KR20130062998A - Bonded abrasive articles, method of forming such articles, and grinding performance of such articles - Google Patents

Abstract

의 파워 편차를 가지는데, 여기서 P_o는 처음 연삭 사이클에서 상기 접합된 연마 본체로 가공물을 연삭하기 위한 연삭력을 나타내고 P_n은, n>4 인 n 번째 연삭 사이클에 대해 가공물을 연삭하기 위한 연삭력을 나타낸다.An abrasive tool having a bonded abrasive body having abrasive particles contained in a bonding material comprising a metal. During the grinding operation, the bonded abrasive body is about 40% or less

Where P _o represents the grinding force for grinding the workpiece with the bonded abrasive body in the first grinding cycle and P _n is for grinding the workpiece for the n th grinding cycle with n> 4. Power.

Description

Bonded abrasive articles, methods of making such articles, and grinding performance of such articles {BONDED ABRASIVE ARTICLES, METHOD OF FORMING SUCH ARTICLES, AND GRINDING PERFORMANCE OF SUCH ARTICLES}

The following relates to the performance of bonded abrasive articles, more particularly bonded abrasive articles comprising abrasive particles contained in a bonding material comprising a metal or metal alloy.

Abrasives used in the field of machining generally include bonded abrasive articles and coated abrasive articles. Coated abrasive articles are generally layered articles having a backplate and an adhesive layer to secure abrasive particles to the backplate, the most common example being sandpaper. Bonded abrasive tools are rigid, generally agglomerated, three-dimensional abrasive composites, in the form of wheels, disks, segments, mounted points, horns, and other tool shapes, and grinding. Or in a machining apparatus such as a polishing apparatus.

The bonded abrasive tools typically have at least two phases comprising abrasive particles and a joining material. Some bonded abrasive articles may have additional phases in the form of pores. Bonded abrasive tools are a variety of "grade" and "structures" defined according to the practice of the art by the relative hardness and density of abrasive composites (grades) and by the volume percentage of abrasive particles, bonds, and pores in the composites (structures). Can be made with ".

Some bonded abrasive tools may be particularly useful for grinding and forming certain types of workpieces, including metals, ceramics, and crystalline materials, for example, used in the electronics and light industries. In another example, certain bonded abrasive tools can be used to form superabrasive materials for use in the industrial sector. With regard to grinding and forming a workpiece with a metal bonded abrasive article, the process generally involves a significant amount of time and labor in maintaining the bonded abrasive article. That is, abrasive articles, in which metal is generally bonded, require normal truing and dressing to maintain the grinding ability of the abrasive article. There is a continuing need for improved grinding methods and articles in the industry.

According to one aspect, the abrasive article comprises a bonded abrasive body having abrasive particles contained within a bonding material comprising a metal or metal alloy, wherein the bonded abrasive body is at least about 5 compared to conventional metal bonded abrasive articles. % Grinding is performed on the workpiece at a faster grinding speed.

In another aspect, the abrasive article comprises a bonded abrasive body having abrasive particles contained within a bonding material comprising a metal or metal alloy, the bonded abrasive body performing a grinding operation and comparing with conventional metal bonded abrasive articles. Thus, as measured by the grinding wear rate, there is an increase in grinding efficiency in workpieces that are at least less than about 5% wear.

In yet another aspect, the abrasive article comprises a bonded abrasive body having abrasive particles contained in a bonding material comprising a metal or metal alloy, the bonded abrasive body performing a grinding operation and combining with a conventional metal bonded abrasive article. In comparison, there is an increase in grinding efficiency in workpieces that are at least about 10%, as measured in parts / dress.

In yet another aspect, a method of manipulating an abrasive tool includes grinding a workpiece comprising a carbide material having an average Vickers hardness of at least about 5 GPa with a bonded abrasive body comprising abrasive particles contained within the metal bonding material. do. The bonded abrasive workpiece performs at least 17 consecutive grinding cycles without exceeding the maximum spindle power of the grinding machine.

에 의해 정의되는 바로서 40% 이하의 처음 연삭력에서 증가를 나타내는데, 여기서 P_o는 처음 연삭 사이클에서 접합된 연마 본체로 가공물을 연삭하기 위한 처음 연삭력을 나타내고 P_n은, n≥16 인 n 번째 연속되는 연삭 사이클에서 접합된 연마 본체로 가공물을 연삭하기 위한 연삭력을 나타낸다.According to another aspect, a method of manipulating an abrasive tool includes truing an abrasive body bonded with a diamond roll wheel and then grinding the workpiece with the bonded abrasive body, wherein, during grinding, the workpiece has an average Vickers hardness of at least about 5 GPa. The bonded body bonded with

An increase in the initial grinding force of 40% or less as defined by P _o , where P _o represents the initial grinding force for grinding the workpiece with the bonded abrasive body in the first grinding cycle and P _n is n with n ≧ 16 The grinding force for grinding the workpiece with the bonded abrasive body in the first successive grinding cycle.

In another aspect, a method of manipulating an abrasive tool includes truing an abrasive body bonded with an abrasive truing wheel, wherein the bonded abrasive body comprises abrasive particles contained in a metal bonding material, wherein the bonding material is about 4.0 MPa m has an average fracture toughness (K _1C ) of ^0.5 or less. The method further includes grinding the workpiece with the bonded bonded body directly after truing, wherein the bonded bonded body during the grinding operation of the metal workpiece is at least about 1200 at a material removal rate of at least about 1.0 in ³ / min / in. It has a G-ratio, where the G-ratio is defined as the volume of material removed from the workpiece divided by the volume of material lost through wear from the bonded abrasive body.

의 파워 편차를 가지는데, 여기서 P_o는 처음 연삭 사이클에서 접합된 연마 본체로 가공물을 연삭하기 위한 처음 연삭력을 나타내고 P_n은, n≥4 인 n 번째 연삭 사이클에 대해 가공물을 연삭하기 위한 연삭력을 나타낸다.According to another aspect, a method of manipulating an abrasive tool includes truing an abrasive body bonded with an abrasive truing wheel, the bonded abrasive body comprising abrasive particles contained within a metal bonding material. The method includes grinding the workpiece with the bonded abrasive body after sticking without stick dressing the bonded abrasive body, wherein during grinding, the bonded abrasive body is 40% or less.

Has a power deviation of, where P _o represents the initial grinding force for grinding the workpiece with the bonded body bonded in the first grinding cycle and P _n is for grinding the workpiece for the n th grinding cycle with n≥4. Power.

