阅读说明：本技术 磨料制品及其形成方法 (Abrasive article and method of forming the same ) 是由 斯里坎特·拉帕卡 纳兰扬·沙兰吉 罗杰·P·扎列斯基 于 2019-06-28 设计创作，主要内容包括：本发明公开了一种磨料制品,所述磨料制品包含：粘结磨料,所示粘结磨料具有至少260mm直径的本体和至少20立方厘米的体积,所述本体还具有包括无机材料的粘结材料；包含在所述粘结材料内的磨料颗粒,所述磨料颗粒具有至少40微米的磨料粒度；以及某种均质性因子。(An abrasive article is disclosed, the abrasive article comprising: a bonded abrasive having a body with a diameter of at least 260mm and a volume of at least 20 cubic centimeters, the body further having a bond material comprising an inorganic material; abrasive particles contained within the bond material, the abrasive particles having an abrasive particle size of at least 40 microns; and a certain homogeneity factor.)

1. An abrasive article comprising:

a bonded abrasive having a body, comprising:

a bonding material comprising an inorganic material;

abrasive particles contained within the body, wherein the abrasive particles have an average particle size (D50) of at least 40 microns; and

a homogeneity factor of not more than 85.

2. The abrasive article of claim 1, wherein the body comprises a diameter of at least 260mm and at least 20cm³The volume of (a).

3. The abrasive article of claim 1 or 2, wherein the body comprises a thickness in a range of at least 4mm and not greater than 500 mm.

4. The abrasive article of claim 1 or 2, wherein the body comprises an ABR factor (Cb/Cap) in a range from at least 0.5 to not greater than 10, wherein Cb represents a volume percent of the bond material based on a total volume of the body and Cap represents a volume percent of the abrasive grains based on the total volume of the body.

5. The abrasive article of claim 1 or 2, wherein the porosity comprises an average pore size (D50) in a range of at least 10 microns and not greater than 1000 microns.

6. The abrasive article of claim 1 or 2, wherein the body comprises a total porosity in a range of at least 20 vol% and not greater than 95 vol% of the total volume of the body.

7. The abrasive article of claim 6, wherein at least a portion of the total porosity is open porosity, wherein the open porosity defines interconnected channels extending through the body, and wherein at least a portion of the total porosity is closed porosity, wherein the closed porosity defines discrete and independent voids contained within the bond material.

8. The abrasive article of claim 1 or 2, wherein the abrasive particles have an average particle size (D50) of at least 65 microns.

9. The abrasive article of claim 1 or 2, wherein the body comprises an abrasive particle content of at least 20 vol% and not greater than 65 vol% of the total volume of the body.

10. The abrasive article of claim 1 or 2, wherein the body comprises a bond material content of at least 1 vol% and not greater than 65 vol% of the total volume of the body.

11. The abrasive article of claim 1 or 2, wherein the body comprises the bond material content within a range of at least 1 vol% and not greater than 15 vol% of the total volume of the body.

12. The abrasive article of claim 1 or 2, wherein the bond material comprises an inorganic material selected from the group consisting of: metal, metal alloy, ceramic, glass, or any combination thereof.

13. The abrasive article of claim 1 or 2, wherein the bond material comprises a polycrystalline phase, an amorphous phase, a single crystalline phase, or any combination thereof.

14. A method of making an abrasive article comprising:

forming a mixture comprising abrasive particles, bond precursor material, and gelling agent;

forming a bonded abrasive body from the mixture, wherein the bonded abrasive body comprises a bond material comprising an inorganic material and further comprising a homogeneity factor of not greater than 85.

15. The method of claim 14, wherein forming a mixture further comprises adding a cationic agent to the mixture and forming a gel, wherein the cationic agent comprises a compound comprising a sulfate, a chloride, a chromate, a nitrate, a carbonate (e.g., bicarbonate), a hydrate, or any combination thereof.

Technical Field

The present invention relates generally to abrasive articles, and in particular to bonded abrasive articles having a particular homogeneity.

Background

Abrasive articles for machining applications typically include bonded abrasive articles and coated abrasive articles. Bonded abrasive articles typically have a bond matrix containing abrasive particles. The bonded abrasive article can be mounted to suitable processing equipment and used in a variety of applications, such as shaping, grinding, polishing, and cutting. The industry continues to demand improved abrasive tools to meet the needs of gear grinding.

Brief description of the drawings

The present disclosure may be better understood, and its numerous features and advantages made apparent to those skilled in the art by referencing the accompanying drawings.

FIG. 1 includes a flow chart containing a method for forming an abrasive article according to one embodiment.

FIG. 2 includes a perspective view of an abrasive article according to an embodiment.

FIG. 3 includes an ultrasound image of an abrasive article according to an embodiment.

FIG. 4 includes an ultrasound image of a conventional abrasive article.

Fig. 5 includes normalized probability maps of samples S1 and C1 to evaluate homogeneity factors.

FIG. 6A includes a graph showing the cylindricity versus CMR' for samples S2 and C2.

FIG. 6B includes a graph showing the average straightness versus CMR' for samples S2 and C2.

Detailed Description

The following is generally directed to bonded abrasive articles suitable for use in material removal operations. Bonded abrasive articles can be used in a variety of applications including, for example, surface grinding, precision grinding operations (e.g., gear grinding operations), and the like. In a particular aspect, the abrasive article may include a bonded abrasive of a size and configuration that improves performance in foundry applications.

Reference herein to a bonded abrasive article includes reference to a three-dimensional volume of abrasive material having abrasive particles contained within a volume of bond material. Bonded abrasive articles may differ from coated abrasive articles, which may utilize a single layer of abrasive particles contained within a layer of bonding or bonding material. In addition, the bonded abrasive articles of the embodiments herein can include a certain porosity within the three-dimensional volume of the bond material.

FIG. 1 includes a flow diagram for forming an abrasive article according to an embodiment. As shown, the method for forming an abrasive article may begin by forming a mixture at step 101. The mixture may be a slurry comprising a plurality of components homogeneously mixed therein. According to one embodiment, a method of forming a mixture may include providing a support material. The carrier material may be a liquid suitable for containing solid components therein. For example, in one particular embodiment, the carrier can include water, and more particularly, can consist essentially of water, such as deionized water.

The method of forming a mixture may further include adding a bonding precursor material to the carrier. The bond precursor material can be the bond material of the final shaped abrasive article. According to one embodiment, the bond precursor material may include a powder material configured to form the bond material of the final shaped abrasive article. In one embodiment, the bonding precursor material may include an inorganic material such as, but not limited to, a metal alloy, a ceramic, a vitreous material, or a frit material, or any combination thereof. The bonding precursor material may include an inorganic material in an amorphous phase, a polycrystalline phase, a single crystalline phase, or any combination thereof.

According to one embodiment, the bonding precursor material may be added at a specific level. For example, the mixture may comprise at least 1 wt%, such as at least 2 wt%, or at least 3 wt%, or at least 4 wt%, or at least 5 wt%, or at least 6 wt%, or at least 7 wt%, or at least 8 wt%, or at least 9 wt%, or at least 10 wt%, or at least 12 wt%, or at least 14 wt%, or at least 16 wt%, or at least 18 wt%, or at least 20 wt%, or at least 22 wt%, or at least 24 wt%, or at least 26 wt%, or at least 28 wt%, or at least 30 wt% of the bonding precursor material, based on the total weight of the mixture. Additionally, in another non-limiting embodiment, the mixture can include not greater than 30 wt%, such as not greater than 28 wt%, or not greater than 25 wt%, or not greater than 22 wt%, or not greater than 20 wt%, or not greater than 18 wt%, or not greater than 15 wt%, or not greater than 12 wt%, or not greater than 10 wt%, or not greater than 8 wt%, or not greater than 5 wt%, or not greater than 3 wt% of the bonding precursor material, based on the total weight of the mixture. The mixture may contain a level of bonding precursor material within any of the above ranges including any minimum and maximum percentages.

According to another embodiment, a method of forming a mixture may include adding a gelling agent to the mixture. The addition of the gelling agent to the mixture can be accomplished at various times, including, for example, prior to the addition of any dry components. The gelling agent may be a material that helps to turn the mixture into a gel. The gelling agent may be used in conjunction with the gelling process, including, for example, heating, to facilitate the gelling process.

According to one embodiment, the gelling agent may be an organic material, such as a gum. For example, the gelling agent may be selected from the group consisting of: agar, agarose, xanthan gum, carboxymethyl cellulose, gellan gum, carrageenan, guar gum, tara gum, cellulose gum, locust bean gum, pectin, or any combination thereof. According to a particular embodiment, the gelling agent may preferably be gellan gum. According to another particular embodiment, the gelling agent may comprise pectin or a combination of pectin and at least one other gelling agent mentioned in the examples herein.

