WO2021112967A1 - Article abrasif - Google Patents

Article abrasif Download PDF

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Publication number
WO2021112967A1
WO2021112967A1 PCT/US2020/057051 US2020057051W WO2021112967A1 WO 2021112967 A1 WO2021112967 A1 WO 2021112967A1 US 2020057051 W US2020057051 W US 2020057051W WO 2021112967 A1 WO2021112967 A1 WO 2021112967A1
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WO
WIPO (PCT)
Prior art keywords
nap
abrasive article
abrasive
major surface
average
Prior art date
Application number
PCT/US2020/057051
Other languages
English (en)
Inventor
Michael W. Klett
Davinder S. DHAMI
Original Assignee
Saint-Gobain Abrasives, Inc.
Saint-Gobain Abrasifs
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Saint-Gobain Abrasives, Inc., Saint-Gobain Abrasifs filed Critical Saint-Gobain Abrasives, Inc.
Publication of WO2021112967A1 publication Critical patent/WO2021112967A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D5/00—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting only by their periphery; Bushings or mountings therefor
    • B24D5/02—Wheels in one piece
    • B24D5/04—Wheels in one piece with reinforcing means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D7/00—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting otherwise than only by their periphery, e.g. by the front face; Bushings or mountings therefor
    • B24D7/02—Wheels in one piece
    • B24D7/04—Wheels in one piece with reinforcing means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D5/00—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting only by their periphery; Bushings or mountings therefor
    • B24D5/16—Bushings; Mountings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D7/00—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting otherwise than only by their periphery, e.g. by the front face; Bushings or mountings therefor
    • B24D7/16—Bushings; Mountings

Definitions

  • Some grinding wheels are made by sequentially charging layers of an abrasive mix and fiber glass web reinforcements into a mold, consolidating the components with pressure, and then subsequently curing in an oven at elevated temperatures. Grinding wheels of this type are generally used for cutting, abrading, and shaping various materials, such as stone, metal, glass, plastics, and other materials. With continued use, the diameter of a grinding wheel constantly decreases, and an operator must continuously adjust the grinding angle in order to maintain a constant material removal rate, while simultaneously preventing the newly formed tapered edge of the wheel from ‘biting-in’ and gouging the workpiece. The industry continues to demand abrasive articles capable of improved performance.
  • the present invention relates in general to abrasive articles, and in particular, to an abrasive article (e.g., grinding wheel) having improved performance of reduced gouging and an increased range of grinding angle operation.
  • an abrasive article e.g., grinding wheel
  • NAP non-abrasive portion
  • AP abrasive portion comprising abrasive particles contained in a bond material
  • An embodiment of an abrasive article disclosed herein may include: a body including: a non-abrasive portion (NAP) essentially free of abrasive particles; and an abrasive portion (AP) comprising abrasive particles contained in a bond material; wherein the abrasive portion comprises an average normalized percent theoretical density of not greater than 28%/mm.
  • NAP non-abrasive portion
  • AP abrasive portion comprising abrasive particles contained in a bond material
  • An embodiment of an abrasive article disclosed herein may include: a body including: a non-abrasive portion (NAP) essentially free of abrasive particles; and an abrasive portion (AP) comprising abrasive particles contained in a bond material; wherein the body comprises a functional grinding angle within a range of 0 degrees to 90 degrees.
  • NAP non-abrasive portion
  • AP abrasive portion
  • An embodiments of a method of fabricating an abrasive article disclosed herein may include: (a) forming a precursor body including a non-abrasive portion (NAP) and a green abrasive portion (AP); and (b) forming the precursor body into an abrasive article by selectively applying a different force on the green AP as compared to the NAP for at least a portion of the forming process.
  • NAP non-abrasive portion
  • AP green abrasive portion
  • An embodiment of a method of conducting a material removal operation disclosed herein may include: moving an abrasive article relative to a workpiece, wherein the abrasive article comprises a body including: a non-abrasive portion (NAP) essentially free of abrasive particles; an abrasive portion (AP) comprising abrasive particles contained in a bond material; and wherein moving the abrasive article relative to the workpiece includes tilting the abrasive article at a functional grinding angle within a range of 0 degrees to 90 degrees.
  • NAP non-abrasive portion
  • AP abrasive portion
  • FIG. 1 is a top view of an abrasive article according to an embodiment of the disclosure.
  • FIG. 2 is a bottom view of the abrasive article of FIG. 1.
  • FIG. 3 is a cross-sectional oblique view of a discontinuous fiber of the abrasive article of FIGS. 1 and 2.
  • FIG. 4 is a cross-sectional side view of the abrasive article of FIGS. 1 and 2.
  • FIG. 5 is a cross-sectional side view of another abrasive article according to an embodiment of the disclosure.
  • FIG. 6 is a simplified diagram of functional grinding angles of embodiments of abrasive articles of the disclosure.
  • FIG. 7 is a flowchart of a method of fabricating an abrasive article according to an embodiment of the disclosure.
  • FIG. 8 is a flowchart of a method of conducting a material removal operation according to an embodiment of the disclosure.
  • FIG. 9 is a chart providing comparative data of conventional abrasive articles and embodiments of abrasive articles of the disclosure.
  • FIG. 10 is a graph of the comparative data of the conventional abrasive articles and embodiments of abrasive articles of the disclosure depicted in the chart of FIG. 6.
  • FIG. 11 is a chart of the comparative data of the conventional abrasive articles and embodiments of abrasive articles of the disclosure depicted in the chart of FIG. 6 and the graph of FIG. 7.
  • Abrasive article 100 may generally comprise a body 102, a central aperture 104 disposed through the body 102, a central axis 106, and an outer wheel diameter 108.
  • the body 102 may comprise a non abrasive portion (NAP) 110 and an abrasive portion (AP) 112.
  • the NAP 110 may comprise one or more features and/or dimensions that may facilitate improved manufacturing and/or performance of the abrasive article 100. In some embodiments, the NAP 110 may be free of abrasive particles.
  • the NAP 110 may include an organic material, such as phenolic resin, boron-modified resin, nano-particle-modified resin, urea-formaldehyde resin, acrylic resin, epoxy resin, polybenzoxazine, polyester resin, isocyanurate resin, melamine- formaldehyde resin, polyimide resin, other suitable thermosetting or thermoplastic resins, or any combination thereof.
  • organic material such as phenolic resin, boron-modified resin, nano-particle-modified resin, urea-formaldehyde resin, acrylic resin, epoxy resin, polybenzoxazine, polyester resin, isocyanurate resin, melamine- formaldehyde resin, polyimide resin, other suitable thermosetting or thermoplastic resins, or any combination thereof.
  • the NAP 110 may consist essentially of any one of phenolic resin, boron-modified resin, nano-particle-modified resin, urea- formaldehyde resin, acrylic resin, epoxy resin, polybenzoxazine, polyester resin, isocyanurate resin, melamine-formaldehyde resin, polyimide resin, other suitable thermosetting or thermoplastic resins, or any combination thereof.
  • the NAP 110 may include at least 10 vol% of an organic material for a total volume of the NAP 110.
