abrasive article and method for forming an abrasive article

专利摘要:
ABRASIVE ARTICLE AND METHOD FOR FORMING AN ABRASIVE ARTICLE This is an abrasive article that includes a body that has abrasive grains contained in a bonding material that comprises a metal or metal alloy, in which the body comprises a ratio of VAG / VBM of at least about 1.3, where VAG is the percentage of abrasive grain volume within the total volume of the body and VBM is the percentage of volume of bonding material within the total volume of the body.
公开号:BR112013005026B1
申请号:R112013005026-8
申请日:2011-09-02
公开日:2021-02-02
发明作者:Kenneth A. Saucier；Rachana Upadhyay；Srinivasan Ramanath
申请人:Saint-Gobain Abrasives, Inc.；Saint-Gobain Abrasifs；
IPC主号:

专利说明:

TECHNICAL FIELD
The following is directed to bonded abrasive articles and 5 more particularly bonded abrasive articles that include abrasive grains contained in a bonding material that includes a metal or metal alloy. BACKGROUND TECHNIQUE
Abrasives used in machining applications typically include 16 bonded abrasive articles and coated abrasive articles. Coated abrasive articles are generally ■ layered articles that have a backing and an adhesive coating for attaching abrasive grains to the backing, the most common example of which is sandpaper. The bonded abrasive tools 15 consist of abrasive, three-dimensional, rigid and typically monolithic composites in the form of wheels, discs, segments, mounted points, sharpening stones and other tool formats, which can be mounted on a machining apparatus, such as a polishing or grinding apparatus. .
Bonded abrasive tools usually have at least two phases that include abrasive grains and bonding material. Certain bonded abrasive articles may have an additional phase * in the form of porosity. The bonded abrasive tools 25 can be manufactured in a variety of 'grades' and 'structures' that have been defined according to practice in the art by the density and relative hardness of the abrasive composite (grade) and by the percentage of abrasive grain volume, bonding and porosity within composite 30 (structure).
Some bonded abrasive tools can be particularly useful in grinding and shaping certain types of workpieces including, for example, metals, ceramics and crystalline materials, used in the electronics and optics industries. In other examples, certain bonded abrasive tools can be used in shaping. superabrasive materials for use in applications ~ 'lndustria-is-7- In-context, grinding and molding certain workpieces with metal-bonded abrasive articles, 10 the process generally involves a significant amount of time and targeted work keeping the abrasive article on. That is, generally, metal bonded abrasive articles require regular profiling and coating operations to maintain the grinding capabilities of the abrasive article.
The industry continues to demand improved methods and articles that have the crushing capacity. DISCLOSURE OF THE INVENTION
According to a first aspect, an abrasive article 20 includes a body having abrasive grains contained in the bonding material which comprises a metal or metal alloy. The body comprises a VAG / VBM ratio of at least about 1.3, where VAG is the volume percentage of abrasive grains within the total volume of the body and VBM is the volume percentage of bonding material within the volume total body.
According to another aspect, an abrasive article includes a body that has abrasive grains contained in a bonding material that comprises a metal or metal alloy, wherein the body comprises a VP / VBM ratio of at least about 1, 5, where VP is the percentage of volume of particulate material that includes abrasive grains and fillers within the total volume of the body and VBM is the percentage of volume of bonding material within the total volume of the body. The bonding material has an average fracture resistance (Kic) of no more than about 4.0 MPa m0.5.
In yet another aspect, an abrasive article includes a body that has abrasive grains contained in one. bonding material comprising a metal, the body comprising an active bonding composition comprising at least about 1% by volume of an active bonding composition of the total volume of the bonding material. The body additionally includes a porosity of at least about 5% by volume and in which the bonding material comprises an average fracture resistance (Kic) not greater than about 4.0 MPa m0'5.
In yet another aspect, an abrasive article includes a body that has abrasive grains contained in a bonding material that comprises a metal or metal alloy, wherein the body 20 comprises a VP / VBM ratio of at least about 1.5 , in which VP is the volume percentage of the particulate material that includes abrasive grains and fillers within the total volume of the body and VBM is the percentage of volume of bonding material within the total volume of the body. The body includes at least 25 about 5% by volume porosity of the total volume of the body, where a majority of the porosity is the interconnected porosity that defines a network of interconnected pores that extends through the volume of the body.
According to another aspect, an abrasive article includes a body that has abrasive grains contained in a bonding material that comprises a metal or metal alloy, wherein the body comprises a VAG / VBM ratio of at least about 1, 3, where VAG is the percentage of abrasive grains volume within the total volume of the body and VBM is the percentage of 5 volume of bonding material within the total volume of the body. The body includes an active bonding composition comprising at least 10% by volume of an active bonding composition of the total volume of the bonding material.
In yet another aspect, a method of forming an abrasive article 10 includes forming a mixture that includes the abrasive grains and bonding material, wherein the bonding material comprises a metal or metal alloy and shaping the mixture to form a green article. The method further includes sintering the green article at a temperature 15 to conduct the liquid phase sintering, and forming an abrasive body comprising the abrasive grains contained in the bonding material, wherein the body comprises a ratio of VP: VBM of at least about 3: 2, where VP is a percentage of volume of particulate material that includes abrasive grains and fillers within the total volume of the body and VBM is a percentage of volume of bonding material within the total volume of the body. .
Another aspect includes an abrasive article that has a bonded abrasive body that includes abrasive grains contained in a bonding material made of a metal or metal alloy, wherein the bonding material comprises a composite material that includes a bonding phase and a precipitated phase, the precipitated phase having a composition that includes at least one element of an active binding composition and at least one element of the binding material. BRIEF DESCRIPTION OF THE DRAWINGS
The present disclosure can be better understood and its numerous features and advantages made apparent to those skilled in the art by reference to the accompanying drawings.
Figure 1 includes a plot of shredding energy (kW / cm (Hp / in)) versus number of shredding cycles for an abrasive body bonded according to one modality.
Figure 2 includes a plot of surface roughness 10 (Ra) versus number of crushing cycles for an abrasive body bonded according to an embodiment.
Figure 3 includes a plot of shredding energy (kW / cm (Hp / in)) versus number of shredding cycles for abrasive bodies bonded according to a modality 15 and a conventional sample.
Figure 4 includes a grind energy bar graph (kW (Hp)) versus two different material removal rates (ie 45 mm3 / sec / mm and 51 mm3 / sec / mm (4.5 in3 / min / in and 5.1 in3 / min / in)) for an abrasive body 20 connected according to a modality and a conventional sample.
Figure 5 includes a bar graph of crushing ratio (G-ratio) at two different material removal rates for an abrasive body bonded according to a modality and a conventional sample.
Figure 6 includes a plot of axis energy (kW (Hp)) grinding time (seconds) for an abrasive body bonded according to a modality and a conventional sample.
Figure 7 includes a plot of axis energy (kW (Hp)), grinding time (seconds) for an abrasive body - connected according to a modality and a conventional sample.
Figures 8 to 11 include enlarged images of the microstructure of an abrasive body connected according to an embodiment.
Figure 12 includes an enlarged image of an abrasive body connected according to an embodiment.
The use of the same reference symbols in 10 different designs indicates similar or identical items. DESCRIPTION OF THE PREFERENTIAL MODE (S)
The following is generally intended for bonded abrasive articles that incorporate abrasive grains within a three-dimensional matrix of the material. Bonded abrasive articles 15 use a volume of abrasive grains trapped within a three-dimensional matrix of the bonding material. In addition, the following includes the description relating to methods for forming such bonded abrasive articles and applications for such bonded abrasive articles.
According to one embodiment, the process for forming an abrasive article can be initiated by forming a mixture containing abrasive grains and bonding material. Abrasive grains can include a hard material. For example, abrasive grains can have a Mohs hardness of 25 at least about 7. In other abrasive bodies, abrasive grains can have a Mohs hardness of at least 8 or. even at least 9.
In particular cases, the abrasive grains can be made of an inorganic material. Suitable inorganic materials 30 may include carbides, oxides, nitrides, borides, oxycarbons, oxyborides, oxy nitrides and a combination thereof. Particular examples of abrasive grains include silicon carbide, boron carbide, alumina, zirconia, alumina-zirconia composite particles, silicon nitride, SiAlON and titanium boride.
In certain instances, abrasive grains may include a superabrasive material, such as diamond, cubic boron nitride and a combination thereof. In particular cases, the abrasive grains may consist essentially of diamond. In other embodiments, the abrasive grains may consist essentially of cubic boron nitride.
Abrasive grains can have an average grain size of no more than about 1,000 microns. In other 15 embodiments, the abrasive grains can have an average grain size of no more than about 750 microns, such as no more than about 500 microns, no more than about 250 microns, no more than about 200 microns or even no larger than about 150 microns. In particular instances, the abrasive grains of the embodiments in this document may have an average granulation size, within a range between about 1 micron and about 1,000 microns, such as between about 1 micron and 500 microns or even between about 1 micron and 200 microns.
In further reference to abrasive grains, the morphology of the abrasive grains can be described by an aspect ratio, which is the ratio between the length-to-width dimensions. It will be found that the length is the longest dimension of the abrasive grain and the width is the second longest dimension of a given abrasive grain. In accordance with the modalities in this document, abrasive grains can have an aspect ratio (length: width) not greater than about 3: 1 or even not greater than about 2: 1. In particular instances, the abrasive grains can be essentially equiaxial, such that they have an aspect ratio of approximately 1: 1.
Abrasive grains can include other features including, for example, a coating. The abrasive grains can be coated with a coating material which can be an inorganic material. Suitable inorganic materials can include a ceramic, glass, metal, alloy. metal and a combination of them. In particular instances, the abrasive grains can be galvanized with a metal material and, more particularly, a transition metal composition. Such coated abrasive grains can facilitate the improved bonding (e.g., chemical bonding) between the abrasive grains and the bonding material.
In certain instances, the mixture may include a particular distribution of the abrasive grains. For example, the mixture may include a multimodal distribution of granulation sizes of the abrasive grains, such that a particular distribution of fine, intermediate and coarse granulation sizes is present within the mixture. In a particular instance, the mixture may include a bimodal distribution of abrasive grains that include fine grains that have a medium coarse grain size and coarse grains that have a coarse average grain size, where the coarse average grain size is significantly larger than the average fine-grained size. For example, the average coarse grain size can be at least about 10% larger, at least about 20%, at least about 30% or at least 5 about 50% larger than the average fine grain size ( based on the size of fine abrasive grain). It will be appreciated that the mixture may include another multimodal distribution of the abrasive grains including, for example, a trimodal distribution or a quadrimodal distribution.
It will also be seen that abrasive grains of the same composition can have various mechanical properties including, for example, friability. The mixture and the final formed bonded abrasive body may incorporate a mixture of abrasive grains, which may have the same composition, but which have varying degrees or mechanical properties. For example, the mixture may include abrasive grains from a single composition, such that the mixture includes only diamond or cubic boron nitride. However, the diamond or cubic boron nitride may include a mixture of 20 different grades of diamond or cubic boron nitride, such that the abrasive grains have varying degrees and varying degrees and varying mechanical properties.