For certain embodiments, the mixture may include a gelling agent in an amount to facilitate improved formation of the abrasive article. For example, the mixture can comprise at least 0.1 wt%, such as at least 0.2 wt%, or at least 0.5 wt%, or at least 0.8 wt%, or at least 1 wt%, or at least 1.5 wt%, or at least 2 wt%, or at least 2.5 wt%, or at least 3 wt%, or at least 3.5 wt%, or at least 4 wt%, or at least 4.5 wt%, or at least 5 wt%, or at least 5.5 wt%, or at least 6 wt%, or at least 6.5 wt%, or at least 7 wt%, or at least 7.5 wt% of gelling agent, based on the total weight of the mixture. In one non-limiting example, the mixture can include no greater than 10 wt%, such as no greater than 9 wt%, or no greater than 8 wt%, or no greater than 7 wt%, or no greater than 6 wt%, or no greater than 5 wt%, or no greater than 4 wt%, or no greater than 3 wt%, or no greater than 2 wt%, or no greater than 1 wt% of the total weight of the mixture of gelling agent. The mixture may contain a gelling agent in an amount within the ranges above including any minimum and maximum percentages.

The mixture may further include abrasive particles configured to form the abrasive component of the final shaped abrasive article. The abrasive particles can be added to the mixture at various times, including, for example, after the bond precursor material is added to the mixture. Additionally, it should be understood that in other embodiments, the abrasive particles may be added in combination with one or more other components of the mixture, including, for example, but not limited to, a gelling agent, a bond precursor material, or one or more additives. The abrasive particles may comprise materials such as the group consisting of: an oxide, boride, nitride, carbide, oxynitride, oxycarbide, amorphous, single crystal, polycrystalline, superabrasive, or any combination thereof. In one particular embodiment, the abrasive particles can comprise alumina, and can consist essentially of alumina.

The mixture may include a certain amount of abrasive particles to facilitate improved manufacture and/or performance of suitable abrasive articles. For example, in one embodiment, the mixture can include at least 20 wt%, such as at least 22 wt%, or at least 24 wt%, or at least 26 wt%, or at least 28 wt%, or at least 30 wt%, or at least 35 wt%, or at least 40 wt%, or at least 45 wt%, or at least 50 wt%, or at least 55 wt%, or at least 60 wt%, or at least 65 wt%, or at least 70 wt% of abrasive particles, based on the total weight of the mixture. In another non-limiting embodiment, the mixture can include not greater than 80 wt%, such as not greater than 75 wt%, or not greater than 70 wt%, or not greater than 65 wt%, or not greater than 60 wt%, or not greater than 55 wt%, or not greater than 50 wt%, or not greater than 45 wt%, or not greater than 40 wt%, or not greater than 35 wt%, or not greater than 30 wt%, such as not greater than 25 wt%, of the abrasive particles, based on the total weight of the mixture. The mixture may contain an amount of abrasive particles within any of the above ranges including any minimum and maximum percentages.

The mixture may further include one or more additives that may be beneficial in improving the manufacture and/or performance of the abrasive article. Some exemplary additives may include, but are not limited to, dispersants, surfactants, cationic agents, or any combination thereof. As used herein, a dispersant may prevent flocculation of the mixture due to static or steric repulsion. As used herein, a surfactant can reduce the surface tension between two liquids, i.e., a solid and a liquid or a gas and a liquid. As used herein, a cationic agent can be an ionic compound (e.g., a salt) that is crosslinked with a gelling agent, which can be an anionic material.

One or more additives may be added to the mixture at various times, including, for example, after the solid components are added to the mixture, including, for example, the bond precursor material and the abrasive particles. Additionally, it should be understood that in other embodiments, one or more additives may be added in combination with one or more other components of the mixture, including for example, but not limited to, a gelling agent, a bond precursor material, or one or more additives. The order of addition of the additives may also be of significance in promoting proper formation of the abrasive article. For example, in at least one embodiment, the cationic agent can be added after any other additives are added to the mixture.

The dispersant can include at least one of sodium polyacrylate (e.g., Darvan 811), a copolymer having pigment affinic groups (e.g., BYK192), ammonium polymethacrylate (e.g., Darvan C-N), polyacrylate ammonium (e.g., Darvan 821A), polyacrylic acid, an ammonium salt of an acrylic polymer in water (e.g., Dispex), citric acid, sodium dodecylbenzenesulfonate, cetyltrimethylammonium bromide, or any combination thereof.

The mixture may include a particular amount of dispersant to facilitate improved manufacture and/or performance of the abrasive article. For example, the mixture may comprise at least 0.1 wt%, such as at least 0.2 wt%, or at least 0.5 wt%, or at least 0.8 wt%, or at least 1 wt%, or at least 1.5 wt%, or at least 2 wt%, or at least 2.5 wt%, or at least 3 wt%, or at least 3.5 wt%, or at least 4 wt%, or at least 4.5 wt%, or at least 5 wt% of the dispersant, based on the total weight of the mixture. In another non-limiting embodiment, the mixture can include no greater than 6 wt.%, such as no greater than 5 wt.%, or no greater than 4 wt.%, or no greater than 3 wt.%, or no greater than 2 wt.%, or no greater than 1 wt.% of the dispersant, based on the total weight of the mixture. The mixture may contain a dispersant in an amount within any of the above ranges including any minimum and maximum percentages.

Suitable examples of surfactants may include inorganic materials, organic materials, or combinations thereof. Suitable surfactants may include sulfates, sarcosinates, laurates, stearates, lecithins, and the like. In a particular embodiment, the surfactant may include sodium lauroyl sarcosinate, sodium lauryl sulfate, sodium laurate, sodium stearate, sodium alkyl sulfate, sodium lauryl sulfate, sorbitan, polyethylene glycol, polysorbate, glycerol monostearate, lecithin, or any combination thereof.

The mixture may include a specific level of surfactant that facilitates improved manufacture and/or performance of the abrasive article. For example, the mixture can include at least 0.1 wt%, such as at least 0.2 wt%, or at least 0.5 wt%, or at least 0.8 wt%, or at least 1 wt%, or at least 1.5 wt%, or at least 2 wt%, or at least 2.5 wt%, or at least 3 wt%, or at least 3.5 wt%, or at least 4 wt%, or at least 4.5 wt%, or at least 5 wt% of the surfactant, based on the total weight of the mixture. In another non-limiting embodiment, the mixture can include no greater than 6 wt%, such as no greater than 5 wt%, or no greater than 4 wt%, or no greater than 3 wt%, or no greater than 2 wt%, or no greater than 1 wt% of the surfactant, based on the total weight of the mixture. The mixture may contain a surfactant in an amount within any of the above ranges including any minimum and maximum percentages.

Some suitable examples of cationic agents may include inorganic compounds, particularly salts, such as sulfates, chlorides, chromates, nitrates, carbonates (e.g., bicarbonates), hydrates, and the like. In particular instances, the cationic agent can include a compound comprising an alkali metal element, an alkaline earth metal element, a transition metal element, hydrogen, or a combination thereof. More specifically, the cationic agent may include a compound comprising sodium, potassium, lithium, ammonium, copper, magnesium, iron, calcium, or any combination thereof. In a particular embodiment, the cationic agent is preferably calcium chloride or sodium chloride. For example, the cationic agent may consist of calcium chloride or sodium chloride.

The cationic agent can be added to the mixture at various times, including, for example, after the solid components (e.g., abrasive particles, one or more fillers, bonding precursor mixture) are added to the mixture. In a particular embodiment, the cationic agent may be the last component added to the slurry prior to gelation. Additionally, it should be understood that in other embodiments, the cationic agent may be added in combination with one or more other components of the mixture, including, for example, but not limited to, a gelling agent, a bond precursor material, abrasive particles, or one or more additives.

The mixture can include a particular amount of a cationic agent that facilitates improved manufacture and/or performance of the abrasive article. For example, the mixture can include at least 0.1 wt%, such as at least 0.2 wt%, or at least 0.5 wt%, or at least 0.8 wt%, or at least 1 wt%, or at least 1.5 wt%, or at least 2 wt%, or at least 2.5 wt%, or at least 3 wt%, or at least 3.5 wt%, or at least 4 wt%, or at least 4.5 wt%, or at least 5 wt% of the cationic agent, based on the total weight of the mixture. In another non-limiting embodiment, the mixture can include no greater than 6 wt%, such as no greater than 5 wt%, or no greater than 4 wt%, or no greater than 3 wt%, or no greater than 2 wt%, or no greater than 1 wt% of the cationic agent, based on the total weight of the mixture. The mixture may contain a cationic agent in an amount within any of the ranges above including any minimum and maximum percentages.