  • the content of organic material may be greater, such as at least 20 vol%, at least 25 vol%, at least 30 vol%, at least 40 vol%, at least 50 vol%, at least 60 vol%, at least 70 vol%, at least 80 vol% or at least 90 vol%.
  • the NAP 110 may include not greater than 95 vol% organic material for a total volume of the NAP 110, such as not greater than 90%, not greater than 80%, not greater than 70%, not greater than 60%, not greater than 50%, not greater than 40%, not greater than 30%, or not greater than 20%. It will be appreciated that the content of organic material can be within a range between any of the minimum and maximum percentages noted above, including for example at least 10 vol% to not greater than 95 vol%.
  • the NAP 110 may further include one or more fillers contained within the organic material.
  • the fillers may comprise fibers, particles, bundled fibers, agglomerates, and the like.
  • the fillers may include natural and/or synthetic materials.
  • the filler may comprise a matrix of discontinuous fibers (120 in FIG. 3) comprising chopped strand fibers (CSF), milled fibers, microfibers, organic fillers, inorganic fillers or any combination thereof.
  • CSF chopped strand fibers
  • the CSF may comprise a pre-formed chopped strand fiber mat. Alternatively, the CSF may be chopped directly into a mold, or pre-chopped, and then added to a mold.
  • the NAP 110 may comprise at least about 20% by volume (20 vol%) of the CSF for a total volume of the NAP 110, at least about 25 vol%, at least about 30 vol%, or at least about 35 vol%. Further, in some embodiments, the NAP 110 may comprise not greater than about 40 vol% of the CSF for a total volume of the NAP, not greater than about 35 vol%, not greater than about 30 vol%, or not greater than about 25 vol%. It will be appreciated, that the content of the CSF in the NAP can be within a range between any of the minimum and maximum percentages noted above, including for example at least about 20 vol% to not greater than about 40 vol%.
  • the NAP 110 may comprise porosity, milled fibers, microfibers, organic fillers, and/or inorganic fillers.
  • the AP 112 comprises an abrasive mixture comprising an organic bond material and a plurality of abrasive particles dispersed throughout the organic bond material.
  • a discrete layer of CSF may be located at least partially in the organic bond material and coupled (e.g., chemically and mechanically bonded) to the AP 112 for reinforcement thereof.
  • the discrete layer can be a sintered mat of the CSF, such that the CSF are integral.
  • abrasive article 100 may comprise at least one continuous fiber reinforcement web in the body 102, such that the body 102 is reinforced by the discontinuous fibers 120 and the continuous fiber reinforcement web.
  • the body 102 may not have a continuous fiber reinforcement web, such that the body 102 is reinforced only by the discontinuous fibers 120.
  • the abrasive article 100 may be free of any fibers.
  • Discontinuous fiber 120 may generally comprise a chopped strand fiber (CSF). It will be appreciated that the shapes, numbers, and relative sizes of the fibers, filaments, and coatings can vary, depending on the application. Discontinuous fiber 120 may comprise a substantially cylindrical or other rounded cross- sectional shape, such as and oval or elliptical shape. Discontinuous fiber 120 may generally formed from a plurality of multiple individual filaments 122, which may comprise a primary coating 124. Collectively, the individual filaments 122 may be encased within a secondary coating. For example, the CSF can have a direct sized coating, and the thermoplastic coating can be a secondary coating 126 on the direct sized coating 124.
  • CSF chopped strand fiber
  • the direct sized coating can have a loss on ignition (LOI), which may be defined as the wt% of the coating relative to the total weight of the CSF.
  • LOI loss on ignition
  • the LOI can be less than about 2 wt%, such as less than or equal to about 1 wt%.
  • Other embodiments of the reinforcement can have a LOI of at least about 2 wt%.
  • the LOI can be at least about 3 wt%, such as at least about 5 wt%, at least about 7 wt%, at least about 9 wt%, at least about 12 wt%, or even at least about 15 wt%.
  • Alternate embodiments of the LOI can be not greater than about 25 wt%, such as not greater than about 20 wt%, not greater than about 15 wt%, or even not greater than about 12 wt%.
  • the LOI may be in a range between any of these minimum and maximum values.
  • Discontinuous fibers 120 may generally comprise a sectional aspect ratio of width (W) to thickness (“T”).
  • the sectional aspect ratio can be in a range of about 1:1 to about 3:1.
  • the sectional aspect ratio may be about 1.75:1 to about 2.75:1, or even about 2:1 to about 2.5:1.
  • the discontinuous fibers 120 may comprise a width (e.g., a radial width) of at least about 0.1 mm.
  • the radial width may be at least about 0.2 mm, such as at least about 0.3 mm.
  • the radial width can be not greater than about 0.5 mm, such as not greater than about 0.4 mm, not greater than about 0.3 mm, or even not greater than about 0.2 mm.
  • the width may be in a range between any of the minimum and maximum values.
  • Discontinuous fibers 120 may also comprise an axial length (AL) of at least about 6 mm.
  • the axial length may be at least about 7 mm, such as at least about 8 mm, at least about 10 mm, at least about 15 mm, or even at least about 20 mm.
  • the axial length may be not greater than about 150 mm, such as not greater than about 100 mm, not greater than about 75 mm, not greater than about 50 mm, not greater than about 40 mm, or not greater than about 30 mm. Further, the axial length may be in a range between any of these minimum and maximum values.
  • Embodiments of the strand of discontinuous fibers 120 may have an aspect ratio of axial length to radial width of at least about 10.
  • the aspect ratio may be at least about 12, such as at least about 25, such as at least about 50, at least about 75, at least about 100, at least about 250, or even at least about 500.
  • the aspect ratio can be not greater than about 1500, such as not greater than about 1000, not greater than about 750, not greater than about 500, not greater than about 250, not greater than about 200, or even not greater than about 150. Further, the aspect ratio may be in a range between any of these minimum and maximum values.
  • Embodiments of the body 102 may comprise a volume percentage of the discontinuous fibers 120 of at least about 1 vol% of organic bond material.
  • the volume percentage of the discontinuous fibers can be at least about 2 vol%, such as at least about 5 vol%, at least about 10 vol%, at least about 15 vol%, at least about 20 vol%, at least about 25 vol%, at least about 30 vol%, or at least about 35 vol%.
  • the volume percentage of the discontinuous fibers 120 can be not greater than about 50 vol% of organic bond material, such as not greater than 40 vol%, not greater than about 35 vol%, not greater than about 30 vol%, not greater than about 25 vol%, or not greater than about 20 vol%.
  • volume percentage of the discontinuous fibers 120 can be within a range between any of these minimum and maximum values, for example, within a range of at least 1 vol% to not greater than 50 vol% of organic bond material, such as at least about 10 vol% to not greater than 40 vol% or at least 20 vol% to not greater than 40 vol%.
  • abrasive article 100 may comprise a body 102 comprised of the NAP 110 and the AP 112.
  • the NAP 110 comprises a NAP back 110a and a NAP core 110b.
  • the NAP back 110a and the NAP core 110b may be bonded together.
  • the NAP back 110a and the NAP core 110b may be formed as a unitary, substantially homogeneous component.
  • the NAP back 110a and the NAP core 110b are axially aligned along axis 106, such that the aperture 104 is disposed through both of the NAP back 110a and NAP core 110b.
