |
Document ID | / |
Family ID | |
Filed Date | 2022-06-30 |
United States Patent
Application |
20220203502 |
Kind Code |
A1 |
MEJEAN; Cecile O. ; et
al. |
June 30, 2022 |
ABRASIVE ARTICLE AND METHOD OF USE
Abstract
An abrasive article including a body comprising abrasive
segments coupled to a major planar surface of a substrate, where a
first abrasive segment comprises a first wear life index (w1) that
is different than a second wear life index (w2) of the second
abrasive segment by at least 5%.
Inventors: |
MEJEAN; Cecile O.; (Acton,
MA) ; HWANG; Taewook; (Acton, MA) ; ODEH;
Samuel H.; (Greer, SC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SAINT-GOBAIN ABRASIVES, INC.
SAINT-GOBAIN ABRASIFS |
Worcester
Conflans-Sainte-Honorine |
MA |
US
FR |
|
|
Appl. No.: |
17/646174 |
Filed: |
December 28, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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63131524 |
Dec 29, 2020 |
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International
Class: |
B24D 11/04 20060101
B24D011/04; B24B 9/02 20060101 B24B009/02 |
Claims
1. An abrasive article comprising: a body comprising abrasive
segments coupled to a major planar surface of a substrate; wherein
the abrasive segments include a first abrasive segment and a second
abrasive segment; wherein the first set abrasive segment has a
first bond composition and the second abrasive segment has a second
bond composition, and the first bond composition and the second
bond composition are different; and further wherein the first
abrasive segment comprises a first wear life index (w1) that is
different than a second wear life index (w2) of the second abrasive
segment by at least 5%.
2. The abrasive article of claim 1, wherein the first wear life
index is at least 1.
3. The abrasive article of claim 1, wherein the first wear life
index is not greater than 15.
4. The abrasive article of claim 1, wherein the second wear life
index is not greater than 2.
5. The abrasive article of claim 1, wherein the second wear life
index is at least 0.05.
6. The abrasive article of claim 1, wherein the first wear life
index (w1) is different than the second wear life index (w2) of the
second abrasive segment by at least 10%.
7. The abrasive article of claim 1, wherein the first wear life
index (w1) is different than the second wear life index (w2) of the
second abrasive segment by not greater than 99%.
8. The abrasive article of claim 1, wherein the difference between
the first wear life index and the second wear life is at least
1.
9. The abrasive article of claim 1, wherein the difference between
the first wear life and the second wear life is not greater than
12.
10. The abrasive article of claim 1, wherein the ratio of the first
wear life index to the second wear life, w1/w2, is at least 1.
11. The abrasive article of claim 1, wherein w1/w2 is not greater
than 25.
12. The abrasive article of claim 1, wherein the body comprises a
first set of abrasive segments having the first bond composition
and a second set of abrasive segments having the second bond
composition, wherein the first set of abrasive segments provides a
first abrasive surface area SA1 and the second set of abrasive
segments provides a second abrasive surface area SA2, and wherein
the first abrasive surface area to the second abrasive surface
area, SA1/SA2, is at least 0.15.
13. The abrasive article of claim 1, wherein the first set of
abrasive segments provides a first abrasive surface area SA1 and
the second set of abrasive segments provides a second abrasive
surface area SA2, and wherein the first abrasive surface area to
the second abrasive surface area, SA1/SA2, is not greater than
10.
14. The abrasive article of claim 1, wherein the first abrasive
segment comprises a first set of abrasive particles having a median
particle size D50ap1 and a second set of abrasive particles having
a median particle size D50ap2, wherein D50ap2/D50ap1 is at least
1.1.
15. The abrasive article of claim 1, wherein the first bond
composition comprises a vitreous bond material.
16. The abrasive article of claim 1, wherein the second bond
composition comprises a resinous bond material.
17. The abrasive article of claim 1, further comprising a plurality
of abrasive bodies attached to a major planar surface of a
substrate, wherein the plurality of abrasive bodies includes a
plurality of first abrasive bodies and a plurality of second
abrasive bodies, wherein the first and second abrasive bodies are
arranged in a radial alternating manner relative to each other.
18. The abrasive article of claim 1, wherein the abrasive article
is a cup wheel.
19. A method of using the abrasive article of claim 1, comprising
edge grinding.
20. A method of using the abrasive article of claim 1, comprising
grinding a material that comprises AlTiC.
