Abrasive tools and methods of forming the same

• US 9,242,345 B2
• Filed: 06/12/2014
• Issued: 01/26/2016
• Est. Priority Date: 06/15/2013
• 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: Ramanath, Srinivasan, Tunstall, John, Upadhyay, Rachana, Khaund, Arup K., Roy, Debdutta
• Primary Examiner(s): Parvini, Pegah
• Application Number:
  US14/303,348
• Publication Number:
  US 20140366457A1
• Time in Patent Office: 593 Days
• US Class Current: 1/1
• CPC Class Codes: B24D 3/06 metallic or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements

Abstract

An abrasive tool is provided that may include a body, which may include abrasive particles contained within a bond material. The abrasive particles may be a super abrasive material. The body may further include at least one of a ratio of tungsten to cast iron (W/CI) of not greater than about 1, a ratio of copper-containing compositions to cast iron (CCC/CI) of not greater than about 1, a ratio of titanium-containing compositions to cast-iron (TiCC/CI) of not greater than about 1, a ratio of tungsten carbide to cast iron (WC/CI) of not greater than about 1, a ratio of tungsten carbide to copper-containing compositions (WC/CCC) of not greater than about 1, a ratio of copper-containing compositions and titanium-containing compositions to cast iron ((CCC+TiC)/CI) of not greater than about 1.5 or a combination thereof.

Claims

1. An abrasive tool comprising:

a body including;

abrasive particles comprising a superabrasive material contained within a bond material;

an active bonding agent comprising a titanium-containing composition contained within the bond material;

at least about 25 wt. % cast iron for a total weight of the bond material; and

at least one of;

a ratio of tungsten to cast iron [W/CI] of not greater than about 1;

a ratio of copper-containing compositions to cast iron [CCC/CI] of not greater than about 1;

a ratio of titanium-containing compositions to cast iron [TiCC/CI] of not greater than about 1;

a ratio of tungsten carbide to cast iron [WC/CI] of not greater than about 1;

a ratio of tungsten carbide to copper-containing compositions [WC/CCC] of not greater than about 1;

a ratio of copper-containing compositions and titanium-containing compositions to cast iron [(CCC+TiC)/CI] of not greater than about 1.5; and

a combination thereof.

2. The abrasive tool of claim 1, wherein the body further comprises comprising a ratio of nickel to cast iron [Ni/CI] of not greater than about 1.

3. The abrasive tool of any one of claim 1, wherein the body further comprises a ratio of chromium to cast iron [Cr/CI] of not greater than about 1.

4. The abrasive tool of any one of claim 1, wherein the body further comprises a ratio of titanium-containing compositions to abrasive particles [TiCC/AP] of not greater than about 1.

5. The abrasive tool of claim 1, wherein the body further comprises a ratio of cast iron to abrasive particles [CI/AP] of not greater than about 1.

6. The abrasive tool of any one of claim 1, wherein the body comprises a first titanium-containing composition preferentially located adjacent to the cast iron and a second titanium-containing composition preferentially located adjacent to the abrasive particles.

7. The abrasive tool of claim 1, wherein the body comprises not greater than about 10 wt. % titanium-containing compositions for a total weight of the bond material.

8. The abrasive tool of any one of claim 1, wherein the body comprises not greater than about 10 wt. % tungsten for a total weight of the bond material.

9. The abrasive tool of claim 1, wherein the body comprises not greater than about 50 wt. % copper-containing compound for a total weight of the bond material.

10. The abrasive tool of claim 1, wherein the copper-containing compound comprises elemental copper.

11. The abrasive tool of claim 1, wherein the body comprises not greater than about 50 wt. % elemental copper for a total weight of the bond material.

12. The abrasive tool of claim 1, wherein the body comprises not greater than about 20 wt. % tin for a total weight of the bond material.

13. The abrasive tool of claim 1, wherein the cast iron comprises not greater than about 5 wt. % chromium for a total weight of the cast iron.

14. The abrasive tool of claim 1, wherein the body comprises not greater than about 10 wt. % chromium for the total weight of the bond material.

15. A method of forming an abrasive tool comprising:

providing a mixture comprising;

a bond material;

abrasive particles comprising a superabrasive material;

an active bonding agent comprising a titanium-containing compositions;

at least about 25 wt. % cast iron for a total weight of the bond material; and

at least one of;

a ratio of tungsten to cast iron [W/CI] of not greater than about 1;

a ratio of copper-containing compositions to cast iron [CCC/CI] of not greater than about 1;

a ratio of titanium-containing compositions to cast iron [TiCC/CI] of not greater than about 1;

a ratio of tungsten carbide to cast iron [WC/CI] of not greater than about 1;

a ratio of tungsten carbide to copper-containing compositions [WC/CCC] of not greater than about 1;

a ratio of copper-containing compositions and titanium-containing compositions to cast iron [(CCC+TiC)/CI] of not greater than about 1.5; and

a combination thereof; and

forming the mixture into the abrasive tool.

16. The method of forming an abrasive tool of claim 15, wherein the body further comprises a ratio of titanium-containing compositions to abrasive particles [TiCC/AP] of not greater than about 1.

17. The method of forming an abrasive tool of claim 15, wherein the body further comprises a ratio of cast iron to abrasive particles [CI/AP] of not greater than about 1.

18. The method of forming an abrasive tool of claim 15, wherein the body comprises a first titanium-containing composition preferentially located adjacent to the cast iron and a second titanium-containing composition preferentially located adjacent to the abrasive particles.

19. The method of forming an abrasive tool of claim 15, wherein the copper-containing compound comprises elemental copper.

20. The method of forming an abrasive tool of claim 15, wherein the cast iron comprises not greater than about 5 wt. % chromium for a total weight of the cast iron.