에 의해 정의되고, P_o는 제1 연삭 사이클에서 접합된 연마 본체로 가공물을 연삭하기 위한 처음 연삭력을 나타내고 P_n은 400초의 연삭 후에 접합된 연마 본체로 가공물을 연삭하기 위한 연삭력을 나타낸다.Another aspect includes an abrasive tool comprising a bonded abrasive body having abrasive particles contained in a bonding material comprising a metal, the body having a ratio of V _AG / V _BM that is at least about 1.3, wherein V _AG is The volume percentage of abrasive particles in the total volume of the body, and V _BM is the volume percentage of bonding material in the total volume of the body. During the grinding operation of a workpiece having an average Vickers hardness of at least about 5 GPa, the bonded abrasive body has an increase in initial grinding force of 10% or less for a grinding time of at least about 400 seconds at a minimum feed rate of at least about 3 inches / minute. Where the increase in the initial grinding force is

P _o represents the initial grinding force for grinding the workpiece into the bonded abrasive body in the first grinding cycle and P _n represents the grinding force for grinding the workpiece into the bonded abrasive body after 400 seconds of grinding.

According to another aspect, an abrasive tool comprises a bonded abrasive body having abrasive particles contained within a bonding material comprising a metal or metal alloy, and wherein the bonded abrasive is in operation of grinding a workpiece having a Vickers hardness of at least about 5 GPa. The body has an increase in the initial grinding force of 40% or less as defined by the formula [(P _n P _o ) / P _o ] x 100%, where P _o is the abrasive body joined in the first grinding cycle. Represents the initial grinding force for grinding and P _n represents the grinding force for grinding the workpiece into the abrasive body joined in the nth grinding cycle of n ≧ 16.

According to another aspect, an abrasive tool comprises a bonded abrasive body having abrasive particles contained in a bonding material comprising a metal or metal alloy, the body comprising a ratio of V _AG / V _BM that is at least about 1.3. Where V _AG is the volume percentage of abrasive particles in the total volume of the body and V _BM is the volume percentage of bonding material in the total volume of the body. During the grinding operation of the metal workpiece, the bonded abrasive body has a G-ratio of at least about 1200 at a material removal rate of at least about 1.0 in ³ / min / in, where the G-ratio is removed from the workpiece. Volume of material obtained is divided by the volume of material lost through wear from the bonded abrasive body.

의 파워 편차를 가지는데, 여기서 P_o는 처음 연삭 사이클에서 접합된 연마 본체로 가공물을 연삭하기 위한 처음 연삭력을 나타내고 P_n은, n≥4 인 n 번째 연삭 사이클에 대해 가공물을 연삭하기 위한 연삭력을 나타낸다.According to certain embodiments, the abrasive tool comprises a bonded abrasive body having abrasive particles contained in a bonding material comprising a metal or metal alloy, wherein during the undressing grinding operation, the bonded abrasive body is 40% or less.

Has a power deviation of, where P _o represents the initial grinding force for grinding the workpiece with the bonded body bonded in the first grinding cycle and P _n is for grinding the workpiece for the n th grinding cycle with n≥4. Power.

The present disclosure will be better understood with reference to the accompanying drawings, and many features and advantages can be apparent to those skilled in the art.
1 includes a plot of grinding force (Hp / in) versus the number of grinding cycles for a bonded abrasive body in accordance with an embodiment.
Figure 2 contains a diagram of a grinding cycle number against the surface roughness (R _a) on the bonded abrasive body according to an embodiment.
3 includes a plot of grinding force (Hp / in) versus the number of grinding cycles for bonded abrasive bodies in accordance with an embodiment and a typical sample.
4 shows the grinding force (Hp) versus two different material removal rates (eg, 4.5 in ³ / min / in and 5.1 in ³ / min / in) for the bonded abrasive body according to the examples and conventional samples. Contains a bar graph.
5 includes a bar graph of the grinding ratio (G-ratio) at two different material removal rates for the bonded abrasive body according to the examples and conventional samples.
FIG. 6 includes a plot of spindle power (Hp) versus grinding time (seconds) for bonded abrasive bodies according to examples and conventional samples.
FIG. 7 includes a plot of spindle power (Hp) versus grinding time (seconds) for bonded abrasive bodies according to examples and conventional samples.
8-11 include enlarged images of the microstructure of the bonded abrasive body according to the embodiment.
Use of the same reference numerals in different drawings indicates similar or identical articles.

The following generally relates to bonded abrasive articles comprising abrasive particles in a three-dimensional matrix of material. The bonded abrasive articles utilize large amounts of abrasive particles fixed in a three dimensional matrix of bonding material. The following also includes descriptions relating to the methods of forming such bonded abrasive articles and the application to such bonded abrasive articles.

According to an embodiment, the process of forming the abrasive article may begin by forming a mixture containing abrasive particles and bonding material. The abrasive particles may comprise a hard material. For example, the abrasive particles can have a Mohs hardness of at least about 7. In other abrasive bodies, the abrasive particles may have a Mohs hardness that is at least 8, or at least 9.

In certain examples, the abrasive particles can be made of an inorganic material. Suitable inorganic materials may include carbides, oxides, nitrides, borides, oxycarbide, oxyboride, oxynitride, and combinations thereof. In particular, examples of abrasive particles include silicon carbide, boron carbide, alumina, zirconia, alumina-zirconia composite particles, silicon nitride, SiAlON, and titanium boride. Include. In some examples, the abrasive particles may include super abrasive material, such as diamond, cubic boron nitride, and combinations thereof. In certain examples, the abrasive particles may consist essentially of diamond. In other embodiments, the abrasive particles may consist essentially of cubic boron nitride.

The abrasive particles can have an average grit size of about 1000 microns or less. In other embodiments, the abrasive particles may have an average grit size of about 750 microns or less, such as 500 microns or less, 250 microns or less, 200 microns or less, or even 150 microns or less. In certain examples, the abrasive particles of the embodiments herein have an average grit in the range between about 1 micron and about 1000 microns, such as between about 1 micron and 500 microns, or even between about 1 micron and 200 microns. May have a size.

In addition to the abrasive particles, the shape of the abrasive particles can be described by an aspect ratio, which is the ratio between the dimensions of the length to the width. The length will be understood as the longest dimension of the abrasive grit and the width as the second longest dimension of the given abrasive grit. According to an embodiment herein, the abrasive particles may have an aspect ratio (length: width) of about 3: 1 or less, or even about 2: 1 or less. In certain instances, the abrasive particles can be essentially equiaxed, with an aspect ratio of about 1: 1.

