CN112041120A

CN112041120A - Abrasive particles comprising shaped abrasive particles having a predetermined angle of inclination

Info

Publication number: CN112041120A
Application number: CN201980027983.9A
Authority: CN
Inventors: 尼格斯·B·艾德弗里斯; 斯科特·R·卡勒; 约瑟夫·B·埃克尔; 约翰·D·哈斯; 托马斯·J·纳尔逊; 阿龙·K·尼纳贝尔; 史蒂文·J·凯佩特; 文森特·优素福; 费伊·T·萨蒙; 夏豫之; 迈克尔·J·沃尔德
Original assignee: 3M Innovative Properties Co
Current assignee: 3M Innovative Properties Co
Priority date: 2018-04-24
Filing date: 2019-04-17
Publication date: 2020-12-04
Anticipated expiration: 2039-04-17
Also published as: US20210268627A1; JP2021522075A; WO2019207423A1; KR102651262B1; KR20210002524A; CN112041120B; EP3784437A1

Abstract

The present disclosure provides an abrasive article (10). The abrasive article (10) has a direction of use, a y-axis, and a z-axis orthogonal to the y-axis and the direction of use. The abrasive article (10) further includes a backing (12) and shaped abrasive particles attached to the backing. About 5% to about 100% of the shaped abrasive particles (14) independently comprise: a first side surface (16); a second side surface (18) opposite the first side surface (16); a front surface (20) connected to the first side surface (16) at a first edge (24) and to the second side surface (18) at a second edge (26); an angle of inclination (30) between the backing (12) and the front surface (20) and in a range of about 10 degrees to about 110 degrees; and a z-direction rotational angle (50) between a line (52) intersecting the first edge (16) and the second edge (18) and the use direction (22) of the abrasive article (10), and in a range from about 10 degrees to about 170 degrees.

Description

Abrasive particles comprising shaped abrasive particles having a predetermined angle of inclination

Background

Abrasive particles and abrasive articles including abrasive particles can be used to abrade, condition, or grind a variety of materials and surfaces during the manufacture of the products. Accordingly, there is a continuing need for improved cost, performance, or life of abrasive particles or abrasive articles.

Disclosure of Invention

The present disclosure provides an abrasive article. The abrasive article has a use direction, a y-axis, and a z-axis orthogonal to the y-axis and the use direction. The abrasive article further includes a backing and shaped abrasive particles attached to the backing. About 5% to about 100% of the shaped abrasive particles independently comprise a first side surface, a second side surface opposite the first side surface, a front surface connected to the first side surface at a first edge and to the second side surface at a second edge, an inclination angle between the backing and the front surface in a range from about 10 degrees to about 110 degrees, and a z-direction rotation angle between a line intersecting the first edge and the second edge and a direction of use of the abrasive article in a range from about 10 degrees to about 170 degrees.

The present disclosure also includes an abrasive article having a first direction of use. The abrasive article includes abrasive particles attached to a backing. Under the same test conditions, a greater amount of material is removed from the workpiece in contact with the abrasive article than when the abrasive article is moved in a second direction different from the first direction of use.

The present disclosure also includes an abrasive article having a first direction of use. The abrasive article includes abrasive particles attached to a backing. Under the same test conditions, the workpiece in contact with the abrasive article has a surface roughness that is greater than the surface roughness of the workpiece when the abrasive article is moved in a second use direction that is different from the first use direction.

The present disclosure also provides a method of making an abrasive article. The method includes orienting the shaped abrasive particles and adhering the shaped abrasive particles to a backing. About 5% to about 100% of the abrasive particles are shaped and independently comprise a first side surface, a second side surface opposite the first side surface, a front surface connected to the first side surface at a first edge and to the second side surface at a second edge, an inclination angle between the backing and the front surface in a range from about 10 degrees to about 110 degrees, and a z-direction rotation angle between a line intersecting the first edge and the second edge and a direction of use of the abrasive article in a range from about 10 degrees to about 170 degrees.

The present disclosure also includes a method of using the abrasive article. The method includes contacting shaped abrasive particles with a workpiece, moving the abrasive article relative to the workpiece in a direction of use; and removing a portion of the workpiece. About 5% to about 100% of the abrasive particles are shaped and independently comprise a first side surface, a second side surface opposite the first side surface, a front surface connected to the first side surface at a first edge and to the second side surface at a second edge, an inclination angle between the backing and the front surface in a range from about 10 degrees to about 110 degrees, and a z-direction rotation angle between a line intersecting the first edge and the second edge and a direction of use of the abrasive article in a range from about 10 degrees to about 170 degrees.

Drawings

In the drawings, which are not necessarily drawn to scale, like reference numerals describe substantially similar components throughout the several views. Like reference numerals having different letter suffixes represent different instances of substantially similar components. The drawings are generally shown by way of example, and not by way of limitation, to the various embodiments discussed in this document.

Fig. 1A is a side view of an abrasive belt according to various embodiments.

Fig. 1B is a front view of an abrasive belt according to various embodiments.

Fig. 1C is a bottom view of an abrasive belt according to various embodiments.

Fig. 2 is a side view of an abrasive belt having shaped abrasive particles according to various embodiments.

Fig. 3 is a bottom view of an abrasive disc according to various embodiments.

Fig. 4 is a schematic diagram illustrating a method of making an abrasive article according to various embodiments.

Fig. 5 is a schematic diagram illustrating an orientation of shaped abrasive particles according to the method of fig. 4, according to various embodiments.

Fig. 6 is a schematic diagram illustrating an orientation of shaped abrasive particles according to the method of fig. 4, according to various embodiments.

Fig. 7 is a schematic diagram illustrating an orientation of shaped abrasive particles according to the method of fig. 4, according to various embodiments.

Fig. 8 is a graph of data from grinding process a according to various embodiments.

Fig. 9 is a graph of data from grinding process B according to various embodiments.

Fig. 10 is a graph of data from grinding procedure C according to various embodiments.

Fig. 11 is a 2D color contour plot of a substrate following a reverse-lapped surface analysis procedure D according to various embodiments.

Fig. 12 is a 2D color contour plot of a substrate of surface analysis process D along a forward polish according to various embodiments.

Fig. 13 is a 3D image of a substrate following a backlapped surface analysis procedure D according to various embodiments.

Fig. 14 is a 3D image of a substrate according to various embodiments along a surface analysis procedure D of forward grinding.

Detailed Description

Reference will now be made in detail to specific embodiments of the presently disclosed subject matter, examples of which are illustrated in the accompanying drawings. While the presently disclosed subject matter will be described in conjunction with the recited claims, it will be understood that the exemplary subject matter is not intended to limit the claims to the presently disclosed subject matter.

Throughout this document, values expressed in a range format should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. For example, a range of "about 0.1% to about 5%" or "about 0.1% to 5%" should be interpreted to include not only about 0.1% to about 5%, but also include individual values (e.g., 1%, 2%, 3%, and 4%) and sub-ranges (e.g., 0.1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%) within the indicated range. Unless otherwise indicated, the expression "about X to Y" has the same meaning as "about X to about Y". Likewise, unless otherwise indicated, the expression "about X, Y or about Z" has the same meaning as "about X, about Y, or about Z".

In this document, the terms "a", "an" or "the" are used to include one or more than one unless the context clearly indicates otherwise. The term "or" is used to refer to a non-exclusive "or" unless otherwise indicated. The expression "at least one of a and B" has the same meaning as "A, B or a and B". Also, it is to be understood that the phraseology or terminology employed herein, and not otherwise defined, is for the purpose of description only and not of limitation. Any use of section headings is intended to aid in the understanding of the document and should not be construed as limiting; information related to a section header may appear within or outside of that particular section.

In the methods described herein, various actions may be performed in any order, except when a time or sequence of operations is explicitly recited, without departing from the principles of the invention. Further, the acts specified may occur concurrently unless the express claim language implies that they occur separately. For example, the claimed act of performing X and the claimed act of performing Y may be performed simultaneously in a single operation, and the resulting process would fall within the literal scope of the claimed process.

As used herein, the term "about" can allow, for example, a degree of variability in the value or range, e.g., within 10%, within 5%, or within 1% of the stated value or limit of the range, and includes the exact stated value or range.

The term "substantially" as used herein refers to a majority or majority, such as at least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9%, 99.99%, or at least about 99.999% or more, or 100%.

In accordance with various embodiments of the present disclosure, an abrasive article is disclosed. The abrasive article may be selected from a number of different abrasive articles, such as an abrasive belt, sheet, or disc. Fig. 1A-1C are various views of an abrasive belt 10. Fig. 1A is a side view of belt 10, fig. 1B is a front view of belt 10, and fig. 1C is a bottom view of belt 10. Fig. 1A-1C illustrate many of the same features and will be discussed concurrently. As shown in fig. 1A-1C, the abrasive belt 10 has a z-axis and a y-axis orthogonal to the z-axis. The direction of use 22 of the abrasive belt 10 extends in a direction along an x-axis that is orthogonal to both the z-axis and the y-axis. Relative to FIG. 1A, the use direction 22 is from left to right; relative to FIG. 1B, the direction of use 22 is away from the page toward the reader; relative to FIG. 1C, the direction of use 22 is from the bottom of the page to the top of the page.

Abrasive belt 10 includes a backing 12 having shaped abrasive particles 14 attached thereto. The backing 12 may have any desired degree of flexibility. The backing 12 may comprise any suitable material. For example, the backing 12 may comprise a polymeric film, a metal foil, a woven fabric, a knitted fabric, paper, vulcanized fiber, a nonwoven, a foam, a screen, a laminate, or a combination thereof. The backing 12 may also include various additives. Examples of suitable additives include colorants, processing aids, reinforcing fibers, heat stabilizers, ultraviolet stabilizers, and antioxidants. Examples of useful fillers include clay, calcium carbonate, glass beads, talc, clay, mica, wood flour, and carbon black.

As shown, the edges of at least one shaped abrasive particle 14 are substantially in contact with the backing 12. In further embodiments, the edge or portion of the edge may not be in contact with the backing 12.

The shaped abrasive particles 14 are abrasive particles in which at least a portion of the abrasive particles have a predetermined shape. The predetermined shape may be replicated, for example, from a mold cavity used to form the precursor shaped abrasive particles. In embodiments where the shaped abrasive particles 14 are formed in a mold cavity, the predetermined geometry may substantially replicate the mold cavity used to form the shaped abrasive particles 14. In examples where the shaped abrasive particles are formed by extrusion, the shaped abrasive particles 14 may also replicate the shape of the mold. If the shaped abrasive particles 14 or abrasive article are formed by an additive manufacturing process, the shaped abrasive particles 14 may also replicate the shape present in a program, such as a Computer Aided Design (CAD) program. Shaped abrasive particles 14 are not intended to refer to randomly sized crushed abrasive particles formed, for example, by a mechanical crushing operation.

The shaped abrasive particles 14 include a number of geometric features. For example, as shown in fig. 1A-1C, the shaped abrasive particles 14 include a first side surface 16, a second side surface 18, a front surface 20, and a back surface 28. The surfaces of the shaped abrasive particles 14 are joined at the edges. For example, front surface 20 is joined to first side surface 16 at edge 24 and further joined to second side surface 18 at edge 26. In operation, the front surface 20 is the front surface of the shaped abrasive particles 14 relative to the direction of use 22, and the back surface 28 is oppositely disposed relative to the front surface 20. In some embodiments, the anterior surface 20, the posterior surface 28, or either of the two surfaces may be an edge formed at the intersection of the two surfaces.

First side surface 16, second side surface 18, front surface 20, and back surface 28 may have any suitable shape. For example, the first side surface 16, the second side surface 18, the front surface 20, and the rear surface 28 may have a polygonal shape, which may be a regular polygon or an irregular polygon. In some embodiments, the polygonal shape may substantially conform to a triangular shape, a quadrilateral shape, a pentagonal shape, a hexagonal shape, a heptagonal shape, or an octagonal shape. Other higher order polygonal shapes are also within the scope of the present disclosure. In embodiments where the polygonal shape substantially conforms to a quadrilateral shape, the quadrilateral shape can be, for example, a square, a rectangle, or a trapezoid. In embodiments where the polygonal shape substantially conforms to a triangular shape, the triangular shape can be, for example, a right triangle, a scalene triangle, an isosceles triangle, an acute triangle, or an obtuse triangle. In some embodiments, the triangular shape is not an equilateral triangle.

First side surface 16, second side surface 18, front surface 20, and back surface 28 may have the same shape or have different shapes. Additionally, at least one of the surface areas, maximum length dimensions, maximum width dimensions, or any combination thereof, of first and second side surfaces 16, 18 may be substantially the same dimensions or substantially different dimensions. The front and back surfaces 20, 28 may each be smaller in at least one of surface area, maximum length dimension, maximum width dimension, or any combination thereof, as compared to each of the first and second side surfaces 16, 18.

Any of first side surface 16, second side surface 18, front surface 20, and back surface 28 may be substantially planar or non-planar. Additionally, any of first side surface 16, second side surface 18, front surface 20, and back surface 28 may extend substantially parallel or non-parallel relative to one another. In embodiments in which any of first side surface 16, second side surface 18, front surface 20, and back surface 28 are non-planar, these surfaces may have a substantially concave or convex shape. In some embodiments, a portion of any one of first side surface 16, second side surface 18, front surface 20, and back surface 28 may be substantially planar, and another portion of the same surface may be non-planar. In further embodiments, a portion of any one of first side surface 16, second side surface 18, front surface 20, and back surface 28 may be substantially convex, and another portion of the same surface may be substantially concave.