  • the NAP back 110a and the NAP core 110b comprise substantially similar inner diameters, which collectively define a smooth inner annular surface 128 within the aperture 104.
  • the NAP back 110a generally comprises a larger outer diameter than the NAP core 110b.
  • the NAP back 110a may also comprise a greater thickness than the NAP core 110b. Still, in other embodiments such as the embodiment shown, the NAP back 110a and the NAP core 110b comprise substantially similar thicknesses.
  • the NAP 110 may generally comprise a molding compound (MC), such as a bulk molding compound (BMC) or a sheet molding compound (SMC).
  • MC molding compound
  • BMC bulk molding compound
  • SMC sheet molding compound
  • the organic material may include bulk molding compound, and even more particularly, the organic material may consist essentially of an SMC, a BMC, or combination thereof. In another embodiment, the organic material may consist essentially of bulk molding compound (BMC) and sheet molding compound (SMC). In still another embodiment, the NAP 110 can include a molding compound, and more particularly, may consist of a molding compound, such as BMC, SMC, or any combination thereof.
  • the MC may comprise at least one of a solvent-free liquid phenolic resin resole and a novalac phenolic resin having a melting temperature less than about 90°C, less than about 80°C, less than about 75°C, or less than about 70°C.
  • the MC may comprise at least one of hexamethylene tetramine (HMTA) and a novalac phenolic resin having a melting temperature at least about 70°C, at least about 75°C, at least about 80°C, at least about 90°C, or at least about 100°C.
  • the MC may comprise a thermoset material.
  • the MC may comprise a specific gravity that is at least about 1.4, at least about 1.5, at least about 1.6, or at least about 1.7. Additionally, the MC may also comprise a specific gravity that is not greater than about 1.9, not greater than about 1.8, or not greater than about 1.7. The specific gravity of the MC may also be in a range including any of these minimum and maximum values.
  • NAP 110 comprises a MOHS scale hardness that is less than about 9.
  • NAP 110 may comprise a MOHS scale hardness that is less than about 8, less than about 7, less than about 6, or less than about 5.
  • NAP 110 may also comprise a MOHS scale hardness that is at least about 1, at least about 2, at least about 3, or at least about 4.
  • the MOHS scale hardness of the NAP 110 may also be in a range including any of these minimum and maximum values.
  • the AP 112 may generally comprise an abrasive mixture comprising an organic bond material and a plurality of abrasive particles dispersed throughout the organic bond material.
  • the AP 112 may be bonded to the NAP 110, and more specifically, at least partially to each of the NAP back 110a and the NAP core 110b.
  • the AP 112 may at least partially define or be associated with a first major surface 114 of the body 102 and at least partially define or be associated with an opposing second major surface 116 of the body 102.
  • the NAP back 110a may define the remainder of the second major surface 116 of the body 102 not defined by the AP 112.
  • aperture 104 may be disposed through each of the NAP back 110a and NAP core 110b, such that the NAP back 110a and the NAP core 110b define the inner annular surface 128 of the body 102. As such, no portion of the AP 112 defines a portion of the inner annular surface 128.
  • the NAP core 110b may be disposed on an opposing side of the NAP back 110a from the second major surface 116 of the body 102 and at least partially define or be associated with the first major surface 114 of the body 102.
  • the NAP core 100b may also be disposed radially within the AP 112, such that the AP 112 defines the entirety of a peripheral side surface 130 of the body 102. Accordingly, no portion of the NAP back 110a or the NAP core 110b defines the peripheral side surface 130, and no portion of the AP 112 defines the inner annular surface 128.
  • the abrasive article 100 may also comprise a reinforcing member 118 distinct from the NAP 110 and the AP 112.
  • the reinforcing member 118 may generally comprise a thin layer overlying at least a portion of the body 102 and in contact with and/or overlying at least a portion of the NAP 110 and at least a portion of the AP 112. More specifically, in the embodiment shown, reinforcing member 118 overlies the AP 112 on the first major surface 114 and overlies the NAP 110 and a portion of the AP 112 on the second major surface 116.
  • the thin layer of reinforcing material 118 may generally comprise an average thickness less than an average thickness of each of the NAP 110 and the AP 112.
  • the reinforcing member 118 may comprise a continuous glass web.
  • the reinforcing member may comprise a glass, fibers such as CSF, mat, woven material, non-woven material, or any combination thereof.
  • the CSF may be coated with a coating, such as one or more of a thermoplastic, thermoplastic phenolic, phenoxy, polyurethane, and novolac, which may be cross-linked.
  • reinforcing member 118 may form a thin layer over a portion of the NAP 110 and/or the AP 112, it will be appreciated that dimensions of the reinforcing member 118 are not used in calculating or determining any relative compositions or dimensions of the body 102, the NAP 110, or the AP 112, and/or ratios between the body 102, the NAP 110, and the AP 112 as described herein.
  • the body 102 of the abrasive article 100 may comprise an average thickness (Ti).
  • the body 102 of the abrasive article may comprise an average thickness (Tp).
  • the AP 112 may comprise a peripheral side surface thickness (TAP) as also measured at the peripheral side surface 130.
  • TAP may comprise at least about 1% of Tp, at least about 3% of Tp, at least about 5% of Tp, at least about 10% of Tp, at least about 20% of Tp, at least about 30% of Tp, at least about 40% of Tp, at least about 50% of Tp, at least about 60% of Tp, at least about 70% of Tp, at least about 80% of Tp, at least about 90% of Tp, or at least about 95% of Tp.
  • TAP may be equal to Tp, such that AP 112 extends for the entirety of the total average thickness of the peripheral side surface.
  • At may be at least 1.01. However, in some embodiments, At may be at least about 1.02, at least about 1.03, at least about 1.04, at least about 1.05, at least about 1.06, at least about 1.07, at least about 1.08, at least about 1.09, at least about 1.10, at least about 1.11, at least about 1.12, at least 1.13, at least about 1.14, at least about 1.15, at least about 1.16, at least about 1.17, at least about 1.18, at least about 1.19, at least about 1.20, at least about 1.21, at least about 1.22, at least about 1.23, at least about 1.24, at least about 1.25, at least about 1.26, at least about 1.27, at least about 1.28, at least about 1.29, or at least about 1.30.
  • At may not be greater than about 5.00, not greater than about 4.00, not greater than about 3.00, not greater than about 2.00, not greater than about 1.90, not greater than about 1.70, or not greater than about 1.50. Further, At may also be in a range between any of these minimum and maximum values, including for example at least about 1.01 and not greater than about 5.00.
  • the body 102 of the abrasive article 100 may comprise an average radial length (RL).
  • NAP 110 such as NAP core 110b
  • AP 112 comprises an average radial length (RLAP).
  • the NAP 110 such as NAP back 110a
  • the NAP 110 may comprise an average radial length (RLNAP2)
  • AP 112 comprises an average radial length (RLAP2).
  • RLAP may be less than RL, such that the AP 112 does not span the entirety of the radial length of the body 102 along the first major surface 114. In some embodiments, RLAP may not be greater than 90% of RL, not greater than 80% of RL, not greater than 70% of RL, not greater than 60% of RL, not greater than 50% of RL, not greater than 40% of RL, not greater than 30% of RL, not greater than 20% of RL, or not greater than 10% of RL.