Abrasive particles can include other features including, for example, a coating. The abrasive particles may be coated with a coating material which may be an inorganic material. Suitable inorganic materials may include ceramics, glass, metals, metal alloys, and combinations thereof. In certain instances, the abrasive particles may be electroplated with a metal material, and more specifically, with a transition metal composition. Such coated abrasive particles can promote improved bonding (eg, chemical bonding) between the abrasive particles and the bonding material.

In some instances, the mixture may comprise a particular distribution of abrasive particles. For example, the mixture may include grit sizes of abrasive particles in a multi-modal distribution such that there is a specific distribution of fine, medium and coarse grit sizes in the mixture. In one particular example, the mixture includes bimodal distribution abrasive particles comprising fine particles having a fine average grit size and coarse abrasive particles having a coarse average grit size, wherein the coarse average grit The size is significantly larger than the fine average grit size. For example, the coarse average grit size may be at least about 10% or more, at least about 20%, at least about 30%, or even at least about 50% or more than the fine average grit size (based on the fine abrasive grit size). It is to be understood that the mixture may include abrasive particles of other multiphase distributions, including, for example, three or four phase distributions.

Abrasive particles of the same composition may have various mechanical properties, including, for example, friability. The mixture and the finally formed bonded abrasive body may comprise a mixture of abrasive particles, which may be of the same composition but have various mechanical properties or grades. For example, the mixture may comprise abrasive particles of a single composition such that the mixture will contain only diamond or cubic boron nitride. However, diamond or cubic boron nitride may comprise a mixture of diamond or cubic boron nitride of different grades, such that the abrasive particles have various grades and various mechanical characteristics.

The abrasive particles can be provided in a mixture in amount such that the finally formed abrasive article will contain a certain amount of abrasive particles. For example, the mixture may include abrasive particles having a major content (eg, at least 50 vol%).

According to an embodiment, the bonding material may be a metal or a metal alloy. For example, the bonding material may comprise a powder composition comprising at least one transition metal element. In certain examples, the bonding material may comprise a metal selected from the group comprising copper, tin, silver, molybdenum, zinc, tungsten, iron, nickel, antimony, and combinations thereof. In one particular embodiment, the bonding material can be a metal alloy including copper and tin. The metal alloy of copper and tin can be a bronze material, and is made 60:40 each by weight composition of copper and tin.

According to certain embodiments, the metal alloy of copper and tin may comprise a certain amount of copper such that the finally formed bonded abrasive article has appropriate mechanical properties and grinding performance. For example, copper and tin metal alloys may contain up to about 70% copper, such as up to about 65% copper, up to about 60%, up to about 50% copper, up to about 45% copper, or even up to 40% It may include copper. In certain examples, the amount of copper is in a range between about 30% and about 65%, and more particularly between about 40% and about 65%.

Certain metal alloys of copper and tin may have a minimum amount of tin. For example, the metal alloy may comprise at least about 30% tin of the total amount of the composition. In other examples, the amount of tin can be, for example, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 60%, at least about 65%, or even at least about 75% or more. Some bonding materials may include copper and tin metal alloys having an amount of tin in the range of about 30% to about 80%, between about 30% to about 70%, or even between about 35% to about 65%. Can be.

In alternative embodiments, the bonding material may be a tin based material, which includes the metals and metal alloys in which tin constitutes the major content relative to other compositions present in the material. For example, the bonding material may consist essentially of tin. In addition, any tin-based materials may be used including other alloy materials that are up to about 10%, in particular metals.

The mixture may comprise abrasive particles in equivalent portions to the bond. However, in some embodiments, the mixture may be formed such that the amount of bonding material is smaller than the amount of abrasive particles in the mixture. Such a mixture may facilitate a bonded abrasive article having certain properties, which will be described in more detail herein.

In addition to the abrasive particles and the bonding material, the mixture may further comprise an active bonding composition precursor. The active bonding composition precursor is a mixture that subsequently promotes a chemical reaction between certain components of the bonded abrasive body, including, for example, particulate material (eg, bonded particles and / or fillers) and a bonding material. It includes a material, which can be added to. The active bonding composition precursor may be added to the mixture in a small amount, especially in an amount less than the amount of abrasive particles present in the mixture.

According to an embodiment, the active bonding composition precursor may comprise a composition comprising a metal or a metal alloy. More specifically, the active conjugated composition precursor may comprise a composition or compound comprising hydrogen. For example, the active bonding composition precursor may comprise a metal hydride, and more particularly, may include a material such as titanium hydride. In one embodiment, the active bonding composition precursor consists essentially of titanium hydride.

The mixture generally contains a small amount of the active bonding composition precursor. For example, the mixture may include up to about 40 wt% of the active bonding composition precursor in the total weight of the mixture. In other embodiments, the amount of active junction composition precursor in the mixture may be less, such as up to about 35 wt%, up to about 30 wt%, up to about 28 wt%, up to about 26 wt%, up to about 23 wt Up to about 18 wt%, up to about 15 wt%, up to about 12 wt%, or even up to about 10 wt%. In certain examples, the amount of active junction composition precursor in the mixture is between about 2 wt% and about 40 wt%, such as between about 4 wt% and about 35 wt%, between about 8 wt% and about 28 wt%, about 10 wt% To between about 28 wt%, or even between about 12 wt% and about 26 wt%.

The mixture may further comprise a binder material. The binder material may be utilized to provide adequate strength during formation of the bonded abrasive article. Some suitable binder materials may include organic materials. For example, the organic material may be a material such as a thermosetting resin, a thermoplastic resin, an adhesive, and combinations thereof. In one particular example, the organic material of the binder material includes materials such as polyimide, polyamide, resin, aramid, epoxy, polyester, polyurethane, acetate, cellulose, and combinations thereof. In one embodiment, the mixture may include a binder material that utilizes a combination of thermoplastic materials set to cure at a specific temperature. In other embodiments, the binder material may comprise an adhesive material suitable for promoting adhesion between the components of the mixture. The binder may be in liquid form, including, for example, an aqueous or non-aqueous compound.

In general, the binder material may be present in the mixture in small amounts (by weight). For example, the binder may be present in significantly less than the amount of abrasive particles, bonding material, or active bonding composition precursor. For example, the mixture may comprise up to about 40 wt% of the binder material relative to the total weight of the mixture. In other embodiments, the amount of binder material in the mixture may be less, such as 35 wt% or less, about 30 wt% or less, about 28 wt% or less, about 26 wt% or less, about 23 wt% or less, about 18 wt%. Up to about 15 wt%, up to about 12 wt%, or even up to about 10 wt%. In certain examples, the amount of binder material in the mixture is between about 2 wt% and about 40 wt%, such as between about 4 wt% and about 35 wt%, between about 8 wt% and about 28 wt%, between about 10 wt% and about Or between about 28 wt% and even between about 12 wt% and about 26 wt%.