Description
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application claims priority under 35 U.S.C. .sctn.
119(e) to U.S. Provisional Patent Application No. 63/131,524, filed
Dec. 29, 2020, by Cecile O. MEJEAN, et al., entitled "ABRASIVE
ARTICLE AND METHOD OF USE," which is assigned to the current
assignee hereof and incorporated herein by reference in its
entirety for all purposes.
BACKGROUND
Field of the Disclosure
[0002] The following is directed to an abrasive article, and
particularly, an abrasive article including bonded abrasive
segments.
Description of the Related Art
[0003] A variety of abrasive tools have been developed over the
past century for various industries for the general function of
removing material from a workpiece, including, for example, sawing,
drilling, polishing, cleaning, carving, and grinding. Abrasive cup
wheels are typically used for edge grinding AlTiC for HDDs. Cup
wheels that provide the necessary precision can become less
accurate quickly as the wheels wear down. Cup wheels made of longer
lasting materials do not provide the finish necessary for certain
applications. The industry continues to demand improved cup wheel
materials, capable of achieving improved grinding performance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] 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.
[0005] FIG. 1 includes an illustration of an abrasive article
according to an embodiment.
DETAILED DESCRIPTION
[0006] The following description in combination with the FIGURES is
provided to assist in understanding the teachings provided herein.
The following disclosure 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. However,
other teachings can certainly be used in this application.
[0007] 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 method, article, or apparatus that comprises a list of
features is not necessarily limited only to those features but may
include other features not expressly listed or inherent to such
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).
[0008] Also, 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. For example,
when a single item is described herein, more than one item may be
used in place of a single item. Similarly, where more than one item
is described herein, a single item may be substituted for that more
than one item.
[0009] 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. To the extent that certain details
regarding specific materials and processing acts are not described,
such details may include conventional approaches, which may be
found in reference books and other sources within the manufacturing
arts.
[0010] The following is directed toward abrasive articles, and more
particularly, an abrasive article that includes one or more
abrasive bodies, particularly, abrasive bodies of different
abrasive characteristics. The abrasive bodies can be in the form of
bonded abrasive bodies, having abrasive particles contained within
a three-dimensional volume of bond material. The abrasive article
may be suitable for grinding a workpiece, and particularly suited
for grinding of hard materials, and more particularly, AlTiC.
[0011] In an embodiment, an abrasive article 100 can include a body
comprising abrasive segments 101 coupled to a major planar surface
of a substrate 102. The abrasive segments include a first abrasive
segment and a second abrasive segment; wherein the first set
abrasive segment has a first bond composition, and the second
abrasive segment has a second bond composition, and the first bond
composition and the second bond composition are different; and
further wherein the first abrasive segment comprises a first wear
life index (w1) that is different than a second wear life index
(w2). The wear life index of an abrasive segment may be measured by
rubbing the wheel against a 320 mesh SiC sandpaper under a constant
normal force of 30N for 10 s with water coolant and measuring the
amount of material removed.
[0012] In an embodiment, the first abrasive segment can be prepared
from a mixture.
[0013] In an embodiment, the wear life index of the first abrasive
segment w1 may be a particular wear life index that provides
improved manufacturing and/or performance of the abrasive article.
In an embodiment, w1 can be at least 1, at least 2, at least 3, at
least 4, at least 5, or at least 6. In an embodiment, w1 can be not
greater than 8, not greater than 9, not greater than 10, not
greater than 11, not greater than 12, not greater than 13, not
greater than 14 or not greater than 15. It will be appreciated w1
may be between any of the maximum and minimum values noted above,
including, for example, but not limited to, at least 1 and not
greater than 8, at least 2 and not greater than 13, or at least 6
and not greater than 8.
[0014] In an embodiment, the wear life index of the second abrasive
segment w2 may be a particular wear life index that provides
improved manufacturing and/or performance of the abrasive article.
In an embodiment, w2 can be at least 0.05, at least 0.1, at least
0.15, at least 0.2, or at least 0.25. In an embodiment, w2 can be
not greater than 2, not greater than 1.5, not greater than 1.25,
not greater than 1, not greater than 0.9, or not greater than 0.8.
It will be appreciated w1 may be between any of the maximum and
minimum values noted above, including, for example, but not limited
to, at least 0.1 and not greater than 0.8, at least 0.2 and not
greater than 1.25, or at least 0.15 and not greater than 1.