According to the shape or contour of any of first side surface 16, second side surface 18, front surface 20, and back surface 28; any edges, such as

edges

24 and 26, may be straight, tapered, or curved. The edges connecting a particular surface to other surfaces may have the same length or different lengths. For example, as shown in FIG. 1B, edges 24 and 26 are parallel and have the same length in the z-direction. This results in the cutting tips 31 of the shaped abrasive particles 14 extending parallel relative to the x-y plane. The cutting tip 31 is understood to mean an inflection point along the front surface 20 and the rear surface 28. In other embodiments, edges 24 and 26 are of different lengths and cutting tip 31 is angled so as to be non-parallel with respect to the x-y plane. The cutting tip 31 may be free of sharp points having a radius of curvature of at least about 60 microns, at least about 70 microns, at least about 80 microns, at least about 90 microns, or at least about 100 microns.

Any of first side surface 16, second side surface 18, front surface 20, and back surface 28 may include additional shape features, such as openings, concave surfaces, convex surfaces, grooves, ridges, fracture surfaces, low roundness coefficients, or a perimeter including one or more corner points with sharp points.

The shaped abrasive particles 14 may be positioned relative to the backing 12 to achieve several performance characteristics of the abrasive belt 10. The positioning of the shaped abrasive particles 14 can be characterized by a variety of different angles of the shaped abrasive particles 14 relative to the backing 12.

For example, the rake angle 30 may be characterized by an angle measured between the backing 12 and the front surface 20 or the cutting tip 31. As shown in FIG. 1A, the tilt angle 30 is about 90 degrees. However, in other embodiments, the angle of inclination 30 may be selected from a value within a range of about 10 degrees to about 170 degrees, about 80 degrees to about 100 degrees, about 85 degrees to about 95 degrees, or less than, equal to, or greater than about 10 degrees, 15 degrees, 20 degrees, 25 degrees, 30 degrees, 35 degrees, 40 degrees, 45 degrees, 50 degrees, 55 degrees, 60 degrees, 65 degrees, 70 degrees, 75 degrees, 80 degrees, 85 degrees, 90 degrees, 95 degrees, 100 degrees, 105 degrees, 110 degrees, 115 degrees, 120 degrees, 125 degrees, 130 degrees, 135 degrees, 140 degrees, 145 degrees, 150 degrees, 155 degrees, 160 degrees, 165 degrees, or about 170 degrees. The value of the angle of inclination 30 may be selected for the intended purpose of the abrasive belt 10. For example, if the inclination angle 30 is equal to or less than 90 degrees, the abrasive article may be well suited for removing material from a workpiece, achieving deep cuts in a workpiece, or removing large chips from a workpiece. Conversely, if the angle of inclination 30 is greater than 90 degrees, the abrasive belt 10 may still have some of the aforementioned characteristics, but may also be better suited for modifying the surface of a workpiece.

In some embodiments of the abrasive belt 10, it is desirable that a percentage of the shaped abrasive particles 14 have substantially the same angle of inclination 30. For example, in some embodiments, the tilt angle 30 of about 50% to about 100% of the shaped abrasive particles is substantially the same, or about 90% to about 100%, or less than, equal to, or greater than about 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, or 100%. Having 100% of the abrasive particles 14 or the abrasive belt 10 share the same angle of inclination 30 may be desirable to achieve consistent performance in the abrasive belt 10. However, in some embodiments of the abrasive belt 10, different angles of inclination are desired. For example, some embodiments of the abrasive belt 10 may include multiple rows of abrasive particles 14. Referring to fig. 1A, three

rows

40, 42, and 44 are shown, but other embodiments of the abrasive belt 10 may include fewer or more rows. As shown, each of the

rows

40, 42, or 44 extends in the y-direction, and adjacent rows (e.g., 40 and 42 and 44) are spaced apart relative to each other in the x-direction. In embodiments including multiple rows, each abrasive particle 14 in a row may have the same inclination angle 30. For example, each of the shaped abrasive particles 14 of the row 44 may have the same inclination angle 30. In addition, each of the shaped abrasive particles 14 of the row 42 can have the same inclination angle 30, but the inclination angle 30 can be different than the inclination angle of the shaped abrasive particles 14 of the row 42. In addition, each of the shaped abrasive particles 14 of row 44 may have the same inclination angle 30, but the inclination angle 30 may be different than the inclination angles of the shaped abrasive particles 14 of

rows

42 and 40. In this manner, a gradient of the angle of inclination 30 may be formed in the abrasive belt 10.

The relief angle 46 is characterized by the angle measured between the backing 12 and the cutting tip 31 at the inflection point of the back surface 28. As shown in fig. 1A, the relief angle 46 is measured between the backing 12 and the cutting tip 30 along the rear surface 28. In various embodiments, the relief angle 46 may be in a range of about 90 degrees to about 180 degrees, about 120 degrees to about 140 degrees, or less than, equal to, or greater than about 90 degrees, 95 degrees, 100 degrees, 105 degrees, 110 degrees, 115 degrees, 120 degrees, 125 degrees, 130 degrees, 135 degrees, 140 degrees, 145 degrees, 150 degrees, 155 degrees, 160 degrees, 165 degrees, 170 degrees, 175 degrees, or about 180 degrees. In some embodiments, the difference between the inclination angle 30 and the relief angle 46 may be in a range of about 5 degrees to about 50 degrees, about 10 degrees to about 40 degrees, or less than, equal to, or greater than about 5 degrees, 10 degrees, 15 degrees, 20 degrees, 25 degrees, 30 degrees, 35 degrees, 40 degrees, 45 degrees, or about 50 degrees. The value of the relief angle 46 may be selected for the intended purpose of the abrasive belt 10. For example, as the relief angle 46 approaches a higher value, the abrasive belt 10 is able to modify the surface (e.g., if the direction of use 22 is opposite the second direction of use). Additionally, if the relief angle 46 is a high value, material removed from the workpiece may be ejected, thereby helping to prevent jamming of the abrasive belt 10. However, in some embodiments, having a lower value of the relief angle 46 may help to enhance attachment of the abrasive particles 14 to the backing when a force is applied to the abrasive belt 10 during operation.

In some embodiments of the abrasive belt 10, it is desirable that a percentage of the shaped abrasive particles 14 have substantially the same relief angle 46. For example, in some embodiments, the relief angle 46 is substantially the same for about 50% to about 100% of the shaped abrasive particles, or about 90% to about 100%, or less than, equal to, or greater than about 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, or 100%. Having 100% of the abrasive particles 14 or the abrasive belt 10 share the same relief angle 46 may be desirable to achieve consistent performance in the abrasive belt 10. However, in some embodiments of the abrasive belt 10, it is desirable to have a different relief angle 46. For example, each of the shaped abrasive particles 14 of the row 44 may have the same relief angle 46. In addition, each of the shaped abrasive particles 14 of row 42 can have the same relief angle 46, but the relief angle 46 is different than the relief angle of the shaped abrasive particles 14 of row 42. In addition, each of the shaped abrasive particles 14 of row 44 may have the same relief angle 46, but the relief angle 46 is different than the relief angle of the shaped abrasive particles 14 of

rows

42 and 40. In this manner, a gradient of relief angles 46 may be formed in the abrasive belt 10.

The draft angle α 48 is characterized by the angle measured between the backing 12 and either of the first side surface 16 and the second side surface 18. As shown in fig. 1B, draft angle α 48 is about 90 degrees. However, in other embodiments, the draft angle α 48 may be in a range of about 90 degrees to about 130 degrees, about 95 degrees to about 120 degrees, or less than, equal to, or greater than about 90 degrees, 100 degrees, 105 degrees, 110 degrees, 115 degrees, 120 degrees, 125 degrees, or about 130 degrees. In some embodiments of the abrasive belt 10, it is desirable that a percentage of the shaped abrasive particles 14 have substantially the same draft angle α 48. For example, in some embodiments, about 50% to about 100% of the shaped abrasive particles have a draft angle α 48 that is substantially the same, or about 90% to about 100%, or less than, equal to, or greater than about 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, or 100%. Having 100% of the abrasive particles 14 or the abrasive belt 10 share the same draft angle α 48 may be desirable to achieve consistent performance in the abrasive belt 10. However, in some embodiments of the abrasive belt 10, it is desirable to have a different draft angle α 48. For example, each of the shaped abrasive particles 14 of the row 44 can have the same draft angle α 48. In addition, each of the shaped abrasive particles 14 of the row 42 can have the same draft angle α 48, but the draft angle α 48 is different than the draft angle of the shaped abrasive particles 14 of the row 42. In addition, each of the shaped abrasive particles 14 of row 44 can have the same draft angle α 48, but the draft angle α 48 is different than the draft angles of the shaped abrasive particles 14 of

rows

42 and 40. In this manner, a gradient of draft angle α 48 may be formed in the abrasive belt 10. Alternatively, the draft angle α 48 of adjacent shaped abrasive particles within the same row may be different to form a gradient in the y-direction.

Another angle that characterizes the shaped abrasive particles 14 can be the z-direction rotation angle 50. As shown in fig. 1C, a z-direction rotational angle 50 may be defined between a line 52 intersecting the first edge 24 and the second edge 26 and the direction of use 22. The z-direction rotation angle 50 can be in a range of about 10 degrees to about 170 degrees, about 80 degrees to about 100 degrees, about 85 degrees to about 95 degrees, or less than, equal to, or greater than about 10 degrees, 15 degrees, 20 degrees, 25 degrees, 30 degrees, 35 degrees, 40 degrees, 45 degrees, 50 degrees, 55 degrees, 60 degrees, 65 degrees, 70 degrees, 75 degrees, 80 degrees, 85 degrees, 90 degrees, 95 degrees, 100 degrees, 105 degrees, 110 degrees, 115 degrees, 120 degrees, 125 degrees, 130 degrees, 135 degrees, 140 degrees, 145 degrees, 150 degrees, 155 degrees, 160 degrees, 165 degrees, or about 170 degrees.

In some embodiments of the abrasive belt 10, it is desirable that a percentage of the shaped abrasive particles 14 have substantially the same z-direction rotational angle 50. For example, in some embodiments, the z-direction rotation angle 50 of about 50% to about 100% of the shaped abrasive particles is substantially the same, or about 90% to about 100%, or less than, equal to, or greater than about 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, or 100%. Having 100% of the abrasive particles 14 or the abrasive belt 10 share the same z-direction rotational angle 50 may be desirable to achieve consistent performance in the abrasive belt 10. However, in some embodiments of the abrasive belt 10, it is desirable to have a different z-direction rotational angle 50. For example, each shaped abrasive particle in the row 44 of shaped abrasive particles 14 can have the same z-direction rotational angle 50. In addition, each of the shaped abrasive particles 14 of the row 42 can have the same z-direction rotational angle 50, but the z-direction rotational angle 50 is different than the z-direction rotational angle of the shaped abrasive particles 14 of the row 42. In addition, each of the shaped abrasive particles 14 of row 44 can have the same z-direction rotational angle 50, but the z-direction rotational angle 50 is different than the z-direction rotational angle of the shaped abrasive particles 14 of

rows

42 and 40. In this manner, a gradient of z-direction rotational angle 50 may be formed in the abrasive belt 10. Alternatively, the z-direction rotational angles 50 of adjacent shaped abrasive particles within the same row may be different to form a gradient in the y-direction.

Fig. 1A to 1C show that the abrasive particles 14 have a substantially triangular shape conforming to a right triangle. However, in light of the above, any of the shaped abrasive particles 14 of the abrasive belt 10 can have one of many other suitable shapes. For example, fig. 2 shows a side view of an abrasive belt 10A including shaped abrasive particles 14A. As shown, the shaped abrasive particles 14A have a generally triangular shape, whereas the front surface 20A has convex portions 32 and concave portions 34. In embodiments such as those where the front surface 20A is non-linear, the tilt angle 30 may be determined by measuring the angle between the backing 12 and the line 54. The line 54 is a line tangent to the cutting tip 31.

Fig. 1A-1C and 2 illustrate embodiments in which the abrasive article is an abrasive belt or sheet adapted for linear motion. However, in other embodiments, the abrasive article may be an abrasive disc adapted for rotational movement. Fig. 3 is a bottom view of abrasive disc 60. The abrasive disc 60 is adapted for rotational movement about a central axis 62. The direction of use 22A of rotation may be defined by a line tangent to the outer periphery 64 of the abrasive disc 60.

In the abrasive disc 60, the shaped abrasive particles 14 may have the same characteristics as the abrasive belt 10. For example, the shaped abrasive particles may have the same inclination angle 30, draft angle α 48, relief angle 46, and z-direction rotation angle 50 characteristics described herein with reference to fig. 1A-1C and 2. Each of the rake angle 30, draft angle α 48, and relief angle 46 may be measured and determined in a manner consistent with those described above with reference to fig. 1A-1C and 2. To measure the z-direction rotational angle 50 of each shaped abrasive particle 14 in the abrasive disc 60, the centroid 66 of each shaped abrasive particle 14 is determined. A line 68 extends from the central axis 62 through the centroid 66 to the outer periphery 64. A line tangent to the outer perimeter 64 representing the direction of use 22a at the intersection between the line 68 and the outer perimeter 64 is applied to the shaped abrasive particle 14 to pass through the centroid 66 and the front surface 20. The z-direction rotation angle 50 is then measured between the superimposed tangent 22A and the line 52.

Shaped abrasive particles 14 may comprise 100% by weight of the abrasive particles in any abrasive article. Alternatively, the shaped abrasive particles 14 may be part of a blend of abrasive particles distributed on the backing 12. If present as part of a blend, the shaped abrasive particles 14 can be in a range of about 5 wt.% to about 95 wt.%, about 10 wt.% to about 80 wt.%, about 30 wt.% to about 50 wt.%, or less than, equal to, or greater than about 5 wt.%, 10 wt.%, 15 wt.%, 20 wt.%, 25 wt.%, 30 wt.%, 35 wt.%, 40 wt.%, 45 wt.%, 50 wt.%, 55 wt.%, 60 wt.%, 65 wt.%, 70 wt.%, 75 wt.%, 80 wt.%, 85 wt.%, 90 wt.%, or about 95 wt.% of the blend. In the blend, the remainder of the abrasive particles may comprise conventional crushed abrasive particles. Crushed abrasive particles are typically formed by a mechanical crushing operation and do not have a replicated shape. The remainder of the abrasive particles can also comprise other shaped abrasive particles, which can, for example, comprise equilateral triangular shapes (e.g., flat triangular shaped abrasive particles or tetrahedrally shaped abrasive particles, wherein each face of a tetrahedron is an equilateral triangle).