The mixture may further comprise some amount of filler. The fillers can be particulate materials that can replace certain components in the mixture, including, for example, abrasive particles. In particular, the fillers may be particulate material that may be included in the mixture, and the fillers substantially retain their original size and shape in the finally formed bonded abrasive body. Examples of suitable fillers are oxides, carbides, borides, silicides, nitrides, oxynitrides, oxycarbide, silicates, graphite, silicon, intermetallic compounds, ceramics, hollow-ceramic, fused silica, glass, glass-ceramic, hollow glass Neutral materials such as spheres, shells, and combinations thereof.

In particular, some fillers may have a hardness that is less than the hardness of the abrasive particles. In addition, the mixture may be formed such that the fillers are present in an amount up to about 90 vol% of the total volume of the mixture. Volume percentages are used to describe the content of fillers when the fillers can have varying densities depending on the shape of the particles, such as hollow spheres relative to heavy particles. In other embodiments, the amount of filler in the mixture is about 80 vol% or less, such as about 70 vol% or less, about 60 vol% or less, about 50 vol% or less, about 40 vol% or less, about 30 vol% or less, or even About 20 vol% or less.

Some forming processes may utilize a larger amount of filler material than the amount of abrasive particles. For example, almost all of the abrasive particles can be replaced with one or more filler materials. In other examples, most content of abrasive particles may be replaced with a filler material. In other embodiments, a small portion of the abrasive particles may be replaced with a filler material.

In addition, the fillers may have an average particle size significantly smaller than the average grit size of the abrasive particles. For example, the average particle size of the filler is at least about 5%, at least about 10%, at least about 15%, at least about 20%, than the average average grit size of the abrasive particles based on the average grit size of the average grit size of the abrasive particles, Or even at least about 25% smaller.

In some other embodiments, the fillers may have a larger average particle size than abrasive particles, especially with regard to the filler being a hollow body.

In certain examples, the filler material is about 10 MPa m as measured by a nano-indentation test through a standard test of ISO 14577 using a diamond probe available from CSM Indentation Testers, Inc. or similar company in Switzerland. ^It may have a fracture toughness (K _1C ) of ^0.5 or less. In other embodiments, the filler may have a fracture toughness (K _1C ) of about 9 MPa m ^0.5 or less, such as about 8 MPa m ^0.5 or less, or even about 7 MPa m ^0.5 or less. In addition, the average fracture toughness of the fillers ranges from about 0.5 MPa m ^{0.5 to} about 10 MPa m ^0.5 , such as between about 1 MPa m ^0.5 to about 9 MPa m ^0.5 , or even between about 1 MPa m ^0.5 to about 7 MPa m ^0.5. Can be in.

After forming the mixture, the process of forming the bonded abrasive article continues with shearing the mixture so that the mixture has suitable flow characteristics. For example, the mixture may be sheared until it has a certain viscosity, such as at least about 100 centipoises, and may have a concentration that is half liquid (eg, a concentration such as mud). In other examples, the mixture may be of much lower viscosity, such as a paste.

After the shearing of the mixture, the process may continue with the formation of aggregates from the mixture. The process of forming the aggregates may include a process of first drying the mixture. In particular, the drying process may be carried out at a temperature suitable to cure the organic components (eg, thermosetting resins) in the binder contained in the mixture and remove some of the volatiles (eg, moisture) in the mixture. can do. Thus, in properly curing the organic material in the binder material, the mixture may have a cured or semi-cured form. Particularly suitable drying temperatures may be up to 250 ° C. and more particularly in the range between about 0 ° C. and about 250 ° C.

After drying the mixture at an appropriate temperature, the process of forming the aggregates can continue with grinding the cured form. After milling the cured form, the milled particles comprise agglomerates of components contained in the mixture, including abrasive particles and bonding material. The process of forming the agglomerates includes sieving the milled particles to obtain a proper distribution of the agglomerate sizes.

After forming the aggregates, the process may continue with molding the aggregate into the desired shape of the finally formed bonded abrasive article. One suitable molding process involves filling the mold with agglomerated particles. After filling the mold, the aggregates can be pressed to form a green (ie, unsintered) body with the dimensions of the mold. According to one embodiment, pressing may be performed at a pressure of at least about 0.01 ton / in ² to the region of bonded abrasive article. In other embodiments, pressing may be larger, such as at least about 0.1 ton / in ² , at least about 0.5 ton / in ² , at least about 1 ton / in ² , or even at least about 2 ton / in ^{2 or} more. have. In one particular embodiment the pressing may be completed at a pressure in the range between about 0.01 ton / in ² to about 5 ton / in ² , more particularly between about 0.5 ton / in ² to about 3 ton / in ² . .

After molding the mixture to form a green article, the process may continue with processing the green article. The treating step may comprise heat treating the green article, in particular sintering the green article. In one particular embodiment, the treating step includes liquid phase sintering to form a bonded abrasive body. In particular, liquid phase sintering involves making certain components of the green article, in particular the bonding material, in a liquid phase, so that at least a portion of the bonding material is in the liquid phase and flows freely at the sintering temperature. In particular, liquid phase sintering is not a commonly used process for the formation of bonded abrasives utilizing metal bonding materials.

According to an embodiment, treating the green article comprises heating the green article to a liquid phase sintering temperature of at least 400 ° C. In other embodiments, the liquid phase sintering temperature may be for example at least 500 ° C., at least 650 ° C., at least 800 ° C., or even at least 900 ° C. or more. In certain examples, the liquid phase sintering temperature may be within a range between about 400 ° C. and about 1100 ° C., such as between about 800 ° C. and about 1100 ° C., more particularly between about 800 ° C. and about 1050 ° C.

The treating step, and in particular the sintering, can be carried out for a certain duration. Sintering at the liquid phase sintering temperature may be performed for a duration of at least about 10 minutes, at least about 20 minutes, at least about 30 minutes or even at least about 40 minutes. In certain embodiments, the sintering at the liquid phase sintering temperature may continue for a duration within a range between about 10 minutes and about 90 minutes, such as between about 10 minutes and 60 minutes, or even between about 15 minutes and about 45 minutes.

