FIXED ABRASIVE ARTICLES AND METHODS OF FORMING SAME

• US 20180086957A1
• Filed: 09/29/2017
• Published: 03/29/2018
• Est. Priority Date: 09/29/2016
• Status: Active Grant

• Current Assignee: Saint-Gobain Abrasives Incorporated (Compagnie De Saint-Gobain), Saint-Gobain Abrasifs (Compagnie de Saint-Gobain SA)
• Original Assignee: Saint-Gobain Abrasives Incorporated (Compagnie De Saint-Gobain), Saint-Gobain Abrasifs (Compagnie de Saint-Gobain SA)
• Inventors: SAHLIN, Katherine M., HAMPDEN-SMITH, Mark, BREDER, Kristin
• Granted Patent: US 11,230,653 B2
• Time in Patent Office: Days
• CPC Class Codes: B24D 11/001 Manufacture of flexible abrasive materials
• CPC Class Codes: B24D 18/0009 using moulds or presses
• CPC Class Codes: B24D 2203/00 Tool surfaces formed with a pattern
• CPC Class Codes: B24D 3/001 the constituent being used as supporting member
• CPC Class Codes: B24D 3/14 ceramic, i.e. vitrified bondings
• CPC Class Codes: B24D 3/285 Reaction products obtained from aldehydes or ketones
• CPC Class Codes: B24D 5/12 Cut-off wheels
• CPC Class Codes: C08K 2003/164 Aluminum halide, e.g. aluminium chloride
• CPC Class Codes: C08K 2003/2227 of aluminium
• CPC Class Codes: C08K 2003/3009 Sulfides
• CPC Class Codes: C08K 2201/016 Additives defined by their aspect ratio
• CPC Class Codes: C08K 3/16 Halogen-containing compounds
• CPC Class Codes: C08K 3/22 of metals
• CPC Class Codes: C08K 3/30 Sulfur-, selenium- or tellurium-containing compounds
• CPC Class Codes: C08K 7/04 inorganic
• CPC Class Codes: C08L 61/04 Condensation polymers of aldehydes or ketones with phenols only
• CPC Class Codes: C09K 3/1409 Abrasive particles per se preparation of diamond C01B32/25
• CPC Class Codes: C09K 3/1436 Composite particles, e.g. coated particles

Abstract

A fixed abrasive article having a body including abrasive particles contained within a bond material, the abrasive particles including shaped abrasive particles or elongated abrasive particles having an aspect ratio of length:width of at least 1.1:1, each of the shaped abrasive particles or elongated abrasive particles having a predetermined position or a predetermined three-axis orientation, including a placement angle ranging from +90 degrees to −90 degrees and a rake angle ranging from +90 degrees to −90 degrees.

Claims

1. A fixed abrasive article comprising:

a body having abrasive particles contained within a bond material, the abrasive particles including a plurality of shaped abrasive particles, elongated abrasive particles, or a combination thereof, each of the shaped abrasive particles or elongated abrasive particles having an aspect ratio of length;

width of at least 1.1;

1, and each of the shaped abrasive particles or elongated abrasive particles having a placement angle ranging from +90 degrees to −

90 degrees.

2. The fixed abrasive article of claim 1, wherein each of the shaped abrasive particles or elongated abrasive particles has a placement angle ranging from +45 degrees to −

45 degrees.

3. The fixed abrasive article of claim 2, wherein the each of the shaped abrasive particles or elongated abrasive particles further comprise a rake angle within a range of +90 to −

90 degrees with respect to a workpiece surface that is parallel to the edge of the body.

4. The fixed abrasive article of claim 3, wherein the rake angle is within a range of +45 to −

45 degrees with respect to a workpiece surface that is parallel to the edge of the body.

5. The fixed abrasive article of claim 4, wherein each of the shaped abrasive particles or elongated abrasive particles have a predetermined position and a predetermined three-axis orientation.

6. The fixed abrasive article of claim 4, wherein the body comprises a first group of abrasive particles positioned within a first radial plane within the body, and wherein the body comprises a second group of abrasive particles within a second radial plane within the body.

7. The fixed abrasive article of claim 6, wherein the abrasive particles of the first group of abrasive particles are arranged in a controlled distribution relative to each other and wherein the abrasive particles of the second group of abrasive particles are arranged in a controlled distribution relative to each other.

8. The fixed abrasive article of claim 7, wherein the controlled distribution of at least one of the first group of abrasive particles and the second group of abrasive particles comprises a phyllotactic pattern.

9. The fixed abrasive article of claim 7, wherein an abrasive particle of the first group of abrasive particles is radially and axially staggered relative to an abrasive particle of the second group of abrasive particles.

10. The fixed abrasive article of claim 6, wherein the abrasive particles within the first group have a predetermined position having substantially the same axial position within the first radial plane with respect to each other and wherein the abrasive particles within the second group have a predetermined position having substantially the same axial position within the second radial plane with respect to each other.

11. The fixed abrasive article of claim 10, wherein the abrasive particles of the first group comprise a different radial position with respect to each other and wherein the abrasive particles of the second group comprise a different radial position with respect to each other.

12. The fixed abrasive article of claim 6, wherein the first radial plane and second radial plane are axially spaced apart from each other within the body.

13. The fixed abrasive article of claim 6, wherein the first group of abrasive particles have a first placement angle and the second group of abrasive particles have a second placement angle different than the first placement angle.

14. The fixed abrasive article of claim 6, wherein the abrasive particles of the first group and the second group have at least one abrasive characteristic that is different.

15. The fixed abrasive article of claim 4, wherein the body comprises a first axial collection of abrasive particles within a first axial plane within the body, each of the abrasive particles of the first axial collection having a first placement angle, and wherein the body further comprises a second axial collection of abrasive particles within a second axial plane within the body that is different than the first axial plane, each of the abrasive particles of the second axial collection having a second placement angle.

16. The fixed abrasive article of claim 15, wherein the abrasive particles of the first axial collection of abrasive particles are arranged in a controlled distribution relative to each other and wherein the abrasive particles of the second axial collection of abrasive particles are arranged in a controlled distribution relative to each other.

18. The fixed abrasive article of claim 4, wherein the bond material comprises a phenolic resin and iron pyrite.

19. The fixed abrasive article of claim 18, wherein the bond material further comprises potassium aluminum fluoride, mineral wool, or a combination thereof.

20. The fixed abrasive article of claim 19, wherein the bond material comprises:

10 wt % to 40 wt % phenolic resin;

16 wt % to 60 wt % iron pyrite, 0.5 wt % to 15 wt % potassium aluminum fluoride, and 0.5 wt % to 10 wt % mineral wool.

17. A fixed abrasive article comprising:

a body having abrasive particles contained within a bond material, the abrasive particles including a plurality of shaped abrasive particles or elongated abrasive particles having an aspect ratio of length;

width of at least 1.1;

1, and each of the shaped abrasive particles or elongated abrasive particles having a rake angle ranging from +90 to −

90 degrees with respect to a workpiece surface that is parallel to the edge of the body.