Abrasive grains can be supplied in the mixture in. an amount such that the abrasive article finally formed contains a particular amount of abrasive grains. For example, the mixture may include a higher content (for example, greater than 50% by volume) of abrasive grains.
According to one embodiment, the bonding material 30 can be a metal or metal alloy material. For example, the bonding material can include a powder composition that includes at least one transition metal element. In particular instances, the bonding material may include a metal selected from group 5 which includes copper, tin, silver, molybdenum, zinc, tungsten, iron, nickel, antimony and a combination thereof. In a particular embodiment, the bonding material can be a metal alloy including copper and tin. The copper and tin metal alloy can be a bronze material, which can be formed from a composition of 60:40 by weight of copper and tin, respectively.
According to a particular embodiment, the copper and tin metal alloy may include a certain copper content, such that the final formed bonded abrasive article has suitable mechanical characteristics and grinding performance. For example, the copper and tin metal alloy may include no greater than about 70% copper, such as no more than about 65% copper, no greater than about 60% no greater than about 50% copper. copper, no more than 20 about 45% copper or even no more than about 40% copper. In particular instances, the amount of copper is within a range between about 30% and about 65% and, more particularly, between about 40% and about 65%. Certain copper and tin metal alloys may have a minimal amount of tin. For example, the metal alloy can include at least about 30% tin of the total amount of the composition. In other instances, the amount of tin can be greater, such as at least about 35%, at least 30% about 40%, at least about 45%, at least about 11/68 r-. . . - - • - - - - 50%, at least about 60%, at least about 65% on even at least about 75%. Certain bonding materials may include a copper and tin metal alloy that has an amount of tin within a range of between about 5% and about 80%, between about 30% and about 70% or even between about 35% and about 65%.
In an alternative embodiment, the bonding material can be a tin-based material, wherein the tin-based materials include metal and metal alloys which comprise a higher content of tin versus other components present in the material. For example, the bonding material can consist essentially of tin. In addition, certain tin-based bonding materials can be used that include no more than about 10% of the other 15 alloying materials, particularly metals.
The mixture may contain an equal portion of abrasive grains to bond. However, in certain embodiments, the mixture can be formed in such a way that the amount of bonding material can be less than the amount of abrasive grains within the mixture. Such a mixture facilitates a bonded abrasive article that has certain properties, which are described in more detail in the present document.
In addition to abrasive grains and bonding material, the mixture can additionally include a precursor of active bonding composition. The active bonding composition precursor includes a material, which can be added to the mixture which further facilitates a chemical reaction between certain components of the bonded abrasive body including, for example, particulate material (for example, abrasive grains and / or fillers) and connecting material. The active bonding composition precursor can. be added to the mixture in smaller amounts and particularly less than the amount of abrasive grains present within the mixture.
In accordance with one embodiment, the active bonding composition precursor may include a composition that includes a metal or metal alloy. More particularly, the - - precursor to. Active bonding composition can include a composition or complex that includes hydrogen. For example, the active bonding composition precursor may include a metal hydride and, more particularly, may include a material such as titanium hydride. In one embodiment, the precursor to. active bonding composition consists essentially of titanium hydride.
The mixture generally includes a smaller amount of the active binding composition precursor. For example, the mixture can include no greater than about 40% by weight of the active binding composition precursor of the total weight of the mixture. In other embodiments, the amount of active binding composition precursor 20 within the mixture may be less, such as not greater than about 35% by weight, not greater than about 30% by weight, not greater than about 28% by weight, not more than about 26% by weight, not more than about 23% by weight, not more than about 18% by weight, 25 not more than about 15% by weight, not more than about 12 % by weight or even not greater than about 10% by weight. In particular instances, the amount of active binding composition precursor within the mixture can be within a range of between about 2% by weight and about 30 40% by weight, such as between about 4% by weight and about 35% by weight, between about 8% by weight and about 28% by weight, between about 10% by weight and about 28% by weight or even between about 12% by weight and about 26% by weight . The mixture can additionally include a binder material. The binder material can be used to provide adequate strength during the formation of the bonded abrasive article. Certain suitable binder materials may include an 'organic-material'. -For example, the organic material can be a material such as a thermostable, thermoplastic, adhesive and a combination thereof. In a particular instance, the organic material of the binder material includes a material such as polyimides, polyamides, resins, aramides, epoxies, polyesters, polyurethanes, acetates, celluloses and a combination thereof. In one embodiment, the blend may include a binder material that uses a combination of a thermoplastic material configured to cure at a particular temperature. In another embodiment, the bonding material may include a suitable adhesive material to facilitate attachment between the components of the mixture. The binder can be in the form of a liquid including, for example, an aqueous-based or non-aqueous-based compound. Generally, the binder material can be present in a smaller amount (by weight) within the mixture. For example, the binder may be present in an amount significantly less than the amount of the abrasive grains, bonding material or active bonding composition precursor. For example, the mixture can include no greater than about 40% by weight of the binder material for the total weight of the mixture. In another 30 embodiments, the amount of binder material within the mixture may be less, such as not more than about 35% by weight, not more than about 30% by weight, not more than about 28% by weight, not greater than about 26% by weight, not greater than about 23% by weight, not greater than about 5 18% by weight, not greater than about 15% by weight, not greater than about 12% by weight or even not more than about 10% by weight. In particular cases, the amount of light material inside the mix. .can be within a range of between about 2% by weight and about 40% by weight, such as between about 4% by weight and about 35% by weight, between about 8% by weight and about 28% by weight, between about 10% by weight and about 28% by weight or even between about 12% by weight and about 26% by weight.
The mixture may additionally include a certain amount of fillers. The fillers can be a particulate material that can be replaced by certain components within the mixture including, for example, abrasive grains. Notably, the fillers can be a particulate material that can be incorporated into the mixture, where the fillers 20 substantially maintain their original size and shape in the finally formed bonded abrasive body. Examples of fillers may include oxides, carbides, borides, silicides, nitrides, oxynitrides, oxycarbons, silicates, graphite, silicon, intermetallic, ceramics, 25 hollow ceramics, molten silica, glass, glass ceramics, hollow glass spheres, natural materials such as shells and a combination of them.
Notably, certain fillers can have a hardness that is less than the hardness of the abrasive grains. In addition, the mixture can be formed in such a way that the fillers are present in an amount not greater than about 90% by volume of the total volume of the mixture. The volume percentage is used to describe the content of the fillers as the fillers can vary in density depending on the type of particulate, such as hollow spheres versus heavy particulate. In other embodiments, the amount of charge within the mixture can be no greater than about 80% by volume, as well as no greater than about 70% by volume, no greater than about 60% by volume, no greater than about 50% by volume, not more than about 40% by volume, not more than about 30% by volume or even not more than about 20% by volume. Certain forming processes may use a greater amount of filler material than the amount of abrasive grains. For example, almost all abrasive grains can be replaced with one or more filler materials.
In other cases, a higher content of abrasive grains can be replaced by the filler material. In other embodiments, a smaller portion of the abrasive grains can be replaced by the filler.
In addition, the fillers can have an average particle size that is significantly smaller than the average grain size of the abrasive grains. For example, the measured particle size of the charges can be at least about 5% less, such as at least about 10% less, such as at least about 15% less, at least about 20% less or even at least about 25% less than the average granulation size of the abrasive grains based on the average granulation size of the average granulation size of the abrasive grains.
In certain other embodiments, the fillers may have an average particle size that is larger than abrasive grains, particularly in the context of fillers that are hollow bodies.
In particular instances, the load material may have a fracture resistance (Kic) of no more than about 10 MPa m0'5, as measured by a nanoendentation test using the ISO 14577 standard test using a diamond probe available from CSM Indentation Testers, Inc.,
Switzerland or similar companies. In other embodiments, the load may have a fracture strength (Klc) no greater than about 9 MPa m0.5, such as no greater than about 8 MPa m0'- "or even no greater than about 7 MPa m0, 5. Furthermore, the average fracture strength of the loads can be within a range between about 0.5 MPa m0.5 and about 10 MPa m0'5, as well as within a range between about 1 MPa m0.5 about 9 MPa m0.5 or even within a range between about 1 MPa m0.5 about 7 MPa m0.5.
After forming the mixture, the process of forming the bonded abrasive article 20 continues by shearing the mixture in such a way that it has appropriate rheological characteristics. For example, the mixture can be sheared until it has a particular viscosity, such as at least about 0.1 Pascal-seconds (100 Centipoise) and can have a consistency that is semi-liquid (for example, a mud-like consistency. ). In other instances, it could be of a much lower viscosity such as a paste.
After shearing the mixture, the process may continue to form agglomerates of the mixture. The process of forming 30 agglomerates may initially include a process of drying the mixture. In particular, the drying process can be conducted at a temperature suitable for curing an organic component (e.g., thermostable) within the binder contained within the mixture and removing a portion of certain volatiles (e.g., hydration) within the mixture. Thus, after proper curing of the organic material within the binder material, the mixture can have one. hardened or semi-hardened form. Particularly suitable temperatures can be no greater than about 10 250 ° C and, more particularly, within a range between about 0 ° C and about 250 ° C.
After drying the mixture at an appropriate temperature, the process of forming agglomerates can continue to crush the shape. hardened. After crushing the hardened form, the crushed particles include agglomerates of the components contained within the mixture, including the abrasive grains and. connecting material. The process of forming the agglomerates may then include sieving the crushed particulate to obtain an adequate distribution of agglomerate sizes.
After the formation of the agglomerates, the process can continue by modeling the agglomerates in a desirable format of the bonded abrasive article finally formed. A suitable molding process includes filling a mold with the agglomerated particles. After filling the mold, the 25 agglomerates can be designed to form a green (ie, non-sintered) body that has the dimensions of the mold. According to one embodiment, the pressing can be conducted at a pressure of at least about 0.14 Mpa (0.01 ton / in2) of the area of the bonded abrasive article. In other embodiments, the pressure may be greater, such as at least about 1.4 Mpa (0.1 ton / inch), at least about 6.89 Mpa (0.5 ton / inch), when minus about 14 Mpa (1 ton / inch) or even at least about 27.6 Mpa (2 tons / inch). In a particular embodiment, the pressing is completed at a pressure within a range between about 0.14 Mpa (0.01 ton / in2) and 68.9 Mpa (5 ton / in2) or more particularly, within a range between about 6.89 Mpa (0.5 tons / in2) and about 41.4 Mpa (3 tons / in2).
After shaping the mixture to form the green article, the process can continue to treat the green article. Treatment may include heat treating the green article and particularly sintering the green article. In a particular embodiment, the treatment includes liquid phase sintering to form the bonded abrasive body.
Notably, liquid phase sintering includes forming a liquid phase of certain components of the green article, particularly the bonding material, such that at the sintering temperature at least a portion of the bonding material 20 is present in the liquid phase and flow free.