  • RLAP may be at least 1% of RL, at least 3% of RL, at least 5% of RL, at least 8% of RL, at least 10% of RL, at least 12% of RL, at least 15% of RL, at least 18% of RL, at least 20% of RL, at least 30% of RL, at least 40% of RL, at least 50% of RL, at least 60% of RL, at least 70% of RL, or at least 80% of RL.
  • RLAP may also be in a range between any of these minimum and maximum values, including for example at least 1% of RL to not greater than 90% of RL.
  • RLAP2 may also be less than RL, such that AP 112 does not span the entirety of the radial length of the body 102 along the second major surface 116. In some embodiments, RLAP2 may not be greater than 90% of RL, not greater than 80% of RL, not greater than 70% of RL, not greater than 60% of RL, not greater than 50% of RL, not greater than 40% of RL, not greater than 30% of RL, not greater than 20% of RL, or not greater than 10% of RL.
  • RLAP2 may be at least 1% of RL, at least 3% of RL, at least 5% of RL, at least 8% of RL, at least 10% of RL, at least 12% of RL, at least 15% of RL, at least 18% of RL, at least 20% of RL, at least 30% of RL, at least 40% of RL, at least 50% of RL, at least 60% of RL, at least 70% of RL, or at least 80% of RL.
  • RLAP2 may also be in a range between any of these minimum and maximum values, including for example at least 1% of RL to not greater than 90% of RL.
  • RLAP may be different from RLAP2. More specifically, RLAP may be greater than RLAP2. In some embodiments, RLAP is greater than RLAP2 by at least 1%, at least 2%, at least 3%, at least 4%, at least 5%, at least 6%, at least 7%, at least 8%, at least 9%, at least 10%, at least 12%, at least 14%, at least 16%, at least 18%, at least 20%, at least 22%, at least 24%, at least 26%, at least 28%, at least 30%, at least 35%, at least 40%, at least 45%, at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, at least 100%, at least 105%, or at least 110%.
  • RLAP may be greater than RLAP2 by not greater than 1000%, not greater than 500%, not greater than 200%, or not greater than 100%. RLAP2 may also be in a range between any of these minimum and maximum values, including for example greater than RLAP2 by at least 1% to not greater than 1000% of RLAP2.
  • RLNAP may be less than RL, such that NAP 100, more specifically NAP core 110b, may not span the entirety of the radial length of the body 102 along the first major surface 114.
  • RLNAP may not be greater than 90% of RL, not greater than 80% of RL, not greater than 70% of RL, not greater than 60% of RL, not greater than 50% of RL, not greater than 40% of RL, not greater than 30% of RL, not greater than 20% of RL, or not greater than 10% of RL.
  • RLNAP may be at least 5% of RL, at least 10% of RL, at least 20% of RL, at least 30% of RL, at least 40% of RL, at least 50% of RL, at least 60% of RL, at least 70% of RL, or at least 80% of RL.
  • RLNAP may also be in a range between any of these minimum and maximum values, including for example at least 5% of RL to not greater than 90% of RL.
  • RLNAP2 may also be less than RL, such that NAP 110, more specifically NAP back 110a, may not span the entirety of the radial length of the body 102 along the second major surface 116.
  • RLNAP2 may not be greater than 90% of RL, not greater than 80% of RL, not greater than 70% of RL, not greater than 60% of RL, not greater than 50% of RL, not greater than 40% of RL, not greater than 30% of RL, not greater than 20% of RL, or not greater than 10% of RL. Further, RLAP2 may be at least 5% of RL, at least 8% of RL, at least 10% of RL, at least 15% of RL, at least 20% of RL, at least 30% of RL, at least 40% of RL, at least 50% of RL, at least 60% of RL, at least 70% of RL, or at least 80% of RL. RLAP2 may also be in a range between any of these minimum and maximum values, including for example at least 5% of RL to not greater than 90% of RL.
  • RL1 may not be greater than 100.
  • RL1 may not be greater than 90, not greater than 80, not greater than 70, not greater than 60, not greater than 50, not greater than 40, not greater than 30, not greater than 20, not greater than 10, not greater than 5, not greater than 1, not greater than 0.9, not greater than 0.8, not greater than 0.7, not greater than 0.6, not greater than 0.5, not greater than 0.4, not greater than 0.3, not greater than 0.2, or not greater than 0.1.
  • RL1 may be at least 0.01, at least 0.05, at least 0.1, at least 0.2, at least 0.3, at least 0.4, at least 0.5, at least 0.6, at least 0.7, at least 0.8, at least 0.9, at least 1, at least 1.2, at least 1.5, at least 2, at least 3, at least 4, at least 5, at least6, at least 7, at least 8, at least 9, or at least 10.
  • RL1 may also be in a range between any of these minimum and maximum values, including for example at least 0.01 to not greater than 100.
  • RL2 may not be greater than 90, not greater than 80, not greater than 70, not greater than 60, not greater than 50, not greater than 40, not greater than 30, not greater than 20, not greater than 10, not greater than 5, not greater than 1, not greater than 0.9, not greater than 0.8, not greater than 0.7, not greater than 0.6, not greater than 0.5, not greater than 0.4, not greater than 0.3, not greater than 0.2, or not greater than 0.1.
  • RL2 may be at least 0.01, at least 0.05, at least 0.1, at least 0.2, at least 0.3, at least 0.4, at least 0.5, at least 0.6, at least 0.7, at least 0.8, at least 0.9, at least 1, at least 1.2, at least 1.5, at least 2, at least 3, at least 4, at least 5, at least6, at least 7, at least 8, at least 9, or at least 10.
  • RL2 may also be in a range between any of these minimum and maximum values, including for example at least 0.1 to not greater than 90.
  • abrasive article 100 may comprise a reinforcing member 118 that forms a thin layer over a portion of the NAP 110 and/or the AP 112, it will be appreciated that the average or overall thickness or radial length of the reinforcing member 118 is not included for calculations involving At, Ti, Tp, TAP, RLAP, RLNAP, RL, RLAP2, RLNAP2, RL1, or RL2.
  • a cross-sectional side view of another embodiment of an abrasive article 200 is shown according to an embodiment of the disclosure.
  • Abrasive article 200 may be substantially similar to abrasive article 100.
  • abrasive article 200 comprises at least one of first peripheral comer radius 202 and second peripheral comer radius 204.
  • abrasive article 200 may comprise both a first peripheral comer radius 202 and a second peripheral corner radius 204.
  • First peripheral corner radius 202 may generally be defined as a radius between the AP 112 at the first major surface 114 and the peripheral side surface 130
  • the second periphery comer radius 204 may be defined as the radius between the AP 112 at the second major surface 116 and the peripheral side surface 130.
  • the first peripheral corner radius 202 and/or the second peripheral comer radius 204 may comprise a radius that is at least about 5% of the average thickness of the body (Tp) at the peripheral side surface 130, at least about 10%, at least about 15%, at least about 20%, or at least about 25%.