Any abrasive article, such as the abrasive belt 10 or abrasive disc 60, may include a make coat to adhere the shaped abrasive particles 14 or a blend of shaped abrasive particles 14 and crushed abrasive particles to the backing 12. The abrasive article may further include a size layer adhering the shaped abrasive particles to the make layer. The make layer, size layer, or both may comprise any suitable resin, such as a phenolic resin, an epoxy resin, a urea-formaldehyde resin, an acrylate resin, an aminoplast resin, a melamine formaldehyde resin, an acrylic modified epoxy resin, a urethane resin, or a mixture thereof. Additionally, the make layer, size layer, or both may include fillers, grinding aids, wetting agents, surfactants, dyes, pigments, coupling agents, adhesion promoters, or mixtures thereof. Examples of fillers may include calcium carbonate, silica, talc, clay, calcium metasilicate, dolomite, aluminum sulfate, or mixtures thereof.

The shaped abrasive particles 14 can be formed in a number of suitable ways, for example, the shaped abrasive particles 14 can be made according to a multi-operation process. The process can be carried out using any material or precursor dispersion material. Briefly, for embodiments in which the shaped abrasive particles are monolithic ceramic particles, the method may comprise the operations of: preparing a seeded or unseeded precursor dispersion that can be converted to the corresponding (e.g., boehmite sol-gel that can be converted to alpha alumina); filling one or more mold cavities having the desired shape of the shaped abrasive particles 14 with the precursor dispersion; drying the precursor dispersion to form a shaped abrasive particle precursor; removing the precursor shaped abrasive particles 14 from the mold cavity; calcining the precursor shaped abrasive particles 14 to form calcined precursor shaped abrasive particles 14; the calcined precursor shaped abrasive particles 14 are then sintered to form shaped abrasive particles 14. The method will now be described in more detail in the context of alpha alumina containing shaped abrasive particles 14. In other embodiments, the mold cavity can be filled with melamine to form melamine shaped abrasive particles.

The method can include an operation of providing a seeded or unseeded precursor dispersion that can be converted to a ceramic. In the example of seeding the precursor, the precursor may be seeded with iron oxide (e.g., FeO). The precursor dispersion may comprise a liquid as the volatile component. In one example, the volatile component is water. The dispersion may contain a sufficient amount of liquid to make the viscosity of the dispersion low enough to fill the mold cavity and replicate the mold surface, but not so much liquid as to result in excessive costs for subsequent removal of the liquid from the mold cavity. In one example, the precursor dispersion comprises 2 to 90 wt% of particles capable of being converted to ceramic, such as alumina monohydrate (boehmite) particles, and at least 10 wt%, or 50 to 70 wt%, or 50 to 60 wt% of a volatile component, such as water. Conversely, in some embodiments, the precursor dispersion comprises from 30 wt% to 50 wt%, or from 40 wt% to 50 wt% solids.

Examples of suitable precursor dispersions include zirconia sols, vanadia sols, ceria sols, alumina sols, and combinations thereof. Suitable alumina dispersions include, for example, boehmite dispersions as well as other alumina hydrate dispersions. Boehmite can be prepared by known techniques or is commercially available. Examples of commercially available boehmite include products sold under the trade names "DISPERAL" and "DISPAL" both available from Sasol North America, Inc., or under the trade name "HIQ-40" available from BASF. These alumina monohydrate are relatively pure; that is, they contain relatively few, if any, other hydrate phases in addition to a monohydrate, and have a high surface area.

The physical properties of the resulting shaped abrasive particles 14 may generally depend on the type of material used in the precursor dispersion. As used herein, a "gel" is a three-dimensional network of solids dispersed in a liquid.

The precursor dispersion may comprise a modifying additive or a precursor of a modifying additive. Modifying additives may be used to enhance certain desired characteristics of the abrasive particles or to increase the efficiency of subsequent sintering steps. The modifying additive or precursor of the modifying additive may be in the form of a soluble salt, such as a water soluble salt. They may include metal-containing compounds and may be precursors of oxides of magnesium, zinc, iron, silicon, cobalt, nickel, zirconium, hafnium, chromium, yttrium, praseodymium, samarium, ytterbium, neodymium, lanthanum, gadolinium, cerium, dysprosium, erbium, titanium, and mixtures thereof. The specific concentrations of these additives that may be present in the precursor dispersion may vary.

The introduction of the modifying additive or modifying additive precursor can result in gelation of the precursor dispersion. The precursor dispersion can also be gelled by: the heating is carried out over a period of time so as to reduce the liquid content of the dispersion by evaporation. The precursor dispersion may further comprise a nucleating agent. Nucleating agents suitable for use in the present disclosure may include fine particles of alpha alumina, alpha iron oxide or precursors thereof, titanium dioxide and titanates, chromium oxide, or any other substance that nucleates the transformation. If a nucleating agent is used, it should be present in sufficient quantity to convert the alpha alumina.

A peptizing agent can be added to the precursor dispersion to produce a more stable hydrosol or colloidal precursor dispersion. Suitable peptizing agents are monoprotic acids or acidic compounds, such as acetic acid, hydrochloric acid, formic acid and nitric acid. Polyprotic acids may also be used, but they may rapidly gel the precursor dispersion, making it difficult to handle or introduce additional components. Certain commercial sources of boehmite contain an acid titer (e.g., absorbed formic or nitric acid) that aids in the formation of a stable precursor dispersion.

The precursor dispersion can be formed by any suitable means; for example, in the case of a sol-gel alumina precursor, it can be formed by simply mixing alumina monohydrate with water containing a peptizing agent, or by forming an alumina monohydrate slurry with added peptizing agent.

An anti-foaming agent or other suitable chemical may be added to reduce the tendency of air bubbles or entrained air to form during mixing. Other chemicals such as wetting agents, alcohols, or coupling agents may be added if desired.

Further operations may include providing a mold having at least one mold cavity, or a plurality of cavities formed in at least one major surface of the mold. In some examples, the mold is formed as a production tool, which may be an applicator roll such as a belt, sheet, continuous web, rotary gravure roll, sleeve mounted on an applicator roll, or die. In one example, the production tool may comprise a polymeric material. Examples of suitable polymeric materials include thermoplastics such as polyesters, polycarbonates, poly (ether sulfone), poly (methyl methacrylate), polyurethanes, polyvinyl chloride, polyolefins, polystyrene, polypropylene, polyethylene, or combinations thereof, or thermosets. In one example, the entire mold is made of a polymeric or thermoplastic material. In another example, the surfaces of the mold (such as the surfaces of the plurality of cavities) that are contacted with the precursor dispersion when the precursor dispersion is dried comprise a polymeric or thermoplastic material, and other portions of the mold can be made of other materials. By way of example, a suitable polymer coating may be applied to the metal mold to alter its surface tension characteristics.

Polymeric or thermoplastic production tools can be replicated from a metal master tool. The master tool can have the inverse pattern desired for the production tool. The master tool can be made in the same manner as the production tool. In one example, the master tool is made of metal (e.g., nickel) and diamond turned. In one example, the master tool is formed at least in part using stereolithography techniques. The polymeric sheet material can be heated along with the master tool such that the master tool pattern is imprinted on the polymeric material by pressing the two together. A polymer or thermoplastic material can also be extruded or cast onto the master tool and then pressed. The thermoplastic material is cooled to harden it, thereby producing the production tool. If a thermoplastic production tool is utilized, care should be taken not to generate excessive heat, which can deform the thermoplastic production tool, thereby limiting its life.

The cavity is accessible from an opening in either the top or bottom surface of the mold. In some examples, the cavity may extend through the entire thickness of the mold. Alternatively, the cavity may extend only a portion of the thickness of the mold. In one example, the top surface is substantially parallel to the bottom surface of the mold, wherein the cavities have a substantially uniform depth. At least one side of the mold, i.e., the side in which the cavity is formed, may remain exposed to the ambient atmosphere during the step of removing the volatile component.

The cavities have a particular three-dimensional shape to produce the shaped abrasive particles 14. The depth dimension is equal to the vertical distance from the top surface to the lowest point on the bottom surface. The depth of a given cavity may be uniform or may vary along its length and/or width. The cavities of a given mold may have the same shape or different shapes.

Additional operations involve filling the cavities in the mold with the precursor dispersion (e.g., filling by conventional techniques). In some examples, a knife roll coater or a vacuum slot die coater may be used. If desired, a release agent may be used to aid in the removal of the particles from the mold. Examples of release agents include oils (such as peanut oil or mineral oil, fish oil), silicones, polytetrafluoroethylene, zinc stearate, and graphite. Generally, a release agent such as peanut oil in a liquid such as water or alcohol is applied to the surface of the production mold in contact with the precursor dispersion so that when release is desired, about 0.1mg/in is present per unit area of mold²(0.6mg/cm²) To about 3.0mg/in²(20mg/cm²) Or about 0.1mg/in²(0.6mg/cm²) To about 5.0mg/in²(30mg/cm²) The mold release agent of (1). In some embodiments, the top surface of the mold is coated with the precursor dispersion. The precursor dispersion can be pumped onto the top surface.

In a further operation, a doctor blade or smoothing bar may be used to completely press the precursor dispersion into the cavity of the mold. The remainder of the precursor dispersion that does not enter the cavity can be removed from the top surface of the mold and recycled. In some examples, a small portion of the precursor dispersion may remain on the top surface, and in other examples, the top surface is substantially free of dispersion. The pressure applied by the doctor blade or smoothing bar may be less than 100psi (0.6MPa), or less than 50psi (0.3MPa), or even less than 10psi (60 kPa). In some examples, the exposed surface of the precursor dispersion does not substantially extend beyond the top surface.

In those instances where it is desirable to form a planar surface of the shaped ceramic abrasive particles using the exposed surfaces of the cavities, it may be desirable to overfill the cavities (e.g., using a micro-nozzle array) and slowly dry the precursor dispersion.

Further operations involve removing volatile components to dry the dispersion. Volatile components can be removed by a rapid evaporation rate. In some examples, the removal of the volatile component by evaporation is performed at a temperature above the boiling point of the volatile component. The upper limit of the drying temperature generally depends on the material from which the mold is made. For polypropylene molds, the temperature should be below the melting point of the plastic. In one example, the drying temperature may be about 90 ℃ to about 165 ℃, or about 105 ℃ to about 150 ℃, or about 105 ℃ to about 120 ℃ for an aqueous dispersion containing about 40% to 50% solids and a polypropylene mold. Higher temperatures can lead to improved production speeds, but can also lead to degradation of the polypropylene mold, thereby limiting its useful life as a mold.

During drying, the precursor dispersion shrinks, typically causing retraction from the chamber walls. For example, if the cavity has planar walls, the resulting shaped abrasive particle 14 can have at least three major sides that are concave. It has now been found that by recessing the cavity walls (and thus increasing the cavity volume), shaped abrasive particles 14 having at least three substantially planar major sides can be obtained. The extent of dishing generally depends on the solids content of the precursor dispersion.

Additional operations involve removing the resulting precursor shaped abrasive particles 14 from the mold cavity. The precursor shaped abrasive particles 14 may be removed from the cavities by using the following method: the particles are removed from the mold cavity using gravity, vibration, ultrasonic vibration, vacuum or pressurized air methods on the mold alone or in combination.

The precursor shaped abrasive particles 14 may be further dried outside the mold. This additional drying step is not necessary if the precursor dispersion is dried to the desired extent in the mold. However, in some cases, it may be economical to employ this additional drying step to minimize the residence time of the precursor dispersion in the mold. The precursor shaped abrasive particles 14 will be dried at a temperature of 50 ℃ to 160 ℃, or 120 ℃ to 150 ℃, for 10 minutes to 480 minutes, or 120 minutes to 400 minutes.

Additional operations involve calcining the precursor shaped abrasive particles 14. During calcination, substantially all volatile materials are removed and the various components present in the precursor dispersion are converted to metal oxides. Typically, the precursor shaped abrasive particles 14 are heated to a temperature of 400 ℃ to 800 ℃ and maintained within this temperature range until the free water and 90 wt.% or more of any bound volatile materials are removed. In an optional step, it may be desirable to introduce the modifying additive by an impregnation process. The water-soluble salt may be introduced by injecting it into the pores of the calcined precursor shaped abrasive particles 14. The precursor shaped abrasive particles 14 are then pre-fired again.

Additional operations may involve sintering the calcined precursor shaped abrasive particles 14 to form particles. However, in some examples where the precursor comprises a rare earth metal, sintering may not be necessary. Prior to sintering, the calcined precursor shaped abrasive particles 14 are not fully densified and, therefore, lack the hardness required to function as shaped abrasive particles 14. Sintering is performed by heating the calcined precursor shaped abrasive particles 14 to a temperature of 1000 ℃ to 1650 ℃. To achieve this degree of conversion, the length of time that the calcined precursor shaped abrasive particles 14 can be exposed to the sintering temperature depends on a variety of factors, but can be from five seconds to 48 hours.

In another embodiment, the duration of the sintering step is in the range of one minute to 90 minutes. After sintering, the shaped abrasive particles 14 may have a Vickers hardness of 10GPa (gigapascals), 16GPa, 18GPa, 20GPa, or greater.

The process can be modified using additional operations such as rapid heating of the material from the calcination temperature to the sintering temperature and centrifuging the precursor dispersion to remove sludge and/or waste. Furthermore, the method can be modified, if desired, by combining two or more of the method steps.