Processing the green article includes performing a liquid phase sintering process in a specific atmosphere. For example, the atmosphere may be a reduced pressure atmosphere having a pressure of about 10 ⁻² Torr or less. In other embodiments, the reduced pressure atmosphere may have a pressure of about 10 ⁻³ Torr or less, about 10 ⁻⁴ Torr or less, about 10 ⁻⁵ Torr or less, or even about 10 ⁻⁶ Torr or less. In certain examples, the reduced pressure may be in a range between about 10 ⁻² Torr and about 10 ⁻⁶ Torr.

In addition, during the processing of the green article, and particularly during the liquid phase sintering process, the atmosphere may be a non-oxidizing (ie, reducing) atmosphere. Suitable gaseous materials for forming a reducing atmosphere may include hydrogen, nitrogen, noble gases, carbon monoxide, decomposed ammonia, and combinations thereof. In other embodiments, an inert atmosphere can be used during processing of the green article to limit the oxidation of the metal and metal alloy components.

After completing the treatment process, a bonded abrasive article is made comprising abrasive particles in the metal bonding material. According to an embodiment, the abrasive article may have a body having certain characteristics. For example, according to one embodiment, the bonded abrasive body may have a significantly larger volume of abrasive particles than the volume of bonding material in the body. The bonded abrasive body may have a ratio of V _AG / V _{BM that} is at least about 1.3, where V _AG represents the volume percentage of abrasive particles within the total volume of the bonded abrasive body, and V _BM is the volume of the bonded abrasive body. It represents the volume percentage of the bonding material within the total volume. According to another embodiment, the ratio of V _AG / V _BM may 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 has a ratio of V _AG / V _BM between about 1.3 and 9.0, such as between about 1.3 and about 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 2.0. It may be made to be in the range between about 5.0, between about 2.0 and about 4.0, between about 2.1 and about 3.8, or even between about 2.2 and about 3.5.

In more particular conditions, the bonded abrasive body may comprise at least about 30 vol% abrasive particles relative to the total volume of the bonded abrasive body. In other examples, the content of abrasive particles is greater, at least about 45 vol%, at least about 50 vol%, at least about 60 vol%, at least about 70 vol%, or even at least about 75 vol%. In certain embodiments, the bonded abrasive body is between about 30 vol% and about 90 vol%, such as between about 45 vol% and about 90 vol%, between about 50 vol% and about 85, based on the total volume of the bonded abrasive body. abrasive particles between vol%, or even between about 60 vol% and about 80 vol%.

The bonded abrasive body may comprise up to about 45 vol% of the joining material relative to the total volume of the bonded abrasive body. According to some embodiments, the content of the bonding material is less, such as about 40 vol% or less, about 30 vol% or less, about 25 vol% or less, about 20 vol% or less, or even about 15 vol% or less. In certain embodiments, the bonded abrasive body is between about 5 vol% and about 45 vol%, such as between about 5 vol% and about 40 vol%, about 5 vol% to about 30, based on the total volume of the bonded abrasive body. bonding materials that are between vol%, or even between about 10 vol% and about 30 vol%.

According to another embodiment, the bonded abrasive body herein may comprise some amount of pores. For example, the bonded abrasive body may have at least 5 vol% of pores relative to the total volume of the bonded abrasive body. In other embodiments, the bonded abrasive body may have at least 10 vol%, such as at least 12 vol%, at least 18 vol%, at least 20 vol%, at least 25 vol%, at least 30 vol%, or even relative to the total volume of the body. Have pores that are at least 35 vol%. Further, in other embodiments, the bonded abrasive body may include up to about 80 vol% of pores relative to the total volume of the body. In other articles, the bonded abrasive body may comprise up to about 70 vol%, up to about 60 vol%, up to about 55 vol%, such as up to about 50 vol%, up to about 48 vol%, It can have up to about 44 vol%, up to about 40 vol%, or even up to about 35 vol% pores. It will be appreciated that the pores may be within a range between the minimum and maximum listed herein.

The bonded abrasive body may be made such that a certain amount of pores in the bonded abrasive body are pores connected to each other. The interconnected pores define a network of interconnected passages (ie, voids) that extend through the volume of the bonded abrasive body. For example, most of the pores of the body may be pores connected to each other. Indeed, in certain instances, the bonded abrasive body may be a pore with at least 60%, at least about 70%, at least about 80%, at least about 90%, or even at least about 95% of the pores present in the bonded abrasive body. Can be made as possible. In some instances, basically all of the pores present in the body are pores connected to each other. Thus, the bonded abrasive body may be defined by a continuous network of two phases, a second continuous phase defined by pores extending between the solid phase defined by the body and the abrasive particles and the solid phase through the bonded abrasive body. .

According to another embodiment, the bonded abrasive body, as compared with the bonding material (V _BM) for a total volume of the bonded abrasive body can have a certain percentage of the particle material (V _P) comprising abrasive particles and filler have. It will be appreciated that the amount of particulate material and bonding material is measured in volume percentage of the component as part of the total volume of the body. For example, the bonded abrasive bodies of the embodiments herein may have a ratio (V _P / V _BM ) of at least about 1.5. In other embodiments, the V _P / V _BM ratio 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 certain embodiments, the V _P / V _BM ratio is 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 6.0, between about 1.7 and about It may be between 5.5, or even between about 2.0 to about 5.5. As such, the bonded abrasive body may comprise a greater amount of particulate material comprising fillers and abrasive particles than the bonding material.

According to one embodiment, the abrasive body may comprise an amount of filler (vol%) that can be less than, equal to, or greater than the amount of abrasive particles (vol%) present in the total volume of the bonded abrasive body. Can be. Some abrasive articles may utilize a filler no greater than about 75 vol% relative to the total volume of the bonded abrasive body. According to some embodiments, the content of fillers in the body may be about 50 vol% or less, about 40 vol% or less, about 30 vol% or less, about 20 vol% or less, or even about 15 vol% or less. In certain embodiments, the bonded abrasive body is between about 1 vol% and about 75 vol%, such as between about 1 vol% and about 50 vol%, between about 1 vol% and about 20, relative to the total volume of the bonded abrasive body. fillers between vol%, or even between about 1 vol% and about 15 vol%. In one example, the bonded abrasive body may be basically filler free.

The bonded abrasive bodies of the embodiments herein may have a specific content of the active bonding composition. As will be appreciated, the active bonding composition can be a reaction product made from a reaction between the active bonding composition precursor and certain components of the bonded abrasive body, including, for example, abrasive particles, fillers, and bonding material. . The active bonding composition may promote chemical bonding between particles in the body (eg, abrasive particles or filler) and a bonding material that may promote retention of particles in the bonding material.

