Method of using an abrasive article including shaped abrasive particles

• US 9,902,045 B2
• Filed: 05/29/2015
• Issued: 02/27/2018
• Est. Priority Date: 05/30/2014
• 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: Breder, Kristin, Iyengar, Sujatha, Arcona, Christopher
• Primary Examiner(s): Carlson, Marc
• Application Number:
  US14/726,021
• Publication Number:
  US 20150343603A1
• Time in Patent Office: 1,005 Days
• CPC Class Codes: B24B 1/00 Processes of grinding or polishing; Use of auxiliary equipment in connection with such processes
• CPC Class Codes: B24D 11/00 Constructional features of flexible abrasive materials; Special features in the manufacture of such materials
• CPC Class Codes: C09K 3/1409 Abrasive particles per se preparation of diamond C01B32/25

Abstract

A method of removing material from one or more workpieces including moving a coated abrasive article having a plurality of shaped abrasive particles relative to a surface of the one or more workpieces at high material removal rates.

Claims

1. A method of removing material from one or more workpieces including:

moving a coated abrasive article comprising a plurality of shaped abrasive particles relative to a surface of the one or more workpieces at a normalized average material removal rate of at least 6 in³/min/in,

wherein the one or more workpieces comprise stainless steel,

wherein removing material includes a G-ratio variance of not greater than about 28% for at least two different material removal operation at two different normalized average material removal rates within the range of normalized average material removal rates,

wherein removing material comprises removing a cumulative amount of material from the one or more workpieces of at least about 7,500 grams/in., and

wherein the two different normalized average material removal rates differ by at least about 2 in³/min/in.

2. The method of claim 1, wherein the one or more workpieces consist essentially of 304 stainless steel.

3. The method of claim 2, wherein removing material comprises removing a cumulative amount of material from the one or more workpieces of at least about 10,000 grams/in.

4. The method of claim 3, wherein removing comprises a maximum specific grinding energy of not greater than about 2.9 hp min/in³ per 6000 grams/in of initial material removed from the one or more workpieces.

5. The method of claim 1, wherein the normalized average material removal rate is not greater than about 25 in³/min/in.

6. The method of claim 1, wherein each shaped abrasive particle of the plurality of shaped abrasive particles comprises a body having a length (l), a width (w), and a height (h), and wherein the height (h) is at least about 20% of the width (w).

7. The method of claim 1, wherein each shaped abrasive particle of the plurality of shaped abrasive particles comprises a body having a percent flashing of at least about 10%.

8. The method of claim 1, wherein each shaped abrasive particle of the plurality of shaped abrasive particles comprises a body having a two-dimensional polygonal shape as viewed in a plane defined by a length and width, of the body, and wherein the body comprises a shape selected from the group consisting of polygons, ellipsoids, Greek alphabet characters, Latin alphabet characters, Russian alphabet characters, and a combination thereof.

9. The method of claim 1, wherein each shaped abrasive particle of the plurality of shaped abrasive particles comprises a body, and wherein the body is essentially free of a binder.

10. The method of claim 1, wherein the body comprises a polycrystalline material comprising grains, and wherein the grains are selected from the group of materials consisting of nitrides, oxides, carbides, borides, oxynitrides, diamond, and a combination thereof.

11. The method of claim 10, wherein the grains comprise an oxide selected from the group of oxides consisting of aluminum oxide, zirconium oxide, titanium oxide, yttrium oxide, chromium oxide, strontium oxide, silicon oxide, and a combination thereof.

12. The method of claim 1, wherein each shaped abrasive particle of the plurality of shaped abrasive particles comprises a body, and wherein the body is formed from a seeded sol gel.

13. The method of claim 1, wherein the plurality of shaped abrasive particles comprises a first portion of a batch of abrasive particles and a second portion of the batch distinct from the first portion, wherein the second portion comprises a second plurality of shaped abrasive particles having at least one abrasive characteristic distinct from the plurality of shaped abrasive particles of the first portion, and wherein the abrasive characteristic is selected from the group consisting of two-dimensional shape, average particle size, particle color, hardness, friability, toughness, density, specific surface area, and a combination thereof.

14. The method of claim 1, wherein each shaped abrasive particle of the plurality of shaped abrasive particles is arranged in a controlled orientation relative to the backing, the controlled orientation including at least one of a predetermined rotational orientation, a predetermined lateral orientation, and a predetermined longitudinal orientation.

15. The method of claim 1, wherein a majority of the shaped abrasive particles of the plurality of shaped abrasive particles are coupled to a backing in a side orientation.

16. The method of claim 1, wherein the coated abrasive article comprises an open coat of the plurality of shaped abrasive particles shaped abrasive particles on the backing, and wherein the open coat comprises a coating density of not greater than about 70 particles/cm².

17. The method of claim 1, wherein the coated abrasive article comprises

a backing,

a make coat overlying the backing, wherein the plurality of shaped abrasive particles are disposed on the make coat and coupled to the backing, and

a size coat is disposed overlying the plurality of shaped abrasive particles,

wherein the backing comprises a material selected from the group consisting of cloth, paper, film, fabric, fleeced fabric, vulcanized fiber, woven material, non-woven material, webbing, polymer, resin, phenolic resin, phenolic-latex resin, epoxy resin, polyester resin, urea formaldehyde resin, polyester, polyurethane, polypropylene, polyimides, and a combination thereof,

wherein the make coat comprises a material selected from the group consisting of polyesters, epoxy resins, polyurethanes, polyamides, polyacrylates, polymethacrylates, poly vinyl chlorides, polyethlene, polysiloxane, silicones, cellulose acetates, nitrocellulose, natural rubber, starch, shellac, and a combination thereof, and

wherein the size coat comprises a material selected from the group consisting of polyesters, epoxy resins, polyurethanes, polyamides, polyacrylates, polymethacrylates, polyvinyl chlorides, polyethylene, polysiloxane, silicones, cellulose acetates, nitrocellulose, natural rubber, starch, shellac, and a combination thereof.

18. A method of conducting a high-speed, high-efficiency grinding operation including

removing a cumulative amount of at least about 7,500 grams/in. of material from one or more workpieces comprising stainless steel at a normalized average material removal rate of at least 6 in³/min/in to not greater than 25 in³/min/in by moving a coated abrasive article relative to a surface of the one or more workpieces,

wherein the coated abrasive comprises a polymeric binder disposed on a backing material and a plurality of shaped abrasive particles disposed on or in the polymeric binder,

wherein the coated abrasive is adapted to have a G-ratio variance of not greater than about 30% for two different material removal operations on stainless steel having normalized average material removal rates that are within the range of at least 6 in³/min/in to not greater than 25 in³/min/in and that differ by at least about 2 in³/min/in.

19. The method of claim 18, wherein the stainless steel comprises 304 stainless steel.

20. A method of removing material from a workpiece including:

abrading a workpiece with a coated abrasive article at a normalized average material removal rate of at least 6 in³/min/in,

wherein the coated abrasive article comprising a plurality of shaped abrasive particles,

wherein the workpiece comprises stainless steel,

wherein the coated abrasive is adapted to achieve a cumulative amount of material removed of at least 10,000 Win while maintaining a normalized specific grinding energy of not greater than 2.5 Hp/(in³/min).