The shaped abrasive particles 14 may be independently sized according to an abrasives industry recognized specified nominal grade. The abrasive industry recognized grading standards include those promulgated by ANSI (american national standards institute), FEPA (european union of abrasives manufacturers), and JIS (japanese industrial standard). ANSI grade designations (i.e., specified nominal grades) include, for example: ANSI 4, ANSI 6, ANSI8, ANSI 16, ANSI 24, ANSI 36, ANSI 46, ANSI 54, ANSI 60, ANSI70, ANSI 80, ANSI 90, ANSI 100, ANSI 120, ANSI 150, ANSI 180, ANSI 220, ANSI 240, ANSI 280, ANSI 320, ANSI 360, ANSI 400, and ANSI 600. FEPA grade designations include F4, F5, F6, F7, F8, F10, F12, F14, F16, F18, F20, F22, F24, F30, F36, F40, F46, F54, F60, F70, F80, F90, F100, F120, F150, F180, F220, F230, F240, F280, F320, F360, F400, F500, F600, F800, F1000, F1200, F1500, and F2000. JIS grade designations include: JIS8, JIS12, JIS16, JIS24, JIS36, JIS46, JIS54, JIS60, JIS80, JIS100, JIS150, JIS180, JIS220, JIS240, JIS280, JIS320, JIS360, JIS400, JIS600, JIS800, JIS1000, JIS1500, JIS2500, JIS4000, JIS6000, JIS8000 and JIS10,000.

In addition to the materials already described, at least one magnetic material may be contained within or coated onto individual shaped abrasive particles 14. Examples of magnetic materials include iron; cobalt; nickel; various nickel and iron alloys sold as various grades of Permalloy (Permalloy); various iron, nickel, and cobalt alloys sold as iron-nickel-cobalt alloy (Fernico), Kovar, iron-nickel-cobalt alloy i (Fernico i), or iron-nickel-cobalt alloy ii (Fernico ii); various alloys of iron, aluminum, nickel, cobalt, and sometimes copper and/or titanium, sold as various grades of Alnico (Alnico); alloys of iron, silicon and aluminum (about 85:9:6 by weight) sold as iron-aluminum-silicon alloys; heusler alloys (e.g. Cu)₂MnSn); manganese bismuthate (also known as manganese bismuthate (Bismanol)); rare earth magnetizable materials, such as gadolinium, dysprosium, holmium, europium oxides, and alloys of neodymium, iron, and boron (e.g., Nd)₂Fe₁₄B) And alloys of samarium and cobalt (e.g., SmCo)₅)；MnSb；MnOFe₂O₃；Y₃Fe₅O₁₂；CrO₂(ii) a MnAs; ferrites such as ferrite, magnetite; zinc ferrite; nickel ferrite; cobalt ferrite, magnesium ferrite, barium ferrite, and strontium ferrite; yttrium iron garnet; and combinations of the foregoing. In some embodiments, the magnetizable material is a composition comprising 8 to 12 weight percent (wt%) aluminum, 15 to 26 wt% nickel, 5 to 24 wt% cobalt, up to 6 wt% copper, up to 1 wt% aluminumAn alloy of titanium, wherein the balance of the materials, taken together as 100% by weight, is iron. In some other embodiments, the magnetizable coating may be deposited on the abrasive particles 14 using a vapor deposition technique such as Physical Vapor Deposition (PVD), including magnetron sputtering.

The inclusion of these magnetizable materials may allow the shaped abrasive particles 14 to respond to a magnetic field. Any of the shaped abrasive particles 14 can comprise the same material or comprise different materials. In addition, the shaped abrasive particles 14 and the crushed abrasive particles, if present, may comprise the same or different materials.

The abrasive articles described herein can be made according to a number of suitable methods. The methods described herein may allow at least some of the shaped abrasive particles 14 to be precisely disposed on the backing 12. This may enable a precise and predetermined alignment of the minor surface 20. This may also allow for a variety of predetermined patterns of shaped abrasive particles 14 to be formed. For example, in the abrasive belt 10, the z-direction rotational angle 50 of the shaped abrasive particles 14 may be positioned such that the pattern formed by the shaped abrasive particles 14 comprises a plurality of parallel lines. As another example, in an abrasive disc 60, the z-direction rotational angle 50 of the shaped abrasive particles 14 can be positioned such that the pattern formed by the shaped abrasive particles 14 includes a plurality of circles.

The abrasive articles described herein can be made according to any suitable method. In general, the abrasive article may be formed by orienting at least a portion of the shaped abrasive particles 14 on the backing 12 to achieve at least one of the inclination angle 30, the z-direction rotation angle 50, the relief angle 46, the draft angle α 48, or a combination thereof. The method may further include adhering the shaped abrasive particles 14 to the backing 12.

Orientation of abrasive particles 14 may be achieved, for example, by including one or more cavities in backing 12. The cavity may be shaped in such a way that: the individual shaped abrasive particles 14 are positioned on the backing 12 such that at least one of the inclination angle 30, the z-direction rotation angle 50, the relief angle 46, the draft angle α 48, or a combination thereof achieves a predetermined value.

The inclusion of cavities in the backing 12 may allow the abrasive particles 14 to be drop coated or electrostatically coated onto the backing 12 while achieving a desired orientation. As is generally understood, in the drop coating technique, a large supply of abrasive particles 14 is fed through a hopper and falls under gravity onto the backing 12 and into the cavities. Without cavities, the spatial orientation of the abrasive particles 14 when contacting the backing 12 would be completely random in all directions. However, the cavities eliminate random spatial orientation.

In other embodiments, a dispensing tool or screen may be used to achieve precise orientation of the shaped abrasive particles 14. The dispensing tool or screen may include one or more slots defined by a plurality of walls. The slot may be open at both ends. One end may be configured to receive the shaped abrasive particles 14 and the other end may be in contact with the backing 12. The backing 12 may optionally have a make coat disposed thereon. The slots are designed such that each shaped abrasive particle 14 is positioned on the backing 12 such that at least one of the inclination angle 30, the z-direction rotation angle 50, the relief angle 46, the draft angle α 48, or a combination thereof achieves a predetermined value. Particles that do not properly enter the cavity may be swept out of the dispensing tool and additional particles may come into contact with the dispensing tool to enter the empty slot.

When the shaped abrasive particles 14 are adhered to the make coat, the dispensing tool including the shaped abrasive particles 14 may remain in contact with the backing 12 for any suitable amount of time. After a sufficient amount of time has elapsed to achieve good adhesion between the shaped abrasive particles 14 and the make coat, the production tool is removed and a size coat is optionally disposed on the shaped abrasive particles 14.

In other embodiments, a rotary production tool may be used to achieve precise orientation of the shaped abrasive particles 14. The rotary production tool is circular and includes a plurality of cavities on an outer surface. Each of the cavities is designed to receive the shaped abrasive particles 14 in a particular orientation. To increase the probability of each cavity being filled, an excess of shaped abrasive particles 14 are brought into contact with the production tool. Shaped abrasive particles 14 that do not enter the cavity are collected for later use. Once secured in the cavities, the shaped abrasive particles 14 are contacted with the backing 12, which may be provided in web form. The backing 12 may have a make coat pre-disposed thereon such that upon contact, the shaped abrasive particles 14 adhere to the backing 12 and are removed from the production tool.

In other embodiments, a precise orientation of the shaped abrasive particles 14 may be achieved using shaped abrasive particles that include at least some magnetic material. The shaped abrasive particles included at the magnetic material may be randomly arranged on the backing 12. The shaped abrasive particles 14 may then be exposed to a magnetic field in such a manner that the shaped abrasive particles 14 rotate and align to achieve at least one of the tilt angle 30, the z-direction rotation angle 50, the relief angle 46, the draft angle α 48. Once properly oriented, the shaped abrasive particles 14 may be adhered to the backing 12 with a make layer and optionally a size layer. As a result of the method, each shaped abrasive particle 14 is positioned on the backing 12 such that at least one of the inclination angle 30, the z-direction rotation angle 50, the relief angle 46, the draft angle α 48, or a combination thereof achieves a predetermined value. Examples of this method will be described in more detail below with reference to fig. 4-7.

Fig. 4 shows a web 110 comprising a backing 115 having a make layer precursor 120 disposed thereon moving in a downweb direction 114 (e.g., machine direction) along a web path 112. The web 110 has a cross-web direction (not shown) perpendicular to the downweb direction 114. The make layer precursor 120 includes a first curable binder precursor (not shown). Magnetizable particles 132 (having a structure corresponding to shaped abrasive particles 14) fall through a portion of the applied magnetic field 140 onto the make layer precursor 120. At least some of the magnetizable particles 132 are abrasive particles. Magnetizable particles 132 are primarily deposited on web 110 after traveling down downwardly sloping dispensing surface 185, which is fed from hopper 175. As the downwardly sloping distribution surface 185 travels downwardly, the longest side of the magnetizable abrasive particles tends to align with the applied magnetic field 140. Various web handling components 180 (e.g., rollers, belts, feed rollers, and wind-up rollers) handle the web 110.

Throughout the process, at least prior to transferring the magnetizable abrasive particles to the make precursor layer, the magnetizable particles are continuously oriented by an applied magnetic field, wherein the longest axis of the magnetizable particles is aligned substantially parallel (or anti-parallel) to magnetic field lines 165. Once delivered, the applied magnetic field may continue to exert an orienting influence on the magnetizable abrasive particles, but this is not required.

Generally, the applied magnetic field used in the practice of the present disclosure has a field strength of at least about 10 gauss (1mT), at least about 100 gauss (10mT), or at least about 1000 gauss (0.1T) in the region of the magnetizable particle that is affected (e.g., attracted and/or oriented), although this is not required.

The applied magnetic field may be provided by, for example, one or more permanent magnets and/or electromagnets or a combination of magnets and ferromagnetic members. Suitable permanent magnets include rare earth magnets comprising a magnetizable material as described above. The applied magnetic field may be static or variable (e.g., oscillating). The upper magnetic member (152) and/or the lower magnetic member (154), each having a north pole (N) and a south pole (S), may be monolithic, or they may be composed of, for example, a plurality of component magnets (154a,154b) and/or a magnetizable body. If made up of multiple magnets, the multiple magnets in a given magnetic member may be adjacent and/or co-aligned (e.g., at least substantially parallel) with respect to the magnetic field lines whose component magnets are closest to each other.

Stainless steel retainers

156, 158a and 158b hold the magnets in place. Although stainless steel 304 or equivalent materials are preferred due to their non-magnetic properties, magnetizable materials may also be used. Mild steel mounts 162, 164 support

stainless steel holders

156, 158a and 158b, respectively. Although a steel mount is shown in fig. 4, the mount may be made of any dimensionally stable material, whether magnetizable or not.

The downwardly inclined dispensing surface may be inclined at any suitable angle provided that the magnetizable particles may travel down the surface and be dispensed onto the web. Suitable angles may range from 15 degrees to 60 degrees, although other angles may also be used. In some cases, it is desirable to vibrate the downwardly inclined dispensing surface to facilitate, for example, particle movement.

The downwardly sloping dispensing surface may be constructed of any dimensionally stable material, which may be a non-magnetizable material. Examples include: metals, such as aluminum; wood; and plastics.

Fig. 5-7 illustrate the general flow of fig. 4, showing the alignment of magnetizable particles 132 at a position for transfer from downwardly inclined distribution surface 185 onto web 110, depending on the position of downwardly inclined distribution surface 185 in applied magnetic field 140.

For example, in the configuration shown in fig. 5, the magnetizable shaped abrasive particles 132 are dispensed onto the web 110 with magnetic field lines 165 forming a downweb angle α of less than 90 ° with the web 100 such that when transferred to the web, they achieve an orientation with their long edges tilted from right to left up. As shown, the magnetizable shaped abrasive particles 132 slide down the downwardly sloping distribution surface 185 and begin to orient with their longest edges aligned with the magnetic field lines 165. As the magnetizable shaped abrasive particles 132 contact the make layer precursor 120 of the web 110, they tip down the web. Gravity and/or a lower magnetic member causes the magnetically shaped abrasive particles to seat on the make layer precursor 120 and, after curing, they subsequently adhere to the backing 115. Most of the magnetizable shaped abrasive particles 132 are adhered at a nominal angle of inclination (i.e., an angle of about 90 degrees in the direction of the backstep between the backing and the leading edge of the magnetizable shaped abrasive particles in the indicated direction (e.g., the downweb or the downweb).

Referring now to the configuration shown in fig. 6, the magnetizable shaped abrasive particles 132 are aligned such that when transferred to the web 110 they achieve an orientation with their longest edges inclined from right to left or left to right and up. The magnetizable shaped abrasive particles 132 slide down the downwardly sloping dispensing surface 185 and begin to orient with their longest edges aligned with the magnetic field lines 165. Magnetizable shaped abrasive particles 132 are dispensed onto the web 110 with magnetic field lines 165 substantially perpendicular to the web 110. Magnetizable shaped abrasive particles 132 are disposed on web 110 with their longest edges generally perpendicular to the backing. This allows the particles to rotate around their longest edges. The lower magnetic member and/or gravity causes the magnetizable shaped abrasive particles 132 to seat on the make layer precursor 120 and, after curing, they subsequently adhere to the backing 115. Approximately equal percentages of the magnetizable shaped abrasive particles have a nominal 90 degree angle of inclination facing down-web, as facing up-web.

In the configuration shown in fig. 7, the magnetizable shaped abrasive particles 132 are aligned such that they achieve an orientation with their long edges inclined from left to right upwards when transferred to the web. As the magnetizable shaped abrasive particles 132 slide down the downwardly sloping distribution surface 185, they begin to orient with their longest edges aligned with the magnetic field lines 165. Magnetizable shaped abrasive particles 132 are dispensed onto the backing with magnetic field lines 165 at a downweb angle β greater than 90 degrees to the web 100. As the particles contact the web, they are inclined forward in the downweb direction. The lower magnetic member and/or gravity causes the magnetizable shaped abrasive particles 132 to seat on the make layer precursor 120 and, after curing, they subsequently adhere to the backing 115. The majority of the magnetizable shaped abrasive particles 132 adhere to the web 110 at an angle of inclination of about 90 degrees in the downweb direction.