In particular, the active bonding composition may comprise independent phases, which may be disposed in independent regions of the bonded abrasive body. In addition, the active conjugated composition may have a specific composition depending on the location of the composition. For example, the active bonding composition may comprise a precipitated phase and a boundary phase. The precipitated phase can be present in the bonding material and can be distributed as an independent phase over the volume of the bonding material. The boundary phase may be disposed at the boundary between the particulate material (ie, abrasive particles and / or fillers) and the bonding material. The boundary phase may extend over most of the surface area of the particulate material of the body. Although not fully understood, the differences and independent phases in the composition of the separate phases and the active bonding composition are due to the formation processes, in particular liquid phase sintering.

Thus, the bonding material may be a composite material comprising the bonded phases and the precipitated phases, which are separate phases. The precipitated phase may be made of a composition comprising at least one component of the active bonding composition and at least one component of the bonding material. In particular, the precipitated phase may comprise at least one metal component originally provided in the mixture as a bonding material. The precipitated phase can be a metal or metal alloy compound or complex. In certain embodiments, the precipitated phase may comprise a material selected from the group of materials including titanium, vanadium, chromium, zirconium, hafnium, tungsten, and combinations thereof. In more specific examples, the precipitated phase comprises titanium and may consist essentially of titanium and tin.

The bonding phase of the bonding material may comprise metal elements contained in the original bonding material used to form a mixture with the transition metal element specifically. As such, the junction phase may be made of a material selected from the group of metals consisting of copper, tin, silver, molybdenum, zinc, tungsten, iron, nickel, antimony, and combinations thereof. In certain instances, the junction phase may comprise copper and may be a copper based compound or a complex. In some embodiments, the bonded phase consists essentially of copper.

The boundary phase may comprise at least one component of the active bonding composition. The boundary phase may also include at least one component of the particle material. As such, the boundary phase may be a compound or complex formed through a chemical reaction between the active bonding composition and the particles. Some boundary materials include carbides, oxides, nitrides, borides, oxynitrides, oxyborides, oxycarbides, and combinations thereof. The boundary phase may comprise a metal, and more particularly, may be a compound comprising a metal, such as metal carbide, metal nitride, metal oxide, metal oxynitride, metal oxyboride, or metal oxycarbide. According to one embodiment, the boundary phase consists essentially of a material from the group of titanium carbide, titanium nitride, titanium boron nitride, titanium aluminum oxide, and combinations thereof.

In addition, the boundary phase may have an average thickness of at least about 0.1 micron. However, more particularly, the boundary phase may have varying thicknesses depending on the size of the particle material on which the boundary phase lies. For example, with respect to abrasive particles and / or fillers having an average size of less than 10 microns, the boundary phase may have a thickness in the range between about 1% and 205 of the average size of the particles. For particle materials having an average size in the range between about 10 microns and about 50 microns, the boundary phase may have a thickness in the range between about 1% and 10% of the particle average size. For particle materials having an average size in the range between about 50 microns and about 500 microns, the boundary phase may have a thickness in the range between about 0.5% and 10% of the particle average size. For particle materials having an average size of greater than about 500 microns, the boundary phase may have a thickness in the range between about 0.1% and 0.5% of the particle average size.

8-11 include enlarged images of the microstructure of the bonded abrasive body according to the embodiment. 8 is a scanning electron microscope image (in backscatter mode) of a cross section of a portion of the bonded abrasive body comprising abrasive particles 801 and a bonding material 803 extending between the abrasive particles 801. Engineered). As shown, the bonding material 803 is shown in a darker color and bonded with two independent phases of the material, a precipitated phase 805 that is represented in a lighter color and extends over the volume of the bonding material 803. Bonding phase 806 extending over the volume of material 803.

9-11 include enlarged images of the same area as the bonded abrasive body of FIG. 8, using microprobe analysis to distinguish the presence of select elements in certain areas of the body. FIG. 9 includes a microprobe image for the region of FIG. 8 in mode setting to distinguish regions of high copper content. According to an embodiment, the bonding material 803 may comprise a metal alloy of copper and tin. According to a more particular embodiment, the bonding phase 806 of the bonding material 803, which is one of at least two independent phases of the bonding material 803, may have a greater amount of copper than the precipitation phase 805. .

FIG. 10 includes an enlarged image of the areas of FIGS. 8 and 9, where microprobe analysis was used to distinguish selected elements in certain areas of the bonded abrasive body. Fig. 10 uses microprobes as a mode setting for distinguishing areas with annotations, so that brighter areas represent areas with more annotations. As shown, the precipitated phase 805 of the bonding material 803 has a higher content of tin than the bonding phase 806.

FIG. 11 includes an enlarged image of the area of FIGS. 8-10 using microprobe analysis. In particular, FIG. 11 uses microprobes as a mode setting to distinguish regions with titanium presence, where brighter regions represent regions with more titanium. As shown, the precipitated phase 805 of the bonding material 803 has a higher content of titanium than the bonding phase 806. 11 also provides evidence of the boundary image 1101 at the boundary of the abrasive particles 801 and the bonding material 803. As demonstrated by FIG. 11, the boundary phase 1101 comprises a particularly high content of titanium, such that the titanium of the active bonding composition precursor preferentially moves to the boundary of the particles and chemically reacts with the abrasive particles herein. As described, it is possible to form a heterogeneous phase.

8-11 provide evidence of unexpected phenomena. Although not fully understood, it is hypothesized that the original bonding material consisting of copper and tin is separated during the process, which is due to the liquid phase sintering process. Tin and copper become independent phases; Sedimentary phase 805 and bonded phase 806, respectively. In addition, tin preferentially combines with titanium present in the active bonding composition precursor material to form the precipitated phase 805.

According to an embodiment, the bonded abrasive body may comprise about 1 vol% of the active bonding composition relative to the total volume of the bonding material, including both phases of the active bonding composition, such as the boundary phase and the precipitated phase. In other embodiments, the amount of active conjugate composition in the conjugate is, for example, at least about 4 vol%, at least about 6 vol%, at least about 10 vol%, at least about 12 vol%, at least about 14 vol%, at least about 15 vol%, or Even at least about 18 vol%. In certain examples, the bonding material may be between about 1 vol% and about 40 vol%, such as between about 1 vol% and 30 vol%, between about 1 vol% and about 25 vol%, between about 4 vol% and about 25 vol% , Or in an amount between about 6 vol% and about 25 vol%. In some examples, the amount of active bonding composition is between about 10 vol% and about 30 vol%, between about 10 vol% and about 25 vol%, or between about 12 vol% and about 20 vol%, relative to the total volume of the bonding material. It is in range.