[0015] In an embodiment, the w1 and w2 can have a particular
difference that provides improved manufacturing and/or performance
of the abrasive article. In an embodiment, w1 and w2 can be
different by at least 5%, at least 10%, or at least 15%, or at
least 20%, or at least 25%. In an embodiment, w1 and w2 can be
different by at least 1, or at least 2, or at least 3, or at least
4, or at least 5. In an embodiment, the difference between w1 and
w2 can be not greater than 12, not greater than 11, not greater
than 10, not greater than 9, not greater than 8, or not greater
than 7. In an embodiment, the difference between w1 and w2 can be
not greater than 99%, or not greater than 98%, or not greater than
97%, or not greater than 96%, or not greater than 95%. It will be
appreciated that the difference between w1 and w2 can be between
any of the minimum and maximum values noted above, including, for
example, at least 1 and not greater than 10, or at least 5% and not
greater than 99%.
[0016] In an embodiment, the abrasive article can include a first
set of abrasive segments having the first bond composition and a
second set of abrasive segments having the second bond composition.
The first set of abrasive segments can provide a first surface area
SA1, and the second set of abrasive segments provides a second
abrasive surface area SA2.
[0017] In an embodiment, the abrasive article can include a
particular ratio of SA1/SA2 that provides improved performance
and/or manufacturing of the abrasive article. In an embodiment,
SA1/SA2 can be at least 0.1, or at least 0.2, or at least 0.3, or
at least 0.4, or at least 0.5. In an embodiment, SA1/SA2 can be not
greater than 10, or not greater than 9, or not greater than 8, or
not greater than 7, or not greater than 6, or not greater than 5.
It will be appreciated that SA1/SA2 can be between any of the
minimum and maximum values noted above, including, for example, but
not limited to at least 0.1 and not greater than 10, at least 0.3
and not greater than 7, or at least 0.5 and not greater than 8.
[0018] In an embodiment, the abrasive segments can be arranged in
an alternating fashion. In an embodiment, the abrasive segments can
be arranged such that the first set of abrasive segments is grouped
together, and the second set of abrasive segments is grouped
together. In an embodiment, the abrasive segments can be arranged
in a series of n1 abrasive segments from the first set of abrasive
segments, followed by n2 abrasive segments from the second set of
abrasive segments, followed again by n1 segments from the first set
of abrasive segments, and so on and so forth. In an embodiment, n1
can be any integer from 1-10. In an embodiment, n2 can be any
integer from 1-10.
[0019] In an embodiment, the first abrasive segment can include a
first set of abrasive particles in a first bond composition.
[0020] The first set of abrasive particles can be a particular
material that size provides improved performance and/or
manufacturing of the abrasive article. In an embodiment, the first
set of abrasive particles can include an oxide, carbide, nitride,
boride, diamond, or any combination thereof.
[0021] The first bond composition can be a particular material that
size provides improved performance and/or manufacturing of the
abrasive article. In an embodiment, the first bond composition can
comprise vitreous bond material, a resinous bond material, or a
metal bond material. In an embodiment, the first bond composition
can comprise vitreous bond material.
[0022] In an embodiment, the second abrasive segment can include a
second set of abrasive particles in a second bond composition. The
second set of abrasive particles can be a particular material that
size provides improved performance and/or manufacturing of the
abrasive article. In an embodiment, the second set of abrasive
particles can include an oxide, carbide, nitride, boride, diamond,
or any combination thereof.
[0023] The second bond composition can be a particular material
that size provides improved performance and/or manufacturing of the
abrasive article. In an embodiment, the second bond composition can
comprise vitreous bond material, a resinous bond material, or a
metal bond material. In an embodiment, the second bond composition
can comprise resinous bond material.
[0024] In an embodiment, the abrasive article can be a cup wheel.
In an embodiment, the abrasive segments can be arranged in a radial
alternating manner relative to each other.