Once the magnetizable particles are applied to the curable binder precursor, the curable binder precursor is at least partially cured at a first curing station (not shown) to hold the magnetizable particles firmly in place. In some embodiments, additional magnetizable and/or non-magnetizable particles (e.g., filler abrasive particles and/or grinding aid particles) may be applied to the make layer precursor prior to curing.

For coated abrasive articles, the curable binder precursor comprises a make layer precursor, and the magnetizable particles comprise magnetizable abrasive particles. The size layer precursor may be applied to the at least partially cured make layer precursor and the magnetizable abrasive particles, but this is not required. If present, the size layer precursor is at least partially cured at a second curing station, optionally further curing the at least partially cured make layer precursor. In some embodiments, a supersize layer is disposed on the at least partially cured size layer precursor.

According to various embodiments, a method of using an abrasive article, such as the abrasive belt 10 or abrasive disc 60, includes contacting the shaped abrasive particles 14 with a workpiece or substrate. The workpiece or substrate may comprise many different materials, such as steel, steel alloys, aluminum, plastic, wood, or combinations thereof. Upon contact, one of the abrasive article and the workpiece are moved relative to each other in the use direction 22, and a portion of the workpiece is removed.

According to various embodiments, the depth of cut in the substrate or workpiece may be at least about 10 μm, at least about 20 μm, at least about 30 μm, at least about 40 μm, at least about 50 μm, or at least about 60 μm. A portion of the substrate or workpiece is removed as swarf by the abrasive article. The maximum average size or length of the swarf obtained from the collection of swarf after a grinding cycle may be at least about 1200 μm millimeters, at least about 1250 μm, at least about 1300 μm, at least about 1350 μm, at least about 1400 μm, at least about 1450 μm, at least about 1500 μm, at least about 1550 μm, at least about 1600 μm, or at least about 1650 μm.

According to various embodiments, the abrasive article may have a cut rate of at least about 100m/min, at least about 110m/min, at least about 120m/min, at least about 130m/min, at least about 140m/min, at least about 150m/min, at least about 160m/min, at least about 170m/min, at least about 180m/min, at least about 190m/min, at least about 200m/min, at least about 300m/min, at least about 400m/min, at least about 500m/min, at least about 1000m/min, at least about 1500m/min, at least about 2000m/min, at least about 2500m/min, at least about 3000m/min, or at least about 4000 m/min.

The use direction 22 is a first direction as shown in fig. 1A to 1C, 2 and 3. The abrasive article may be moved in a second direction different from the direction of use 22. The second direction may be in a direction rotated about 1 degree to 360 degrees, about 160 degrees to about 200 degrees, less than, equal to, or greater than about 1 degree, 5 degrees, 10 degrees, 15 degrees, 20 degrees, 25 degrees, 30 degrees, 35 degrees, 40 degrees, 45 degrees, 50 degrees, 55 degrees, 60 degrees, 65 degrees, 70 degrees, 75 degrees, 80 degrees, 85 degrees, 90 degrees, 95 degrees, 100 degrees, 105 degrees, 110 degrees, 115 degrees, 120 degrees, 125 degrees, 130 degrees, 135 degrees, 140 degrees, 145 degrees, 150 degrees, 155 degrees, 160 degrees, 165 degrees, 170 degrees, 175 degrees, 180 degrees, 185 degrees, 190 degrees, 195 degrees, 200 degrees, 205 degrees, 210 degrees, 215 degrees, 220 degrees, 230 degrees, 240 degrees, 250 degrees, 260 degrees, 265 degrees, 270 degrees, 275 degrees, 280 degrees, 285 degrees, 290 degrees, 295 degrees, 300 degrees, 305 degrees, 310 degrees, 315 degrees, 320 degrees, 325 degrees, 330 degrees, 350 degrees, 340 degrees, 355 degrees, or about 360 degrees relative to the use direction 22.

According to various embodiments, the abrasive articles described herein may have several advantages when moving in the use direction 22, rather than moving in any other use direction. For example, the amount of material removed from the workpiece, the length of a chip removed from the workpiece, the depth of cut in the workpiece, the surface roughness of the workpiece, or a combination thereof, is greater in a first direction than in any other second direction at the same applied force, cutting speed, or a combination thereof.

For example, at least about 10%, or at least about 15%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, at least about 80%, at least about 85%, at least about 90%, at least about 95%, at least about 100%, at least about 120%, at least about 130%, at least about 140%, at least about 150% more material is removed from the substrate or workpiece in the first use direction. In some embodiments, about 15% to about 500%, or about 30% to about 70%, or about 40% to about 60%, or less than, equal to, or greater than about 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 100%, 105%, 110%, 115%, 120%, 125%, 130%, 135%, 140%, 145%, 150%, 155%, 160%, 165%, 170%, 175%, 180%, 185%, 190%, 195%, 200%, 205%, 210%, 215%, 220%, 225%, 230%, 235%, 240%, 245%, 250%, 255%, 260%, 265%, 270%, 275%, 285%, 290%, 295%, 300%, 310%, 315%, 320%, 325%, 330%, 335%, 305%, 345%, in the first direction of use is removed in excess, 350%, 355%, 360%, 365%, 370%, 375%, 380%, 385%, 390%, 395%, 400%, 405%, 410%, 415%, 420%, 425%, 430%, 435%, 440%, 445%, 450%, 455%, 460%, 465%, 470%, 475%, 480%, 485%, 490%, 495%, or about 500% material. The amount of material removed may be referenced to an initial cut (e.g., the first cut of a cutting cycle) or a total cut (e.g., the sum of the amounts of material removed over a set number of cutting cycles).

The process for grinding the workpiece is described herein in grinding processes a and B of the embodiments. The initial cut in the workpiece measured according to grinding procedure a (when the abrasive article is run in the direction of use) can be at least about 9 grams, at least about 9.5 grams, at least about 10 grams, at least about 10.5 grams, at least about 11 grams, at least about 11.5 grams, at least about 12 grams, at least about 12.5 grams, at least about 13 grams, at least about 13.5 grams, at least about 14 grams, at least about 14.5 grams, at least about 15 grams, at least about 15.5 grams, at least about 16 grams, at least about 16.5 grams, at least about 17 grams, at least about 17.5 grams, at least about 17.8 grams, at least about 18 grams, at least about 18.5 grams, at least about 19 grams, at least about 19.5 grams, at least about 20 grams, at least about 20.5 grams, at least about 21 grams, at least about 21.5 grams, at least about 22 grams, at least about 22.5 grams, at least about 23 grams, at least about 23.5 grams, at least about 24 grams, at least about 25.5 grams, or at least about 25 grams. The total cut in the workpiece, measured according to grinding procedure a (when the abrasive article is run in the direction of use), may be at least about 65 grams, at least about 70 grams, at least about 75 grams, at least about 80 grams, at least about 85 grams, at least about 90 grams, at least about 95 grams, at least about 100 grams, at least about 105 grams, at least about 110 grams, at least about 115 grams, at least about 118.37 grams, at least about 120 grams, or at least about 125 grams. The initial cut in the workpiece measured according to grinding procedure B (when the abrasive article is run in the direction of use) may be at least about 9mm, at least about 9.5mm, at least about 10mm, at least about 10.5mm, at least about 11mm, at least about 11.5mm, at least about 12mm, at least about 12.5mm, at least about 13mm, at least about 13.5mm, at least about 14mm, at least about 14.5mm, at least about 15mm, at least about 15.5mm, at least about 16mm, at least about 16.5mm, at least about 17mm, at least about 17.5mm, at least about 18mm, at least about 18.47mm, at least about 19mm, at least about 19.5mm, at least about 20mm, at least about 20.5mm, at least about 21mm, at least about 21.5mm, at least about 22mm, at least about 22.5mm, at least about 23mm, at least about 23.5mm, at least about 24mm, at least about 25.5mm, or at least about 25 mm. The total cut in the workpiece as measured according to grinding procedure B (when the abrasive article is run in the direction of use) may be at least about 172mm, at least about 180mm, at least about 190mm, at least about 200mm, at least about 210mm, at least about 220mm, at least about 230mm, at least about 240mm, at least about 250mm, at least about 260mm, at least about 270mm, at least about 280mm, at least about 290mm, at least about 300mm, at least about 310mm, at least about 320mm, at least about 330mm, at least about 340mm, at least about 350mm, at least about 360mm, at least about 370mm, at least about 380mm, at least about 390mm, at least about 400mm, at least about 410mm, at least about 420mm, at least about 430mm, at least about 440mm, at least about 450mm, at least about 460mm, at least about 470mm, at least about 480mm, at least about 485.29mm, at least about 490mm, at least about 500mm, at least about 510mm, at least about 520mm, At least about 530mm, at least about 540mm, at least about 550mm, at least about 560mm, at least about 570mm, at least about 580mm, at least about 590mm, or at least about 600 mm.

As another example, the depth of cut in the substrate or workpiece may be at least about 10%, or at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, at least about 80%, at least about 85%, at least about 90%, at least about 95%, at least about 100%, at least about 120%, at least about 130%, at least about 140%, at least about 150% deeper in the first use direction. In some embodiments, the depth in the first use direction is from about 10% to about 500%, or from about 30% to about 70%, or from about 40% to about 60%, or less than, equal to, or greater than about 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 100%, 105%, 110%, 115%, 120%, 125%, 130%, 135%, 140%, 145%, 150%, 155%, 160%, 165%, 170%, 175%, 180%, 185%, 190%, 195%, 200%, 205%, 210%, 215%, 220%, 225%, 230%, 235%, 240%, 245%, 250%, 255%, 260%, 265%, 270%, 275%, 280%, 285%, 290%, 295%, 300%, 310%, 315%, 320%, 325%, 330%, 335%, 340%, 345%, 350%, (ii., 355%, 360%, 365%, 370%, 375%, 380%, 385%, 390%, 395%, 400%, 405%, 410%, 415%, 420%, 425%, 430%, 435%, 440%, 445%, 450%, 455%, 460%, 465%, 470%, 475%, 480%, 485%, 490%, 495%, or about 500%.

As another example, the arithmetic mean roughness value (Sa) of a workpiece or substrate cut by moving the abrasive article in the first direction of use 22 may be higher than a corresponding substrate or workpiece cut under identical conditions but in the second direction of movement. For example, when cutting a workpiece or substrate in a first direction, the surface roughness may be about 30% higher, or about 40% higher, about 50% higher, about 60% higher, about 70% higher, about 80% higher, about 90% higher, about 100% higher, about 110% higher, about 120% higher, about 130% higher, about 140% higher, about 150% higher, about 160% higher, about 170% higher, about 180% higher, about 190% higher, about 200% higher, about 210% higher, about 220% higher, about 230% higher, about 240% higher, about 250% higher, about 260% higher, about 270% higher, about 280% higher, about 290% higher, about 300% higher, about 310% higher, about 320% higher, about 330% higher, about 340% higher, about 350% higher, about 360% higher, about 370% higher, about 380% higher, about 390% higher, about 400% higher, about 410% higher, about 420% higher, about 430% higher, about 440% higher, about 450% higher, about 460% higher, about 470% higher, about 480% higher, about 490% higher, or about 500% higher. The arithmetic mean roughness value may be in a range of about 1000 to about 2000, about 1000 to about 1100, or less than, equal to, or greater than about 1000, 1050, 1100, 1150, 1200, 1250, 1300, 1350, 1400, 1450, 1500, 1550, 1600, 1650, 1700, 1750, 1800, 1850, 1900, 1950, or about 2000.

While it is desirable to move the abrasive article in the first direction of use 22, there are some reasons to move the abrasive article in a second direction of movement other than the first direction of use 22. For example, contacting the substrate or workpiece with the abrasive article and moving the abrasive article in the second direction may be beneficial for conditioning the substrate or workpiece. While not intending to be bound by any particular theory, the inventors assume that movement in the second direction may expose the substrate or workpiece to a relief angle 46 having a different value than the tilt angle 30, which is more suitable for finishing applications.

Examples

Assembly of magnet apparatus (MA1)

The upper magnet assembly UM1 was formed from 3 identical rectangular magnets each 10.16cm wide by 7.62cm deep by 5.08cm thick magnetized by the thickness of N52 grade magnetic material (SM Magnetics, Pelham, AL) available from SM Magnetics corporation of pellem, alabama, usa). These 3 magnets were arranged to form a magnet assembly 15.08cm wide by 7.62cm deep by 5.08cm thick with the poles of each magnet oriented in the same direction with similar poles in the same plane. The magnet arrangement was adhered with epoxy (DP460, 3M company of saint paul, mn) to 1018 steel plate (110.16cm wide by 12.7cm deep by 7.62cm thick) and covered with a 0.476cm thick sheet of 304 stainless steel.

The first lower magnet assembly LM1 is formed in the same manner as the UM, except that the opposite pole faces away from the steel plate.

The second lower magnet assembly LM2 was formed from 3 identical rectangular magnets each 10.16cm wide by 15.24cm deep by 5.08cm thick magnetized by the thickness of N52 grade magnetic material (obtained from SM Magnetics, perlem, alabama, usa). These 3 magnets were arranged to form a 15.08cm wide by 15.24cm deep by 5.08cm thick magnet assembly with the poles of each magnet oriented in the same direction as LM1 with similar poles in the same plane. The magnet arrangement was adhered with epoxy (DP460, 3M company of saint paul, mn) to 1018 steel plate (110.16cm wide by 20.32cm deep by 7.62cm thick) and covered with 0.47625cm thick 304 stainless steel sheet.

A composite lower magnetic assembly LM3 is formed by combining LM1 and LM 2. The LM1 and LM2 were arranged to form a 15.08cm wide by 22.86cm deep by 5.08cm thick magnet assembly with 30.48cm by 5.08cm magnets in face contact and the poles of each magnet oriented in the same direction with similar poles in the same plane. Both LM1 and LM2 were bolted to 1018 steel plates (110.16cm wide by 27.94cm deep by 2.54cm thick) to form LM 3.

The LM3 was positioned parallel to the upper magnet UM with a gap of 15.24cm and the two trailing edges aligned. UM1 and LM3 have opposite poles facing each other to form magnet arrangement MA 1.