  • the first peripheral corner radius 202 and/or the second peripheral corner radius 204 may comprise a radius that is not greater than 35%, not greater than 30%, not greater than 25%, not greater than 20%, not greater than 15% of the average thickness of the body (Tp) at the peripheral side surface 130.
  • the radius of the first peripheral corner radius 202 and the second peripheral corner radius 204 may comprise any value between these minimum and maximum values, including for example at least about 5% of the average thickness of the body (Tp) at the peripheral side surface 130 to not greater than not greater than 35% of the average thickness of the body (Tp) at the peripheral side surface 130.
  • first peripheral comer radius 202 and the second peripheral corner radius 204 may comprise different values.
  • first peripheral corner radius 202 may comprise a radius that is greater than the radius of the second peripheral comer radius 204. While each is shown as a rounded surface having a constant radius, first peripheral comer radius 202 and second corner peripheral radius 204 may alternatively comprise chamfered surfaces disposed at an angle to the peripheral side surface 130.
  • Abrasive articles 100, 200 may include an abrasive-free NAP 110 that does not intersect the periphery side surface 130 of the body 102 with the AP 112 disposed on the periphery of the abrasive article 100 as opposed to throughout the diameter of traditional abrasive wheels.
  • the need to constantly and/or significantly change the grinding angle as the size of the abrasive article 100, 200 decreases may be significantly reduced or even eliminated.
  • abrasive article 100, 200 may be capable of grinding angles from 0 to 90 degrees. Further, at least in some instances, the range of grinding angle may be less than 0 degrees (e.g., -10 degrees) or greater than 90 degrees (e.g., 110 degrees).
  • Method 700 may begin at block 702 by forming a precursor body including a non-abrasive portion (NAP) and a green abrasive portion (AP).
  • NAP non-abrasive portion
  • AP green abrasive portion
  • the NAP comprises a pre-preg, and forming includes placing the pre-preg into a cavity of a mold.
  • the NAP may comprise a NAP back 110a and NAP core 110b, each comprising a pre-preg, and forming includes placing the pre-preg NAP back 110a in a mold, and placing the pre-preg NAP core 110b in the mold subsequently.
  • the pre-preg may be a fully cured polymeric material having a softening point below 150°C.
  • the NAP preform comprises at least one of bulk molding compound (BMC) and sheet molding compound (SMC).
  • the NAP may be free of abrasive particles, may comprise chopped strand fibers (CSF), and/or may be formed an uncured mixture of molding compound (MC) and chopped strand fibers (CSF).
  • method 700 may also comprise placing a shim in the mold and in contact with the NAP pre- preg. More specifically, in some embodiments, the shim may be in contact with the NAP core 110b.
  • the shim may generally comprise a compressible shim, which at least in some embodiments, may allow or provide for better and/or increased compression (an consequently increased density and increased average normalized percent theoretical density) of the green AP as compared to utilizing a non-compressible shim or alternatively, no shim at all.
  • Method 700 may continue at block 704 by forming the precursor body into an abrasive article 100, 200 by selectively applying a different force on the green AP as compared to the NAP for at least a portion of the forming process.
  • forming may include applying a different force on the green AP as compared to the NAP.
  • forming the precursor body into an abrasive article 100, 200 includes forming the green AP to have a greater thickness than the NAP and applying force to the green AP prior to applying force to the NAP.
  • selectively applying a different force includes applying a greater force to the green AP as compared to the NAP in at least one portion of the forming process.
  • selectively applying a different force includes applying a force to the green AP prior to applying any force to the NAP.
  • selectively applying a different force includes a force configured to increase the density of the green AP.
  • the NAP includes a fully densified body prior to the process of forming the precursor body into an abrasive article 100, 200.
  • forming includes densification of the green AP to form a densified AP.
  • the densified AP may be AP 112.
  • the result of method 700 may be the AP 112 comprising a density of at least about 90%.
  • Method 700 may also comprise curing the densified AP after densification.
  • an abrasive article 100, 200 disclosed herein may achieve a measured density and/or an average normalized percent theoretical density greater than that of conventional abrasive articles.
  • an abrasive article 100, 200 may comprise a measured density of at least about 2.50 grams per cubic centimeter (g/cc), such as at least about 2.51 g/cc, at least about 2.52 g/cc, or at least about 2.53 g/cc, at least about 2.54 g/cc, at least about 2.55 g/cc, at least about 2.56 g/cc, at least about 2.57 g/cc, at least about 2.58 g/cc, or at least about 2.59 g/cc.
  • g/cc grams per cubic centimeter
  • an abrasive article 100, 200 may comprise a measured density of not greater than 3.0 g/cc, such as not greater than 2.75 g/cc, not greater than 2.65 g/cc, not greater than 2.61 g/cc, not greater than 2.62 g/cc, not greater than 2.61 g/cc, or not greater than 2.60 g/cc.
  • abrasive article 100, 200 may also comprise a measured density between any of these minimum and maximum values, including for example, at least 2.51 g/cc to not greater than 2.55 g/cc, at least 2.53 g/cc to not greater than 2.56 g/cc, at least 2.52 g/cc to not greater than 2.54 g/cc, at least 2.57 g/cc to not greater than 2.60 g/cc, or even at least 2.43 g/cc to not greater than 2.52 g/cc.
  • an abrasive article 100, 200 may comprise an average percent density of at least about 87.0%, such as at least about 87.1%, at least about 87.2%, at least about 87.3%%, at least about 87.4%, at least about 87.5%, at least about 87.6%, at least about 87.7%, at least about 87.8%, at least about 87.9%, at least about 88.0%, at least about 89%, at least about 90%, at least about 90.1%, at least about 90.2%, at least about 90.3%, at least about 90.4%, at least about 90.5%, at least about 90.6%, at least about 90.7%, at least about 90.8%, at least about 90.9%, at least about 91.0%, at least about 92.0%, at least about 92.1%, at least about 92.2%, at least about 92.3%, at least about 92.4%, at least about 92.5%, or at least about 93.0%.
  • an abrasive article 100, 200 may comprise a percent density of not greater than 95%, not greater than 94%, not greater than 93.5%, not greater than 93.4%, not greater than 93.3%, not greater than 93.2%, not greater than 93.1%, not greater than 93.0%, not greater than 92.9%, not greater than 92.8%, not greater than 92.7%, not greater than 92.6%, not greater than 92.5%, not greater than 92.4%, not greater than 92.3%, not greater than 92.2%, not greater than 92.1%, not greater than 92.0%, not greater than 91.9%, not greater than 91.8%, not greater than 91.7%, not greater than 91.6%, not greater than 91.5%, not greater than 91.4%, not greater than 91.3%, not greater than 91.2%, not greater than 91.1%, not greater than 91.0%, not greater than 90.9%, not greater than 90
  • abrasive article 100, 200 may also comprise a percent density between any of these minimum and maximum values, including for example, at least 90.0% to not greater than 91.4%, at least 90.7% to not greater than 91.8%, at least 90.3% to not greater than 91.0%, at least 92.1% to not greater than 93.2%, or even at least 87.1% to not greater than 90.3%.