The method of forming the mixture may include continuous mixing while adding one or more components. In particular, mixing may continue throughout the process of adding the components. In some cases, the components may be added in a particular order, for example, the gelling agent may be added first, followed by the bond precursor material and abrasive particles. One or more additives, such as dispersants, surfactants, and cationic agents, may be added before or after the addition of the bond precursor material and/or abrasive particles. In a particular embodiment, the cationic agent may be added at the end of all components. In another embodiment, a mixer may be used to assist in mixing, such as a shear mixer, a ball mill, or any combination thereof. In one aspect, the shear mixer can be a high shear mixer or a low shear mixer. In a particular aspect, to aid mixing, the shear rate can be at least 500S^-1At least 700S^-1At least 800S^-1Or at least 900S^-1. In another particular aspect, the shear rate can be up to 1200S^-1At most 1100S^-1Or at most 1000S^-1. It will be appreciated that the shear rate may be within a range including any of the minimum and maximum values noted herein. For example, a suitable shear rate may be 500S^-1To 1200S^-1。

In at least one embodiment, a method of making an abrasive article includes changing a mixture into a gel. The gelling of the mixture may be facilitated by the addition of one or more components, including, for example, a gelling agent and/or one or more additives. According to a particular embodiment, a method of forming a gel from a mixture may include first forming a mixture including a gel and a carrier, such as water. After forming the mixture comprising the gel and the water, the method may continue by adding at least one of, or any combination of, a bond precursor material, abrasive particles, and one or more additives. After adding the bond precursor material, the abrasive particles, and/or one or more additives to the mixture, the method may continue by adding a cationic agent to the mixture. In certain cases, the cationic agent may be added in the final step of forming the mixture before the mixture forms a gel.

The method of forming the gel may include hydrating the gel. In a particular embodiment, the method of forming the gel may be a method of hydrating the gel. In particular, the method of forming the gel may include heating the mixture to a gelation temperature. More specifically, the mixture may be mixed while the mixture is heated to the gelation temperature. In at least one embodiment, the gelation temperature may be at least 50 ℃, such as at least 60 ℃, or at least 70 ℃, or at least 80 ℃, or at least 90 ℃, or at least 100 ℃. Additionally, in one non-limiting embodiment, the gelation temperature can be no greater than 100 ℃, such as no greater than 90 ℃, or no greater than 80 ℃, or no greater than 70 ℃. It should be understood that the gelation temperature can be within a range including any of the minimum and maximum temperatures described above.

After the gel (which may also be referred to herein as a foamed gel) is formed, the method may continue by forming a green body from the gel. According to one embodiment, the method of forming a green body may comprise at least one method from the group of: pressing, molding, casting, drying, freezing, cooling, or any combination thereof. In a particular embodiment, the method of forming a green body may comprise casting. Casting may be accomplished by pouring the gel into a production tool or casting of appropriate shape and size. Some gel may still be formed during the formation of the green body. That is, gelation need not necessarily be completed during the formation of the green body. Additionally, in some instances, it may be desirable for the mixture to completely gel prior to the process of forming the green body. As used herein, reference to a gel includes a solid self-supporting structure comprising water contained in an integrated network defined by solid particles in the gel. The gel may have a specific yield stress, so it is self-supporting. For example, the gel may have a yield stress of at least 30Pa, such as at least 60Pa or at least 130 Pa.

In particular embodiments, the method of forming a green body may include degassing during green body formation. For example, degassing may be performed during molding to remove air bubbles.

After the green body is formed, the green body may be further processed to modify or convert the green body into a bonded abrasive body. After completing step 101, the method may continue with step 103 by forming a bonded abrasive body having a certain homogeneity factor. For example, one or more methods for converting the green body into a final shaped bonded abrasive body may include drying, sintering, cooling, pressing, vitrifying, or any combination thereof. In a particular embodiment, the method may include casting, cooling, drying, and firing. In the case of vitrified bond materials, the firing conditions may be appropriate to form vitrified bond materials. For example, the firing temperature may be at least 800 ℃ or at least 900 ℃ or at least 1000 ℃ or at least 1100 ℃ or at least 1200 ℃. Additionally, in one embodiment, the firing temperature may be no greater than 1400 ℃ or no greater than 1300 ℃ or no greater than 1200 ℃ or no greater than 1100 ℃ or no greater than 1000 ℃ or no greater than 900 ℃.

The final shaped abrasive article may be a bonded abrasive body defining an interconnected network of bond material comprising abrasive particles in a three-dimensional volume (i.e., matrix) of bond material. Further, the bonded abrasive body can have an amount of porosity distributed throughout the body and define a phase that is distinct from the phases of the bond material and the abrasive grains.

The bonded abrasive body formed by the example methods described herein may have particular characteristics. For example, the bonded abrasive body may have a relatively large size compared to most conventional bonded abrasive bodies, and may further have relatively large abrasive grains contained therein, which may be particularly suitable for large scale cutting and abrading operations, such as the foundry industry.

FIG. 2 includes a perspective view of a bonded abrasive body according to an embodiment. The abrasive article 200 may include a bonded abrasive body 201. The bonded abrasive body 201 may include a spindle bore 202 configured to engage a spindle of an abrading machine to rotate the abrasive article 200 relative to a workpiece. As further shown in fig. 2, the bonded abrasive body includes an axial axis 203 defining an axial direction and a transverse axis 204 defining an axis in a radial direction. The axial axis 203 extends in a vertical direction defined by the thickness (t) of the bonded abrasive body 201. The transverse axis 204 extends in a radial direction that defines a radius or diameter (D) of the bonded abrasive body 201.

According to one embodiment, the bonded abrasive body may have a diameter (D) of at least 260mm, such as a diameter of at least 270mm, or at least 280mm, or at least 290mm, or at least 300mm, or at least 325mm, or at least 350mm, or at least 375mm, or at least 400mm, or at least 425mm, or at least 450mm, or at least 475mm, or at least 500mm, or at least 525mm, or at least 550mm, or at least 575 mm. Additionally, in one non-limiting embodiment, the bonded abrasive body can have a diameter (D) of not greater than 800mm, or not greater than 700mm, or not greater than 600mm, or not greater than 575mm, or not greater than 550mm, or not greater than 525mm, or not greater than 500mm, or not greater than 475mm, or not greater than 450mm, or not greater than 425mm, or not greater than 400mm, or not greater than 375mm, or not greater than 350mm, or not greater than 325mm, or not greater than 300mm, or not greater than 290mm, or not greater than 280 mm. It will be appreciated that the diameter (D) may be within a range including any of the minimum and maximum values noted above. The diameter referred to herein may be the average diameter of the bonded abrasive body, which is the average from multiple measurements.

In another embodiment, the bonded abrasive body 201 may have a particular volume depending on the application. For example, bonded abrasivesThe volume of the body 201 may be at least 1cm³. In other instances, the volume of the bonded abrasive body 201 can be at least 10cm³Or at least 20cm³Or at least 30cm³Or at least 50cm³Or at least 75cm³Or at least 100cm³. Additionally, in another non-limiting embodiment, the volume of the body can be no greater than 1000cm³Or not more than 900cm³Or not more than 800cm³Or not more than 700cm³Or not more than 600cm³Or not more than 500cm³. It will be appreciated that the volume of the bonded abrasive body can be within a range including any of the minimum and maximum values noted above, such as at least 10cm³To not more than 1000cm³The volume of (a).

In yet another embodiment, the bonded abrasive body 201 can have a particular thickness (t) configured for certain applications. For example, the bonded abrasive body 201 may have a body thickness comprising at least 2mm, such as at least 3mm, or at least 4mm, or at least 5mm, or at least 10mm, or at least 15mm, or at least 20mm, or at least 30mm, or at least 50mm, or at least 100mm, or at least 200mm, or at least 300 mm. Additionally, in another embodiment, the thickness (t) of the bonded abrasive body 201 can be no greater than 500mm, such as no greater than 400mm, or no greater than 300mm, or no greater than 200mm, or no greater than 100mm, or no greater than 80mm, or no greater than 60mm, or no greater than 40mm, or no greater than 20mm, or no greater than 10 mm. It should be appreciated that the thickness (t) of the bonded abrasive body 201 can be within a range including any of the minimum and maximum values noted above, such as a volume of at least 2mm to no greater than 400 mm. The thickness referred to herein may be an average thickness of the bonded abrasive body, which is an average value from multiple measurements.

The bonded abrasive body 201 can have a particular aspect ratio (D: t), which can be at least 5: 1, such as at least 10: 1, or at least 20: 1, or at least 40: 1, or at least 50: 1, or at least 100: 1, or at least 150: 1, or at least 300: 1, or at least 500: 1, or at least 800: 1, or at least 1000: 1. Additionally, in another non-limiting embodiment, the aspect ratio (D: t) can be no greater than 100,000: 1, or no greater than 10,000: 1, or no greater than 1000: 1, or no greater than 500: 1. It will be appreciated that the aspect ratio can be within a range including any of the minimum and maximum values noted above.