Preparation of magnetizable abrasive particles (MAP1)

AP1 was coated with 304 stainless steel using physical vapor deposition and magnetron sputtering. A 304 stainless steel sputter target (Thin Solid Films, described by Barbee et al, 1979, volume 63, page 143-150) is deposited in a cubic form centered on magnetic ferrite. An apparatus for making 304 stainless steel film coated abrasive particles (i.e., magnetizable abrasive particles) is disclosed in U.S. patent 8,698,394(McCutcheon et al). Physical vapor deposition was performed at 1.0 kilowatt for 4 hours at an argon sputtering gas pressure of 10 millitorr (1.33 pascals) for 51.94 grams of AP 1. The weight percent of metal coating in the coated AP1 was about 0.65%, and the coating thickness was about 1 micron.

Preparation of magnetizable abrasive particles (MAP2)

AP2 was coated with 304 stainless steel using physical vapor deposition and magnetron sputtering. A 304 stainless steel sputter target (Thin Solid Films, described by Barbee et al, 1979, volume 63, page 143-150) is deposited in a cubic form centered on magnetic ferrite. An apparatus for making 304 stainless steel film coated abrasive particles (i.e., magnetizable abrasive particles) is disclosed in U.S. patent No.8,698,394(McCutcheon et al). The gas physical vapor deposition was performed at 1.0 kw for 4 hours at an argon sputtering gas pressure of 10 mtorr (1.33 pascals) for 51.94 grams of AP 2. The weight percent of metal coating in the coated AP2 was about 0.65%, and the coating thickness was about 1 micron.

Example 1

The basis weight is 300-²The untreated polyester fabric of (a) is available under the trade designation "POWERSTRAIT" from Milliken, Spartburg, south Carolina, USA&Company, Spartanburg, South Carolina) with a composition comprising113g/m²Is coated with a pre-glue layer, the composition comprising: 75 parts of an epoxy resin (bisphenol A diglycidyl ether, available under the trade designation "EPON 828" from Ruizhen advanced Products, Houston, Tex., USA), 10 parts of trimethylolpropane triacrylate (available under the trade designation "TMPTA" from Cytec Industrial Inc., Woodland Park, N.J.), 8 parts of a dicyandiamide curing agent (available under the trade designation "DICYANEX 1400B" from Air Products and Chemicals, Allentown, Pennsylvania), 5 parts of a novolac resin (available under the trade designation "RUTAPHEN 8656" from Columbus high-tech materials, Inc., Molliva Specialty Chemicals, Pennsylvania, Ohio.), 5 parts of a novolac resin (available under the trade designation "RUTAPHEN 8656" from BASE 2, Columbus 2-Dimethoxybenzene Acetophenon, Inc., Columbus 2-Ocimum 2, Inc., Columbus 2-Dimethoxybenzene initiator, Inc., Columbo 2, Pennsylurea, Inc., of Houston Paeon, U.S. Corporation, Florham Park, New Jersey)) and 0.75 parts of 2-propylimidazole (available under the trade designation "ACTIRON NXJ-60 LIQUID" from pioneer Corporation of morgan, morganon, North Carolina, usa).

Using 209g/m²The phenolic make coat resin coated cloth backing of (1.5: 1 to 2.1:1 (formaldehyde: phenol) condensate catalyzed by 1% to 5% metal hydroxide, 52 parts of a 75% by weight aqueous solution of a resol, and obtained from Georgia-Pacific corporation of Atlanta, Georgia-Pacific, Atlanta, Georgia, usa, 45 parts of calcium metasilicate (obtained under the trade designation "M400 wollascoat" from NYCO corporation, Willsboro, NY, of wils berler, NY, usa) and 2.5 parts of water.

Abrasive particle MAP1 was dispensed via an inclined dispensing ramp to the primed resin-coated backing as the backing passed through magnet apparatus MA1 as shown in fig. 4. The end of the inclined dispensing ramp is 1.27cm from the surface of the backing and 15.87cm from the bottom trailing corner of the upper magnet, as shown in fig. 4. MAP1 coating weight 480g/m². Immediately after coating abrasive particle MAP1 on the backing, at 376g/m²Coating the abrasive particles AP3 onto the backing.

The abrasive coated backing was placed in an oven at 90 ℃ for 1.5 hours to partially cure the make resin. Compounding glue resin at 712g/m²Is applied to each strip of backing material, the size resin consists of 45.76 parts of a 75 wt% aqueous solution of a resol (1.5: 1 to 2.1:1 (formaldehyde: phenol) condensate catalyzed by 1% to 5% metal hydroxide and obtained from Georgia-Pacific corporation of Atlanta, Georgia, 4.24 parts of water, 24.13 parts of cryolite (Solvay Fluorides, LLC, Houston, Texas, usa), 24.13 parts of calcium metasilicate (available as "M400 WOLLASTOCOAT" from NYCO Company of wilsburk, New York), and 1.75 parts of red iron oxide, and the strip is placed in an oven at 90 ℃ for 102 hours and maintained at 102 ℃ for 8 hours. After curing, the coated abrasive strip is converted into a belt as is known in the art.

Comparative example A

The basis weight is 300-²The untreated polyester fabric of (a) is available under the trade designation "POWERSTRAIT" from Milliken, Spartburg, south Carolina, USA&Company, Spartanburg, South Carolina) with a composition of 113g/m²Is coated with a pre-glue layer, the composition consisting of: 75 parts of an epoxy resin (bisphenol A diglycidyl ether, available under the trade designation "EPON 828" from Resolution Performance Products, Houston, Tex., USA), 10 parts of trimethylolpropane triacrylate (available under the trade designation "TMPTA" from Cytec Industrial Inc., Woodland Park, Woodland Park, N.J.), 8 parts of a dicyandiamide curative (available under the trade designation "DICYANEX 1400B" from Air Products and Chemicals, Allentown, Pesylvanvania, Albumin), 5 parts of a novolac resin (available under the trade designation "RUPHTAEN 6" from Irondan, U.S.A.)Maiden materials Corporation of columbu, Ohio, 1 part of 2, 2-dimethoxy-2-phenylacetophenone (available under the trade designation "IRGACURE 651" photoinitiator from BASF Corporation, Florham Park, New Jersey, Florham) and 0.75 part of 2-propylimidazole (available under the trade designation "ACTIRON NXJ-60 LIQUID" from pioneer Corporation, Morganton, North Carolina, morden), morganin.

Using 209g/m²The phenolic primer resin coating cloth backing is composed of the following substances: 52 parts of a 75 weight percent aqueous solution of a resole (1.5: 1 to 2.1:1 (formaldehyde: phenol) condensate catalyzed by 1% to 5% metal hydroxide and obtained from Georgia-Pacific, Atlanta, Georgia, of Atlanta, Georgia), 45 parts of calcium metasilicate (obtained under the trade designation "M400 WOLLASTOCOAT" from NYCO Company, Willsboro, NY, of Willeboro, N.Y.) and 2.5 parts of water.

Abrasive particle MAP2 was dispensed onto the primed resin coated backing as the backing passed through magnet apparatus MA1 as shown in fig. 4. The end of the inclined dispensing ramp is 1.27cm from the surface of the backing and 15.87cm from the bottom trailing corner of the upper magnet, as shown in fig. 4. MAP1 coating weight 480g/m². Immediately after coating abrasive particle MAP1 on the backing, at 376g/m²Coating the abrasive particles AP3 onto the backing.

The abrasive coated backing was placed in an oven at 90 ℃ for 1.5 hours to partially cure the make resin. Compounding glue resin at 712g/m²Applied to each strip of backing material, the size resin having 45.76 parts of a 75 wt.% aqueous solution of a resole (1.5: 1 to 2.1:1 (formaldehyde: phenol) condensate catalyzed by 1 to 5% metal hydroxide and obtained from Georgia-Pacific corporation of Atlanta, Georgia-Pacific, LLC, Houston, Texas, Georgia), 4.24 parts water, 24.13 parts cryolite (Solvay Fluorides, LLC, Houston, Texas, usa), 24.13 parts partial fluorideCalcium silicate (available as "M400 WOLLASTOCOAT" from NYCO Company, Willsboro, New York, Wallsberger, N.Y.) and 1.75 parts red iron oxide, and the coated strips were placed in an oven at 90 deg.C for 1 hour and then at 102 deg.C for 8 hours. After curing, the coated abrasive strip is converted into a belt as is known in the art.

Comparative example B

Comparative example B an abrasive grinding BELT available from 3M Company (3M Company, St. Paul, MN), St. Paul, Minn., under the trade designation CUBITRON II CLOTH BELT 991FZ, 36+ -%Comparative example C

Comparative example B an abrasive grinding BELT available from 3M Company of St.Paul, MN, St.Paul, Minn, under the trade designation CUBITRON II CLOTH BELT 984F, 36+ (R)Grinding test procedure A

Grinding test procedure a was used to evaluate the efficacy of the abrasive belts of example 1, comparative example a, and comparative example C. The workpiece was an aluminum 6061 bar presented to the abrasive belt along 5.08cm x 91.44cm of the abrasive belt. A serrated (1:1 matrix to groove ratio) rubber contact pad with a diameter of 20.3cm and a shore a hardness of 70 was used. The belt was run at 5500 surface feet per minute (SFM). The workpiece is pushed against the central portion of the strip with a combination of normal forces of 10 to 15 pounds (4.53 to 6.8 kg). The test involves measuring the weight loss of the workpiece after grinding for 15 seconds (1 cycle). The workpiece was then cooled and tested again. The test was terminated after 15 test cycles. Cycle 1 is referred to as the initial cut for each example. For example 1 and comparative example C, the test was performed in a first use direction in the forward direction and in a second, opposite use direction in the reverse direction. The cut in grams after each cycle was recorded.

The results of grinding procedure a (aluminum) are shown in table 1 herein. A graph of the data is also provided in fig. 8.

Table 1: results of grinding test procedure A。

Grinding test procedure B (Wood)

A 40.6cm long by 30.48cm by 1.6cm thick piece of particle BOARD (available under The trade designation COLLINS PINE PARTICLE BOARD from The COLLINS Company, Portland, Oregon, usa) was secured to a test fixture in a position to be abraded on its 30.48cm edge by The abrasive belts of example a and comparative example B, each being an endless abrasive belt having dimensions of 5.08cm by 91.44 cm. In each test, the abrasive belt was supported by a graphite covered platen. In each test, the panel was pressed into the abrasive belt as the belt was moved at a feed rate of 5500 face feet per minute. A total force of 15 pounds was applied to the plate and the plate was contacted with the abrasive belt for a grinding time of 10 seconds. The plate was removed from the belt and the amount of material removed from the plate was measured. This process was repeated for a total of 25 cycles. Cycle 1 is referred to as the initial cut for each example. For example 1 and comparative example B, the test was performed in a first use direction in the forward direction and in a second, opposite use direction in the reverse direction. The amount of material of the particle board removed in mm was recorded after each cycle. The results of grinding procedure B (particle board) are shown in table 2 herein. A graph of the data is also provided in fig. 9.

Table 2: results of grinding test procedure B。

Belt force data procedure C

The abrasive belts of examples, comparative example a, and comparative example B. The test strips were annular strips each having a size of 5.08cm × 91.44 cm. The abrasive belt was mounted on a belt sander equipped with a 20.6cm steel contact wheel. A 40.6cm long by 30.48cm by 1.6cm thick piece of particle BOARD (COLLINS PINE PARTICLE BOARD, corins co., of Portland, Oregon, usa) was secured in place in the test fixture for grinding on its edges by an endless abrasive belt. The test fixture was adjusted to provide a 10mm interference between the proximal surface of the workpiece edge and the surface of the abrasive belt. The belt sander was started to a surface speed of 1753m/min and the workpiece was moved laterally along a 40.6cm dimension at a rate of 150 mm/sec. For example 1 and comparative example B, the test was performed in a first use direction in the forward direction and in a second, opposite use direction in the reverse direction. For comparative example B, the test was performed in the reverse, second use direction. The cut in grams after each cycle was recorded.

The normal force at the abrasive belt/workpiece interface is measured as a specified volume of wood is abraded. After this first pass, the edge of the particle board was retracted from the abrasive belt, returned to its starting position, adjusted to provide another 10mm interference, and moved laterally for another pass of grinding. This process was repeated 25 times in total. The results of grinding procedure C are shown in table 3 herein. A graph of the data is also provided in fig. 10.

Table 3: results of Process C with force data

Workpiece surface analysis Process D

The workpiece of example 1, run in the forward direction and a portion of the workpiece of example 1, run in the reverse direction in grinding procedure A was analyzed using a microscope commercially available from Keyence Corporation of America, Itasca Illinois, Ill.A. under the trade designation KEYENCE VK-X250 laser confocal microscope. A 10 x objective lens is used. The 10 x objective has a field of view of 1mm x 1.43 mm. To analyze larger areas, images are generated by stitching together a 3x 3 array of individual images. This results in a field of view of the final image of 2.9mm x 3.9 mm.

The stitched images were then analyzed using a Keyence multi-file analyzer. The 2D color isocontour is shown in fig. 11 and 12. Fig. 11 shows the substrate of example 1 running in the reverse direction, and fig. 12 shows the substrate of example 1 running in the forward direction. A 3D image of each surface is also generated to show the differences between the samples. Fig. 13 shows a 3D image of the substrate of example 1 running in the reverse direction, and fig. 14 shows a 3D image of the substrate of example 1 running in the forward direction. Additionally, surface finish measurements for each surface were recorded and are shown in table 4.

The parameters mentioned include the arithmetic mean height (Sa). Sa is the extension of Ra (arithmetic mean height of the thread) to the surface. Expressed as an absolute value, the difference in height of each point is compared to the arithmetic mean of the surfaces. This parameter is commonly used to evaluate surface roughness.