Notably, liquid phase sintering is not a process generally used for the formation of bonded abrasives that use a metal bonding material.
According to one modality, treating green article 25 includes heating the green file to a liquid phase sintering temperature of at least 400 ° C. In other embodiments, the liquid phase sintering temperature may be higher, such as at least 500 ° C, at least about 650 ° C, at least about 800 ° C or even at least about 900 ° C. In particular cases, the temperature of. liquid phase sintering can be within a range between about 400 ° C and about 1,100 ° C, such as between about 800 ° C, and about 1,100 ° C and, more particularly, within a range between about 800 ° C and 1,050 ° C. The treatment and, particularly, sintering can be. driven for a particular duration. The sintering at the liquid phase sintering temperature can be conducted for a duration of at least about 10 minutes, at least about 20 minutes, at least about 30 minutes 10 or even at least about 40 minutes. In particular embodiments, sintering at the liquid phase sintering temperature can last for a range between about 10 minutes and about 90 minutes, such as between about 10 minutes and 60 minutes or even between about 15 and 15 minutes and about 45 minutes.
The treatment of the green article may additionally include conducting a liquid phase sintering process in a particular atmosphere. For example, the atmosphere can be a reduced pressure atmosphere that has a pressure not greater than about 13.332 Pa (IO-2 Torr). In other embodiments, the reduced pressure atmosphere may have a pressure no greater than about 0.133 Pa (10 ~ 4 Torr), no greater than. about 0.013 Pa (IO-5 Torr) or no greater than about 0.001 Pa (10 '° Torr). In particular cases, the non-greater than 25 which can be within a range between about 13.332 Pa (IO'2 Torr) and about 0.001 Pa (10 “6 Torr).
In addition, during the treatment of the green article and particularly during the liquid phase sintering process, the atmosphere can be a non-oxidizing (i.e., reducing) atmosphere 30. Gaseous species suitable for forming the reducing atmosphere may include hydrogen, nitrogen, noble gases, carbon monoxide, disassociated ammonia and a combination thereof. In other embodiments, an inert atmosphere can be used during the treatment of the green article, to limit the oxidation of the metal and metal alloy components.
After completing the treatment process, an abrasive - bonded article that incorporates the abrasive grains with a metal bonding material is formed. According to a modality, the abrasive article may have a body that has particular features. For example, in accordance with one embodiment, the bonded abrasive body may have a significantly greater volume of abrasive grains than the volume of bonding material within the body. The bonded abrasive body 15 can have a VAG / VBM ratio of at least about 1.3, where VAG represents a volume percentage of abrasive grains within the total volume of the bonded abrasive body and VBM represents the percentage volume of material bonding within the total volume of the bonded abrasive body. In agreement with another modality, the SG&A / VBM ratio can be at least about 1.5, such as at least about .1.7, at least about 2.0, at least about 2.1, at least about 2.2 or even at least about 2.5. In other embodiments, the bonded abrasive body can be formed in such a way that the ratio of SGV / VBM is within a range between about 1.3 and about 9.0, such as between about 1.3 and about of 8.0, such as between about 1.5 and about 7.0, such as between about 1.5 and about 6.0, between about 2.0 and about 5.0, between about from 2.0 to about 30 4.0, between about 2.1 and about 3.8 or even between about 2.2 and about 3.5.
More particularly, the bonded abrasive body can include at least about 30% by volume of abrasive grains for the total bonded abrasive body volume. In 5 other occurrences, the content of abrasive grains is higher, such as at least about 45% by volume, at least about 50% by volume, at least about 60% by volume, at least about 70% by volume or even at least about 75% by volume. In particular embodiments, the bonded abrasive body 10 comprises between about 30% by volume and about 90% by volume. volume, such as between about 45% by volume and about 90% by volume, between about 50% by volume and about 85% by volume or even between about 60% by volume and about 80% by volume abrasive grains for the total volume of the 1.5 bonded abrasive body.
The bonded abrasive body can include no greater than about 45% by volume of bonding material for the total volume of the bonded abrasive body. According to certain embodiments, the content of the bonding material is less, such as not more than about 40% by volume,. no greater than about 30% by volume, no greater than about 25% by volume, no greater than about 20% by volume or even no greater than about 15% by volume. In particular embodiments, the bonded abrasive body comprises between about 5% by volume and about 25 45% by volume, as well as between about 5% by volume and about 40%. by volume, between about 5% by volume and about, 30% by volume or even between about 10% by volume and about 30% by volume bonding material for the total volume of the bonded abrasive body.
In accordance with another embodiment, the abrasive body bonded in this document may include a certain amount of porosity. For example, the bonded abrasive body can have at least 5% by volume porosity for the total volume of the bonded abrasive body. In other 5 embodiments, the bonded abrasive body can have at least about 10% by volume, as well as at least about 12% by volume, at least about 18% by volume, at least about 20% by volume, at the same time. minus about 25% by volume, at least about 30% by volume or even at least about 35% by volume porosity for the total volume of the body. Still, in other embodiments, the bonded abrasive body may include no greater than about 80% by volume of porosity for the total body volume. In other articles, the bonded abrasive body may have no greater than about 70% by volume, no greater than about 60% by volume, 55% by volume porosity, as well as no greater than about 50% by volume porosity, no greater than about 48% in porosity volume, not more than about 44% in porosity volume, not more than about 40% in porosity volume or even not more than about 35% in porosity volume for the total body volume. It will be verified that the porosity can be within a range between any of the minimum and maximum values listed in this document.
The bonded abrasive body can be formed such that a certain porosity content within the bonded abrasive body is the interconnected porosity. Interconnected porosity defines a network of interconnected channels (ie, pores) that extend through the volume of the bonded abrasive body. For example, a majority of the body's porosity may be interconnected porosity. In fact, in particular instances, the bonded abrasive body can be formed in such a way that at least 60%, at least about 70%, at least about 80%, at least about 90% or even at least about 95 % of the porosity present within the bonded abrasive body is the interconnected porosity. In certain instances, essentially all the porosity present within the body is the interconnected porosity. Consequently, the bonded abrasive body can be defined by a continuous two-phase network, a solid phase 10 defined by the bond and abrasive grains and a second continuous phase defined by the porosity that extends between the solid phase throughout the bonded abrasive body.
In accordance with another embodiment, the bonded abrasive body may have a particular particulate material (PV) ratio, which includes abrasive grains and fillers, in. comparison to the bonding material (VBM) for the total volume of the bonded abrasive body. It will be verified that the quantities of the particulate material and the material of. connection are measured as a percentage of component volume. as part of the total body volume. For example, the bonded abrasive body of the embodiments in this document can have a ratio (VP / VBM) of at least about 1.5. In other embodiments, the ratio (VP / VBM) can be at least about 1.7, at least about 2.0, at least about 2.2, at least about 2.5 or even at least about 2.8. In particular instances, the ratio (VP / VBM) can be within a range between 1.5, and about 9.0, such as between about 1.5 and 8.0, such as between about 1.5 and about 7.0, between about 1.7 and about 7.0, between about 1.7 and about 30 6.0, between about 1.7 and about 5.5 or even between about of 2.0 and about 5.5. As such, the bonded abrasive body may incorporate a higher content of particulate material that includes abrasive fillers and grains than the bonding material.
According to one embodiment, the abrasive body may include an amount (% by volume) of fillers which may be less. that, equal to or even greater than the quantity (% by volume) of abrasive grains present within the total volume of the bonded abrasive body. Certain abrasive articles may use no more than about 75% by volume of fillers for the total volume of the bonded abrasive body. According to certain modalities, the content of charges in the body can be no greater than about 50% by volume, no greater than about 40% by volume, no greater than about 30% by volume, no greater than about 20 % by volume or even not greater than about 15% by volume. In particular embodiments, the bonded abrasive body comprises between about 1% by volume and about 75% by volume, such as between about 1% by volume and about 50% by volume, between about 1% by volume and about 20% by volume or even between about 1% by volume and about 15% by volume of fillers for the total volume of the bonded abrasive body. In one instance, the bonded abrasive body can be essentially free of loads.
The bonded abrasive bodies of the embodiments in this document may have a particular content of the active bond composition. As will be seen, the active bonding composition can be a reaction product formed from a reaction between the active bonding composition precursor and certain components of the bonded abrasive body including, for example, abrasive grains, fillers and bonding material. The active bonding composition can facilitate the chemical bond between the particulates (e.g., abrasive grains or filler) within the body and the bonding material, which can facilitate the retention of particulates within the bonding material.
In particular, the active bonding composition can include distinct phases, which can be arranged in different regions of the bonded abrasive body. In addition, the active binding composition can have a particular composition depending on the location of the composition. For example, the active binding composition can include a precipitated phase and an interfacial phase. The precipitated phase can be present within the bonding material and can be dispersed as a separate phase throughout the volume of the bonding material. The interfacial phase can be arranged at the interface between the particulate material (i.e., abrasive grains and / or fillers) and the bonding material. The interfacial phase can extend around a majority of the surface area of the particulate material in the body. Although not fully understood, it is theorized that the distinct phases and differences in the composition of the active bond composition are due to the formation processes, particularly the liquid phase sintering.
Consequently, the bonding material can be one. composite material which includes a bonding phase and a precipitated phase which are separate phases. The precipitated phase can be made of a composition that includes at least one element of the active bonding composition and at least one element of the bonding material. Notably, the precipitated phase can include at least one metal element 30 originally supplied in the mixture as the bonding material. The precipitated phase can be a metal or metal alloy compound or complex. In particular embodiments, the precipitated phase may include a material selected from the group of materials consisting of titanium, vanadium, chromium, zirconium, hafnium, tungsten and a combination thereof. In more particular instances, the precipitated phase includes titanium and may consist essentially of titanium and tin. .
The bonding step of the bonding material can include a transition metal element and particularly a metal element included in the original bonding material used to form the mixture. As such, the bonding phase can be formed from a material selected from the group of metals consisting of copper, tin, silver, molybdenum, zinc, tungsten, iron, nickel, antimony and a combination thereof. In particular instances, the bonding phase may include copper and may be a copper-based compound or complex. In certain embodiments, the connection phase consists essentially of copper.
The interfacial phase can include at least one element of the active bonding composition. In addition, the interfacial phase can include at least one element of the particulate material. As such, the interfacial phase can be a compound or complex formed through a chemical reaction between the active bonding composition and the particulate. Certain interfacial phase materials include carbides, oxides, nitrides, borides, oxynitrides, oxyborides, oxycarbons and a combination thereof. The interfacial phase can include a metal and, more particularly, it can be a compound that incorporates a metal, such as a metal carbide, metal nitride, metal oxide, metal oxinitride, metal oxybide or metal oxycarbonate. According to one embodiment, the interfacial phase essentially consists of a material from the group of titanium carbide, titanium nitride, titanium boronitride and titanium and aluminum oxide and a combination thereof.