The bonded abrasive body can be made such that the bonding material can have a particular fracture toughness K _1C . Toughness of the bonding material can be measured via micro-indentation test or nano-indentation test. The micro-indentation test includes fracture toughness through the principle of causing cracks in a polished sample by applying an indentor at a specific location within the material in the bonding material, including, for example, in this example. Measure For example, suitable micro-indentation tests can be performed according to the methods described in Microindentation Techniques in Materials Science and Engineering, ASTM STP 889, DB Marshall and BR Lawn pp 26-46, "Indentation of Brittle materials". According to an embodiment, the bonded abrasive body has a joining material having an average fracture toughness (K 1 _C ) of about 4.0 MPa m ^0.5 or less. In other embodiments, the average fracture toughness (K _1C ) of the bonding material is about 3.75 MPa m ^0.5 or less, such as about 3.5 MPa m ^0.5 or less, about 3.25 MPa m ^0.5 or less, about 3.0 MPa m ^0.5 or less, about 2.8 MPa m ^0.5 or less, or about 2.5 MPa m ^0.5 or less. The average fracture toughness of the bonding material is in the range of about 0.6 MPa m ^{0.5 of} about 4.0 MPa m ^0.5 , such as in the range of about 0.6 MPa m ^{0.5 of} about 3.5 MPa m ^0.5 , or in the range of about 0.6 MPa m ^{0.5 of} about 3.0 MPa m ^0.5 . There may be.

The abrasive articles of the embodiments herein may have certain characteristics. For example, the bonded abrasive body may have a modulus of rupture (MOR) that is at least about 2000 psi, such as at least about 4000 psi, and more particularly, at least about 6000 psi.

The bonded abrasive bodies of the embodiments herein exhibit certain characteristics when used in certain grinding operations. In particular, the bonded abrasive wheel can be used in a grinding operation that is not dressing, where the bonded abrasive body does not require a dressing operation after the body performs a truing operation. Typically, truing operations are completed to give the polishing body the desired contour and shape. After truing, the abrasive body is generally dressed with equally harder or lighter abrasive elements to remove worn grit and expose new abrasive particles. Dressing is a time consuming and necessary process for conventional abrasive articles to ensure proper operation of the abrasive article. The bonded abrasive bodies of the embodiments herein require significantly less dressing during use and have significantly improved coefficients of performance for conventional abrasive articles.

로 설명된다. P_o는 처음 연삭 사이클에서 접합된 연마 본체로 가공물을 연삭하기 위한 연삭력(Hp 또는 Hp/in)을 나타내고 P_n은, n≥4 인 n 번째 사이클에 대해 가공물을 연삭하기 위한 연삭력(Hp 또는 Hp/in)을 나타낸다. 따라서, 파워 편차는 처음 연삭 사이클로부터 적어도 4회 연삭 사이클이 수행된 후의 연삭 사이클로의 연삭력에 있어 변화를 측정한다.For example, in one embodiment, during an undressed grinding operation, the bonded abrasive body of the embodiment may have a power deviation of about 40% or less, where the power deviation is

. P _o represents the grinding force (Hp or Hp / in) for grinding the workpiece into the abrasive body joined in the first grinding cycle and P _n is the grinding force (Hp) for grinding the workpiece for the nth cycle with n≥4 Or Hp / in). Thus, the power deviation measures the change in the grinding force from the first grinding cycle to the grinding cycle after at least four grinding cycles have been performed.

In particular, the grinding cycle may be completed in a continuous manner, meaning that no truing or dressing operation is performed on the abrasive article bonded between the grinding cycles. The bonded abrasive bodies of the embodiments herein may have a power deviation of about 25% or less of certain polishing operations. In still other embodiments, the power variation of the bonded abrasive body may be about 20% or less, such as about 15% or less, or about 12% or less. The power variation of certain abrasive bodies may be in the range between about 1% and about 40%, such as between about 1% and about 20%, or between about 1% and about 12%.

Further related to the power deviation, the change between the grinding force in the first grinding cycle (P _o ) and the grinding force used to grind the workpiece in the _nth grinding cycle (P _n ) is the difference between grinding cycles where "n" is 4 or more. It should be noted that it can be measured against the number of times. In other examples, “n” may be at least 6 (ie, at least six grinding cycles), at least 10, or at least 12. It is also to be understood that the nth grinding cycle may represent a continuous grinding cycle, where dressing is not performed on the abrasive article between the grinding cycles.

According to an embodiment, the bonded abrasive body can be used in grinding operations, wherein the material removal rate MRR 'is at least about 1.0 in ³ / min / in [10 mm ³ / sec / mm]. In other embodiments, the grinding operation using the bonded abrasive body of the embodiments herein is at least about 4.0 in ³ / min / in [40 mm ³ / sec / mm], such as at least about 6.0 in ³ / min / in [60 mm ³ / sec / mm], at least about 7.0 in ³ / min / in [70 mm ³ / sec / mm], or even at least about 8.0 in ³ / min / in [80 mm ³ / sec / mm] It can be performed at a phosphorous material removal rate. Some grinding operations utilizing the bonded abrasive bodies of the embodiments herein are between about 1.0 in ³ / min / in [10 mm ³ / sec / mm] to about 20 in ³ / min / in [200 mm ³ / sec / mm], within about 5.0 in ³ / min / in [50 mm ³ / sec / mm] to about 18 in ³ / min / in [180 mm ³ / sec / mm], about 6.0 in Within a range from ³ / min / in [60 mm ³ / sec / mm] to about 16 in ³ / min / in [160 mm ³ / sec / mm], or even about 7.0 in ³ / min / in [70 mm ³ / sec / mm] to about 14 in ³ / ^m in / in [140 mm ^{3 /} sec / mm] can be carried out at a material removal rate (MRR ').

In addition, the bonded abrasive body can be utilized in a grinding operation in which the bonded abrasive body rotates at a specific surface speed. Surface speed refers to the speed of the wheel at the point of contact with the workpiece. For example, the bonded abrasive body may be at a speed of at least surface feet per minute (sfpm), such as at least about 1800, such as at least about 2000 sfpm, at least about 2500 sfpm, at least about 5000 sfpm, or even at least It can be rotated at a speed of 10000 sfpm. In certain examples, the bonded abrasive body may be rotated at a speed within a range between about 2000 sfpm and about 15000 sfpm, such as between about 2000 sfpm and 12000 sfpm.