  • an abrasive article 100, 200 may comprise an average normalized percent theoretical density, which may be defined as the average percent density (%) divided by the average thickness (TAVG, measured in millimeters) of the abrasive article 100, 200 at the peripheral side surface (Tp).
  • an abrasive article 100, 200 may comprise an average normalized percent theoretical density of at least about 16%/mm, such as at least about 17%/mm, at least about 18%/mm, at least about 19%/mm, at least about 20%/mm, at least about 21 %/mm, at least about 22%/mm, at least about 23%/mm, or at least about 24%/mm.
  • an abrasive article 100, 200 may comprise an average normalized percent theoretical density of not greater than 28%/mm, such as not greater than 27%/mm, not greater than 26%/mm, or not greater than 25 %/mm. It will be appreciated than abrasive article 100, 200 may also comprise an average normalized percent theoretical density between any of these minimum and maximum values, including for example, at least about 16%/mm to not greater than 28 %/mm.
  • Method 800 may begin at block 802 by moving an abrasive article 100, 200 relative to a workpiece 300, wherein the abrasive article 100, 200 comprises a body 102 including: a non-abrasive portion (NAP) 110 essentially free of abrasive particles; an abrasive portion (AP) 112 comprising abrasive particles contained in a bond material; and wherein moving the abrasive article 100, 200 relative to the workpiece 300 includes tilting the abrasive article 100, 200 at a functional grinding angle within a range of 0 degrees to 90 degrees.
  • NAP non-abrasive portion
  • AP abrasive portion
  • moving the abrasive article 100, 200 includes changing the functional grinding angle during the material removal operation to a functional grinding angle within a range of at least 0 degrees to 90 degrees.
  • the workpiece 300 comprises a corner defining an interior angle of less than 180 degrees, and moving the abrasive article 100, 200 includes removing material in the comer at the functional grinding angle.
  • the comer comprises a comer radius within a range of at least about 5% of an average thickness of the body at a peripheral side surface (Tp) and not greater than 35% of Tp.
  • moving the abrasive article 100, 200 includes maintaining substantially a same material removal rate over the range of functional grinding angles of at least 0 degrees to 90 degrees.
  • FIG. 9 comparative data of a conventional abrasive articles and embodiments of abrasive articles 100, 200 of the disclosure is shown.
  • a conventional abrasive article having an abrasive-free BMC NAP formed without a shim is compared to embodiments of abrasive articles 100, 200 having an abrasive-free BMC NAP 110 formed with shims of various thickness (1.66 mm, 2.80 mm, 2.3 mm, and 4.5 mm). While these representative thicknesses of shims are used in forming abrasive articles 100, 200 disclosed herein, it will be appreciated that these thicknesses are for example only and not intended to be limiting.
  • any thickness of shim may be used to form abrasive articles 100, 200.
  • the conventional abrasive article formed without a shim achieved a measured density from 2.43g/cc to 2.52g/cc (87.1% density to 90.3% density).
  • Abrasive articles 100, 200 formed using shims achieved measured densities between 2.51g/cc and 2.60g/cc (90.3% density to 93.2% density). Accordingly, abrasive articles 100, 200 formed utilizing shims achieved higher measured densities and percent densities than the conventional abrasive article formed without a shim.
  • the average normalized percent theoretical density may be defined as the average percent density (%) divided by the average thickness (TAVG, measured in millimeters) of the abrasive article 100, 200 at the peripheral side surface (Tp).
  • the abrasive articles 100, 200 achieved average percent densities of 90.7%, 91.25%, 90.65%, and 92.65% and had average thickness at the peripheral side surface of 4.21 mm, 4.62 mm, 5.29 mm, and 3.84 mm, respectively.
  • abrasive articles 100, 200 achieved average normalized percent theoretical densities of 21.54%/mm, 19.75%/mm, 17.13%/mm, and 24.12%/mm.
  • FIG. 7 shows a graph of the comparative data depicted in the chart of FIG. 6 of the conventional abrasive article formed without a shim and embodiments of abrasive articles 100, 200 formed with a shim.
  • FIG. 8 shows a chart of the means, standard deviations, lower 95%, and upper 95% of the percentage of densities achieved in the conventional abrasive article formed without a shim and embodiments of abrasive articles 100, 200 formed with a shim as depicted in the chart of FIG. 6 and the graph of FIG. 7.
  • an abrasive article may include one or more of the following items:
  • NAP non-abrasive portion
  • AP abrasive portion comprising abrasive particles contained in a bond material
  • Embodiment 2 An abrasive article comprising: a body including: a non-abrasive portion (NAP) essentially free of abrasive particles; and an abrasive portion (AP) comprising abrasive particles contained in a bond material; wherein the AP comprises an average normalized percent theoretical density of not greater than 28 %/mm.
  • NAP non-abrasive portion
  • AP abrasive portion
  • Embodiment 3 An abrasive article comprising: a body including: a non-abrasive portion (NAP) essentially free of abrasive particles; and an abrasive portion (AP) comprising abrasive particles contained in a bond material; wherein the body comprises a functional grinding angle within a range of 0 degrees to 90 degrees.
  • NAP non-abrasive portion
  • AP abrasive portion
  • Embodiment 7 The abrasive article of any one of Embodiments 1 and 3, wherein the AP comprises an average normalized percent theoretical density of not greater than 28 %/mm.
  • Embodiment 8 The abrasive article of any one of Embodiments 2 and 7, wherein the AP comprises a density of at least 90%.
  • Embodiment 9 The abrasive article of any one of Embodiments 1 and 2, wherein the body comprises a functional grinding angle range of at least 0 degrees to 90 degrees.
  • Embodiment 10 The abrasive article of any one of Embodiments 1, 2 and 3, wherein the body comprises a first peripheral comer radius defined by a portion of the AP at the intersection of a first major surface and a peripheral side surface of not greater than 35% of Tp.
  • Embodiment 11 The abrasive article of any one of Embodiments 1, 2 and 3, wherein the body comprises a second peripheral corner radius defined by a portion of the AP at the intersection of a second major surface and a peripheral side surface of not greater than 35% of Tp.
  • Embodiment 12 The abrasive article of any one of Embodiments 1, 2, and 3, wherein the body further comprises: first major surface; a second major surface; a peripheral side surface extending between the first major surface and second major surface; and an inner annular side surface extending between the first major surface and the second major surface.
  • Embodiment 13 The abrasive article of Embodiment 12, wherein the AP defines a portion of the first major surface and a portion of the second major surface.
  • Embodiment 14 The abrasive article of Embodiment 12, wherein the AP comprises an average radial length (RLap) at the first major surface, and wherein the RLap is less than an average length (RL) of the body, wherein RLap is not greater than 90% of RL or not greater than 80% or not greater than 70% or not greater than 60% or not greater than 50% or not greater than 40% or not greater than 30% or not greater than 20% or not greater than 10%.
  • RLap average radial length
  • RLap average radial length at the first major surface
  • RLap is less than an average length (RL) of the body
  • RLap is not greater than 90% of RL or not greater than 80% or not greater than 70% or not greater than 60% or not greater than 50% or not greater than 40% or not greater than 30% or not greater than 20% or not greater than 10%.