[0025] In an embodiment, the first set of abrasive particles may be
a particular median particle size D50ap1 provides improved
performance and/or manufacturing of the abrasive article. In an
embodiment, D50ap1 can be at least 1 micron, at least 1.1 microns,
or at least 1.2 microns, or at least 1.3 microns, or at least 1.4
microns, or at least 1.5 microns, or at least 1.6 microns, or at
least 1.7 microns, or at least 1.8 microns, or at least 1.9
microns, or at least 2 microns, or at least 2.1 microns, or at
least 2.2 microns, or at least 2.3 microns, or at least 2.4
microns, or at least 2.5 microns. In an embodiment, D50ap1 can be
not greater than 7 microns, or not greater than 7.5 microns, or not
greater than 8 microns, or not greater than 8.5 microns, or not
greater than 9 microns, or not greater than 9.5 microns, or not
greater than 10 microns. It will be appreciated that D50ap1 can be
between any of the minimum and maximum values noted above,
including, for example, but not limited to at least 1 micron and
not greater than 10 microns, or at least 1.5 microns and not
greater than 8 microns.
[0026] In an embodiment, the second set of abrasive particles may
be a particular median particle size D50ap2 that provides improved
performance and/or manufacturing of the abrasive article. In an
embodiment, D50ap2 can be at is at least 5 microns, or at least 5.2
microns, or at least 5.4 microns, or at least 5.6 microns, or at
least 5.8 microns, or at least 6 microns, or at least 6.2 microns,
or at least 6.4 microns, or at least 6.6 microns, or at least 6.8
microns, or at least 7 microns, or at least 7.2 microns, or at
least 7.4 microns, or at least 7.6 microns, or at least 7.8
microns, or at least 8 microns. In an embodiment, D50ap2 can be not
greater than 30 microns, or not greater than 29.5 microns, or not
greater than 29 microns, or not greater than 28.5 microns, or not
greater than 28 microns, or not greater than 27.5 microns, or not
greater than 27 microns, or not greater than 26.5 microns, or not
greater than 26 microns, or not greater than 25.5 microns, or not
greater than 25 microns. It will be appreciated that D50ap2 can be
between any of the minimum and maximum values noted above,
including, for example, but not limited to at least 5 microns and
not greater than 25 microns, or at least 8 microns and not greater
than 25 microns.
[0027] In an embodiment, the abrasive article can include a
particular ratio of D50ap1/D50ap2 that provides improved
performance and/or manufacturing of the abrasive article. In an
embodiment, D50ap1/D50ap2 can be at least 1.1, or at least 1.15, or
at least 1.2, or at least 1.25, or at least 1.3, or at least 1.35,
or at least 1.4, or at least 1.45, or at least 1.5. In an
embodiment, D50ap1/D50ap2 can be no greater than 10, or no greater
than 9.5, or no greater than 9, or no greater than 8.5, or no
greater than 8, or no greater than 7.5, or no greater than 7. It
will be appreciated that D50ap1/D50ap2 can be between any of the
minimum and maximum values noted above, including, for example, but
not limited to at least 1.1 and not greater than 8, or at least 1.2
and not greater than 7.
[0028] In an embodiment, the first abrasive segment can include a
particular wt. % of abrasive particles that provides improved
performance and/or manufacturing of the abrasive article. In an
embodiment, the first segment can include at least 30% abrasive
particles for a total weight of the abrasive segment or at least
31%, or at least 32%, or at least 33%, or at least 34%, or at least
35%, or at least 36%, or at least 37%, or at least 38%, or at least
39%, or at least 40%, or at least 41%, or at least 42%, or at least
43%, or at least 44%, or at least 45% abrasive particles for a
total weight of the abrasive segment. In an embodiment, the first
segment can include not greater than 70% abrasive particles for a
total weight of the abrasive segment, or not greater than 69%, or
not greater than 68%, or not greater than 67%, or not greater than
66%, or not greater than 65%, or not greater than 64%, or not
greater than 63%, or not greater than 62%, or not greater than 61%,
or not greater than 60%, abrasive particles for a total weight of
the abrasive segment. It will be appreciated that the wt. % of
abrasive particles can be between any of the minimum and maximum
values noted above, including, for example, but not limited to at
least 31% and not greater than 67%, or at least 40% and not greater
than 60%.