The bonded abrasive body 201 can include abrasive particles having an average particle size (D50) of at least 40 microns. The bonded abrasive bodies herein can utilize relatively large sized abrasive particles, which historically have proven difficult to uniformly distribute throughout the mixture and the resulting bonded abrasive body. Notably, due to their relatively large size, such abrasive particles tend to separate and agglomerate in gels and mixtures, resulting in abrasive products having non-uniformity and density variations. In a particular embodiment, the abrasive particles may have an average particle size (D50) of at least 50 microns, or at least 55 microns, or at least 60 microns, or at least 65 microns, or at least 70 microns, or at least 75 microns, or at least 80 microns, or at least 85 microns, or at least 90 microns, or at least 95 microns, or at least 100 microns, or at least 105 microns, or at least 110 microns, or at least 115 microns, or at least 120 microns, or at least 130 microns, or at least 150 microns, or at least 175 microns, or at least 200 microns, or at least 250 microns, or at least 300 microns, or at least 350 microns, or at least 400 microns, or at least 450 microns, or at least 500 microns, or at least 600 microns, or at least 700 microns, or at least 800 microns. Additionally, in one non-limiting embodiment, the abrasive particles can have an average particle size (D50) of not greater than 5000 microns, or not greater than 4000 microns, or not greater than 3000 microns, or not greater than 2000 microns, or not greater than 1000 microns, or not greater than 900 microns, or not greater than 800 microns, or not greater than 700 microns, or not greater than 600 microns, or not greater than 500 microns, or not greater than 400 microns, or not greater than 300 microns, or not greater than 200 microns, or not greater than 150 microns, or not greater than 130 microns. The abrasive particles can have an average particle size (D50) within a range including any of the minimum and maximum values noted above, including for example and without limitation, within a range of at least 50 microns and not greater than 5000 microns, or within a range of at least 100 microns and not greater than 2000 microns, or within a range of at least 50 microns and not greater than 800 microns, or even within a range of at least 50 microns and not greater than 400 microns. .

The abrasive particles can have various compositions, shapes, sizes, and other characteristics. For example, the abrasive particles may include abrasive particle types, such as from the group of claims: non-agglomerated particles, shaped abrasive composites, Constant Thickness Abrasive Particles (CTAP), randomly shaped abrasive particles, or any combination thereof. In another embodiment, the abrasive particles may comprise a material such as from the group of: an oxide, boride, nitride, carbide, oxynitride, oxycarbide, amorphous, single crystal, polycrystalline, superabrasive, or any combination thereof.

According to one embodiment, the bonded abrasive body 201 may have a particular structure that may be beneficial for improved performance. For example, the bonded abrasive body 201 can comprise an abrasive particle content of at least 20 vol, such as at least 25 vol, or at least 30 vol, or at least 35 vol, or at least 40 vol, or at least 45 vol, or at least 50 vol, or at least 55 vol of the total volume of the bonded abrasive body 201. Additionally, in one non-limiting embodiment, the bonded abrasive body 201 can comprise an abrasive particle content of not greater than 65 vol, such as not greater than 60 vol, or not greater than 55 vol, or not greater than 50 vol, or not greater than 45 vol, or not greater than 40 vol, or not greater than 35 vol, or not greater than 30 vol for the total volume of the bonded abrasive body 201. The content of abrasive particles in the bonded abrasive body 201 can range from any minimum to maximum percentage including those mentioned above.

In a particular aspect, the bonded abrasive body 201 can include a bond material comprising an inorganic material. Some suitable examples of inorganic materials may include metals, metal alloys, ceramics, glass phases, or any combination thereof. Further, the bonding material may include at least one of a glassy phase, an amorphous phase, a polycrystalline phase, a single crystalline phase, or any combination thereof. In some cases, the bonding material may consist essentially of a polycrystalline phase, a glassy phase, or a single crystalline phase.

For at least one embodiment, the bonding material may include an oxide, such as a glassy oxide-containing material. Some suitable examples of oxides may include silica, boron oxide, alumina, alkali metal oxides (M)₂O), an alkaline earth Metal Oxide (MO), a transition metal oxide, a rare earth metal oxide, or any combination thereof. In particular instances, the binding material may be a soda lime glass material, a borosilicate material, or an aluminosilicate material.

The bonded abrasive body 201 can include a particular content of bond material, which can be beneficial for improved performance. For example, the bonded abrasive body 201 can comprise a bond material content of at least 2 vol, such as at least 3vol, or at least 4 vol, or at least 5 vol, or at least 6 vol, or at least 8 vol, or at least 10 vol, or at least 12 vol, or at least 14 vol, or at least 16 vol, or at least 18 vol, or at least 20 vol, or at least 25 vol, or at least 30 vol, or at least 35 vol, or at least 40 vol, of the total volume of the bonded abrasive body 201. Additionally, in one non-limiting embodiment, the bonded abrasive body 201 can comprise a bond material content of not greater than 65 vol, or not greater than 60 vol, or not greater than 55 vol, or not greater than 50 vol, or not greater than 45 vol, or not greater than 40 vol, or not greater than 35 vol, or not greater than 30 vol, or not greater than 25 vol, or not greater than 22 vol, or not greater than 20 vol, or not greater than 18 vol, or not greater than 16 vol, or not greater than 14 vol, or not greater than 12 vol, or not greater than 10 vol, or not greater than 8 vol, or not greater than 6 vol for the total volume of the bonded abrasive body 201. It will be appreciated that the binder material content can be within a range including any of the minimum and maximum values noted above, including, for example, a binder material content within a range of at least 1 vol% and no greater than 15 vol% for the total volume of the body.

The bonded abrasive body 201 can include a particular structure such that it has a controlled content of bonding material relative to the content of abrasive particles. For example, in certain instances, the body can have an ABR factor (Cb/Cap) in a range of at least 0.5 to not greater than 10, where Cb represents the volume percent of the bond material based on the total volume of the bonded abrasive body 201 and Cap represents the volume percent of the abrasive grains based on the total volume of the bonded abrasive body 201. In particular instances, the bonded abrasive body 201 can have a Cb factor (or at least a Cb factor of at least 0.55, such as at least 0.6, or at least 0.65, or at least 0.7, or at least 0.75, or at least 0.8, or at least 0.85, or at least 0.9, or at least 0.95, or at least 1, or at least 1.05, or at least 1.1, or at least 1.15, or at least 1.2, or at least 1.25, or at least 1.3, or at least 1.35, or at least 1.4, or at least 1.45, or at least 1.5, or at least 1.55, or at least 1.6, or at least 1.65, or at least 1.7, or at least 1.75, or at least 1.8, or at least 1.85, or at least 1.9, or at least 1.95, or at least 2, or at least 2.2, or at least 2.5, or at least 2.8, or at least 3, or at least 3.5, or at least 4, or at least 5. Additionally, in another non-limiting embodiment, the bonded abrasive body 201 can have an ABR factor (Cb/Cap) of no greater than 9, such as no greater than 8.5, or no greater than 8, or no greater than 7.5, or no greater than 7, or no greater than 6.5, or no greater than 6, or no greater than 5.5, or no greater than 5, or no greater than 4.5, or no greater than 4, or no greater than 3.5, or no greater than 3, or no greater than 2.5, or no greater than 2, or no greater than 1.5, or no greater than 1, or no greater than 0.9. It will be appreciated that the ABR factor (Cb/Cap) can be within a range including any of the minimum and maximum values noted above.

In another embodiment, the bonded abrasive body 201 can include a particular type and content of porosity that can be beneficial for improving the performance of the abrasive article. For example, the bonded abrasive body 201 can have an average pore size (D50) of at least 10 microns, such as at least 20 microns, or at least 30 microns, or at least 40 microns, or at least 50 microns, or at least 60 microns, or at least 70 microns, or at least 80 microns, or at least 90 microns, or at least 100 microns, or at least 200 microns, or at least 300 microns, or at least 400 microns, or at least 500 microns, or at least 600 microns, or at least 700 microns, or at least 800 microns, or at least 900 microns. Additionally, in one non-limiting embodiment, the bonded abrasive body 201 porosity can have an average pore size (D50) of not greater than 1000 microns, or not greater than 900 microns, or not greater than 800 microns, or not greater than 700 microns, or not greater than 600 microns, or not greater than 500 microns, or not greater than 400 microns, or not greater than 300 microns, or not greater than 200 microns, or not greater than 100 microns, or not greater than 80 microns, or not greater than 60 microns, or not greater than 40 microns, or not greater than 20 microns, or not greater than 10 microns. It will be appreciated that the average pore diameter can be within a range including any of the minimum and maximum values noted above.

