Resin bonded abrasive tool and method of making the tool

• US 5,912,216 A
• Filed: 11/05/1997
• Issued: 06/15/1999
• Est. Priority Date: 09/08/1997
• Status: Expired due to Fees

• Current Assignee: Norton Company (Compagnie De Saint-Gobain), Grindwell Norton Ltd. (Compagnie de Saint-Gobain SA)
• Original Assignee: Norton Company (Compagnie De Saint-Gobain), Grindwell Norton Ltd. (Compagnie de Saint-Gobain SA)
• Inventors: Thimmappaiah, Channarayapatna N., Kurubaran, Murugesan K., Meyer, Gerald W.
• Primary Examiner(s): JONES, DEBORAH D
• Application Number:
  US08/964,766
• Time in Patent Office: 587 Days
• Field of Search: 51/298, 51/306, 51/293
• US Class Current: 51/298
• CPC Class Codes: B24D 3/344 the bonding agent being organic
• CPC Class Codes: B24D 3/346 utilised during polishing, or grinding operation

Abstract

A resin bonded abrasive tool consists of abrasive grain and an organic bond comprising a thermosetting resin, such as epoxy resin, phenolic resin or rubber or blends thereof and a precursor filler system capable of forming in situ an active filler system by reacting under the heat generated during grinding. The organic bond optionally further comprises a filler system. A method of making the resin bonded abrasive tool consists of mixing the abrasive grain and the organic bond with the precursor filler system, pressing the resulting mixture into shape, and curing the abrasive tool at about 150 to 200° C.

Claims

1. A resin bonded abrasive tool consisting essentially of abrasive grain and an organic bond, the organic bond comprising a thermosetting resin binder and a precursor filler system capable of forming in situ an active filler system by reacting under the heat generated during grinding.

2. The resin bonded abrasive tool of claim 1, wherein the precursor filler system comprises 60-70% by wt potassium chloride, 15-20% by wt manganese oxide and 15-20% by wt chlorine or hydrogen chloride generating compound.

3. The resin bonded abrasive tool of claim 1, wherein the precursor filler system comprises 65% by wt potassium chloride, 17.5% by wt of manganese oxide and 17.5% by wt of a chlorine source selected from the group consisting of chlorine generating compound and hydrogen chloride generating compound, and combinations thereof.

4. The resin bonded abrasive tool of claim 3, wherein the chlorine source is selected from the group consisting of polyvinyl chloride, polyvinylidene chloride and perchloropentacyclooctene, and combinations thereof.

5. The resin bonded abrasive tool of claim 1, wherein the precursor filler system comprises 30 to 50% by wt aluminum fluoride, and 40 to 70% by wt of sodium fluoride.

6. The resin bonded abrasive tool of claim 1, wherein the precursor filler system comprises 30 to 70% by wt iron oxide, and 30 to 70% by wt of at least one organic sulfur compound.

7. The resin bonded abrasive tool of claim 6, wherein the organic sulfur compound is selected from the group consisting of thiazoles, sulfenamides, thiurams, dithiocarbamates, and combinations and derivatives thereof.

8. The resin bonded abrasive tool of claim 1, wherein the precursor filler system comprises 70 to 99.5% by wt barium sulfate, and 0.5 to 30% by wt of at least one source of catalytic carbon.

9. The resin bonded abrasive tool of claim 8, wherein the source of catalytic carbon is selected from the group consisting of carbon black, activated charcoal and graphite, and combinations thereof.

10. The resin bonded abrasive tool of claim 1 wherein the organic bond comprises a binder selected from the group consisting of epoxy resin, phenolic resin, phenolic novolac resin, rubber, modified rubber and combinations thereof.

11. The resin bonded abrasive tool of claim 1 wherein the organic bond further comprises at least one filler in addition to the active filler system.

12. The resin bonded abrasive tool of claim 1 wherein the abrasive grain is selected from the group consisting of fused aluminum oxide, sintered aluminum oxide, sintered sol gel microcrystalline alpha-alumina, silicon carbide, alumina zirconia, cubic boron nitride and diamond grains, and combinations thereof.

13. The resin bonded abrasive tool of claim 1, wherein the tool consists of 34 to 56 vol % abrasive grain, and 2 to 64 vol % organic bond.

14. The resin bonded abrasive tool of claim 13, wherein the organic bond comprises 5 to 60 vol % active filler system.

15. A method of making a resin bonded abrasive tool having an active filler system consisting of:

a) mixing abrasive grain and organic bond comprising a binder and a precursor filler system capable of forming in situ the active filler system by reacting under the heat generated during grinding, to form a uniform mixture;

b) pressing the uniform mixture into shape;

c) curing the abrasive tool at about 150 to 200°

C.; and

d) grinding with the cured abrasive tool at forces sufficient to generate temperatures of about 300°

to 1000°

C. at the grinding interface, and thereby forming the active filler system.

16. The method of claim 15, wherein the precursor filler system comprises 60-70% by wt potassium chloride, 15-20% by wt manganese oxide and 15-20% by wt chlorine or hydrogen chloride generating compound.

17. The method of claim 16, wherein the precursor filler system comprises 65% by wt potassium chloride, 17.5% by wt manganese oxide and 17.5% by wt chlorine or hydrogen chloride generating compound.

18. The method of claim 15, wherein the abrasive tool is cured at 175-185°

C.

19. The method of claim 15, wherein the precursor filler system comprises 30 to 50% by wt aluminum fluoride, and 40 to 70% by wt of sodium fluoride.

20. The method of claim 15, wherein the precursor filler system comprises 30 to 70% by wt iron oxide, and 30 to 70% by wt of at least one organic sulfur compound.

21. The method of claim 20, wherein the organic sulfur compound is selected from the group consisting of thiazoles, sulfenamides, thiurams, dithiocarbamates and dithiocarbamic acids, and combinations thereof.

22. The method of claim 15, wherein the precursor filler system comprises 70 to 99.5% by wt barium sulfate, and 0.5 to 30% by wt of at least one source of catalytic carbon.

23. The method of claim 22, wherein the source of catalytic carbon is selected from the group consisting of carbon black, activated charcoal and graphite, and combinations thereof.

24. The method of claim 15, wherein the organic bond comprises a binder selected from the group consisting of epoxy resin, phenolic resin, phenolic novolac resin, rubber, modified rubber and combinations thereof.

25. The method of claim 15, wherein the organic bond comprises at least one filler in addition to the precursor filler system.