In addition, the interfacial phase can have an average thickness of at least about 0.1 microns. However and more particularly, the interfacial phase can have a variable thickness depending on the size of the particulate material that the interfacial phase overlaps. For example, in relation to abrasive grains and / or fillers that have an average size of less than 10 microns, the interfacial phase can have a thickness within a range between about 1% to 205 of the average particle size. For particulate material that has an average size within a range between about 10 microns and about 50 microns, the interfacial phase can have a thickness within a range between about 1% to about 10% of the average size of the particulate. For particulate material that has an average size within a range between about 50 microns and about 500 microns, the interfacial phase can have a thickness within a range between about 0.5% to about 10% of the size particulate average. For particulate material that has an average size greater than about 500 microns, the interfacial phase can have a thickness within a range between about 0.1% to about 0.5% of the average particle size.
Figures 8 to 11 include enlarged images of the microstructure of an abrasive body connected in accordance with one embodiment. Figure 8 includes a scanning electron microscope image (operated in a backscatter mode) of a cross-section of a portion of a bonded abrasive body that includes abrasive grains 801 and bonding material 803 that extends between the abrasive grains 801. As shown, the bonding material 803 includes two distinct phases of the material, a precipitated phase 805 represented by a lighter color and extending through the volume of bonding material 80'3 and a bonding phase 806 represented by a darker color that extends through the volume of the bonding material 803.
Figures 9 to 11 include enlarged images of the same area of the bonded abrasive body as Figure 8, using a micro probe analysis to identify the selected elements present in certain regions of the body. The Figure includes a microprobe image of the region of Figure 8 in a set of modes to identify the regions with a high copper content, such that the lighter regions indicate where the copper is present. According to one embodiment, the bonding material 803 may include a copper and tin metal alloy. According to a more particular embodiment, the bonding phase 806 of the bonding material 803, which is one of at least two distinct phases - of the bonding material 803, may have a greater amount of copper present than the precipitated phase 805.
Figure 10 includes an enlarged image of the region of Figures 8 and 9, using a micro probe analysis to identify the selected elements present in certain regions of the body. Figure 10 uses a microprobe in a set mode to identify the regions with tin present, such that the lighter regions indicate where the tin is most prevalent. As illustrated, the precipitated phase 805 of the bonding material 803 has a higher tin content than the bonding phase 806.
Figure 11 includes an enlarged image of the region from Figure 8 to 10, using the micro probe analysis. In particular, Figure 11 uses a microprobe in a mode set to identify the regions that have titanium present, in such a way that the lighter regions 10 indicate where titanium is most prevalent. As shown, the precipitated phase 805 of the bonding material 803 has a higher titanium content than the bonding phase 806.
Figure 11 also provides evidence of interfacial phase 1101 at the interface of abrasive grains 801 and bond material 803. As evidenced by Figure 11, interfacial phase 1101 includes a particularly high content of titanium, indicating that the titanium of the composition precursor active bonding agent can preferentially migrate to the particulate interface (i.e., abrasive grains 801) and react chemically with the abrasive grains to form an interracial phase compound as described in the present document.
Figures 8 to 11 provide evidence of an unexpected phenomenon. Although not fully understood, the original bonding material comprising copper and tin is separated during processing which is theorized to be due to the liquid fade sintering process. Tin and copper become distinct phases; the precipitated phase 805 and the binding phase 806, respectively.
In addition, the tin preferably combines with the titanium present in the precursor material of active bonding composition to form the precipitated phase 805.
In accordance with one embodiment, the bonded abrasive body may include at least about 1 volume% of the active bonding composition 5, which includes all phases of the active bonding composition, such as the interfacial phase and the precipitate phase for the total volume of the bonding material. In other instances, the amount of active bond composition within the bond may be greater, such as at least about 10% by volume, at least about 6% by volume, at least about 10% by volume, at least about 12% by volume, at least about 14% by volume, at least about 15% by volume or even at least about 18% by volume. In particular instances, the bonding material contains an amount of active bonding composition within the range of between about 1% by volume and about 40% by volume, such as between about 1% by volume and 30% by volume, between about 1% by volume and about 25% by volume, between about 4% by volume and about 25% by volume, or between about 20 6% by volume and about 25% by volume. In some instances, the amount of active binding composition is within a range of between about 10% by volume and about 30% by volume, between about 10% by volume and about 25% by volume or even between about 12% by volume and about 20% by volume of the total volume of the bonding material.
The bonded abrasive body can be formed so that the bonding material can have a fracture resistance. particular (Kic). The strength of the bonding material can be measured by means of a micro-indentation test or a nano-indentation test. Micro-indentation testing measures fracture resistance through a principle of crack generation in a polished sample by loading an indentator to a particular location within the material, 5 including, for example, in the present case, the bonding material . For example, a suitable micro-indentation test can be conducted according to the methods disclosed in "Indentation of Brittle materials", Microindentation Techniques in Materials Science and Engineering, ASTM STP 889, D.B.Marshall and B.R. Lawn pages 26 to 46. According to one modality, the bonded abrasive body has a bonding material that has a mean fracture resistance (Kic) not greater than about 4.0 MPa m0.5. In other embodiments, the strength the average fracture (Kic) of the bonding material can be no greater than about 3.75
MPa m0.5, such as not greater than about 3.5 MPa m0.5, not greater than about 3.25 MPa m0.5, not greater than about 3.0 MPa m0.5, not greater than about 2.8 MPa m0.5, or even no greater than about 2.5 MPa m0.5. The average fracture strength of the bonding material can be within a range between about 0.6 MPa m0.5 and about 4.0 MPa m0.5, such as within a range between about 0.6 MPa m0, 5 about 3.5 MPa m0'5, or even within a range between about 0.6 MPa m0.5 and about 3.0 MPa m0.5. Abrasive articles in the embodiments of this document may have particular properties. For example, the bonded abrasive body may have a rupture module (MOR) of at least about 13.79 MPa (2,000 psi), such as at least about 27.58 MPa (4,000 psi) and more particularly, at least about 41.32 MPa (6,000 psi). - -
The bonded abrasive bodies of the modalities of this document demonstrate particular properties when used in certain crushing operations. In particular, bonded abrasive wheels can be used in non-covered crushing operations, in which the bonded abrasive body does not require a covering operation after the body has undergone a profiling operation. Traditionally, profiling operations are completed to give the abrasive body a desired contour and shape. After profiling, the abrasive body is covered, typically with a harder or equally hard abrasive element to remove worn grain and expose new abrasive grains. Covering is a necessary and time-consuming process for conventional abrasive articles to ensure proper operation of the abrasive article. The bonded abrasive bodies of the modalities of this document have been found to require significantly less coverage during use. and have performance parameters that are significantly improved over conventional abrasive articles. For example, in a modality, during an uncoated grinding operation, the bonded abrasive body of a modality, can have an energy variance not greater than about 40%, in which an energy variance is described by the equation [(Po - Pn) / Po] x 100%. Po represents the grinding energy (kW or kW / cm (kW (Hp) or kW (Hp) / in)) for grinding a workpiece with the abrasive body connected in an initial grinding cycle and Pn represents the grinding energy (kW or kW / cm (kW (Hp) or kW (Hp) / in)) to grind the workpiece for an nth cycle of grinding, where n> 4. In this way, the energy variance measures the change in the crushing energy from an initial crushing cycle to a subsequent crushing cycle, in which at least 4 crushing cycles are performed.
In particular, the grinding cycles can be completed in a consecutive manner, which means that no profiling or covering operations are carried out on the abrasive article bonded between the grinding cycles. The bonded abrasive bodies of the embodiments in this document may have an energy variance of no more than 10 about 25% during certain grinding operations. In still other embodiments, the energy variance of the bonded abrasive body can be no greater than about 20%, as well as no greater than about 15%, or even no greater than about 12%. The energy variance of certain bodies. Abrasives can be within a range of between about 1% and about 40%, such as between about 1% and about 20%, or even between about 1% and about 12%.
In further reference to the energy variance, it will be noticed that the change in the crush energy between the initial crush cycle (Po) and the crush energy used to crush the workpiece in an nth crush cycle (Pn) can be measured by a number of shredding cycles where "n" is greater than or equal to 4. In other cases, "n" may be greater than or equal to 6 (that is, at least 25 minus 6 shredding cycles), greater or equal to 10, or even greater than or equal to 12. In addition, it must be realized that the nth grinding cycle can represent consecutive grinding cycles, in which the coverage is not completed on the abrasive article between the grinding cycles .
According to one modality, the bonded abrasive body can be used in crushing operations, where the material removal rate (MRR ') is at least about 1.0 in3 / min / in [10 mm3 / sec / mm ]. In other embodiments, a grinding operation using an abrasive body 5 connected to the embodiments of this document, can be conducted at a material removal rate of at least about 4.0 in3 / min / in [40 mm3 / sec / mm], such as at least about 6.0 in3 / min / in [60 mm3 / sec / mm], at least about 7.0 in3 / min / in [70 mm3 / sec / mm], or even at least about 10 8.0 in3 / min / in [80 mm3 / sec / mm]. Certain shredding operations using the bonded abrasive bodies of the modalities of this document can be carried out at a material removal rate (MRR ') within a range between about 1.0 in3 / min / in [10 mm3 / sec / mm] and about 20 15 in3 / min / in [200 mm3 / sec / mm], within a range between about 5.0 in3 / min / in [50 mm3 / sec / mm] and about 18 in3 / min / in [180 mm3 / sec / mm], within a range between about 6.0 in3 / min / in [60 mm3 / sec / mm] and about 16 in3 / min / in [160 mm3 / sec / mm] 'or even within a range 20 between about 7.0 in3 / min / in [70 mm3 / sec / mm] and about 14 in3 / min / in [140 mm3 / sec / mm].
In addition, the bonded abrasive body can be used in crushing operations where the bonded abrasive body is rotated at particular surface speeds. 25 Surface speed refers to the speed of the wheel at the point of contact with the workpiece. For example, the bonded abrasive body can be rotated at a speed of at least 2,335.35 normal cubic meters per hour (NCMH) (1,500 square feet per minute (sfpm)), as well as at least 30 about 2,802.42 NCMH ( 1,800 sfpm), such as at least about 3,113.8 NCMH (2,000 sfpm), at least about 3,892.25 NCMH (2,500 sfpm), at least about 7,784.5 NCMH (5,000 sfpm), or even at least 15,569 NCMH (10,000 sfpm). In particular cases, the bonded abrasive body can be rotated at a speed within a range between about 3,113.8 NCMH (2,000 sfpm) and about 23,353.5 NCMH (15,000 sfpm), as well as between about 3,113.8 NCMH (2,000 sfpm) and 18,682.8 NCMH (12,000 sfpm).
The bonded abrasive body may be suitable for use in various grinding operations, including, for example, plunger grinding operations, drag feed grinding operations, peeling grinding operations, grooving operations and the like. In a particular case, the bonded abrasive body is suitable for use in 15 end mill milling applications. In other cases, the bonded abrasive body can be useful in thinning hard and delicate workpieces, including, for example, sapphire and quartz materials.