The bonded abrasive body 201 can have a particular porosity content, which can be beneficial for improved performance. For example, the bonded abrasive body 201 can comprise a porosity of at least 20 vol, such as at least 25 vol, or at least 30 vol, or at least 35 vol, or at least 40 vol, or at least 45 vol, or at least 50 vol, or at least 55 vol, or at least 60 vol, or at least 65 vol, or at least 70 vol, or at least 75 vol, or at least 80 vol, of the total volume of the bonded abrasive body 201. Additionally, in one non-limiting embodiment, the bonded abrasive body 201 can comprise a porosity of not greater than 95 vol, such as not greater than 90 vol, or not greater than 85 vol, or not greater than 80 vol, or not greater than 75 vol, or not greater than 70 vol, or not greater than 65 vol, or not greater than 60 vol, or not greater than 55 vol, or not greater than 50 vol, or not greater than 45 vol, or not greater than 40 vol, or not greater than 35 vol, or not greater than 30 vol for the total volume of the bonded abrasive body 201. It should be appreciated that the porosity content of the bonded abrasive body 201 can range from any minimum to maximum percentage including those mentioned above.

The porosity of the bonded abrasive body 201 can include open porosity, closed porosity, or a combination thereof. Open porosity may be defined as interconnected channels extending through the bonded abrasive body 201. Closed porosity may be defined as discrete and independent voids contained within the bond material. In accordance with one embodiment of the present invention,

the bonded abrasive body 201 can include a particular content of open porosity, which can be beneficial for improved performance. For example, the bonded abrasive body 201 can comprise an open porosity of at least 15 vol, such as at least 20 vol, or at least 30 vol, or at least 40 vol, or at least 50 vol, or at least 60 vol, or at least 70 vol, or at least 80 vol, or at least 90 vol of the total volume of porosity. Additionally, in one non-limiting embodiment, the bonded abrasive body 201 can comprise an open porosity of not greater than 95 vol, such as not greater than 90 vol, or not greater than 80 vol, or not greater than 70 vol, or not greater than 60 vol, or not greater than 50 vol, or not greater than 40 vol, or not greater than 30 vol, or not greater than 20 vol for the total volume of porosity of the bonded abrasive body 201. In at least one embodiment, all of the porosity in the bonded abrasive body 201 can be open porosity. It is to be understood that the amount of open porosity can range from any of the minimum to maximum percentages noted above.

According to one embodiment, the bonded abrasive body 201 can include a particular content of closed porosity, which can facilitate improved performance. For example, the bonded abrasive body 201 may comprise a closed porosity of at least 10 vol, such as at least 15 vol, or at least 20 vol, or at least 30 vol, or at least 40 vol, or at least 50 vol, or at least 60 vol, or at least 70 vol, or at least 80 vol, or at least 90 vol, of the total content of porosity of the bonded abrasive body 201. Additionally, in one non-limiting embodiment, the bonded abrasive body 201 can comprise a closed porosity of not greater than 95 vol, such as not greater than 90 vol, or not greater than 80 vol, or not greater than 70 vol, or not greater than 60 vol, or not greater than 50 vol, or not greater than 40 vol, or not greater than 30 vol, or not greater than 20 vol for the total volume of porosity of the bonded abrasive body 201. In at least one embodiment, all of the porosity in the bonded abrasive body 201 can be closed porosity. It is to be understood that the closed porosity content can range from any of the minimum to maximum percentages noted above.

The example methods described herein may facilitate forming bonded abrasive articles having a particular grade and/or structure that utilize relatively large abrasive particles and have excellent homogeneity in phase distribution throughout the body, which has not previously been achievable by conventional processing. Notably, the bonded abrasive body 201 can have a particular homogeneity factor of not greater than 85. For example, the homogeneity factor can be no greater than 84, or no greater than 82, or no greater than 80, or no greater than 78, or no greater than 76, or no greater than 74, or no greater than 72, or no greater than 70, or no greater than 68, or no greater than 66, or no greater than 64, or no greater than 62, or no greater than 60, or no greater than 58, or no greater than 56, or no greater than 54, or no greater than 52, or no greater than 50, or no greater than 48, or no greater than 46, or no greater than 44, or no greater than 42, or no greater than 40, or no greater than 38, or no greater than 36, or no greater than 34, or no greater than 32, or no greater than 30, or no greater than 28, or no greater than 26, or no greater than 24, or no greater than 22, or no greater than 20, or no greater than 18, or no greater than 16, or no greater, Or not greater than 4, or not greater than 2. Additionally, in one non-limiting embodiment, the homogeneity factor can be at least 1, such as at least 2, or at least 4, or at least 6, or at least 8, or at least 10, or at least 12, or at least 14, or at least 16, or at least 18, or at least 20, or at least 22, or at least 24, or at least 26, or at least 28, or at least 30, or at least 32, or at least 34, or at least 36, or at least 38, or at least 40, or at least 42, or at least 44, or at least 46, or at least 48, or at least 50, or at least 52, or at least 54, or at least 56, or at least 58, or at least 60, or at least 62, or at least 64, or at least 66, or at least 68, or at least 70, or at least 72, or at least 74, or at least 76, or at least 78, or at least 80. It will be appreciated that the homogeneity factor can be within a range including any of the minimum and maximum values noted above.

The homogeneity factor can be assessed by measuring the time of flight information through the bonded abrasive body by the ultrasonic system Mistras UltraPAC (UPK-T36-HS). In particular, the bonded abrasive body may be immersed in water to fill all open porosity with water. A single pulse-echo ultrasonic transducer (model # KS75-1) with a 1mHz immersion transducer and an effective diameter of 19.0mm was placed 1 inch from the wheel. The sensor was mounted on a dc stepper motor that moved the sensor across the surface of the wheel while maintaining a 1 inch distance. UTWin V3.62 software is used to control the motion of the stepper motor. The gain was set to 10cB, a 400V pulse generator, a 2.0mHz LP filter, a 0.5mHz HP filter, and a 100mHz sample rate. And acquiring and processing the data in a JET color mapping array format by UTWin software to generate an RGB image. The scanning resolution was 1.0X 1.0mm and the scanning speed in the X direction was 150mm/s and the scanning speed in the Z direction was 50 mm/s.

Using a color (red-green-blue or RGB) image in ultrasound analysis, the image can be analyzed by image processing software such as Matlab. The RGB image can be converted to a LAB image in Matlab using the "RGB 2 LAB" function in Matlab, which creates a suitable image to identify only the areas associated with the wheel. The image portion with a value of 100 is associated with open space (i.e., not a wheel) and is deleted from the image.

Next, the RGB image is converted to an index image, where each pixel is assigned a color value of 256 possible colors (i.e., values from 0-255). This is done by the "rgb 2 ind" function of Matlab. The darkest blue is associated with a minimum value or 0 and the brightest red is associated with a maximum value or 255.

After the index image is created, it is compared to the LAB image to ensure that only the pixels associated with the wheel are evaluated. The comparison is done using a logical indexing operation, where pixels in the indexed image that are not relevant to the wheel region are removed from further analysis. The result is an area corrected index image.

The area corrected index image is then used to create a normalized probability map, as shown in FIG. 5. Each box on the graph represents 5 consecutive values between 0 and 255. For example, the first box (leftmost) represents a number of pixels between 0 and 4. The statistical percentile is evaluated based on the normalized probability map and the data used to generate the map. The percentile comprises a 25 th percentile, a 50 th percentile and a 75 th percentile. The homogeneity factor is the difference between the 75 th percentile and the 25 th percentile. The distribution range of the bodies with higher homogeneity of the respective components is smaller between 0 and 255, and thus the difference between the 75 th percentile and the 25 th percentile is also smaller.

Many different aspects and embodiments are possible. Some of these aspects and embodiments are described herein. After reading this description, those skilled in the art will appreciate that those aspects and embodiments are illustrative only and do not limit the scope of the present invention. Embodiments may be in accordance with any one or more of the embodiments listed below.

Examples

Embodiment 1. an abrasive article comprising:

a bonded abrasive having a body comprising a diameter of at least 260mm and a volume of at least 20 cubic centimeters, the body further comprising:

a bonding material comprising an inorganic material;

abrasive particles contained within the body, wherein the abrasive particles have an average particle size (D50) of at least 40 microns; and

a homogeneity factor of not more than 85.

Embodiment 2. the abrasive article of embodiment 1, wherein the body comprises an ABR factor (Cb/Cap) in a range from at least 0.5 to not greater than 10, wherein Cb represents the volume percent of the bond material and Cap represents the volume percent of the abrasive grains based on the total volume of the body.