Skewness (Ssk) was also measured, and the Ssk value represents the degree of bias of the asperity shape. An Ssk greater than 0 indicates that the height distribution is skewed above the mean plane (peak); an Ssk equal to 0 indicates that the height distribution (peak and pit) is symmetrical around the mean plane; and an Ssk less than 0 indicates that the height distribution is skewed below the mean land (pit).

The maximum peak height (Sp) was also measured. Sp is the height of the highest peak within the defined region. The maximum pit height (Sv) was also measured. Sv is the absolute value of the height of the largest pit in the defined area. Each of Sa, Ssk, Sp, and Sv is measured according to a standard called ISO 25178.

Table 4: surface Properties of example 1。

Work chip analysis step E

A portion of the swarf was collected from the workpiece of example 1, which was run in the forward direction. A portion of the swarf was also collected from the workpiece of comparative example C, which was run in the forward direction.

The corresponding chip parts were analyzed using Scanning Electron Microscopy (SEM). The image of the chip was captured using a field emission scanning electron microscope (FEOL Ltd, Tokyo Japan) available from JEOL Ltd, Tokyo Japan, under the trade name JSM-7600F. Images were taken using Jeol JSM-7600F at 33X and 45 degree tilt angles and stitched into a 2X 2 composite image.

The average length of the chips collected from example 1 and comparative example C was measured using a microscope commercially available from Keyence Corporation of America (Itasca Illinois) under the trade designation KEYENCE 5000 digital microscope. The average length is measured using binary image analysis to calculate the maximum diagonal length.

Analysis showed that the average length of 78 chips collected from example 1 was 1772 μm. Further analysis showed that the average length of 89 chips collected from comparative example C was 1109 μm.

Additional embodiments：

The present invention provides the following exemplary embodiments, the numbering of which should not be construed as specifying the degree of importance:

embodiment 1 provides an abrasive article having a direction of use, a y-axis, and a z-axis orthogonal to the y-axis and the direction of use, the abrasive article comprising:

a backing;

shaped abrasive particles attached to the backing, about 5% to about 100% of the shaped abrasive particles independently comprising:

the first side surface is provided with a first side surface,

a second side surface opposite the first side surface,

a front surface connected to the first side surface at a first edge and to the second side surface at a second edge,

an angle of inclination between the backing and the front surface, the angle of inclination being in a range of about 10 degrees to about 110 degrees, an

A z-direction rotational angle between a line intersecting the first edge and the second edge and the direction of use of the abrasive article, the z-direction rotational angle being in a range from about 10 degrees to about 170 degrees.

Embodiment 2 provides an abrasive article having a first direction of use, the abrasive article comprising:

abrasive particles attached to a backing, wherein under the same testing conditions, a greater amount of material is removed from a workpiece in contact with the abrasive article than the workpiece when the abrasive article is moved in a second direction different from the first direction of use.

Embodiment 3 provides the abrasive article of embodiment 2, wherein at least 15% more material is removed in the first use direction.

Embodiment 4 provides the abrasive article of any one of

embodiments

2 or 3, wherein at least 50% more material is removed in the first use direction.

Embodiment 5 provides the abrasive article of embodiment 2, wherein about 10% to about 500% more material is removed in the first use direction.

Embodiment 6 provides the abrasive article of any one of

embodiments

1 or 5, wherein about 30% to about 70% more material is removed in the first use direction.

Embodiment 7 provides the abrasive article of any one of

embodiments

1 or 5 to 6, wherein about 40% to about 60% more material is removed in the first use direction.

Embodiment 8 provides the abrasive article of any one of embodiments 2 to 7, wherein about 5% to about 100% of the abrasive particles are shaped abrasive particles independently comprising:

the first side surface is provided with a first side surface,

a second side surface opposite the first side surface,

Embodiment 9 provides the abrasive article of any one of embodiments 2-8, wherein the material is removed according to at least one of grinding procedure a and grinding procedure B.

Embodiment 10 provides the abrasive article of embodiment 9, wherein the work piece has an initial cut of at least 9 grams when the abrasive article is operated according to grinding procedure a in the use direction.

Embodiment 11 provides the abrasive article of any one of

embodiments

9 or 10, wherein the work piece has an initial cut of at least 11 grams when the abrasive article is operated according to grinding procedure a in the use direction.

Embodiment 12 provides the abrasive article of any one of embodiments 9-11, wherein the work piece has an initial cut of at least 17.8 grams when the abrasive article is operated according to grinding procedure a in the use direction.

Embodiment 13 provides the abrasive article of any one of embodiments 9-12, wherein the workpiece has a total cut of at least 65 grams after 15 cycles when the abrasive article is operated according to grinding procedure a in the use direction.

Embodiment 14 provides the abrasive article of any one of embodiments 9-13, wherein the workpiece has a total cut of at least 118.37 grams after 15 cycles when the abrasive article is operated according to grinding procedure a in the use direction.

Embodiment 15 provides the abrasive article of any one of embodiments 9-14, wherein the workpiece has a total cut of at least 120 grams after 15 cycles when the abrasive article is operated according to grinding procedure a in the use direction.

Embodiment 16 provides the abrasive article of embodiment 9, wherein the work piece has a stock removal of at least 9mm when the abrasive article is operated according to grinding procedure B in the use direction.

Embodiment 17 provides the abrasive article of any one of

embodiments

9 or 16, wherein the work piece has an initial cut of at least 11mm when the abrasive article is operated according to grinding procedure B in the use direction.

Embodiment 18 provides the abrasive article of any one of

embodiments

9, 16, or 17, wherein the work piece has an initial cut of at least 18.47mm when the abrasive article is operated according to grinding procedure B in the use direction.

Embodiment 19 provides the abrasive article of any one of

embodiments

9 or 16 to 19, wherein the total cut of the workpiece after 25 cycles is at least 180mm when the abrasive article is operated according to grinding procedure B in the use direction.

Embodiment 20 provides the abrasive article of any one of

embodiments

9 or 16 to 19, wherein the total cut of the workpiece after 25 cycles is at least 187mm when the abrasive article is operated according to grinding procedure B in the use direction.

Embodiment 21 provides the abrasive article of any one of

embodiments

9 or 16 to 20, wherein the total cut of the workpiece after 25 cycles is at least 485.29mm when the abrasive article is operated according to grinding procedure B in the use direction.

Embodiment 22 provides an abrasive article having a first direction of use, the abrasive article comprising:

abrasive particles attached to a backing, wherein under the same test conditions, an average surface roughness of a workpiece abraded with the abrasive article is greater than an average surface roughness of a workpiece abraded when the abrasive article is moved in a second use direction different from the first use direction.

Embodiment 23 provides the abrasive article of embodiment 22, wherein the average surface roughness is at least 90% greater in the first use direction.

Embodiment 24 provides the abrasive article of any one of

embodiments

22 or 23, wherein the average surface roughness is at least 105% greater in the first use direction.

Embodiment 25 provides the abrasive article of embodiment 22, wherein the average surface roughness is about 10% to about 500% in the first use direction.

Embodiment 26 provides the abrasive article of any one of embodiments 22 to 25, wherein about 5% to about 100% of the abrasive particles are shaped abrasive particles independently comprising:

the first side surface is provided with a first side surface,

a second side surface opposite the first side surface,

Embodiment 27 provides the abrasive article of any one of embodiments 9-26, wherein the workpiece is abraded according to at least one of grinding procedure a and grinding procedure B.

Embodiment 28 provides the abrasive article of any one of embodiments 1 to 27, wherein about 25% to about 100% comprises the first side surface, the second side surface, the front surface, the inclination angle, and the z-direction rotation angle.

Embodiment 29 provides the abrasive article of any one of embodiments 1 to 28, wherein about 50% to about 100% comprises the first side surface, the second side surface, the front surface, the inclination angle, and the z-direction rotation angle.

Embodiment 30 provides the abrasive article of any one of embodiments 1 to 29, wherein the backing is a flexible backing comprising a polymeric film, a metal foil, a woven fabric, a knitted fabric, paper, vulcanized fiber, a nonwoven, a foam, a screen, a laminate, or a combination thereof.

Embodiment 31 provides the abrasive article of any one of embodiments 1 to 30, wherein at least one of the shaped abrasive particles is a ceramic shaped abrasive particle.

Embodiment 32 provides the abrasive article of any one of embodiments 1 to 31, wherein the shaped abrasive particles independently comprise alpha alumina, sol-gel derived alpha alumina, or a mixture thereof.

Embodiment 33 provides the abrasive article of any one of embodiments 1 to 32, wherein the shaped abrasive particles independently comprise fused aluminum oxide, heat treated aluminum oxide, ceramic aluminum oxide, sintered aluminum oxide, silicon carbide material, titanium diboride, boron carbide, tungsten carbide, titanium carbide, diamond, cubic boron nitride, garnet, fused alumina-zirconia, ceria, zirconia, titania, or a combination thereof.

Embodiment 34 provides the abrasive article of any one of embodiments 1 to 33, wherein the first and second side surfaces of at least one of the shaped abrasive particles comprises a polygonal shape.

Embodiment 35 provides the abrasive article of embodiment 34, wherein the polygonal shapes of the first and second side surfaces are independently regular or irregular polygons.

Embodiment 36 provides the abrasive article of any one of embodiments 33 or 34, wherein the polygonal shapes of the first and second side surfaces are independently triangular or quadrilateral shapes.

Embodiment 37 provides the abrasive article of embodiment 36, wherein the polygonal shape is a quadrilateral shape.

Embodiment 38 provides the abrasive article of embodiment 37, wherein the quadrilateral shape comprises a trapezoid, a square, or a rectangle.

Embodiment 39 provides the abrasive article of embodiment 36, wherein the polygonal shape is a triangular shape.

Embodiment 40 provides the abrasive article of embodiment 39, wherein the triangular shape comprises a right triangle, a scalene triangle, an isosceles triangle, an acute triangle, or an obtuse triangle.

Embodiment 41 provides the abrasive article of any one of embodiments 39 or 40, wherein the triangular shape is free of equilateral triangles.

Embodiment 42 provides the abrasive article of any one of embodiments 39 to 41, wherein at least one of the shaped abrasive particles further comprises a third side surface having a triangular shape, wherein

The front surface has a triangular shape, and

the shaped abrasive particles are tetrahedral.

Embodiment 43 provides the abrasive article of any one of embodiments 1 to 42, wherein the relief angle between the backing and the back surface or edge at the cutting tip of at least one of the shaped abrasive particles is in the range of about 90 degrees to about 180 degrees.

Embodiment 44 provides the abrasive article of any one of embodiments 1 to 43, wherein a relief angle between the backing and a back surface or edge at the cutting tip of at least one of the shaped abrasive particles is in a range from about 120 degrees to about 140 degrees.

Embodiment 45 provides the abrasive article of any one of embodiments 1 to 44, wherein the first and second side surfaces of at least one of the shaped abrasive particles have substantially the same dimension in at least one of a surface area, a maximum length dimension, and a maximum width dimension.

Embodiment 46 provides the abrasive article of any one of embodiments 1 to 45, wherein the first and second side surfaces of at least one of the shaped abrasive particles have different dimensions in at least one of surface area, maximum length dimension, and maximum width dimension.

Embodiment 47 provides the abrasive article of any one of embodiments 1 to 46, wherein the first side surface, the second side surface, and the front surface of at least one of the shaped abrasive particles are substantially planar.

Embodiment 48 provides the abrasive article of any one of embodiments 1 to 46, wherein at least one of the first side surface, the second side surface, and the front surface of at least one of the shaped abrasive particles is substantially non-planar.

Embodiment 49 provides the abrasive article of any one of embodiments 1 to 46, wherein the first side surface, the second side surface, and the front surface of at least one of the shaped abrasive particles are substantially parallel to one another.

Embodiment 50 provides the abrasive article of any one of embodiments 1 to 46, wherein the first side surface, the second side surface, and the front surface of at least one of the shaped abrasive particles are not substantially parallel to one another.

Embodiment 51 provides the abrasive article of any one of embodiments 1 to 46, wherein at least one of the first side surface, the second side surface, and the front surface of at least one of the shaped abrasive particles has a concave shape.

Embodiment 52 provides the abrasive article of embodiment 46, wherein for at least one of the shaped abrasive particles:

the first side surface has a concave shape and the second side surface is substantially planar;

the first side surface has a convex shape and the second side surface has a concave shape; or

The first side surface is inwardly shaped and the second side surface is inwardly shaped.

Embodiment 53 provides the abrasive article of any one of embodiments 1 to 28, wherein at least one of the shaped abrasive particles comprises at least one shape feature comprising: an opening, a concave surface, a convex surface, a groove, a ridge, a fracture surface, a low roundness factor, or a perimeter including one or more corner points with a sharp tip.

Embodiment 54 provides the abrasive article of any one of embodiments 1 to 53, wherein at least one of the shaped abrasive particles comprises openings.

Embodiment 55 provides the abrasive article of any one of embodiments 1 to 54, wherein the first and second edges of at least one of the shaped abrasive particles are substantially parallel.

Embodiment 56 provides the abrasive article of any one of embodiments 1 to 55, wherein the first and second edges of at least one of the shaped abrasive particles are tapered.

Embodiment 57 provides the abrasive article of any one of embodiments 1 to 55, wherein the first and second edges of at least one of the shaped abrasive particles are curved.

Embodiment 58 provides the abrasive article of any one of embodiments 1 to 55, wherein a draft angle a between the second side surface and the front surface of at least one of the shaped abrasive particles is in a range from about 95 degrees to about 130 degrees.

Embodiment 59 provides the abrasive article of any one of embodiments 1 to 58, wherein the cutting tip of at least one of the shaped abrasive particles is substantially aligned with the y-direction.

Embodiment 60 provides the abrasive article of any one of embodiments 1 to 59, wherein the inclination angle of at least one of the shaped abrasive particles is in the range of about 80 degrees to about 100 degrees.

Embodiment 61 provides the abrasive article of any one of embodiments 1 to 60, wherein the inclination angle of at least one of the shaped abrasive particles is in the range of about 85 degrees to about 95 degrees.

