Abrasive Article for Use in Grinding of Superabrasive Workpieces

• US 20120036789A1
• Filed: 08/16/2011
• Published: 02/16/2012
• Est. Priority Date: 08/16/2010
• 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, UPADHYAY, Rachana, Arcona, Christopher, Gillespie, John E.
• Granted Patent: US 8,992,645 B2
• Time in Patent Office: Days
• US Class Current: 51/298
• CPC Class Codes: B24D 18/0009 using moulds or presses
• CPC Class Codes: B24D 3/06 metallic or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements
• CPC Class Codes: B24D 3/28 Resins or natural or synthetic macromolecular compounds B24D3/22 takes precedence
• CPC Class Codes: B24D 5/02 Wheels in one piece

Abstract

An abrasive article including a bonded abrasive having a body formed of abrasive grains contained within a bond material, wherein the body grinds a superabrasive workpiece having an average Vickers hardness of at least about 5 GPa at an average specific grinding energy (SGE) of not greater than about 350 J/mm³, at a material removal rate of at least about 8 mm³/sec, and wherein grinding is a centerless grinding operation.

Claims

1. An abrasive article comprising:

a bonded abrasive having a body including abrasive grains contained within a bond material, wherein the body is capable of grinding a superabrasive workpiece having an average Vickers hardness of at least about 5 GPa at an average specific grinding energy (SGE) of not greater than about 350 J/mm³ at an average material removal (MRR) rate of at least about 8 mm³/sec for a centerless grinding operation.

9. The abrasive article of claim 1, wherein the body comprises a threshold power for grinding of not greater than about 150 W/mm during centerless grinding of the superabrasive workpiece.

15. The abrasive article of claim 1, wherein the body achieves an average material removal rate (MRR) of at least about 10 mm³/sec.

24. The abrasive article of claim 1, wherein the average Vickers hardness of the workpiece is at least about 10 GPa.

27. The abrasive article of claim 1, wherein the workpiece is a composite material comprising a substrate and an abrasive layer overlying the substrate.

28. The abrasive article of claim 1, wherein the workpiece comprises a polycrystalline diamond compact (PDC) cutting element.

31. The abrasive article of claim 27, wherein the substrate comprises a metal having a Mohs hardness of at least about 8.

32. The abrasive article of claim 27, wherein the substrate comprises a metal element comprising a transition metal material.

41. The abrasive article of claim 1, wherein the workpiece is in the shape of cylindrical body.

2-8. -8. (canceled)

10-14. -14. (canceled)

16-23. -23. (canceled)

25-26. -26. (canceled)

29-30. -30. (canceled)

33-40. -40. (canceled)

42. An abrasive article comprising:

a bonded abrasive having a body including abrasive grains contained within a composite bond material comprising an organic material and a metal material, wherein the composite bond material has a fracture toughness of not greater than about 3.0 MPa m^0.5.

46. The abrasive article of claim 42, wherein the bond material comprises an organic material.

47. The abrasive article of claim 46, wherein the bond material comprises a composite including an organic material and a metal material.

48. The abrasive article of claim 47, wherein the organic material comprises a material selected from the group of materials consisting of polyimides, polyamides, epoxies, resins, aramids, polyesters, polyurethanes, and a combination thereof.

51. The abrasive article of claim 47, wherein the organic material comprises not greater than about 20 vol % of the total volume of the bond material.

56. The abrasive article of claim 47, wherein the metal material comprises a metal alloy.

57. The abrasive article of claim 56, wherein the metal material comprises a transition metal element.

58. The abrasive article of claim 57, wherein the metal material comprises copper and tin.

60. The abrasive article of claim 47, wherein the metal material comprises at least about 20 vol % of the total volume of the bond material.

65. The abrasive article of claim 42, wherein the bond material comprise a ratio (OM/MM) of organic material by volume (OM) to metal material by volume (MM) of not greater than about 0.25.

81. The abrasive article of claim 42, wherein the body comprises a porosity of not greater than about 10 vol % of the total volume of the body.

43-45. -45. (canceled)

49-50. -50. (canceled)

52-55. -55. (canceled)

59. (canceled)

61-64. -64. (canceled)

66-80. -80. (canceled)

82-87. -87. (canceled)

88. An abrasive article comprising:

a bonded abrasive having a body including abrasive grains contained within a composite bond material comprising an organic material and a metal material, wherein the bond material comprise a ratio (OM/MM) of organic material by volume (OM) to metal material by volume (MM) of not greater than about 0.25.

89-100. -100. (canceled)

101. An abrasive article comprising:

a bonded abrasive having a body configured to grind workpieces comprising superabrasive material, wherein the body comprises abrasive grains contained within a composite bond material including an organic material and a metal material, wherein not less than about 82% of the abrasive grains by volume are contained within the metal material of the composite bond material.

102. The abrasive article of claim 101, wherein not less than about 85% of the abrasive grains are contained within the metal material of the composite bond material.

103-110. -110. (canceled)

111. An abrasive article comprising:

a bonded abrasive having a body including abrasive grains contained within a composite bond material, wherein the composite bond material comprises a fracture toughness of not greater than about 3.0 MPa m^0.5 and the body comprises a threshold power for grinding of not greater than about 150 W/mm for an average material removal rate (MRR) of at least about 8 mm³/sec during centerless grinding of a superabrasive workpiece having an average Vickers hardness of at least about 5 GPa.

125. The abrasive article of claim 111, wherein the workpiece comprises a fracture toughness of at least about 4.0 MPa m^0.5.

129. The abrasive article of claim 111, wherein the workpiece comprises a fracture toughness of not greater than about 16.0 MPa m^0.5.

112-124. -124. (canceled)

126-128. -128. (canceled)

130-135. -135. (canceled)

136. A method of forming an abrasive article comprising:

forming a mixture including organic material, metal material, and abrasive grains; and

treating the mixture to form an abrasive article having a body including abrasive grains contained within a composite bond material comprising an organic material and a metal material, wherein the bond material comprise a ratio (OM/MM) of organic material by volume (OM) to metal material by volume (MM) of not greater than about 0.25.

138. The method of claim 136, wherein treating comprises conducting a hot pressing process on the mixture.

139. The method of claim 138, wherein hot pressing is conducted at a pressing temperature of not greater than about 600°

C.

137. (canceled)

140-145. -145. (canceled)