Bonded abrasive article and method of grinding

• US 9,833,877 B2
• Filed: 03/31/2014
• Issued: 12/05/2017
• Est. Priority Date: 03/31/2013
• 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, Lane, William H., Upadhyay, Rachana, Hitchiner, Michael P.
• Primary Examiner(s): Parvini, Pegah
• Application Number:
  US14/231,066
• Publication Number:
  US 20140298729A1
• Time in Patent Office: 1,345 Days
• CPC Class Codes: B24D 3/10 for porous or cellular structure, e.g. for use with diamonds as abrasives

Abstract

An abrasive article configured to grind a workpiece having a fracture toughness of at least about 5.5 MPa·m^0.5 may include a body comprising abrasive particles contained within a bond material comprising a metal, wherein the body comprises a ratio of V_AG/V_BM of at least about 1.3, wherein V_AG is a volume percent of abrasive particles within a total volume of the body and V_BM is a volume percent of bond material within the total volume of the body, and wherein the abrasive particles have an average particle size of at least about 1 micron and not greater than about 20 microns.

Claims

1. An abrasive wheel configured to grind a workpiece having a fracture toughness of at least about 5.5 MPa·

m^0.5 comprising;

a body comprising abrasive particles contained within a bond material comprising a metal and at least about 1 vol. % of an active bond composition for a total volume of the bond material,

wherein the body comprises a ratio of V_AG/V_BM of at least 1.7 and not greater than 9.0, wherein V_AG is a volume percent of abrasive particles within a total volume of the body and V_BM is a volume percent of bond material within the total volume of the body,

wherein the abrasive particles have an average particle size of at least about 1 micron and not greater than about 20 microns,

wherein the body comprises at least about 30 vol. % porosity, and

wherein the abrasive wheel comprises a tip radius of not greater than 0.002 inches.

2. The abrasive wheel of claim 1, wherein the abrasive particles comprise diamonds, wherein the diamonds are synthetic and wherein the diamonds are single crystal.

3. The abrasive wheel of claim 1, wherein the active bond composition is chemically bonded to at least a portion of a surface of at least a portion of the abrasive particles.

4. The abrasive wheel of claim 1, wherein the bond material comprises at least about 1 vol. % and not greater than about 40 vol % for a total volume of the bond material.

5. The abrasive wheel of claim 1, wherein the ratio of V_P/V_BM is within a range between about 1.5 and about 9.0, wherein V_P is a volume percent of particulate material including abrasive grains and fillers within a total volume of the body and V_BM is a volume percent of bond material within the total volume of the body.

6. An abrasive wheel configured to grind threads on a workpiece comprising a carbide, the abrasive wheel comprising:

a body comprising abrasive particles contained within a bond material comprising a metal and at least about 1 vol. % of an active bond composition for a total volume of the bond material,

wherein the body comprises a ratio of V_AG/V_BM of at least 1.7 and not greater than 9.0, wherein V_AG is a volume percent of abrasive particles within a total volume of the body and V_BM is a volume percent of bond material within the total volume of the body,

wherein the abrasive wheel comprises a tip radius of not greater than about 0.002 inches, and

wherein the body comprises at least about 30 vol. % porosity.

7. The abrasive wheel of claim 6, wherein the abrasive particles comprise diamonds, wherein the diamonds are synthetic and wherein the diamonds are single crystal.

8. The abrasive wheel of claim 6, wherein the abrasive particles have an average particle size of at least about 1 micron and not greater than about 20 microns.

9. The abrasive wheel of claim 6, wherein the abrasive wheel is configured to grind a workpiece having a fracture toughness of at least about 5.5 MPa·

m^0.5.

10. The abrasive wheel of claim 6, wherein the ratio of V_P/V_BM is within a range between about 1.5 and about 9.0, wherein V_P is a volume percent of particulate material including abrasive grains and fillers within a total volume of the body and V_BM is a volume percent of bond material within the total volume of the body.

11. A method of forming an abrasive wheel configured to grind threads on a workpiece comprising a carbide, the method comprising:

providing a mixture including abrasive particles and bond material, wherein the bond material comprises a metal and at least about 1 vol. % of an active bond composition for a total volume of the bond material; and

forming an abrasive body including the abrasive particles contained within the bond material,

wherein the body comprises a ratio of V_AG/V_BM of at least 1.7 and not greater than 9.0, wherein V_AG is a volume percent of abrasive particles within a total volume of the body and V_BM is a volume percent of bond material within the total volume of the body;

wherein the body comprises a ratio of V_P;

V_BM of at least about 3;

2, wherein V_P is a volume percent of particulate material including abrasive particles and fillers within a total volume of the body and V_BM is a volume percent of bond material within the total volume of the body,

wherein the abrasive wheel comprises a tip radius of not greater than about 0.002 inches, and

wherein the body comprises at least about 30 vol. % porosity.

12. The abrasive wheel of claim 11, wherein the abrasive particles comprise diamonds, wherein the diamonds are synthetic and wherein the diamonds are single crystal.

13. The abrasive wheel of claim 11, wherein the abrasive particles have an average particle size of at least about 1 micron and not greater than about 20 microns.

14. The method of claim 11, wherein the abrasive wheel is configured to grind a workpiece having a fracture toughness of at least about 5.5 MPa·

m^0.5.