POROUS ABRASIVE TOOL AND METHOD FOR MAKING THE SAME
First Claim
1. A method for fabricating an abrasive article having at least 50 volume percent interconnected porosity, said method comprising:
- a) blending a mixture of abrasive grain, bond material, and dispersoid particles, said mixture including from about 0.5 to about 25 volume percent abrasive grain, from about 19.5 to about 49.5 volume percent bond material, and from about 50 to about 80 volume percent dispersoid particles;
b) pressing said mixture into an abrasive laden composite;
c) thermally processing the composite; and
d) immersing said composite into a solvent for a period of time suitable to dissolve substantially all of said dispersoid, said dispersoid being soluble in said solvent;
said abrasive grain and said bond material being substantially insoluble in said solvent.
1 Assignment
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Accused Products
Abstract
An abrasive article including from about 40 to about 80 volume percent interconnected porosity, the article being useful as a segment for a segmented grinding wheel, and a method for fabricating the same. The method includes blending a mixture of abrasive grain, bond material and dispersoid particles, the mixture including from about 40 to about 80 volume percent dispersoid particles. In one embodiment the mixture includes from about 50 to about 80 volume percent dispersoid particles. In another embodiment the mixture includes an organic bond material and from about 40 to about 80 volume percent dispersoid particles. The powder mixture is then pressed into an abrasive laden composite and thermally processed. After cooling the composite is immersed into a solvent, which dissolves substantially all of the dispersoid particles, leaving a highly porous, bonded abrasive article.
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Citations
75 Claims
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1. A method for fabricating an abrasive article having at least 50 volume percent interconnected porosity, said method comprising:
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a) blending a mixture of abrasive grain, bond material, and dispersoid particles, said mixture including from about 0.5 to about 25 volume percent abrasive grain, from about 19.5 to about 49.5 volume percent bond material, and from about 50 to about 80 volume percent dispersoid particles;
b) pressing said mixture into an abrasive laden composite;
c) thermally processing the composite; and
d) immersing said composite into a solvent for a period of time suitable to dissolve substantially all of said dispersoid, said dispersoid being soluble in said solvent;
said abrasive grain and said bond material being substantially insoluble in said solvent. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26)
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27. An abrasive segment for a segmented grinding wheel, said abrasive segment comprising:
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a composite including a plurality of superabrasive grains and a metal bond matrix sintered together, said composite having a plurality of interconnected pores disposed therein, said composite including from about 0.5 to about 25 volume percent abrasive grain, from about 19.5 to about 49.5 percent metal bond and from about 50 to about 80 volume percent interconnected porosity;
said metal bond matrix including from about 35 to about 70 weight percent copper, from about 30 to about 65 weight percent tin, and from about 0.2 to about 1.0 weight percent phosphorus, wherein said plurality of superabrasive grains are selected from the group consisting of diamond and cubic boron nitride, said superabrasive grains having an average particle size of less than about 300 microns. - View Dependent Claims (28, 29, 30, 31, 32, 33, 34, 35, 36)
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37. A segmented grinding wheel comprising:
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a core having a minimum specific strength of 2.4 MPa-cm3/g, a core density of 0.5 to 8.0 g/cm3, and a circular perimeter;
an abrasive rim including a plurality of segments, each of said segments including a composite including a plurality of abrasive grains and a metal bond matrix sintered together, said composite having a plurality of interconnected pores disposed therein, said composite including from about 50 to about 80 volume percent interconnected porosity; and
a thermally stable bond between said core and each of said plurality of segments. - View Dependent Claims (38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51)
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52. A method for fabricating an abrasive article having from about 40 to about 80 volume percent interconnected porosity, said method comprising:
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a) blending a mixture of abrasive grain, non-metallic bond material, and dispersoid particles, said mixture including from about 0.5 to about 25 volume percent abrasive grain, from about 19.5 to about 65 volume percent non-metallic bond material, and from about 40 to about 80 volume percent dispersoid particles;
b) pressing said mixture into an abrasive laden composite;
c) thermally processing the composite; and
d) immersing the composite into a solvent for a period of time suitable to dissolve substantially all of the dispersoid, the dispersoid being soluble in the solvent;
the abrasive grain and the non-metallic bond material being substantially insoluble in the solvent. - View Dependent Claims (53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63)
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64. An abrasive segment for a segmented grinding wheel, said abrasive segment comprising:
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a composite including a plurality of superabrasive grains and a non-metallic bond matrix cured together, said composite having a plurality of interconnected pores disposed therein, said composite including from about 0.5 to about 25 volume percent abrasive grain, from about 19.5 to about 65 percent non-metallic bond and from about 40 to about 80 volume percent interconnected porosity; and
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wherein said plurality of superabrasive grains are selected from the group consisting of diamond and cubic boron nitride, said superabrasive grains having an average particle size of less than about 300 microns. - View Dependent Claims (65, 66, 67, 68)
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69. A segmented grinding wheel comprising:
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a core having a minimum specific strength of 2.4 MPa-cm3/g, a core density of 0.5 to 8.0 g/cm3, and a circular perimeter;
an abrasive rim including a plurality of segments, each of said segments including a composite of abrasive grains and a non-metallic bond matrix cured together, said composite having a plurality of interconnected pores disposed therein, said composite including from about 40 to about 80 volume percent interconnected porosity; and
a thermally stable adhesive bond between said core and each of said plurality of segments. - View Dependent Claims (70, 71, 72, 73, 74, 75)
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Specification