In addition, the bonded abrasive bodies of modalities of the present document can be used in crushing operations, where after crushing, the workpiece has a medium surface roughness (Ra) that is not greater than about 50 microinches ( about 1.25 microns). In other cases, the average surface roughness of the workpiece can be no greater than about 40 microlegs (about 1 micron), or even no greater than about 30 microlegs (about 0.75 microns).
In other embodiments, when grinding with abrasive articles linked to embodiments of this document, the average surface roughness variance for at least three consecutive grinding operations may not be. greater than about 35%. It should be noted that consecutive shredding operations are operations in which a profiling operation is not conducted between each of the 5 shredding operations. The variance in the average surface roughness can be calculated as a standard deviation of the measured average surface roughness (Ra) of the workpiece at each of the locations on the workpiece, where each separate milling operation is conducted. In . 10 agreement with certain modalities, the average surface roughness variance for at least three consecutive grinding operations may not be greater than about 25%, not greater than about 20%, not greater than about 15%, not greater than about 10%, or even no greater than 15 about 5%.
In accordance with other embodiments, the bonded abrasive article may have a G ratio of at least about 1,200. The ratio G is the volume of material removed from the workpiece divided by the volume of material lost from the abrasive body 20 connected through wear. In accordance with another embodiment, the bonded abrasive body can have a G ratio of at least about 1,300, such as at least about 1,400, at least about 1,500, at least about 1,600, at least about 1,700, or even at least about 1,800. In certain cases, the G ratio of the bonded abrasive body can be within a range of between about 1,200 and about 2,500, such as between about 1,200 and about 2,300, or even between about 1,400 and about 2,300. The values of the ratio G. quoted in this document can be achieved at the material removal rates quoted in this document. In addition, the described G-ratio values can be achieved in a variety of types of workpiece material described in this document.
In other words, the bonded abrasive article can have a G ratio which is significantly improved over conventional abrasive articles, particularly metal bonded abrasive articles. For example, the G ratio of "bonded" abrasive bodies according to the modalities of this document can be at least about 5% greater than 10 the G ratio of a conventional abrasive article. In other cases, the improvement in the ratio G can be larger, such as at least about 10%, at least about 15%, at least about 20%, at least about 25%, or even at least about 30%. 15 demonstrate an increase in the G ratio compared to a conventional bonded abrasive within a range of between about 5% and about 200%, between about 5% and about 150%, between about 5% and about 125% , between about 5% and about 100%, between about 10% and about 75% or even 20 between about 10% and about 60%.
Certain bonded abrasive bodies demonstrate an initial crushing energy that is close enough to a steady-state crushing energy. In general, the steady-state grinding energy is significantly different from an initial grinding energy for conventional metal bonded abrasive articles. As such, the increase in crushing energy from an initial crushing energy is particularly low for the bonded abrasive bodies of embodiments of this document compared to conventional metal bonded abrasive articles. For example, the bonded abrasive bodies of the modalities of this document may have an increase in the initial crushing energy of no more than about 40% as defined by the equation [(Pn - Po) / Po] x 100%. In equation 5, Po represents the initial crushing energy (kW or kW / cm ((Hp) or kW (Hp) / in)) to crush the workpiece with the abrasive body connected in a 'crushing-initial- cycle and Pn_ represents the grinding energy (kW or kW / cm ((Hp) or kW (Hp) / in)) to grind the workpiece with the abrasive body connected in an n-th grinding cycle, where n > 16. It should be noted that the shredding cycles can be consecutive shredding cycles, in which no profiling or covering of the bonded abrasive body is conducted.
According to one embodiment, during a grinding operation using the bonded abrasive article of embodiments of this document, the increase in initial crush energy is not greater than about 35%, nor is it greater than about 30%, not greater than about 25%, not greater than about 20%, not greater than about 18%, not greater than about 15%, not greater than about 12%, not greater than about 10%, or even not more than about 8%.
In particular cases, the bonded abrasive body can conduct crushing operations in which the increase in. initial milling energy can be within a range of about 0.1% to about 40%, such as within a range of about 0.1% to about 30%, within a range of about 1 % and about 15%, within a range between about 1% and about 12%, or even within a range between about 1% and about 8%.
In other embodiments, the bonded abrasive bodies demonstrate an increase in initial crushing energy of no more than about 10% for a crushing time of at least 400 seconds at a minimum feed rate of about 0.127 cm / s (3 inches) / min). The increase in the initial crushing energy can be defined by the equation [(P400 Po) / Po] x 100%, where Po represents the “initial (kW or kW / cm ((Hp). Or kW _ (Hp) crushing energy ) / in)) to initially crush the workpiece with the abrasive body 10 connected in a first crushing cycle and P400 represents the crushing energy (kW or kW / cm ((Hp) or kW (Hp) / in)) to grind the workpiece with the abrasive body on after 400 seconds of grinding. In certain other grinding operations, the bonded abrasive body 15 may have an increase in the initial grinding energy of not more than about 8%, such as not more than about 6%, such as not more than about 4%, or even not greater than about 2% for a grinding time of at least 400 seconds at a minimum feed rate of about 0.127 20 cm / s (3 inches / min). In particular grinding applications, the bonded abrasive body demonstrates an increase in the initial grinding energy within a range of between about 0.1% and about 10%, such as between about 0.1% and about 8% , such as between about 0.1% and about 6%, 25 or even between about 0.1% and about 4%, for a grinding time of at least 400 seconds at a minimum feed rate of about 0.127 cm / s (3 inches / min).
The bonded abrasive bodies of embodiments of this document may have a particular grinding performance, '' '------ -, J in which the increase in initial grinding energy is not greater than about 20% for a time crushing time of at least about 800 seconds at a minimum feed rate of at least 0.127 cm / s (3 inches / min). The 5 increase in the initial crushing energy for such applications can be defined by the equation [(P8oo ~ Po) / Po] x 100%, where Po represents the initial crushing energy (kW or kW / cm ((Hp) oü ' kW - (Hp) / in)) - to initially crush the workpiece with the abrasive body connected in a first crushing cycle and P8oo represents the crushing energy (kW or kW / cm ((Hp) or kW (Hp ) / in)) to crush the workpiece with the abrasive body on after 800 seconds of crushing. In addition, for certain abrasive articles linked to the modalities of this document, the increase in initial crushing energy may be less, such as no greater than about 15%, no greater than about 10%, or even no greater than about 8 % for a time of at least 800 seconds at a minimum feed rate of 0.127 cm / s (3 inches / min). The bonded abrasive bodies. of this document may have an increase in the initial milling energy within a range of between about 0.1% and about 20%, such as between about 0.1% and about 18%, such as between about 0 , 1% and about 15%, or even between about 0.1% and about 8%, for a grinding time of at least 800 seconds at a minimum feed rate of about 0.127 cm / s (3 inches) / min). These properties can be particularly suitable for the operation of the bonded abrasive body ■ when crushing hard or very hard workpieces.
In accordance with another modality, the abrasive body. . on may have a limited increase in initial milling energy for a milling time of at least 800 seconds at a minimum feed rate of at least about 0.254 cm / s (6 inches / min). For example, the increase in initial crush energy may not be greater than about 20%, as well as no greater than about 15%, no greater than about 12%, or even no greater than about 10%, for a "crushing time" of at least 800 seconds at a minimum feed rate of about 0.254 cm / s (610 inches / min). These properties may be particularly suitable for the operation of the bonded abrasive body when grinding pieces of hard or very hard work.
The bonded abrasive bodies of the embodiments of this document may be suitable for crushing certain workpieces, such as particularly hard workpieces.
For example, workpieces can have a Vickers hardness of at least 5 GPa. In other cases, the average Vickers hardness of workpieces can be at least about 10 GPa or even at least about 15 GPa.
Workpieces can be made of metal, metal alloys, nitrides, borides, carbides, oxides, oxynitrides., Oxyborates, oxycarbons, in a combination thereof. In particular cases, the workpieces can be metal carbides, including, for example, tungsten carbide. In exemplary conditions where crushing is carried out on workpieces made of tungsten carbide, the amount of cobalt inside the tungsten carbide workpiece can. be within a range between about 5% and about 12% by weight.
When conducting certain crushing operations, for example, on particularly hard materials, the bonded abrasive body can be operated at a rate of at least 2,802, 42 NCMH (1,800 sfpm). In other cases, the bonded abrasive body can be rotated at a rate of at least 2,958.11 NCMH (1,900 sfpm), at least about 3,425.18 NCMH (2,200 sfpm), or even at least 3,658.71 NCMH (2,350 sfpm). In particular cases, 'body-abrasive - bonded ... can be rotated at a rate within the range of about 2,802.42 NCMH 10 (1,800 sfpm) to about 4,826.39 NCMH (3,100 sfpm), more particularly, within a range between about .2,958.11 NCMH (1,900 sfpm) and about 3,658.71 NCMH (2,350 sfpm) during milling operations.
In addition, bonded abrasive articles of embodiments 15 of this document are suitable for certain grinding operations, such as, for example, on particularly hard workpieces at certain feed rates. For example, the feed rate can be at least about 0.084 cm / s (2 inches / min). In other cases, the feed rate may be higher, such as at least about 0.127 cm / s (3 inches / min), at least about 1.481 cm / s (3.5 inches / min), or at least about 0.169 cm / s (4 inches / min). Particular modalities may use the bonded abrasive body in a grinding operation in which the feed rate is within a range between about 0.084 cm / s (2 inches / min) and about 0.423 cm / s (10 inches / min ), such as between about 0.127 cm / s (3 inches / min) and about 0.338 cm / s (8 inches / min). In another embodiment, the bonded abrasive body can be used in a grinding operation in which after profiling the bonded abrasive body with an abrasive profiling wheel, the bonded abrasive body can crush a workpiece that has a medium Vickers hardness of at least 5 GPa is at least 17 consecutive 5-milling cycles without exceeding the maximum axis energy of the milling machine. As such, the bonded abrasive bodies demonstrate an improved working life particularly - in the context of shredding workpieces from rigid material. In fact, the bonded abrasive body 10 can conduct at least about 20 consecutive grinding cycles, at least about 25 consecutive grinding cycles or at least about 30 consecutive grinding cycles before a profiling operation is used. It should be noted that the reference to the consecutive grinding cycles is a reference to the grinding cycles conducted in a continuous manner without profiling or covering the abrasive body connected between grinding cycles.