[0029] In an embodiment, the second abrasive segment can include a
particular wt. % of abrasive particles that provides improved
performance and/or manufacturing of the abrasive article. In an
embodiment, the second segment can include at least 30% abrasive
particles for a total weight of the abrasive segment or at least
31%, or at least 32%, or at least 33%, or at least 34%, or at least
35%, or at least 36%, or at least 37%, or at least 38%, or at least
39%, or at least 40%, or at least 41%, or at least 42%, or at least
43%, or at least 44%, or at least 45% abrasive particles for a
total weight of the abrasive segment. In an embodiment, the second
segment can include not greater than 70% abrasive particles for a
total weight of the abrasive segment, or not greater than 69%, or
not greater than 68%, or not greater than 67%, or not greater than
66%, or not greater than 65%, or not greater than 64%, or not
greater than 63%, or not greater than 62%, or not greater than 61%,
or not greater than 60% abrasive particles for a total weight of
the abrasive segment. It will be appreciated that the wt. % of
abrasive particles can be between any of the minimum and maximum
values noted above, including, for example, but not limited to at
least 31% and not greater than 67%, or at least 40% and not greater
than 60%.
[0030] 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 embodiments as listed below.
EMBODIMENTS
Embodiment 1
[0031] An abrasive article comprising: a body comprising abrasive
segments coupled to a major planar surface of a substrate; wherein
the abrasive segments include a first abrasive segment and a second
abrasive segment; wherein the first set abrasive segment has a
first bond composition and the second abrasive segment has a second
bond composition, and the first bond composition and the second
bond composition are different; and further wherein the first
abrasive segment comprises a first wear life index (w1) that is
different than a second wear life index (w2) of the second abrasive
segment by at least 5%.
Embodiment 2
[0032] The abrasive article of embodiment 1, wherein the first wear
life index is at least 1, at least 2, at least 3, at least 4, at
least 5, or at least 6.
Embodiment 3
[0033] The abrasive article of embodiment 1, wherein the first wear
life index is not greater than 8, not greater than 9, not greater
than 10, not greater than 11, not greater than 12, not greater than
3, not greater than 14 or not greater than 15.
Embodiment 4
[0034] The abrasive article of embodiment 1, wherein the second
wear life index is not greater than 2, not greater than 1.5, not
greater than 1.25, not greater than 1, not greater than 0.9, or not
greater than 0.8.
Embodiment 5
[0035] The abrasive article of embodiment 1, wherein the second
wear life index is at least 0.05, at least 0.1, at least 0.15, at
least 0.2, or at least 0.25.
Embodiment 6
[0036] The abrasive article of embodiment 1, wherein the first wear
life index (w1) is different than the second wear life index (w2)
of the second abrasive segment by at least 5% or at least 10% 10%
or at least 15%, or at least 20%, or at least 25%.
Embodiment 7
[0037] The abrasive article of embodiment 1, wherein the first wear
life index (w1) is different than the second wear life index (w2)
of the second abrasive segment by not greater than 99%, or not
greater than 98%, or not greater than 97%, or not greater than 96%,
or not greater than 95%.
Embodiment 8
[0038] The abrasive article of embodiment 1, wherein the difference
between the first wear life index and the second wear life is at
least 1, or at least 2, or at least 3, or at least 4, or at least
5.
Embodiment 9
[0039] The abrasive article of embodiment 1, wherein the difference
between the first wear life and the second wear life is not greater
than 12, not greater than 11, not greater than 10, not greater than
9, not greater than 8, or not greater than 7.
Embodiment 10
[0040] The abrasive article of embodiment 1, wherein the ratio of
the first wear life index to the second wear life, w1/w2, is at
least 1, or at least 2, or at least 3, or at least 4, or at least
5, or at least 6, or at least 7, or at least 8, or at least 9, or
at least 10.
Embodiment 11
[0041] The abrasive article of embodiment 1, wherein w1/w2 is not
greater than 20, or not greater than 21, or not greater than 22, or
not greater than 23, or not greater than 24, or not greater than
25.
Embodiment 12
[0042] The abrasive article of embodiment 1, wherein the body
comprises a first set of abrasive segments having the first bond
composition and a second set of abrasive segments having the second
bond composition, wherein the first set of abrasive segments
provides a first abrasive surface area SA1 and the second set of
abrasive segments provides a second abrasive surface area SA2, and
wherein the first abrasive surface area to the second abrasive
surface area, SA1/SA2, is at least 0.1, or at least 0.2, or at
least 0.3, or at least 0.4, or at least 0.5.
Embodiment 13
[0043] The abrasive article of embodiment 1, wherein the first set
of abrasive segments provides a first abrasive surface area SA1,
and the second set of abrasive segments provides a second abrasive
surface area SA2, and wherein the first abrasive surface area to
the second abrasive surface area, SA1/SA2 not greater than 10, or
not greater than 9, or not greater than 8, or not greater than 7,
or not greater than 6, or not greater than 5.