Embodiment 62 provides the abrasive article of any one of embodiments 1 to 61, wherein the z-direction rotational angle of at least one of the shaped abrasive particles is in a range from about 80 degrees to about 100 degrees.

Embodiment 63 provides the abrasive article of any one of embodiments 1 to 62, wherein the z-direction rotational angle of at least one of the shaped abrasive particles is in a range from about 85 degrees to about 95 degrees.

Embodiment 64 provides the abrasive article of any one of embodiments 1 to 63, wherein for at least one of the shaped abrasive particles:

the first side surface and the second side surface comprise a triangular shape that does not comprise an equilateral triangular shape;

the first edge and the second edge are substantially parallel;

the inclination angle is in the range of about 80 degrees to about 110 degrees; and

the z-direction rotation angle is in a range of about 80 degrees to about 110 degrees.

Embodiment 65 provides the abrasive article of embodiment 64, wherein the triangular shape is a right triangle.

Embodiment 66 provides the abrasive article of any one of embodiments 1 to 65, wherein an edge of at least one of the shaped abrasive particles is substantially aligned with the backing in the x-y plane.

Embodiment 67 provides the abrasive article of any one of embodiments 1 to 66, wherein the at least one of the shaped abrasive particles is responsive to a magnetic field.

Embodiment 68 provides the abrasive article of any one of embodiments 1 to 67, wherein at least one of the shaped abrasive particles comprises a magnetic material.

Embodiment 69 provides the abrasive article of embodiment 68, wherein the magnetic material at least partially coats the surface of the shaped abrasive particles.

Embodiment 70 provides the abrasive article of embodiment 69, wherein at least one of the shaped abrasive particles is a monolithic abrasive particle.

Embodiment 71 provides the abrasive article of any one of embodiments 1 to 70, wherein the inclination angles of about 50% to about 100% of the shaped abrasive particles are substantially the same.

Embodiment 72 provides the abrasive article of any one of embodiments 1 to 71, wherein the inclination angles of about 90% to about 100% of the shaped abrasive particles are substantially the same.

Embodiment 73 provides the abrasive article of any one of embodiments 1 to 72, wherein the z-direction rotational angles of about 50% to about 100% of the shaped abrasive particles are substantially the same.

Embodiment 74 provides the abrasive article of any one of embodiments 1 to 73, wherein the z-direction rotational angles of about 90% to about 100% of the shaped abrasive particles are substantially the same.

Embodiment 75 provides the abrasive article of any one of embodiments 1 to 74, further comprising crushed abrasive particles.

Embodiment 76 provides the abrasive article of embodiment 75, wherein the crushed abrasive particles and the shaped abrasive particles comprise different materials.

Embodiment 77 provides the abrasive article of any one of embodiments 75 or 76, wherein the shaped abrasive particles comprise about 5 to about 95 weight percent of the blend of the shaped abrasive particles and the crushed abrasive particles.

Embodiment 78 provides the abrasive article of any one of embodiments 1 to 77, wherein the abrasive article comprises a belt, a disc, or a sheet.

Embodiment 79 provides the abrasive article of any one of embodiments 1 to 78, further comprising a make coat adhering the shaped abrasive particles to the backing.

Embodiment 80 provides the abrasive article of embodiment 79, further comprising a size coat adhering the shaped abrasive particles to the make coat.

Embodiment 81 provides the abrasive article of any one of embodiments 79 or 80, wherein at least one of the make coat and the size coat comprises a phenolic resin, an epoxy resin, a urea-formaldehyde resin, an acrylate resin, an aminoplast resin, a melamine resin, an acrylated epoxy resin, a urethane resin, or a mixture thereof.

Embodiment 82 provides the abrasive article of any one of embodiments 78 to 81, wherein at least one of the make and size layers comprises a filler, a grinding aid, a wetting agent, a surfactant, a dye, a pigment, a coupling agent, a tackifier, or a mixture thereof.

Embodiment 83 provides the abrasive article of embodiment 82, wherein the filler comprises calcium carbonate, silica, talc, clay, calcium metasilicate, dolomite, aluminum sulfate, or a mixture thereof.

Embodiment 84 provides the abrasive article of any one of embodiments 1-83, wherein the abrasive article comprises a disc and the z-direction rotational angle circumferentially positions the front surface and the pattern formed by the shaped abrasive particles comprises a plurality of circles.

Embodiment 85 provides the abrasive article of any one of embodiments 1-84, wherein the abrasive article comprises a sheet or a belt and the z-direction rotational angle positions the substantially planar surface at an angle such that a pattern formed by the shaped abrasive particles comprises a plurality of parallel lines.

Embodiment 86 provides a method of making an abrasive article according to any one of embodiments 1 to 85, the method comprising:

orienting the shaped abrasive particles; and

adhering the shaped abrasive particles to the backing.

Embodiment 87 provides the method of embodiment 87, wherein orienting the shaped abrasive particles comprises depositing at least one of the shaped abrasive particles in cavities of the backing, the cavities being shaped such that at least one shaped abrasive particle has the z-direction rotational orientation.

Embodiment 88 provides the method of embodiment 87, wherein orienting the shaped abrasive particles comprises passing the at least one of the shaped abrasive particles through a screen such that the at least one shaped abrasive particle has the z-direction rotational orientation.

Embodiment 89 provides the method of embodiment 88, wherein orienting the at least one shaped abrasive particle comprises placing the at least one shaped abrasive particle in a single cavity of a transfer tool and contacting the at least one shaped abrasive particle with the backing such that the at least one shaped abrasive particle has the z-direction rotational orientation.

Embodiment 90 provides the method of embodiment 89, wherein orienting the at least one shaped abrasive particle comprises exposing the at least one shaped abrasive particle to a magnetic field.

Embodiment 91 provides the method of embodiment 90, further comprising rotating the at least one shaped abrasive particle in a magnetic field.

Embodiment 92 provides the method of any one of embodiments 87-91, wherein adhering the shaped abrasive particles to the backing comprises contacting the shaped abrasive particles with a make coat disposed on at least a portion of the backing.

Embodiment 93 provides the method of embodiment 92, wherein adhering the shaped abrasive particles to the backing further comprises disposing a size layer on at least a portion of the shaped abrasive particles and at least one of the make coat and the backing.

Embodiment 94 provides a method of using an abrasive article according to any one of embodiments 1 to 85 or an abrasive article made using the method of any one of embodiments 86 to 93, the method comprising:

contacting the shaped abrasive particles with a workpiece;

moving at least one of the abrasive article and the workpiece relative to each other in a use direction; and

removing a portion of the workpiece.

Embodiment 95 provides the method of embodiment 94, wherein the cutting tip of the at least one of the shaped abrasive particles contacts the workpiece.

Embodiment 96 provides the method of embodiment 95, wherein the cutting tip is free of sharp points having a radius of curvature of at least 60 microns.

Embodiment 97 provides the method of any one of embodiments 94-96, wherein the depth of cut in the workpiece is at least 10 μ ι η.

Embodiment 98 provides the method of any one of embodiments 94-97, wherein the depth of cut in the workpiece is at least 30 μ ι η.

Embodiment 99 provides the method of any one of embodiments 94 to 98, wherein the abrasive article has a cut rate of at least 100 m/min.

Embodiment 100 provides the method of any one of embodiments 94 to 99, wherein the abrasive article has a cut rate of at least 300 m/min.

Embodiment 101 provides the method of any one of embodiments 94-100, wherein at least a portion of the workpiece is removed as a chip by the abrasive article.

Embodiment 102 provides the method of embodiment 101, wherein a longest average dimension of a single chip generated in one grinding cycle is at least 1200 μm millimeters.

Embodiment 103 provides the method of any one of embodiments 101 or 102, wherein the longest average dimension of individual chips generated in one grinding cycle is at least 1772 μ ι η.

Embodiment 104 provides the method of any one of embodiments 102 or 103, wherein the cuttings comprise low carbon steel.

Embodiment 105 provides the method of any one of embodiments 94-104, wherein the direction of use is a first direction and the amount of material removed from the workpiece in the first direction is greater than the amount of material removed in a second direction different from the first direction under the same test conditions.

Embodiment 106 provides the method of any one of embodiments 94-105, wherein the direction of use is a first direction and the amount of force required to remove the same amount of material from the workpiece under the same test conditions is less than the amount of force required to remove the same amount of material at the same feed rate when the direction of use is a second direction different from the first direction.

Embodiment 107 provides the method of embodiment 106, wherein the workpiece feed rate is about 110mm/s to about 200 mm/s.

Embodiment 108 provides the method of any one of embodiments 106 or 107, wherein the workpiece feed rate is about 140mm/s to about 160 mm/s.

Embodiment 109 provides the method of embodiment 105, wherein the article is moved in the second direction to finish the workpiece.

Embodiment 110 provides the method of any one of embodiments 98-109, wherein the use direction is a linear direction or a rotational direction.

Embodiment 111 provides the method of embodiment 110, wherein the direction of use is a direction of rotation, and the z-direction rotational angle is between a line intersecting the first edge and the second edge and a line tangent to the direction of rotation.

Embodiment 112 provides the method of embodiment 111, wherein the abrasive article is a belt or a sheet and the direction of use is along an x-axis orthogonal to the y-axis and the z-axis.

Embodiment 113 provides the method of any one of embodiments 94-112, wherein the workpiece comprises steel, aluminum, alloys thereof, wood, or mixtures thereof.

Embodiment 114 provides a method according to any of embodiments 94-113, wherein the amount of workpiece material removed under the force applied to the abrasive article is greater than a corresponding abrasive article comprising shaped abrasive particles having equilateral triangles.

Embodiment 115 provides the method of any one of embodiments 94-114, wherein the arithmetic mean roughness value of the workpiece material when the abrasive article is moved in the first use direction is in the range of about 1000 to about 2000.

Embodiment 116 provides the method of any one of embodiments 94-115, wherein an arithmetic mean roughness value of the workpiece material as the abrasive article moves in the first use direction is in a range from about 1000 to about 1100.

Embodiment 117 provides the method of any one of embodiments 94-116, wherein an arithmetic mean roughness value of the workpiece material when the abrasive article is moved in the first use direction is higher than an arithmetic mean roughness value when the abrasive article is moved in the second use direction.

Although the terms and expressions which have been employed are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, it being recognized that various modifications are possible within the scope of the embodiments of the invention. Thus, it should be understood that although the present disclosure has been specifically disclosed by specific embodiments and optional features, modification and variation of the concepts herein disclosed may be resorted to by those skilled in the art, and that such modifications and variations are considered to be within the scope of embodiments of this invention.

The claims (modification according to treaty clause 19)

1. An abrasive article having a first direction of use, the abrasive article comprising:

2. The abrasive article of claim 2, wherein at least 15% more material is removed in the first use direction.

3. The abrasive article of

claim

1 or 2, wherein at least 50% more material is removed in the first use direction.

4. The abrasive article according to any one of claims 1 to 3, wherein the material is removed according to at least one of grinding procedure A and grinding procedure B.

5. An abrasive article having a direction of use, a y-axis, and a z-axis orthogonal to the y-axis and the direction of use, the abrasive article comprising:

a backing;

the first side surface is provided with a first side surface,

a second side surface opposite the first side surface,

6. The abrasive article of claim 5, wherein at least one of the shaped abrasive particles is a ceramic shaped abrasive particle.

7. The abrasive article of any one of

claims

5 or 6, wherein the inclination angle of at least one of the shaped abrasive particles is in a range between about 80 degrees and about 100 degrees.

8. The abrasive article of any one of claims 5 to 7, wherein the inclination angle of at least one of the shaped abrasive particles is in a range between about 85 degrees and about 95 degrees.

9. The abrasive article of any one of claims 5 to 8, wherein the z-direction rotational angle of at least one of the shaped abrasive particles is in a range between about 80 degrees and about 100 degrees.

10. The abrasive article of any one of claims 5 to 9, wherein the z-direction rotational angle of at least one of the shaped abrasive particles is in a range between about 85 degrees and about 95 degrees.

11. The abrasive article of any one of claims 5 to 10, wherein a relief angle between the backing and a back surface or edge at a cutting tip of at least one of the shaped abrasive particles is in a range from about 90 degrees to about 180 degrees.

12. The abrasive article of any one of claims 5 to 11, wherein an edge of at least one of the shaped abrasive particles is substantially aligned with the backing in an x-y plane.

13. The abrasive article of any one of claims 5 to 12, wherein the inclination angles of about 50% to about 100% of the shaped abrasive particles are substantially the same.

14. The abrasive article of any one of claims 5 to 13, wherein the z-direction rotational angles of about 90% to about 100% of the shaped abrasive particles are substantially the same.

15. The abrasive article of any one of claims 5 to 14, further comprising crushed abrasive particles.

16. A method of using the abrasive article of any one of claims 5 to 15, the method comprising:

contacting the shaped abrasive particles with a workpiece;

removing a portion of the material of the workpiece.

17. The method of claim 16, wherein the direction of use is a first direction in which a greater portion of material is removed from the workpiece than in a second direction different from the first direction under the same test conditions.

18. The method of any one of

claims

16 or 17, wherein the article is moved in the second direction to trim the workpiece.

19. The method of any one of claims 16 to 18, wherein the direction of use is a linear direction or a rotational direction.

20. The method of any of claims 16 to 19, wherein the workpiece comprises steel, aluminum, alloys thereof, wood, or mixtures thereof.

Claims

3. The abrasive article of any one of claims 2 or 3, wherein at least 50% more material is removed in the first use direction.

a backing;

the first side surface is provided with a first side surface,

a second side surface opposite the first side surface,

7. The abrasive article of any one of claims 5 or 6, wherein the inclination angle of at least one of the shaped abrasive particles is in a range between about 80 degrees and about 100 degrees.

contacting the shaped abrasive particles with a workpiece;

removing a portion of the material of the workpiece.

18. The method of any one of claims 16 or 17, wherein the article is moved in the second direction to trim the workpiece.