When comparing modal bonded abrasive bodies 20 of this document with conventional bonded abrasive bodies, in general, conventional bonded abrasive articles conduct no more than about 16 consecutive grinding cycles in comparatively hard workpieces before needing a grinding operation. 25 profiling for sharpening and resurgence. As such, the bonded abrasive bodies of the embodiments of this document demonstrate an operable grinding time improvement over conventional metal-bonded bonded abrasives, as measured by the number of consecutive milling cycles conducted before a profiling operation is required or the milling energy exceeds the milling machine's energy capabilities. Another notable improvement in shredding performance, as measured in the industry, is parts / coverage, which is a measure of the number of parts that can be machined by a particular abrasive article before the abrasive article needs coverage to maintain performance. According to 'one' - modality, .ps linked abrasive bodies of the modalities of the present document can have an increase in the crushing efficiency in a workpiece, as measured by parts / cover, of at least about 10% in compared to a conventional metal-bonded abrasive article. According to another embodiment, the increase in crushing efficiency is at least about 20%, as well as at least 15% about 30%, at least about 40%, or even at least about 50% compared to abrasive articles conventional metal bonded. Notably, such conventional metal-bonded abrasive articles may include state-of-the-art articles such as G-Force and Spector abrasive articles available from. Saint-Gobain Corporation. In particular cases, the increase in crushing efficiency as measured by parts / cover can be within the range of between about 10% and about 200%, as well as between about 25 20% and about 200%, between about 50% and about 200%, or even between about 50% and about 150%. It should be noted that such improvements can be achieved in workpieces described in this document under crushing conditions described in this document.
In addition, abrasive articles linked to the modalities of this document may have an improvement in crushing performance as measured in the industry by wear rate, which is a measure of the disposal that an abrasive article undergoes during crushing. According to one embodiment, the bonded abrasive bodies of the embodiments of the present document can have an improvement in the wear rate, so that the abrasive article wears out at a rate that is at least 5% less than the wear rate of one. . abrasive article bonded by conventional metal. According to another embodiment, the wear rate is at least about 8% lower, such as at least about 10%, at least about 12%, or even at least about 15% compared to bonded abrasive articles by conventional metal. In particular cases, the improvement in the wear rate can be within a range of between about 5% and about 100%, such as in the order of between about 5% and about 75%, between about 5% and about 0%, or even between about 5% and about 50%. It should. realize that such improvements can be achieved in workpieces described in this document under crushing conditions described in this document.
Another notable improvement in shredding performance as measured in the industry is the wear rate, which is a measure of the wear that an abrasive article over during shredding. According to one embodiment, the bonded abrasive bodies of the embodiments of this document may have an improvement in the wear rate, so that the abrasive article wears out at a rate that is at least 5% less than the wear rate of an article abrasive bonded 30 by conventional metal. According to another modality, the wear rate is at least about 8% lower, as is the case. at least about 10%, at least about 12%, or even at least about 15% compared to conventional metal bonded abrasive articles. In particular cases, the improvement in the wear rate can be within a range of between about 5% and about 100%, such as in the order of between about 5% and about 75%, between about 5% and about 60%, or even between about 5% and about 50%. It should be noted that such improvements can be achieved in workpieces described in this document under crushing conditions described in this document.
Another noted improvement in shredding performance demonstrated by the abrasive articles of the modalities of this document includes an increase in the usable shredding rate. Shredding rate is the speed at which a workpiece can be molded without sacrificing surface finish or exceeding the shredding energy of the machine or bonded abrasive article. According to one embodiment, the bonded abrasive bodies of the embodiments of this document can have an improvement in the wear rate, so that the abrasive article can grind at a rate that is at least 5% faster than an abrasive article bonded by ■ conventional metal. In other cases, the shredding rate may be higher, such as at least about 8% less, at least 25 less than 10%, at least about 12%, at least about 15%, at least about 20% , or even at least about 25% compared to conventional metal bonded abrasive articles. For certain abrasive articles bonded herein, the improvement in the shredding rate may be within a range of between about 5% and about 100%, such as in the order of between about 5% and about 75%, between about 5% and about 60%, or even between about 5% and about 50%. It should be noted that such improvements can be achieved in workpieces described in this document under crushing conditions described in this document.
Notably, such improvements in the shredding rate can be achieved while maintaining other shredding parameters cited in this document. For example, the 10 improvements in the shredding rate can be achieved while also having a limited increase in the initial shredding energy as quoted in this document, the limited variance in surface finish as quoted in this document and limited wear rate 15. as quoted in this document.
Figure 12 includes an enlarged image of an abrasive body bonded according to an embodiment. As shown, the bonded abrasive body includes abrasive grains 1201 contained within and surrounded by a bonding material 20 1202 which includes a metal or metal alloy material. As further illustrated, the bonded abrasive body has a substantially open structure, including pores 1203 extending between abrasive grains 1201 and bonding material 1202. As evident from Figure 12, the bonded abrasive body includes a significant amount ( abrasive grains 1201 by volume, so that the structure primarily contains abrasive grains 1201 which are bonded together by the bonding material 1202. In addition, the abrasive grains 1201 are in close proximity to each other and little 30 bonding material 1202 separates the abrasive grains 1201, demonstrating the high ratio between abrasive grains 1201 and bonding material 1202. EXAMPLES Example 1
A first sample of bonded abrasive is poured onto a 10.16 cm (4 ") diameter wheel that has a 1A1 shape as understood in the industry. Sample formation includes creating a mixture that includes 45.96 grams of powdered bronze (ie 60:40 copper weight: tin) which has a size of 325 US mesh obtained from the Connecticut Engineering Associate Corporation located at 27 Philo Curtis Road, Sandy Hook, CT 06482, USA. Powdered bronze is dry mixed with 5.11 grams of titanium hydride of the same size purchased from Chemetall Chemical 15 Products, New Providence New Jersey, USA The cubic boron nitride abrasive grains which have a US mesh size of -120 / + 140 are also mixed with powdered bronze and titanium hydride.The abrasive grains are from Saint-Gobain Ceramics and Plastics, Worcester, MA and 20 commercially available as CBN-V.
After adding the abrasive grains, 8.15 grams of organic binder is added to the mixture and the mixture is sheared to a slurry consistency. The organic binder includes a thermoplastic resin sold under the trade name S-binder 25 by Wall Colmonoy Co. and a K424 binder from Vitta Corporation. The mixture is then oven dried to remove hydration. The dry mixture is crushed and sieved to obtain agglomerates. The pellets are placed in a steel mold that has an annular shape and that defines a nominal diameter of 10.16 centimeters (4 inches) and an internal diameter of 8.13 centimeters (3.2 inches). The pellets are pressed to 2.4 tonnes / 6.42 cm2 (2.4 tonnes / inch) to form a green article. The green article is sintered at 950 ° C for 30 minutes in a reduced atmosphere that has a pressure of approximately 1.33 KPa (10 ~ 4 Torr). The bonded abrasive finally formed has a ratio (VAG / VBM) of 3.0 and a quantity of porosity (100% interconnected porosity) of 34 percent of volume and total body volume.
A steel core is attached to the abrasive body bonded with the use of epoxy and still finalized, balanced and speed tested to complete the wheel manufacturing process. The wheel was marked as Sample 1 for identification.
Sample 1 is used to grind a 152100 steel bearing workpiece 52100, originally hardened to 58 to 62 HRC, in an external cylindrical piston grinding mode in a Bryant OD / ID crusher. The workpieces are in the form of steel disks 52100, 10, 16 centimeters (4 inches) in diameter and the milling operation is a milling by external cylindrical piston. Initially, before crushing, Sample 1 is mounted on the machine shaft and profiled with a BPR diamond roller, commercially available from Saint-Gobain Abrasives, Arden, NC, as a BPR roller. The profiling parameters are 25 shown in Table 1. Table 1

Sample 1 is not covered with an abrasive adhesive after profiling, as the abrasive granulations are sufficiently exposed, preparing the abrasive bodies for an uncoated grinding operation. The crushing parameters 5 are given in Table 2. Table 2

Figure 1 includes a plot of shredding energy (kW / cm (Hp / in)) versus number of shredding cycles for Sample 1 under the shredding conditions provided in Table 2 at the two different material removal rates (MRR ' ) (i.e., 10 mm3 / sec / mm (1 in3 / min / in) and 20 mm3 / sec / mm (2 in3 / min / in)). As shown, plot 101 demonstrates that Sample 1 can crush the workpiece at an MRR 'of 10 mm3 / sec / mm (1 in3 / min / in) at an initial crushing energy of 3.18 kW / cm ( 11 Hp / in) and a crushing energy 10 after 5 consecutive crushing cycles of 2.89 kW / cm (10 Hp / in). Plot 102 shows that Sample 1 can grind the workpiece at an MRR 'of 20 nun3 / sec / mm (2 in3 / min / in) at an initial grinding energy of 2.6 kW / cm (19 Hp / in) and a shredding energy after 5 consecutive shredding cycles of 4.63 kW / cm (16 Hp / in). The energy variance for Sample 1 when grinding the workpiece at an MRR 'of 10 mm3 / sec / mm (1 in3 / min / in) was 9% and the energy variance for Sample 1 when grinding the workpiece work at an MRR 'of 20' mm3 / sec / mm (2 in3 / min / in) was 16%. In this way, the
Sample 1 shows little variance between an initial milling energy and a steady-state milling energy after 5 consecutive milling operations. The workpiece was approximately 0.64 cm (0.25 inch) wide and the abrasive wheel samples were formed to be 1.27 cm (0.5 inch) wide. The width used to calculate the MRR 'was 0.64 centimeters (0.25 inches); the width of the workpiece.
Figure 1 also includes two 20-crushing energy plots (kW / cm (HP / in)) versus the number of crushing cycles for a conventional metal-bonded abrasive article (Sample MBS1) commonly available as a G-Force B181- wheel 75UP061 with Saint-Gobain Corporation.
As shown, plot 103 demonstrates that the
Sample MBS1 can crush the workpiece at an initial crushing energy of 11.56 kW / cm (40 kW (Hp) / in) at an MRR 'of 10 mm3 / sec / mm (1 in3 / min / in). After 5 consecutive grinding cycles, the MBS1 Sample grinds at an energy of 2.89 kW / cm (10 kW (Hp) / in) for an MRR 'of 10 mm3 / sec / mm (1 in3 / min / in). The MBS1 Sample demonstrates an energy variance in a non-covered ■ 5% shredding operation.
Plot 104 demonstrates that the MBS1 Sample can crush the workpiece at an initial milling energy of 5 14.45 kW / cm (50 kW (Hp) / in) at an MRR 'of 20 mm3 / sec / mm (2 in3 / min / in). After 5 consecutive grinding cycles, the MBS1 Sample grinds at an energy of 2.89 kW / cm (10 kW (Hp) / in) for an MRR 'of 20 mm3 / sec / mm (2 in3 / min / in). The MBS1 Sample demonstrates an energy variance in an uncoated grinding operation of 84%. Clearly, in a non-covered grinding operation, the bonded abrasive articles of the embodiments of this document demonstrate significantly improved performance of grinding energy variance with respect to the prior art abrasive wheels 15.