Embodiment 3. the abrasive article of embodiment 2, wherein the body comprises a Cb factor of at least 0.55, or at least 0.6, or at least 0.65, or at least 0.7, or at least 0.75, or at least 0.8, or at least 0.85, or at least 0.9, or at least 0.95, or at least 1, or at least 1.05, or at least 1.1, or at least 1.15, or at least 1.2, or at least 1.25, or at least 1.3, or at least 1.35, or at least 1.4, or at least 1.45, or at least 1.5, or at least 1.55, or at least 1.6, or at least 1.65, or at least 1.7, or at least 1.75, or at least 1.8, or at least 1.85, or at least 1.9, or at least 1.95, or at least 2, or at least 2.2, or at least 2.5, or at least 2.8, or at least 3, or at least 3.5, or at least 4, or at least 4.5, or at least 5, or at least 2.5, or at least 3, or at least 5, or at least 3, at least 5, or at least.

Embodiment 4. the abrasive article of embodiment 2, wherein the body comprises an ABR factor (Cb/Cap) of not greater than 9, or not greater than 8.5, or not greater than 8, or not greater than 7.5, or not greater than 7, or not greater than 6.5, or not greater than 6, or not greater than 5.5, or not greater than 5, or not greater than 4.5, or not greater than 4, or not greater than 3.5, or not greater than 3, or not greater than 2.5, or not greater than 2, or not greater than 1.5, or not greater than 1, or not greater than 0.9.

Embodiment 5 the abrasive article of embodiment 1, wherein the body comprises a homogeneity factor of at least 1, at least 2, or at least 4, or at least 6, or at least 8, or at least 10, or at least 12, or at least 14, or at least 16, or at least 18, or at least 20, or at least 22, or at least 24, or at least 26, or at least 28, or at least 30, or at least 32, or at least 34, or at least 36, or at least 38, or at least 40, or at least 42, or at least 44, or at least 46, or at least 48, or at least 50, or at least 52, or at least 54, or at least 56, or at least 58, or at least 60, or at least 62, or at least 64, or at least 66, or at least 68, or at least 70, or at least 72, or at least 74, or at least 76, or at least 78, or at least 80.

Embodiment 6 the abrasive article of embodiment 1, wherein the homogeneity factor is not greater than 84, or not greater than 82, or not greater than 80, or not greater than 78, or not greater than 76, or not greater than 74, or not greater than 72, or not greater than 70, or not greater than 68, or not greater than 66, or not greater than 64, or not greater than 62, or not greater than 60, or not greater than 58, or not greater than 56, or not greater than 54, or not greater than 52, or not greater than 50, or not greater than 48, or not greater than 46, or not greater than 44, or not greater than 42, or not greater than 40, or not greater than 38, or not greater than 36, or not greater than 34, or not greater than 32, or not greater than 30, or not greater than 28, or not greater than 26, or not greater than 24, or not greater than 22, or not greater than 20, or not greater than 18, or not greater than 16, or not greater than 8, or not greater than 6, or not greater than 4, or not greater than 2.

Embodiment 7. the abrasive article of embodiment 1, wherein the body comprises a diameter of at least 270mm, or at least 280mm, or at least 290mm, or at least 300mm, or at least 325mm, or at least 350mm, or at least 375mm, or at least 400mm, or at least 425mm, or at least 450mm, or at least 475mm, or at least 500mm, or at least 525mm, or at least 550mm, or at least 575 mm.

The abrasive article of embodiment 1, wherein the body comprises a diameter of not greater than 800mm, or not greater than 700mm, or not greater than 600mm, or not greater than 575mm, or not greater than 550mm, or not greater than 525mm, or not greater than 500mm, or not greater than 475mm, or not greater than 450mm, or not greater than 425mm, or not greater than 400mm, or not greater than 375mm, or not greater than 350mm, or not greater than 325mm, or not greater than 300mm, or not greater than 290mm, or not greater than 280 mm.

Embodiment 9. the abrasive article of embodiment 1, wherein the diameter is in a range of at least 260mm to not greater than 600 mm.

Embodiment 10. the abrasive article of embodiment 1, wherein the body comprises at least 1cm³The volume of (a).

Embodiment 11 the abrasive article of embodiment 1, wherein the body comprises not greater than 1000cm³The volume of (a).

Embodiment 12 the abrasive article of embodiment 1, wherein the body comprises at least 1cm³To not more than 1000cm³The volume of (a).

Embodiment 13. the abrasive article of embodiment 1, wherein the body comprises a thickness of at least 2 mm.

Embodiment 14. the abrasive article of embodiment 1, wherein the body comprises a thickness of not greater than 500 mm.

Embodiment 15 the abrasive article of embodiment 1, wherein the body comprises a thickness in a range of at least 2mm and not greater than 500 mm.

Embodiment 16 the abrasive article of embodiment 1, wherein the body comprises a thickness in a range of at least 4mm and not greater than 20 mm.

Embodiment 17 the abrasive article of embodiment 1, wherein the porosity comprises an average pore size (D50) in a range of at least 10 microns and not greater than 1000 microns.

Embodiment 18 the abrasive article of embodiment 1, wherein the body comprises a porosity of at least 20 vol%, or at least 25 vol%, or at least 30 vol%, or at least 35 vol%, or at least 40 vol%, or at least 45 vol%, or at least 50 vol%, or at least 55 vol%, or at least 60 vol%, or at least 65 vol%, or at least 70 vol%, or at least 75 vol%, or at least 80 vol% of the total volume of the body.

The abrasive article of embodiment 1, wherein the body comprises a porosity of not greater than 95 vol, or not greater than 90 vol, or not greater than 85 vol, or not greater than 80 vol, or not greater than 75 vol, or not greater than 70 vol, or not greater than 65 vol, or not greater than 60 vol, or not greater than 55 vol, or not greater than 50 vol, or not greater than 45 vol, or not greater than 40 vol, or not greater than 35 vol, or not greater than 30 vol for the total volume of the body.

Embodiment 20 the abrasive article of embodiment 1, wherein the body comprises a porosity in a range of at least 20 wt% and not greater than 95 wt% for the total volume of the body.

Embodiment 21. the abrasive article of embodiment 1, wherein at least a portion of the total porosity is open porosity, wherein the open porosity defines interconnected channels extending through the body.

Embodiment 22 the abrasive article of embodiment 21, wherein the body comprises an open porosity of at least 10 vol%, or at least 15 vol%, or at least 20 vol%, or at least 30 vol%, or at least 40 vol%, or at least 50 vol%, or at least 60 vol%, or at least 70 vol%, or at least 80 vol%, or at least 90 vol% of the total content of porosity within the body, or wherein substantially all of the porosity is open porosity.

The abrasive article of embodiment 21, wherein the body comprises an open porosity of not greater than 95 vol, or not greater than 90 vol, or not greater than 80 vol, or not greater than 70 vol, or not greater than 60 vol, or not greater than 50 vol, or not greater than 40 vol, or not greater than 30 vol, or not greater than 20 vol for the total content of porosity within the body.

Embodiment 24. the abrasive article of embodiment 1, wherein at least a portion of the total porosity is closed porosity, wherein the closed porosity defines discrete and independent voids contained within the bond material.

Embodiment 25 the abrasive article of embodiment 24, wherein the body comprises a closed porosity of at least 10 vol%, or at least 15 vol%, or at least 20 vol%, or at least 30 vol%, or at least 40 vol%, or at least 50 vol%, or at least 60 vol%, or at least 70 vol%, or at least 80 vol%, or at least 90 vol% of the total content of porosity within the body, or wherein substantially all of the porosity is closed porosity.

Embodiment 26 the abrasive article of embodiment 24, wherein the body comprises a closed porosity of not greater than 95 vol, or not greater than 90 vol, or not greater than 80 vol, or not greater than 70 vol, or not greater than 60 vol, or not greater than 50 vol, or not greater than 40 vol, or not greater than 30 vol, or not greater than 20 vol for the total content of porosity within the body.

Embodiment 27 the abrasive article of embodiment 1, wherein the abrasive particles have an average particle size (D50) of at least 45 microns, or at least 50 microns, or at least 55 microns, or at least 60 microns, or at least 65 microns, or at least 70 microns, or at least 75 microns, or at least 80 microns, or at least 85 microns, or at least 90 microns, or at least 95 microns, or at least 100 microns, or at least 105 microns, or at least 110 microns, or at least 115 microns, or at least 120 microns, or at least 130 microns, or at least 150 microns, or at least 175 microns, or at least 200 microns, or at least 250 microns, or at least 300 microns, or at least 350 microns, or at least 400 microns, or at least 450 microns, or at least 500 microns, or at least 600 microns, or at least 700 microns, or at least 800 microns.