Embodiment 14
[0044] The abrasive article of embodiment 1, wherein the first
abrasive segment comprises a first set of abrasive particles having
a median particle size D50ap1, wherein D50 ap1 is at least 1
micron, at least 1.1 microns, or at least 1.2 microns, or at least
1.3 microns, or at least 1.4 microns, or at least 1.5 microns, or
at least 1.6 microns, or at least 1.7 microns, or at least 1.8
microns, or at least 1.9 microns, or at least 2 microns, or at
least 2.1 microns, or at least 2.2 microns, or at least 2.3
microns, or at least 2.4 microns, or at least 2.5 microns.
Embodiment 15
[0045] The abrasive article of embodiment 1, wherein the first
abrasive segment comprises a first set of abrasive particles having
a median particle size D50ap1, wherein D50 ap1 is not greater than
7 microns, or not greater than 7.5 microns, or not greater than 8
microns, or not greater than 8.5 microns, or not greater than 9
microns, or not greater than 9.5 microns, or not greater than 10
microns.
Embodiment 16
[0046] The abrasive article of embodiment 1, wherein the second
abrasive segment comprises a second set of abrasive particles
having a median particle size D50ap2, wherein D50 ap2 is at least 5
microns, or at least 5.2 microns, or at least 5.4 microns, or at
least 5.6 microns, or at least 5.8 microns, or at least 6 microns,
or at least 6.2 microns, or at least 6.4 microns, or at least 6.6
microns, or at least 6.8 microns, or at least 7 microns, or at
least 7.2 microns, or at least 7.4 microns, or at least 7.6
microns, or at least 7.8 microns, or at least 8 microns.
Embodiment 17
[0047] The abrasive article of embodiment 1, wherein the second
abrasive segment comprises a second set of abrasive particles
having a median particle size D50ap2, wherein D50 ap2 is not
greater than 30 microns, or not greater than 29.5 microns, or not
greater than 29 microns, or not greater than 28.5 microns, or not
greater than 28 microns, or not greater than 27.5 microns, or not
greater than 27 microns, or not greater than 26.5 microns, or not
greater than 26 microns, or not greater than 25.5 microns, or not
greater than 25 microns.
Embodiment 18
[0048] The abrasive article of embodiment 1, wherein the first
abrasive segment comprises a first set of abrasive particles having
a median particle size D50ap1 and a second set of abrasive
particles having a median particle size D50ap2, wherein
D50ap2/D50ap1 is at least 1.1, or at least 1.15, or at least 1.2,
or at least 1.25, or at least 1.3, or at least 1.35, or at least
1.4, or at least 1.45, or at least 1.5.
Embodiment 19
[0049] The abrasive article of embodiment 1, wherein the first
abrasive segment comprises a first set of abrasive particles having
a median particle size D50ap1 and a second set of abrasive
particles having a median particle size D50ap2, wherein
D50ap2/D50ap1 is no greater than 10, or no greater than 9.5, or no
greater than 9, or no greater than 8.5, or no greater than 8, or no
greater than 7.5, or no greater than 7.
Embodiment 20
[0050] The abrasive article of embodiment 1, wherein the first set
of abrasive particles comprise a wt. % of the first abrasive
segment of at least 30%, or at least 31%, or at least 32%, or at
least 33%, or at least 34%, or at least 35%, or at least 36%, or at
least 37%, or at least 38%, or at least 39%, or at least 40%, or at
least 41%, or at least 42%, or at least 43%, or at least 44% or at
least 45%.
Embodiment 21
[0051] The abrasive article of embodiment 1, wherein the first set
of abrasive particles comprise a wt. % of the first abrasive
segment of not greater than 70%, or not greater than 69%, or not
greater than 68%, or not greater than 67%, or not greater than 66%,
or not greater than 65%, or not greater than 64%, or not greater
than 63%, or not greater than 62%, or not greater than 61%, or not
greater than 60%.
Embodiment 22
[0052] The abrasive article of embodiment 1, wherein the second set
of abrasive particles comprise a wt. % of the second abrasive
segment of at least 30%, or at least 31%, or at least 32%, or at
least 33%, or at least 34%, or at least 35%, or at least 36%, or at
least 37%, or at least 38%, or at least 39%, or at least 40%, or at
least 41%, or at least 42%, or at least 43%, or at least 44%, or at
least 45%.