Figure 2 includes a plot of surface finish or surface roughness (Ra) versus number of shredding cycles for Sample 1 under the shredding conditions provided in Table 2 at the two different material removal rates (MRR ') ( that is, 10 mm3 / sec / mm (1 in3 / min / in) and 20 mm3 / sec / mm (2 in3 / min / in)). As demonstrated, the Sample, represented by plots 201 and 202, provides a surface finish (Ra) on the workpiece after consecutive grinding cycles not greater than 25 than about 0.75 microns (about 30 microinches) at both rates of material removal. In addition, the variance (that is, the standard deviation of all measurements) of all surface finish values measured between the initial milling operation and the fifth milling cycle does not vary by more than 2.
Figure 2 also includes surface finish or surface roughness (Ra) versus number of shredding cycles for Sample BMS1 under the shredding conditions provided in Table 2 at the two different material removal rates (MRR ') (ie , 10 mm3 / sec / mm (1 in3 / min / in) and 20 mm3 / sec / mm (2 in3 / min / in)). As demonstrated by plots 203 and 204, which represent the surface finish achieved by the MBS1 Sample at both material removal rates, it was initially 10 0.75 micron (30 microns) at both material removal rates and rises significantly through additional consecutive shredding at values of 1.25 microns (50 microinches) and about 1.5 microns (60 microinches) at material removal rates of 10 15 mm3 / sec / mm (1 in3 / min / in) and 20 mm3 / sec / mm (2 in3 / min / in), respectively. The average surface finish for Sample MBS1 at both material removal rates was approximately 1 micron (40 microns) and the variance in surface finish (standard deviation) was approximately 10 at both material removal rates. Clearly, Sample 1 can provide superior surface finish on the workpiece after consecutive grinding cycles compared to Sample MBS1. Example 2
Sample 2 is created using the same process as Sample 1 provided in this document. Sample 2 includes an amount of molten silica filler material, which has been replaced by 25% of the abrasive grain material. The fused silica was -120 / + 140 U.S. mesh and sought from Washington Mills. The bonded abrasive finally formed has a ratio (VP / VBM) of 2.3 and a quantity of porosity (100% interconnected porosity) of 29% volume percentage of the total body volume. For comparison, a B126-M160VT2B specification vitrified CBN wheel was also included in the test as Sample Cl. Such a grinding wheel is commonly available from Saint-Gobain Corporation as an abrasive wheel B126-M160VT2B.
Figure 3 includes a milling energy plot (kW / cm (Hp / in)) versus number of milling cycles for Sample 1 as plot 301, Sample 2 as plot 303 and Sample Cl as plot 305, under the shredding conditions provided in Table 2. The material removal rate of 20 mm3 / sec / mm (2 in3 / min / in) is used during shredding. As demonstrated by plot 301, Sample 1 can grind the workpiece to an initial grinding energy of 5.21 kW / cm (18 Hp / in) and a grinding energy after 5 consecutive grinding cycles of 4.63 kw / cm (16 Hp / in), for an energy variance of approximately 16%. Prolatem 303 shows that Sample 2 can crush the workpiece at an initial milling energy of 4.92 kw / cm (17 Hp / in) and a milling energy after 5 consecutive milling cycles of 4.34 kw / cm (15 Hp / in), for an energy variance of approximately 12%. By comparison, as shown by plot 305, the conventional vitrified bonded abrasive sample had the same change in energy as Sample 2 and an energy variance of approximately 12%. As such, and quite unexpectedly, Samples 1 and 2, despite being metal bonded abrasive articles, behaved more like vitrified bonded abrasive article with a delicate bonding component and low energy variance. Example 3
A third sample (Sample 3) was produced using the same forming processes as Sample 1. The initial mixture is formed using 372 grams of a 60/40 copper / tin metal bonding composition, 41 grams of a 10 titanium hydride active bond composition precursor, 359 grams of CBN-V abrasive grains of size B181, 131 grams of charge available as 100 mesh size 38A alumina from Saint-Gobain Grains and Powders and 58 grams of the binder used in Example 1. Sample 3 has a ratio (VP / VBM) of 2.5 and a porosity of approximately 15 29% by volume.
Sample 3 is used in a peeling milling operation on an outside diameter of a workpiece made of 4140 metal in the shape of a round bar that has a diameter of 12.5 centimeters (5 inches) and a length of 27 , 94 centimeters (11 inches). The foot workpiece hardened to 40 to 45 HRC. Sample 3 is compared to a conventional vitrified CBN wheel commercially available from Saint Gobain Abrasives as B150-M150-VT2B (Sample C2).
Sample 3 is formed on a large bonded abrasive wheel, mounted on the periphery of a steel disc to form a 50.8 cm (20 inch) diameter wheel. Sample 3 is profiled using a diamond roller and used to grind the workpiece without any subsequent 30 covers to expose the granulations. Profiling conditions are shown in Table 3 below. The grinding conditions are shown in Table 4. Table 3: Profiling wheels for grinding by 4140 steel detachment
Table 4: Crushing parameters for 4140 steel detachment grinding


The results are summarized in Figures 4 and 5. Figure 4 includes a grind energy bar graph (kW (Hp)) versus two different material removal rates (ie 96 mm3 / sec / mm (9, 6 in3 / min / in) 5 and 120 mm3 / sec / mm (12 in3 / min / in)). The 401 bar represents the ■ shredding energy used during shredding the workpiece by Sample 3 after an initial pass at a material removal rate of 96 mm3 / sec / mm (9.6 in3 / min / in). The bar 402 represents the shredding energy 10 of Sample 3 during shredding the workpiece after 25 consecutive shredding cycles (ie passes) on the workpiece at a material removal rate of 96 mm3 / sec / mm (9 , 6 in3 / min / in). As illustrated, Sample 3 demonstrates a very small change in the energy of 15 shredding for 25 consecutive shredding cycles without going through a profiling operation. In fact, the change in shredding energy is estimated to be less than about 12%.
Bars 403 and 404 demonstrate the shredding energy 20 used during shredding of Sample C2 and after 25 consecutive shredding cycles (i.e. passages) in the workpiece. working at a material removal rate of 96 mm3 / sec / mm (9.6 in3 / min / in). In a comparison of Sample 3 with Sample C2, it is noted that Sample 3 behaves more like a vitrified bonded abrasive article than conventional metal bonded abrasive articles.
Bar 405 represents the shredding energy used during shredding the workpiece by Sample 3 after an initial pass at a material removal rate of 120 mm3 / sec / mm (12 in3 / min / in). Bar 406 represents the shredding energy of Sample 3 during shredding the workpiece after 25 consecutive shredding cycles 5 (ie passes) in the workpiece at a material removal rate of 120 mm3 / sec / mm (12 in3 / min / in). Again, Sample 3 demonstrates a very small change in shredding energy for 25 consecutive shredding cycles without going through a profiling operation. In fact, the change in shredding energy 10 is estimated to be less than about 10%.
Bars 407 and 408 demonstrate the shredding energy used during shredding of Sample C2 and in an initial pass and after 25 consecutive shred cycles (ie 15 passes) in the workpiece at a material removal rate of 120 mm3 / sec / mm (12 in3 / min / in). In a comparison of Sample 3 with Sample C2, it is noted that Sample 3 behaves more like a bonded abrasive article. glazed than conventional metal-bonded abrasive articles.
Figure 5 includes a bar graph of shredding ratio (G ratio) versus two different material removal rates (ie 96 mm3 / sec / mm (9.6 in3 / min / in) and 120 mm3 / sec / mm (12 in3 / min / in) for Sample 3 and Sample 25 C2. As illustrated, at both material removal rates, Sample 3 has a G ratio that is significantly greater than Sample C2. if the shaft energy and surface finish are virtually the same for Sample 3 compared to Sample C2, the G ratio of Sample 3 is 35% to 50% higher than the G ratio of Sample Cl at both removal rates of material. Example 4
A fourth sample (Sample 4) is created according to the 5 processes provided in Example 1. The initial mixture is formed from 138 grams of a 60/40 copper-tin metal bonding composition, 15 grams of hydride titanium as a precursor to the active binding component, 20 grams of the organic binder of Example 1 and 164 grams of 10 diamonds available from Saint-Gobain Ceramics and
Plastics such as RB 270/325 U.S. mesh, diamond granulations. Sample 4 has a ratio (VAG / VBM) of 2.3 and a porosity of approximately 36% by volume.
The shredding operation includes corrugating a piece of 15 working tungsten carbide of 2.54 centimeters (1 inch) in diameter and 10% by weight of cobalt as a binder. The crushing performance of Sample 4 was tested against a state-of-the-art metal bonded wheel (G-Force Abrasive available from Saint-Gobain 20 Corporation) which has 18.75% abrasive grain volume, '71.25% by volume of abrasive grains of bonding diamond type RB 270/325 US mesh.
Both samples were profiled and covered offline before use. The samples were mounted on a 25 steel tree and balanced. The sample is profiled with a 100 H grade, granulated silicon carbide wheel and vitrified bond, commonly used for such processes. The sample is rotated at about 1/10 the surface speed of the silicon carbide wheel that is running at approximately 7,794.5 NCMH (5,000 sfpm). While the sample wheel is rotating, it is profiled at 0.0025 cm (0.001 ") of depth of cut and 25.4 cm / min (10 in / min) of transverse bowl until the wheel is considered profiled. Each sample it is also covered with a 200 mesh silicon carbide wheel to expose the granulation for crushing, the coverage with the stick is completed at the beginning of all the crushing to start from the same reference point.
The results of the shredding test are given in Figure 6. Figure 6 includes a plot of axis energy (kW (kW (Hp)) versus shredding time (sec) for Sample 1 under three different conditions and the Sample C2 in one condition. Sample C2 is represented by plot 601 and the milling was conducted at a wheel speed of 15,000 rpm and a milling rate of 9.53 centimeters / min (3.75 inches / min). As illustrated, Sample C2 experienced a significant increase in the shredding energy required for consecutive shredding cycles. The initial milling energy is approximately 0.74 kW 20 (1.8 kW (Hp)) and increases dramatically to 2.21 kW (3 kW (Hp)) for 16 milling cycles for a duration of approximately 1,200 seconds. Sample C2 experienced an increase in shredding energy from the limit shredding energy of at least 40%.
In contrast, Sample 4 demonstrated a significantly less increase in the initial crush energy for various crush conditions. Plot 602 demonstrates the shredding energy of Sample 4 in the workpiece at 3,000 rpm and a shredding rate of 9.53 centimeters / min (3.75 inches / min). The conditions are identical to the crushing conditions used to test Sample C2. As illustrated by plot 602, Sample 4 has an initial crush energy of approximately 0.74 kW (1.5 kW (Hp)) and a final crush energy of 5 1.47 kW (2 kW (Hp)) after 16 consecutive shredding cycles in almost 1,200 seconds. Sample 4 demonstrates an increase in limit energy of only 25%. Sample 4 demonstrates a significantly improved operable shredding life compared to Sample C2.