Embodiment 28 the abrasive article of embodiment 1, wherein the abrasive particles have an average particle size (D50) of not greater than 5000 microns, or not greater than 4000 microns, or not greater than 3000 microns, or not greater than 2000 microns, or not greater than 1000 microns, or not greater than 900 microns, or not greater than 800 microns, or not greater than 700 microns, or not greater than 600 microns, or not greater than 500 microns, or not greater than 400 microns, or not greater than 300 microns, or not greater than 200 microns, or not greater than 150 microns, or not greater than 130 microns.

Embodiment 29 the abrasive article of embodiment 1, wherein the abrasive particles comprise an abrasive particle type selected from the group consisting of: non-agglomerated particles, shaped abrasive composites, Constant Thickness Abrasive Particles (CTAP), randomly shaped abrasive particles, or any combination thereof.

Embodiment 30. the abrasive article of embodiment 1, wherein the abrasive particles comprise a material selected from the group consisting of: an oxide, boride, nitride, carbide, oxynitride, oxycarbide, amorphous, single crystal, polycrystalline, superabrasive, or any combination thereof.

Embodiment 31 the abrasive article of embodiment 1, wherein the body comprises abrasive particles in an amount of at least 20 vol, or at least 25 vol, or at least 30 vol, or at least 35 vol, or at least 40 vol, or at least 45 vol, or at least 50 vol, or at least 55 vol of the total volume of the body.

Embodiment 32 the abrasive article of embodiment 1, wherein the body comprises abrasive particles in an amount of not greater than 65 vol, or not greater than 60 vol, or not greater than 55 vol, or not greater than 50 vol, or not greater than 45 vol, or not greater than 40 vol, or not greater than 35 vol, or not greater than 30 vol for the total volume of the body.

Embodiment 33. the abrasive article of embodiment 1, wherein the body comprises a content of abrasive particles in a range of at least 20 vol% and not greater than 50 vol% for the total volume of the body.

Embodiment 34 the abrasive article of embodiment 1, wherein the body comprises a bond material content of at least 1 vol, or at least 2 vol, or at least 3vol, or at least 4 vol, or at least 5 vol, or at least 6 vol, or at least 8 vol, or at least 10 vol, or at least 12 vol, or at least 14 vol, or at least 16 vol, or at least 18 vol, or at least 20 vol, or at least 25 vol, or at least 30 vol, or at least 35 vol, or at least 40 vol, based on the total volume of the body.

The abrasive article of embodiment 1, wherein the body comprises a bond material content of not greater than 65 vol, or not greater than 60 vol, or not greater than 55 vol, or not greater than 50 vol, or not greater than 45 vol, or not greater than 40 vol, or not greater than 35 vol, or not greater than 30 vol, or not greater than 25 vol, or not greater than 22 vol, or not greater than 20 vol, or not greater than 18 vol, or not greater than 16 vol, or not greater than 14 vol, or not greater than 12 vol, or not greater than 10 vol, or not greater than 8 vol, or not greater than 6 vol for the total volume of the body.

Embodiment 36. the abrasive article of embodiment 1, wherein the body comprises a bond material content in a range of at least 1 vol% and not greater than 15 vol% for the total volume of the body.

Embodiment 37. the abrasive article of embodiment 1, wherein the bond material comprises an inorganic material selected from the group consisting of: metal, metal alloy, ceramic, glass, or any combination thereof.

Embodiment 38. the abrasive article of embodiment 1, wherein the bond material comprises a polycrystalline phase, an amorphous phase, a single crystalline phase, or any combination thereof.

Embodiment 39. the abrasive article of embodiment 1, wherein the bond material consists essentially of a polycrystalline phase, an amorphous phase, or a single crystalline phase.

Embodiment 40. the abrasive article of embodiment 1, wherein the bond material comprises an oxide.

Embodiment 41. the abrasive article of embodiment 1, wherein the bond material comprises at least one composition selected from the group consisting of: silicon dioxide (SiO2), boron oxide (B2O3), aluminum oxide (Al2O3), alkali metal oxide (M2O), alkaline earth Metal Oxide (MO), transition metal oxide, rare earth metal oxide, or any combination thereof.

Embodiment 42. a method of making an abrasive article, comprising:

forming a mixture comprising abrasive particles, bond precursor material, and gelling agent;

forming a bonded abrasive body from the mixture, wherein the bonded abrasive body comprises a bond material comprising an inorganic material and further comprising a homogeneity factor of not greater than 85.

Embodiment 43 a method of making an abrasive article, comprising:

forming a mixture comprising abrasive particles, bond precursor material, and gelling agent;

adding a cationic agent to the mixture and forming a gel;

forming a green body from the gel; and

a bonded abrasive body is formed from the green body.

Embodiment 44 the method of embodiment 42, wherein forming the mixture further comprises adding a cationic agent to the mixture and forming a gel.

Embodiment 45 the method of any one of embodiments 43 and 44, wherein the cationic agent comprises a cation selected from the group consisting of: sodium, potassium, lithium, ammonium, copper, magnesium, iron, calcium, or any combination thereof.

Embodiment 46. the method of any of embodiments 43 and 44, wherein the mixture comprises at least 0.1 wt% of the cationic agent, based on the total weight of the mixture.

Embodiment 47 the method of any one of embodiments 43 and 44, wherein the mixture comprises no greater than 6 wt% of the cationic agent, based on the total weight of the mixture.

Embodiment 48. the method of any one of embodiments 42 and 43, wherein the gelling agent is selected from the group consisting of: agar, agarose, xanthan gum, carboxymethyl cellulose, gellan gum, carrageenan, guar gum, tara gum, cellulose gum, locust bean gum, or any combination thereof.

Embodiment 49 the method of any one of embodiments 42 and 43, wherein the mixture comprises at least 0.1 wt% gelling agent based on the total weight of the mixture.

Embodiment 50 the method of any of embodiments 42 and 43, wherein the mixture comprises no greater than 10 wt% gelling agent for the total weight of the mixture.

Embodiment 51. the method of any one of embodiments 42 and 43, wherein the abrasive particles comprise a material selected from the group consisting of: an oxide, boride, nitride, carbide, oxynitride, oxycarbide, amorphous, single crystal, polycrystalline, superabrasive, or any combination thereof.

Embodiment 52 the method of any one of embodiments 42 and 43, wherein the mixture comprises at least 20 wt% abrasive particles based on the total weight of the mixture.

Embodiment 53 the method of any one of embodiments 42 and 43, wherein the mixture comprises not greater than 80 wt% abrasive particles, based on the total weight of the mixture.

Embodiment 54 the method of any one of embodiments 42 and 43, wherein the bonding precursor material comprises an inorganic material selected from the group consisting of: metal, metal alloy, ceramic, glass, or any combination thereof.

Embodiment 55 the method of any one of embodiments 42 and 43, wherein the mixture comprises at least 1 wt% of the bonding precursor material based on the total weight of the mixture.

Embodiment 56 the method of any one of embodiments 42 and 43, wherein the mixture comprises not greater than 30 wt% of the bonding precursor material, based on the total weight of the mixture.

Embodiment 57 the method of any one of embodiments 42 and 43, further comprising forming a gel by heating the mixture to a gelation temperature.

Embodiment 58. the method of embodiment 57, wherein the mixture is mixed while heating the mixture to the gelation temperature.

Embodiment 59 the method of embodiment 57, wherein the gelation temperature is at least 50 ℃, or at least 60 ℃, or at least 70 ℃, or at least 80 ℃, or at least 90 ℃, or at least 100 ℃, or at least 120 ℃, or at least 150 ℃.

Embodiment 60 the method of embodiment 57, wherein the gelation temperature is no greater than 300 ℃, or no greater than 250 ℃, or no greater than 200 ℃, or no greater than 150 ℃, or no greater than 100 ℃, or no greater than 90 ℃.

Embodiment 61 the method of any one of embodiments 42 and 43, wherein forming a mixture further comprises adding an aqueous carrier.

Embodiment 62. the method of any one of embodiments 42 and 43, wherein gelling the mixture comprises:

a) forming a mixture comprising a gel and water;

b) adding one of a bond precursor material, abrasive particles, or additives to the mixture after step a); and

c) adding a cationic agent to the mixture after step b).

Embodiment 63 the method of any one of embodiments 42 and 43, wherein forming a mixture comprises adding a dispersant to the mixture, wherein the dispersant is selected from the group consisting of: sodium polyacrylate, copolymer with pigment affinity groups, ammonium polymethacrylate, ammonium polyacrylate, polyacrylic acid, ammonium salt of acrylic acid polymer in water, citric acid, sodium dodecylbenzenesulfonate, cetyltrimethylammonium bromide.

Embodiment 64. the method of any of embodiments 43 and 44, wherein the mixture comprises at least 0.1 wt% of a dispersant, based on the total weight of the mixture.

