Porous abrasive articles with agglomerated abrasives
AssigneeSaint-Gobain Abrasives Technology Company
InventorsEric Bright, Mianxue Wu
Life of this patent
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Abstract
A bonded abrasive tool, having a structure permeable to fluid flow, comprises sintered agglomerates of a plurality of abrasive grains and a binding material, the binding material being characterized by a melting temperature between 500 and 1400° C., and the sintered agglomerates having a loose packing density of ≦1.6 g/cc and three-dimensional shape; a bond material; and about 35-80 volume % total porosity, including at least 30 volume % interconnected porosity. Methods for making the sintered agglomerates and abrasive tools containing the sintered agglomerates are described.
Claims40
A bonded abrasive tool, having a structure permeable to fluid flow, the tool comprising:
- a) about 5-75 volume % sintered agglomerates, comprising a plurality of abrasive grains held with a binding material, the binding material being characterized by a melting temperature between 500 and 1400° C., and the sintered agglomerates having a three dimensional shape;
- b) an effective amount of a bond to hold the sintered agglomerates together within the bonded abrasive tool;
- and
- c) about 35-80 volume % total porosity, of which at least 30 volume % is interconnected porosity;
- wherein at least 50%, by weight, of the sintered agglomerates within the bonded abrasive tool include a plurality of abrasive grains held in a three-dimensional shape after manufacture of the tool.
A vitrified bonded abrasive tool, having a structure permeable to fluid flow, the tool comprising:
- a) about 5-75 volume % sintered agglomerates of a plurality of abrasive grain with a binding material, the binding material being characterized by a viscosity A at the binding material melting temperature;
- b) an effective amount of a vitrified bond to hold the sintered agglomerates together within the bonded abrasive tool, the bond being characterized by a viscosity B at the binding material melting temperature, viscosity B being at least 33% lower than viscosity A;
- and
- c) about 35-80 volume % porosity, of which at least 30 volume % is interconnected porosity.
The vitrified bonded abrasive tool of claim 20, wherein at least 50%, by weight, of the sintered agglomerates within the tool include a plurality of abrasive grains held in a three-dimensional shape.
A vitrified bonded abrasive tool, having a structure permeable to fluid flow, the tool comprising:
- a) about 5-60 volume % sintered agglomerates of a plurality of abrasive grain with a binding material, the binding material being characterized by a melting temperature A;
- b) an effective amount of a vitrified bond to hold the sintered agglomerates together within the bonded abrasive tool, the bond being characterized by a melting temperature B, melting temperature B being at least 150° C. lower than melting temperature A;
- and
- c) about 35-80 volume % porosity, of which at least 30 volume % is interconnected porosity.
A bonded abrasive tool, having a structure permeable to fluid flow, the tool comprising:
- a) about 34-56 volume % abrasive grain;
- b) about 3-25 volume % bond;
- and
- c) about 35-80 volume % total porosity of which at least 30 volume % is interconnected porosity;
- wherein the interconnected porosity has been created without porosity inducing media and without elongated shaped materials having a length to cross-sectional width aspect ration at least 5:1;
- and
- wherein 5-100 volume % of the abrasive grain consists of abrasive grain held within three-dimensional sintered agglomerates, and the sintered agglomerates comprise a plurality of abrasive grains with a binding material, the binding material being characterized by a melting temperature between 500 and 1400° C.
A method of grinding, comprising the steps of:
- a) providing a bonded abrasive tool, having a structure permeable to fluid flow, the tool comprising:
- 1) 5 to 75 volume % sintered agglomerates comprising a plurality of abrasive grains held with a binder material, the binder material being characterized by a melting temperature between 500 and 1400° C., and the sintered agglomerates having a three dimensional shape and an average size distribution;
- 2) an effective amount of a bond to hold the sintered agglomerates together within the bonded abrasive tool;
- and
- 3) about 35-80 volume % total porosity, of which at least 30 volume % is interconnected porosity;
- wherein at least 50%, by weight, of the sintered agglomerates within the bonded abrasive tool include a plurality of abrasive grains held in a three-dimensional shape;
- b) bringing the bonded abrasive tool into contact with a workpiece;
- and
- c) abrading the surface of the workpiece with the bonded abrasive tool.
Dependencies are inferred from the claim text.