Embodiment 23
[0053] The abrasive article of embodiment 1, wherein the second set
of abrasive particles comprise a wt. % of the second abrasive
segment of not greater than 70%, or not greater than 69%, or not
greater than 68%, or not greater than 67%, or not greater than 66%,
or not greater than 65%, or not greater than 64%, or not greater
than 63%, or not greater than 62%, or not greater than 61%, or not
greater than 60%.
Embodiment 24
[0054] The abrasive article of embodiment 1, wherein the first bond
composition comprises a vitreous bond material, a resinous bond
material, or a metal bond material.
Embodiment 25
[0055] The abrasive article of embodiment 1, wherein the first bond
composition comprises a vitreous bond material.
Embodiment 26
[0056] The abrasive article of embodiment 1, wherein the second
bond composition comprises a vitreous bond material, a resinous
bond material, or a metal bond material.
Embodiment 27
[0057] The abrasive article of embodiment 1, wherein the second
bond composition comprises a resinous bond material.
Embodiment 28
[0058] The abrasive article of any of the preceding embodiments
further comprising a plurality of abrasive bodies attached to a
major planar surface of a substrate, wherein the plurality of
abrasive bodies includes a plurality of first abrasive bodies and a
plurality of second abrasive bodies, wherein the first and second
abrasive bodies are arranged in a radial alternating manner
relative to each other.
Embodiment 29
[0059] The abrasive article of embodiment 1, wherein the abrasive
article is a cup wheel.
Embodiment 30
[0060] A method of using the abrasive article of embodiment 1,
comprising edge grinding.
Embodiment 31
[0061] A method of using the abrasive article of embodiment 1,
comprising grinding a material that comprises AlTiC.
Examples
[0062] Vitreous Segments
[0063] Vitreous bond abrasive segments were prepared according to
the following procedure. A mixture of abrasive diamond particles
and glass frit was prepared according to the composition detailed
below in table 1. The mixture was mixed in a Resodyn LabRam
acoustic mixer for 1 min at 100% intensity. A round divot was then
created in the center of the mixture, and a PEG binder was added.
The mixture was again mixed in a Resodyn LabRam acoustic mixer for
1 min at 100% intensity. The mixed powder is then screened through
a 20ss screen and left out to dry overnight. The following day the
mixture is screened again.
TABLE-US-00001 TABLE 1 Material Size Wt. % Abrasive Diamond
Particles 3-6 .mu.m 45-55% Glass Frit 2-4 .mu.m 35-40% PEG Binder
10-15%
[0064] The mix was molded in a steel mold with a diameter of 5.02''
and a target molded thickness of 0.325''. The mold was pressed with
25 tons of force for 15 seconds to form an abrasive body
precursor.
[0065] The abrasive body precursor was placed on a 6'' square batt
and then placed in a furnace for firing. The timing and temperature
of the filing process are detailed below in Table 2.
TABLE-US-00002 TABLE 2 Step Temperature Time Ramp 350.degree. C.
1.degree. C./min Hold 350.degree. C. 60 min Ramp 550.degree. C.
1.degree. C./min Hold 550.degree. C. 60 min Ramp 660.degree. C.
2.9.degree. C./min Ramp 700.degree. C. 1.2.degree. C./min Hold
700.degree. C. 210 min
[0066] The fired abrasive body was allowed to cool and was then
removed from the furnace.
[0067] Resin Segments
[0068] Vitreous bond abrasive segments were prepared according to
the following procedure. A mixture of abrasive diamond particles
and phenolic resin particles was prepared according to the
composition detailed below in Table 3. The mixture was mixed in a
Resodyn LabRam acoustic mixer. Glass spheres were added according
to Table 1, and then the mixture was mixed again.
TABLE-US-00003 TABLE 3 Material Size Wt. % Abrasive Diamond
Particles 10-20 .mu.m 45-55% Phenolic Resin 3-4 .mu.m 25-30% Glass
Spheres 20-40 .mu.m 20-25%
[0069] The mixture was then pressed in a hot press at 180.degree.
C. for 20 minutes in order to form an abrasive body.
[0070] Finishing
[0071] The vitreous and resin abrasive bodies were then cut into
abrasive segments and cemented to a substrate in an alternating
fashion. The cement is then cured 4 hours at 60.degree. C., forming
an abrasive cup wheel.
[0072] 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%.
[0073] 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.
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