  • Embodiment 15 The abrasive article of Embodiment 14, wherein RLap is at least 1% of RL or at least 3% or at least 5% or at least 8% or at least 10% or at least 12% or at least 15% or at least 18% or at least 20% or at least 30% or at least 40% or at least 50% or at least 60% or at least 70% or at least 80%.
  • Embodiment 16 The abrasive article of Embodiment 14, wherein the AP comprises an average radial length (RLap2) at the second major surface, and wherein the RLap2 is less than an average length (RL) of the body, wherein RLap2 is not greater than 90% of RL or not greater than 80% or not greater than 70% or not greater than 60% or not greater than 50% or not greater than 40% or not greater than 30% or not greater than 20% or not greater than 10%.
  • RLap2 average radial length at the second major surface
  • RLap2 is less than an average length (RL) of the body
  • RLap2 is not greater than 90% of RL or not greater than 80% or not greater than 70% or not greater than 60% or not greater than 50% or not greater than 40% or not greater than 30% or not greater than 20% or not greater than 10%.
  • Embodiment 17 The abrasive article of Embodiment 16, wherein RLap2 is at least 1% of RL or at least 3% or at least 5% or at least 8% or at least 10% or at least 12% or at least 15% or at least 18% or at least 20% or at least 30% or at least 40% or at least 50% or at least 60% or at least 70% or at least 80%.
  • Embodiment 18 The abrasive article of Embodiment 16, wherein RLap is different from RLap2.
  • Embodiment 19 The abrasive article of Embodiment 16, wherein RLap is greater than RLap2.
  • Embodiment 20 The abrasive article of Embodiment 19, wherein RLap is greater than RLap2 by at least 1% or at least 2% or at least 3% or at least 4% or at least 5% or at least 6% or at least 7% or at least 8% or at least 9% or at least 10% or at least 12% or at least 14% or at least 16% or at least 18% or at least 20% or at least 22% or at least 24% or at least 26% or at least 28% or at least 30% or at least 35% or at least 40% or at least 45% or at least 50% or at least 55% or at least 60% or at least 65% or at least 70% or at least 75% or at least 80% or at least 85% or at least 90% or at least 95% or at least 100% or at least 105% or at least
  • Embodiment 21 The abrasive article of Embodiment 19, wherein RLap is greater than RLap2 by not greater than 1000% or not greater than 500% or not greater than 200% or not greater than 100%.
  • Embodiment 22 The abrasive article of Embodiment 12, wherein the NAP defines a portion of the first major surface and a portion of the second major surface.
  • Embodiment 23 The abrasive article of Embodiment 22, wherein the NAP defines an average radial length (RLnap) on the first major surface, and wherein the RLnap is less than an average length (RL) of the body, wherein RLnap is not greater than 90% of RL or not greater than 80% or not greater than 70% or not greater than 60% or not greater than 50% or not greater than 40% or not greater than 30% or not greater than 20% or not greater than 10%.
  • RLnap average radial length
  • Embodiment 24 The abrasive article of Embodiment 23, wherein RLnap is at least 5% of RL or at least 10% or at least 20% or at least 30% or at least 40% or at least 50% or at least 60% or at least 70% or at least 80%.
  • Embodiment 25 The abrasive article of Embodiment 22, wherein the NAP defines an average radial length (RLnap2) on the second major surface, and wherein the RLnap2 is less than an average length (RL) of the body, wherein RLnap2 is not greater than 90% of RL or not greater than 80% or not greater than 70% or not greater than 60% or not greater than 50% or not greater than 40% or not greater than 30% or not greater than 20% or not greater than 10%.
  • Embodiment 26 The abrasive article of Embodiment 25, wherein RLnap2 is at least 5% of RL or at least 10% or at least 20% or at least 30% or at least 40% or at least 50% or at least 60% or at least 70% or at least 80%.
  • the first radial length ratio
  • Embodiment 31 The abrasive article of Embodiment 12, wherein the AP defines at least a portion of the peripheral side surface.
  • Embodiment 32 The abrasive article of Embodiment 12, wherein the AP has a peripheral side surface thickness (Tap) of at least 1% of a total average thickness (t) of the body, or at least 3% or at least 5% or at least 10% or at least 20% or at least 30% or at least 40% or at least 50% or at least 60% or at least 70% or at least 80% or at least 90% or at least 95%.
  • Tap peripheral side surface thickness
  • Embodiment 33 The abrasive article of Embodiment 12, wherein the AP has a peripheral side surface thickness (Tap) that extends for the entirety of the total average thickness of the peripheral side surface.
  • Tap peripheral side surface thickness
  • Embodiment 34 The abrasive article of Embodiment 12, wherein the NAP does not intersect the peripheral side surface.
  • Embodiment 35 The abrasive article of Embodiment 12, wherein the AP does not intersect the inner annular side surface.
  • Embodiment 36 The abrasive article of Embodiment 12, wherein NAP defines the entirety of the inner annular side surface.
  • Embodiment 37 The abrasive article of Embodiment 12, wherein the AP defines the entirety of the peripheral side surface.
  • Embodiment 38 The abrasive article of any one of Embodiments 1 and 2, wherein the NAP includes a first NAP portion and a second NAP portion, wherein the first NAP portion has a different size and position compared to the second NAP portion.
  • Embodiment 39 The abrasive article of any one of Embodiments 1 and 2, wherein the NAP includes a molding compound.
  • Embodiment 40 The abrasive article of Embodiment 39, wherein the molding compound is at least one of a bulk molding compound (BMC) and a sheet molding compound (SMC).
  • BMC bulk molding compound
  • SMC sheet molding compound
  • Embodiment 41 The abrasive article of Embodiment 39, wherein the molding compound comprises at least one of a solvent-free, liquid phenolic resin resole, and a novolac phenolic resin having a melting temperature of less than about 90°C, less than about 80°C, less than about 75°C.
  • Embodiment 42 The abrasive article of Embodiment 39, wherein the molding compound comprises at least one of hexamethylene tetramine (HMTA) and a novolac phenolic resin having a melting temperature of at least about 70°C, at least about 80°C, at least about 90°C, or at least about 100°C.
  • HMTA hexamethylene tetramine
  • Embodiment 43 The abrasive article of Embodiment 39, wherein the molding compound comprises a specific gravity of the MC is at least about 1.4, at least about 1.5, at least about 1.6, at least about 1.7, and not greater than about 1.9, not greater than about 1.8, or not greater than about 1.7.
  • Embodiment 44 The abrasive article of Embodiment 39, wherein the molding compound comprises a thermoset material.
  • Embodiment 45 The abrasive article of any one of Embodiments 1 and 2, wherein the NAP has a MOHS scale hardness that is less than about 9, less than about 8, less than about 7, less than about 6, less than about 5, and at least about 1, at least about 2, at least about 3, or at least about 4.
  • Embodiment 46 The abrasive article of any one of Embodiments 1 and 2, further comprising at least one reinforcing member distinct from the AP and NAP.
  • Embodiment 47 The abrasive article of Embodiment 46, wherein the reinforcing member comprises a glass, fibers, a mat, a woven material, a non-woven material, or a combination thereof.
  • Embodiment 48 The abrasive article of Embodiment 46, wherein the reinforcing member comprises an average thickness less than an average thickness of the AP or NAP.