Embodiment 65. the method of any of embodiments 43 and 44, wherein the mixture comprises no greater than 6 wt% dispersant for the total weight of the mixture.

Embodiment 66. the method of any of embodiments 42 and 43, wherein forming a mixture comprises adding a surfactant to the mixture, wherein the surfactant is selected from the group consisting of: sodium lauroyl sarcosinate, sodium lauryl sulfate, sodium laurate, sodium stearate, sodium alkyl sulfate, sodium lauryl sulfate, sorbitan, polyethylene glycol, polysorbate, glycerol monostearate, lecithin.

Embodiment 67. the method of any of embodiments 42 and 43, wherein the mixture comprises at least 0.1 wt% surfactant, based on the total weight of the mixture.

Embodiment 68 the method of any one of embodiments 43 and 44, wherein the mixture comprises no greater than 6 wt% surfactant for the total weight of the mixture.

Embodiment 69 the method of embodiment 42, further comprising:

forming a gel from the mixture; and

a green body is formed from the gel.

Embodiment 70. the method of any of embodiments 43 and 69, wherein forming the green body comprises at least one method selected from the group consisting of: pressing, molding, casting, drying, or any combination thereof.

Embodiment 71. the method of any one of embodiments 43 and 69, wherein the gel comprises a solid self-supporting structure comprising water contained in an integrated network.

Examples of the invention

Example 1

A representative sample (sample S1) was prepared according to the following method. A deionized water carrier was obtained and about 3000kg of water was measured. About 10,000kg of abrasive particles having an average particle size (D50) of about 220 microns were prepared and are commercially available as white fused corundum from Saint-Gobain Corporation. About 2200kg of a bond precursor material was also prepared, commercially available as Vitrium from Saint-Gobain Corporation. About 20g of surfactant was also prepared and is commercially available as Perlastan L30 from Schill & Seilacher GmbH. About 120g of gelling agent was prepared and commercially available as Kelcogel from CP Kelco Corporation. About 60g of dispersant was also prepared and is commercially available as Darvan 821A from Vanderbilt Minerals. Approximately 20g of the cationizing agent was prepared and commercially available as calcium chloride from Fisher Scientific.

The gelling agent was added to the water while stirring. During mixing, the mixture is heated at a gelation temperature of about 80 ℃ to 85 ℃. Then adding a bonding precursor material to the gel, then adding a dispersant, abrasive particles, a surfactant in sequence, and finally adding a cationic agent. The addition of the cationic agent initiates crosslinking and gel formation. Mixing is continued under a reduced pressure atmosphere of about 0.5bar to 0.99bar to remove larger pores from the gel.

The gel is then poured into a production tool and a green body is cast from the gel. During casting, no additional pressure or temperature is applied to the gel and the gel is free-cast to form a green body. The gel was dried and the green body was stabilized. It should be understood that other methods may alternatively apply pressure to the gel to form a green body.

After forming the green body from the gel, the green body is fired to form a vitrified bond material from the bond precursor material. The firing schedule includes a firing temperature from room temperature to about 910 c to about 925 c at a ramp rate of about 100 c/hour and is maintained under normal atmosphere for about 8 hours. After the appropriate time at the firing temperature, the fired body was cooled at a cooling rate of about 30 ℃/hour.

The abrasive article is finished to finishThe size of the bonded abrasive body is determined. The bonded abrasive body has a homogeneity factor of about 62, 13 volume percent of a bond material consisting essentially of a vitreous material, about 44 volume percent abrasive particles, a porosity of about 43 volume percent including an open porosity of about 30 volume percent of a total porosity content and a closed porosity of about 70 volume percent of the total porosity content, and an average pore size of about 110 microns. Further, the bonded abrasive body of sample S1 had a diameter of 127mm, a thickness of about 25mm, and about 225cm³The volume of (a).

Fig. 3 includes an ultrasound image of sample S1 for evaluation of homogeneity factors.

Example 2

A conventional sample (sample C1) was formed according to the following process. The abrasives were weighed and mixed in a large mixer with dextrin as the binder. The contents were mixed for 5 minutes. The animal glue was then added to the mixture and mixed for 3 minutes. Mixing was stopped when the gum wetted the surface of the abrasive particles (so that the dextrin was uniformly coated on the surface). A binder was then added to the mixture and the contents were mixed for 5 minutes until the binder uniformly coated the abrasive particles. To this mixture is added another round of dextrin, applying the necessary green strength to withstand the compaction step. The mixture was then sieved to remove large lumps and then distributed evenly over the mould. The mould was then tilted to remove air and the mixture was then compacted/pressed (80 tonne force applied) to the desired volume. The wheel was then dried at 80 ℃ for 12 hours, then calcined at 915 ℃ at a ramp rate of 100 ℃/hour, and soaked for 8 hours. The wheel was then finished to accepted dimensions and analyzed using ultrasonic techniques.

The bonded abrasive wheel includes 13 volume percent binder, 44 volume percent abrasive, and 43 volume percent porosity.

Fig. 4 includes an ultrasound image of sample C1 for evaluation of homogeneity factors. Fig. 5 includes a normalized probability map of samples S1 and C1, as assessed by ultrasonic analysis for homogeneity factors. The sample S1 has a homogeneity factor of 62, and the sample C1 has a homogeneity factor of 86.

Example 3

Samples S2 and C2 were formed that included the same composition as sample S1. All components were mixed in the same manner as described in example 1. Samples S2 and C2 gel were poured into the mold. During the molding process, only the sample S2 gel was degassed to remove air bubbles. The green body was fired under the same conditions as described in example 1.

Samples S2 and C2 were tested for 3-dimensional tolerance and taper tolerance at the same shear rate. FIGS. 6A and 6B include a graph of cylindricity versus CMR 'and a graph of average straightness versus CMR', respectively. Under the same test conditions, sample S2 improved cylindricity, and thus 3-dimensional tolerance, compared to C2. As shown in fig. 6B, sample S2 also had improved average straightness (also referred to as taper tolerance) compared to sample C2.

Example 4

Sample S3, having a diameter of at least 260mm, a thickness of at least 2mm, and a homogeneity factor of no greater than 85, was formed in the same manner as described in example 1. Sample S3 is expected to exhibit higher consistency when abrasive testing is performed on at least 5 to 10 workpieces using the same abrasive tool barrel, and sample S3 is expected to improve the surface finish of the workpieces when abrasive testing is performed on each workpiece using a new barrel, as compared to an abrasive article conventionally shaped under the same conditions.

The description and illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The description and drawings are not intended to serve as an exhaustive or comprehensive description of all the elements and features of apparatus and systems that utilize the structures or methods described herein. Separate embodiments may also be provided in combination in a single embodiment, and conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any sub-combination. Further, reference to values expressed as ranges includes each and every value within that range. Many other embodiments will be apparent to the skilled person only after reading this description. Other embodiments may be utilized and derived from the disclosure, such that structural substitutions, logical substitutions, or other changes may be made without departing from the scope of the disclosure. The present disclosure is, therefore, to be considered as illustrative and not restrictive. Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. The benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced, however, are not to be construed as a critical, required, or essential feature or feature of any or all the claims.

The description taken in conjunction with the accompanying drawings is provided to assist in understanding the teachings disclosed herein. The following discussion will focus on specific implementations and examples of the present teachings. This emphasis is provided to help describe the teachings and should not be construed as limiting the scope or applicability of the present teachings. However, other teachings can of course be used in this application.

As used herein, the terms "comprises/comprising", "having" or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a method, article, or apparatus that comprises a list of features is not necessarily limited to only those features but may include other features not expressly listed or inherent to such method, article, or apparatus. Furthermore, unless expressly stated to the contrary, "or" means an inclusive "or" and not an exclusive "or". For example, any of the following conditions a or B may be satisfied: a is true (or present) and B is false (or not present), a is false (or not present) and B is true (or present), and both a and B are true (or present).

Also, the use of "a" or "an" is used to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. Unless clearly indicated otherwise, such description should be understood to include one or at least one and the singular also includes the plural or vice versa. For example, when a single item is described herein, more than one item may be used in place of a single item. Similarly, where more than one item is described herein, a single item may be substituted for more than one item.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The materials, methods, and examples are illustrative only and not intended to be limiting. Many details regarding specific materials and processing methods are conventional and can be found in the references and other sources within the field of construction and corresponding manufacturing, regarding aspects not described herein.

The above-disclosed subject matter is to be considered illustrative, and not restrictive, and the appended claims are intended to cover all such modifications, enhancements, and other embodiments, which fall within the true scope of the present invention. Thus, to the maximum extent allowed by law, the scope of the present invention is to be determined by the broadest permissible interpretation of the following claims and their equivalents, and shall not be restricted or limited by the foregoing detailed description.