Plot 603 demonstrates the crushing energy of the. Sample 4 on the workpiece at 2,500 rpm and a shredding rate of 9.53 centimeters / min (3.75 inches / min). As illustrated by plot 603, Sample 4 has an initial crush energy of approximately 0.74 kW (1.8 kW 15 (Hp)) and one. final grinding energy of 0.74 kW (1.8 kW (Hp)) after 16 consecutive grinding cycles in almost 1,200 seconds. Sample 4 effectively demonstrates no increase in limit energy for all cycles. shredders that demonstrate a significantly improved operable shredding life compared to Sample C2.
Plot 604 demonstrates the shredding energy of Sample 4 in the workpiece at 2,500 rpm and a shredding rate of 16.51 centimeters / min (6.5 inches / min). As shown by plot 604, Sample 4 has an initial milling energy of approximately 1.47 kW (2.8 kW (Hp)) and a final milling energy of 0.73 kW (1.9 kW (Hp) ) after 16 consecutive grinding cycles in approximately 800 seconds. Sample 4 effectively demonstrates no increase in limit energy for all I crush cycles that demonstrate a significantly improved operable crush life compared to Sample C2.
In addition to the aforementioned difference in crushing performance, Sample 4 bonded abrasive body (plots 602 and 603) can continue to crush 40 grooves in. total, which corresponds to 10 pieces, before coverage. In contrast, Sample C2 can crush 16 total striations, which corresponds to 4 total pieces before the required coverage. As such, Sample 4 demonstrates an improvement in crushing efficiency, as measured by parts / coverage of approximately 125% over conventional Sample C2.
In addition, in a comparison of plots 601 and 604, it is shown that Sample 4 is capable of improved crushing rate compared to conventional Sample C2. Under plot crushing conditions 604, Sample 4 demonstrated an ability to crush the same number of parts (4 total) in approximately 700 seconds, compared to Sample C2, which required approximately 1,100 seconds. Thus, Sample 4 demonstrated an improvement in the grinding time of 300 seconds, corresponding to an improvement of approximately 36% in relation to the conventional Sample C2. In addition, based on the 25 feed rate conditions for plots 601 and 604, Sample 4 demonstrated a 73% improvement in shredding rate (using cm / min (inches / min)) compared to Sample conventional C2. In addition, Sample 4 achieved improved shredding rates while maintaining. 30 substantially the same shredding energy, while ■ Sample C2 demonstrated a rapid and unsatisfactory increase in shredding energy. Example 5
Sample 4 and Sample C2 are used in a streak milling operation on a 1.27 cm (0.5 inch) diameter tungsten carbide workpiece with 6% cobalt. This type of work material is harder to grind than the workpiece in Example 4 due to the higher 10 tungsten carbide content (94 vs 90%) as evidenced by the difference between plots 701 and 702. Plot 701 represents the shredding energy for Sample C2 in a tungsten carbide workpiece that has 10% cobalt binder at 3,000 rpm and a shredding rate of 15.24 15 centimeters / minute (6 inches / min) for one grinding time of 800 seconds. In fact, plot 701 is the same as plot 601 in Figure 6. Plot 702 represents the shredding energy for Sample C2 in a tungsten carbide workpiece that has 6% cobalt binder at 3,000 rpm and a crushing rate of 15.24 centimeters / minute (6 inches / min) for a crushing time of 800 seconds. As illustrated, the energy required to grind the workpiece that has 10% cobalt is significantly less than the energy required to grind the workpiece made of tungsten carbide with only 6% cobalt for Sample C2. By comparison, plot 703 represents the shredding energy of Sample 4 that conducts a shredding operation on a 30 tungsten carbide workpiece that has only 6% cobalt, at a speed of 2,500 rpm at a shredding rate of 20.32 centimeters / min (8 inches / min) for a shredding time of less than 600 seconds. As illustrated, in a comparison of plots 703 and 702, Sample 4 can crush a larger amount of the tungsten carbide workpiece at a higher and more effective rate. That is, the Sample. 4 on a significantly smaller change in shredding energy for all consecutive shredding cycles compared to Sample C2.
In the additional comparison of plots 702 and 703 that represent the crushing performance of Sample 4 and Sample C2, respectively, it is noted that Sample 4 also showed improvements in the crushing rate. Notably, 15 with little to no increase in shredding energy, the
Sample 4 took only about 500 seconds to grind the same number of pieces as required by Sample C2, which required approximately 800 seconds. Thus, Sample 4 achieved an increase in the crushing rate of approximately 31% compared to conventional Sample C2. In addition, faster than the time required to grind the same number of hairs by Sample C2.
The bonded abrasive bodies of this document 25 demonstrate the compositions and crushing properties that are distinct from conventional metal bonded abrasive articles. The grinding properties of abrasive articles in the embodiments of this document are more related to vitreous bonded abrasive articles than the prior art metal bonded abrasive articles.
The bonded abrasive bodies of the embodiments of this document demonstrate improved effective grinding life, require significantly less coverage than other conventional metal bonded abrasive bodies, and have improved wear properties compared to the state of the art metal bonded abrasive bodies. In particular, the bonded abrasive body may not need a separate covering operation after undergoing a profiling operation, which is distinct from the conditioning operations of conventional bonded, metal-bonded abrasive articles. That is, it is a typical procedure within the industry to use a profiling wheel in combination with a covering rod for resurgence and modeling of abrasive bodies bonded using 15 metallic bonding materials. In this way, the bonded abrasive bodies of the embodiments of this document can crush a larger number of parts per cover, resulting in greater efficiency and a longer service life compared to the metal bonded abrasive articles of the prior art.
In addition, it is believed that particular aspects of the formation process for the bonded abrasive bodies of this document are responsible for certain compositions and microstructural resources. The bonded abrasive bodies 25 of the embodiments of this document include a combination of features, which can be assigned to the forming process and facilitate improved grinding performance, including, for example, an active bonding composition, particular phases of the bonding composition. active and particular locations of such phases, type and amount of porosity, type and amount of abrasive grains, type and amount of fillers, ratios between particulate and bond, ratios between abrasive and bond and mechanical properties (eg fracture resistance) of certain components.
In the previous one, the reference to specific modalities and the connections of certain components is illustrative. It should be noted that the reference to components as being coupled or connected is intended to reveal either direct connection 10 between said components or indirect connection through one or more intervening components to execute the methods as discussed in this document. As such, the subject matter disclosed above should be considered illustrative and not restrictive and the appended claims are intended to include all such modifications, improvements and other modalities that are within the true scope of the present invention. Thus, to the maximum extent permitted by law, the scope of the present invention must be determined by the broadest interpretation allowed of the following claims and their equivalents, and must not be restricted or limited by the previous detailed description. .
The disclosure will not be used to interpret or limit the scope or meaning of the claims. Additionally, 25 in the previous, the description includes several features that. they can be grouped together or described in a single modality for the purposes of simplifying disclosure. This disclosure should not be interpreted as reflecting an intention that the claimed modalities need 30 more resources than are expressly cited in each claim. Rather, as the following claims reflect, the matter at hand invented can be addressed unless all resources of any modalities are revealed.

权利要求:
Claims (15)
[0001]
1. Abrasive article comprising: a body comprising abrasive grains (801, 1201) contained in a bonding material (803, 1202) comprising a metal or a metal alloy, characterized in that the body comprises a VAG / VBM ratio of at least 1.3, where VAG is a percentage of the volume of abrasive grains within a total volume of the body and VBM is a percentage of the volume of bonding material within the total volume of the body and where the body comprises a composition of active bonding in an amount of at least 1% by volume of the total volume of the bonding material and in which the body comprises at least 20 by volume of porosity (1203).
[0002]
Abrasive article according to claim 1, characterized in that the body is a bonded abrasive body and in which the bonding material is a composite material which includes a bonding phase (806) and a precipitated phase (805) in which the precipitated phase is present within the bonding material and is dispersed as a separate phase throughout the volume of the bonding material.
[0003]
Abrasive article according to claim 1 or 2, characterized in that the body comprises an interfacial phase (1101) arranged at the interface of the abrasive grains and the bonding material, the interfacial phase comprises at least one element of the composition active bond and at least one element of the abrasive grains and preferably where the interfacial phase essentially consists of a material selected from the group of titanium carbide, titanium nitride, titanium boronitride, titanium aluminum oxide and a combination of these.
[0004]
Abrasive article according to claim 1 or 2, characterized in that a portion of the active bonding composition within the bonding material surrounds the abrasive grains at an interface between the abrasive grains and the bonding material.
[0005]
Abrasive article according to claim 1 or 2, characterized in that the bonding material comprises bonding positions that extend between the abrasive grains and in which the active bonding composition is distributed within the bonding positions.
[0006]
6. Abrasive article according to claim 1 or 2, characterized by the fact that the abrasive grains have an average granulation size within a range between about 1 micron and about 1,000 microns.
[0007]
Abrasive article according to claim 1 or 2, characterized by the fact that the abrasive grains have an aspect ratio not exceeding 3: 1, in which the aspect ratio is defined as a ratio of the length: width dimensions .
[0008]
8. Abrasive article, according to claim 1, characterized by the fact that the VAG / VBM ratio is within a range between 2.0 and 5.0.
[0009]
9. Abrasive article, according to claim 1 or 2, characterized by the fact that it also comprises a ratio of VP / VBM that is within a range between 1.7 and 7.0 where VP is a percentage of volume of particulate material that includes abrasive grains and fillers within the total volume of the body and VBM is a percentage of the volume of bonding material within the total volume of the body.
[0010]
10. Abrasive article, according to claim 9, characterized by the fact that the loads include particulate materials incorporated into the body that substantially maintain their original shape and size.
[0011]
11. Abrasive article, according to claim 1 or 2, characterized by the fact that most of the porosity is interconnected porosity that defines a network of interconnected pores that extend through the volume of the body.
[0012]
Abrasive article according to claim 1 or 2, characterized in that the active bonding composition is present in an amount within a range between 10% by volume and 30% by volume of the total volume of the bonding material .
[0013]
13. Abrasive article according to claim 2, characterized by the fact that the bonding phase consists essentially of copper.
[0014]
14. Method for forming the abrasive article, as defined in claims 1 to 13, characterized in that it comprises: forming a mixture that includes abrasive grains and bonding material, wherein the bonding material comprises a metal or metal alloy; and shaping the mixture to form a green article; and sintering the green article at a temperature to conduct liquid phase sintering and form the abrasive body of the abrasive article.
[0015]
15. Method according to claim 14, characterized by the fact that it further comprises forming agglomerates of abrasive grains and bonding material of the mixture.

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法律状态:
2020-08-18| B06F| Objections, documents and/or translations needed after an examination request according art. 34 industrial property law|

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2020-08-25| B06U| Preliminary requirement: requests with searches performed by other patent offices: suspension of the patent application procedure|

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2021-01-05| B09A| Decision: intention to grant|

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2021-02-02| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 02/09/2011, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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US37992010P| true| 2010-09-03|2010-09-03|

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US61/379,920|2010-09-03|

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PCT/US2011/050384|WO2012031229A2|2010-09-03|2011-09-02|Bonded abrasive article and method of forming|

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