  • Embodiment 49 The abrasive article of Embodiment 46, wherein the reinforcing member is in the form of a layer in contact with at least a portion of the NAP and at least a portion of the AP.
  • Embodiment 50 The abrasive article of Embodiment 46, wherein the reinforcing member overlies at least a portion of an exterior surface of the body.
  • Embodiment 51 The abrasive article of any one of Embodiments 1, 2 and 3, wherein the NAP comprises at least one of porosity, chopped strand fibers (CSF), milled fibers, microfibers, organic fillers and inorganic fillers.
  • CSF chopped strand fibers
  • Embodiment 52 The abrasive article of any one of Embodiments 1, 2 and 3, wherein the NAP comprises chopped strand fibers (CSF), wherein the NAP comprises at least about 20 vol% CSF for a total volume of the NAP, at least about 25 vol%, at least about 30 vol%, at least about 35 vol%, and not greater than about 40 vol%, not greater than about 35 vol%, not greater than about 30 vol%, not greater than about 25 vol%.
  • CSF chopped strand fibers
  • Embodiment 53 A method of fabricating an abrasive article, comprising: (a) forming a precursor body including a non-abrasive portion (NAP) and a green abrasive portion (AP); and (b) forming the precursor body into an abrasive article by selectively applying a different force on the green AP as compared to the NAP for at least a portion of the forming process.
  • NAP non-abrasive portion
  • AP green abrasive portion
  • Embodiment 54 The method of Embodiment 53, wherein forming the precursor body into an abrasive article includes forming the green AP to have a greater thickness than the NAP and applying force to the green AP prior to applying force to the NAP.
  • Embodiment 55 The method of Embodiment 53, wherein selectively applying a different force includes applying a greater force to the green AP as compared to the NAP in at least one portion of the forming process.
  • Embodiment 56 The method of Embodiment 53, wherein selectively applying a different force includes applying a force to the green AP prior to applying any force to the NAP.
  • Embodiment 57 The method of Embodiment 53, wherein selectively applying a different force includes a force configured to increase the density of the green AP.
  • Embodiment 58 The method of Embodiment 53, wherein the NAP includes a fully densified body prior to the process of forming the precursor body into an abrasive article.
  • Embodiment 59 The method of Embodiment 53, wherein forming includes molding the green AP.
  • Embodiment 60 The method of Embodiment 53, wherein forming includes uniaxial pressing of the precursor body in a mold.
  • Embodiment 61 The method of Embodiment 53, wherein forming includes applying a shim to a portion of the precursor body prior to selectively applying a different force on the green AP as compared to the NAP.
  • Embodiment 62 The method of Embodiment 53, wherein forming includes densification of the green AP to form a densified AP.
  • Embodiment 63 The method of Embodiment 62, further comprising curing the densified AP after densification.
  • Embodiment 64 The method of Embodiment 53, wherein the NAP comprises a pre- preg, and forming includes placing the pre-preg into a cavity of a mold.
  • Embodiment 65 The method of Embodiment 64, wherein the pre-preg is a fully cured polymeric material having a softening point below 150°C.
  • Embodiment 66 The method of Embodiment 64, wherein the NAP preform comprises at least one of bulk molding compound (BMC) and sheet molding compound (SMC).
  • BMC bulk molding compound
  • SMC sheet molding compound
  • Embodiment 67 The method of Embodiment 53, wherein the NAP is free of abrasive particles.
  • Embodiment 68 The method of Embodiment 53, wherein the NAP comprises chopped strand fibers.
  • Embodiment 69 The method of Embodiment 53, wherein the NAP is formed an uncured mixture of molding compound and chopped strand fibers.
  • Embodiment 70 A method of conducting a material removal operation comprising: moving an abrasive article relative to a workpiece, wherein the abrasive article comprises a body including: a non-abrasive portion (NAP) essentially free of abrasive particles; an abrasive portion (AP) comprising abrasive particles contained in a bond material; and wherein moving the abrasive article relative to the workpiece includes tilting the abrasive article at a functional grinding angle within a range of 0 degrees to 90 degrees.
  • NAP non-abrasive portion
  • AP abrasive portion
  • Embodiment 71 The method of Embodiment 70, wherein moving the abrasive article includes changing the functional grinding angle during the material removal operation to a functional grinding angle within a range of at least 0 degrees to 90 degrees.
  • Embodiment 72 The method of Embodiment 70, wherein the workpiece comprises a comer defining an interior angle of less than 180 degrees and moving the abrasive article includes removing material in the corner at the functional grinding angle.
  • Embodiment 73 The method of Embodiment 70, wherein the comer comprises a comer radius within a range of at least about 5% of an average thickness of the body at a peripheral side surface (Tp) and not greater than 35% of Tp.
  • Embodiment 74 The method of Embodiment 70, wherein moving the abrasive article includes maintaining substantially a same material removal rate over the range of functional grinding angles of at least 0 degrees to 90 degrees.
  • Embodiment 75 The method of Embodiment 70, wherein the abrasive article has any of the features of Embodiments 1 through 69.
  • the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion.
  • a process, method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such process, method, article, or apparatus.
  • “or” refers to an inclusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Polishing Bodies And Polishing Tools (AREA)

Abstract

L'invention concerne un article abrasif comprenant un corps ayant une partie non abrasive (NAP) essentiellement exempte de particules abrasives et une partie abrasive ayant des particules abrasives dispersées à l'intérieur et contenues dans un matériau de liaison.
PCT/US2020/057051 2019-12-05 2020-10-23 Article abrasif WO2021112967A1 (fr)

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US201962944147P 2019-12-05 2019-12-05
US62/944,147 2019-12-05

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WO2021112967A1 true WO2021112967A1 (fr) 2021-06-10

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2004188506A (ja) * 2002-12-06 2004-07-08 Mitsubishi Materials Corp カッター刃
US20100056032A1 (en) * 2008-08-27 2010-03-04 Fuji Grinding Wheel Mfg. Co. Ltd Method of manufacturing revolving whetstone and revolving whetstone manufactured by the same
US20140004316A1 (en) * 2012-06-28 2014-01-02 Han Zhang Abrasive article and coating
US20150000206A1 (en) * 2013-06-28 2015-01-01 Saint-Gobain Abrasives, Inc. Abrasive article
CN204868582U (zh) * 2015-09-02 2015-12-16 郑州华菱超硬材料有限公司 既能打磨又能切割的超硬角磨片

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2004188506A (ja) * 2002-12-06 2004-07-08 Mitsubishi Materials Corp カッター刃
US20100056032A1 (en) * 2008-08-27 2010-03-04 Fuji Grinding Wheel Mfg. Co. Ltd Method of manufacturing revolving whetstone and revolving whetstone manufactured by the same
US20140004316A1 (en) * 2012-06-28 2014-01-02 Han Zhang Abrasive article and coating
US20150000206A1 (en) * 2013-06-28 2015-01-01 Saint-Gobain Abrasives, Inc. Abrasive article
CN204868582U (zh) * 2015-09-02 2015-12-16 郑州华菱超硬材料有限公司 既能打磨又能切割的超硬角磨片

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