The bonded abrasive body includes a variety of grinding, including, for example, plunge grinding operations, creep feed grinding operations, peel grinding operations, flute grinding operations, and the like. It may be suitable for use in operations. In another particular example, the bonded abrasive body is suitable for use in end mill grinding applications. In other examples, the bonded abrasive body may be useful for thinning hard brittle workpieces, including, for example, sapphire and quartz materials.

Further, they can be utilized in the polishing operation of the polishing body joint of the embodiments of the present application in, after grinding, the workpiece has an average surface roughness (R _a) of less than or equal to about 50 microinches (about 1.25 microns). In other examples, the average surface roughness of the workpiece may be about 40 micro inches (about 1 micron), or even about 30 micro inches (about 0.75 microns) or less.

In other embodiments, during grinding with the bonded abrasive articles of the embodiments herein, the average surface roughness deviation for at least three consecutive grinding operations may be about 35% or less. It should be noted that successive grinding operations are operations in which the truing operation is not performed between each grinding operation. The deviation in the average surface roughness can be calculated as the standard deviation of the measured average surface roughness of the workpiece at the respective positions of the workpiece on which each individual grinding operation is performed. According to some embodiments, the average surface roughness deviation for at least three consecutive grinding operations may be about 25% or less, about 20% or less, about 15% or less, about 10% or less, or even about 5% or less. .

According to another embodiment, the bonded abrasive article may have a G-ratio of at least about 1200. The G-ratio is the volume of material removed from the workpiece divided by the volume of material missing from the bonded abrasive body through abrasion. According to another embodiment, the bonded abrasive body may have a G-ratio that is at least about 1300, such as at least about 1400, at least about 1500, at least about 1600, at least about 1700, or even at least about 1800. In some examples, the G-ratio of the bonded abrasive body may be in the range between about 1200 and about 2500, such as between about 1200 and about 2300, or between about 1400 and about 2300. The G-ratio values shown herein can be obtained at the material removal rates shown herein. In addition, the described G-ratio values can be obtained in the various workpiece material forms described herein.

In another aspect, the bonded abrasive article may have a significantly improved G-ratio for conventional abrasive articles, especially metal-bonded abrasive articles. For example, the G-ratio of bonded abrasive bodies in accordance with embodiments herein may be at least about 5% more than the G-ratio of a conventional abrasive article. In other examples, the improvement in G-ratio may be at least about 10%, at least about 15%, at least about 20%, at least about 25%, or even at least about 30% or more. Certain embodiments of the bonded abrasive article include 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 An increase in G-ratio is seen compared to conventional bonded polishing in the range between 75% or even between about 10% and about 60%.

에 의해 정의되는 바로서 약 40% 이하의 처음 연삭력에서의 증가를 가질 수 있다. 이 식에서, P_o는 처음 연삭 사이클에서 접합된 연마 본체로 가공물을 연삭하기 위한 처음 연삭력(Hp 또는 Hp/in)을 나타내고 P_n은, n≥16 인 n 번째 연삭 사이클에서 접합된 연마 본체로 가공물을 연삭하기 위한 연삭력(Hp 또는 Hp/in)을 나타낸다. 연삭 사이클은, 접합된 연마 본체의 트루잉 또는 드레싱이 수행되지 않는 연속적인 연삭 사이클이 될 수 있는 것으로 이해해야 할 것이다.Some bonded abrasive bodies exhibit initial grinding forces close enough to steady state grinding forces. In general, the steady state grinding force differs significantly from the initial grinding force for conventional metal-bonded abrasive articles. As such, the increase in grinding force from the initial grinding force is particularly low for the bonded abrasive bodies of the embodiments herein as compared to conventional metal-bonded abrasive articles. For example, the bonded abrasive bodies of the embodiments herein may be

It can have an increase in initial grinding force of up to about 40% as defined by. Where P _o represents the initial grinding force (Hp or Hp / in) for grinding the workpiece into the abrasive body bonded in the first grinding cycle and P _n is the abrasive body bonded in the nth grinding cycle with n≥16 The grinding force (Hp or Hp / in) for grinding a workpiece is shown. It will be appreciated that the grinding cycle can be a continuous grinding cycle in which no truing or dressing of the bonded abrasive body is performed.

According to one embodiment, during a grinding operation using the bonded abrasive article of the embodiments herein, the increase in initial grinding force is about 35% or less, such as about 30% or less, about 25% or less, about 20% or less, About 18% or less, about 15% or less, about 12% or less, about 10% or less, or even about 8% or less. In certain examples, the bonded abrasive body may perform grinding operations, wherein the increase in initial grinding force is in a range between about 0.1% and about 40%, such as in a range between about 0.1% and about 30%. It may be in the range between 1% and about 15%, in the range between about 1% and about 12%, or even in the range between about 1% and about 8%.

에 의해 정의될 수 있는데, 여기서 P_o는 제1 연삭 사이클에서 접합된 연마 본체로 가공물을 처음으로 연삭하기 위한 처음 연삭력(Hp 또는 Hp/in)을 나타내고 P₄₀₀은 400 초의 연삭 후에 접합된 연마 본체로 가공물을 연삭하기 위한 연삭력(Hp 또는 Hp/in)을 나타낸다. 어떤 다른 연삭 조작들에서, 접합된 연마 본체는 약 3 인치/분의 최소 공급속도로 적어도 400 초의 연삭 시간 동안 약 8% 이하인, 예컨대 약 6% 이하인, 약 4% 이하인, 또는 심지어 약 2% 이하인 처음 연삭력에서의 증가를 가질 수 있다. 특정 연삭 적용에서, 접합된 연마 본체는 3 인치/분의 최소 공급속도로 적어도 400 초의 연삭 시간 동안 약 0.1% 내지 약 10% 사이, 예컨대 약 0.1% 내지 약 8% 사이, 약 0.1% 내지 약 6% 사이, 또는 약 0.1% 내지 약 4% 사이의 범위 내에서 처음 연삭력에서의 증가를 나타낸다.In other embodiments, the bonded abrasive bodies exhibit an increase in initial grinding force of about 10% or less for a grinding time of at least 400 seconds at a minimum feed rate of about 3 inches / minute. The increase in initial grinding force is

Where P _o represents the initial grinding force (Hp or Hp / in) for the first grinding of the workpiece with the abrasive body bonded in the first grinding cycle and P ₄₀₀ is the bonded abrasive after 400 seconds of grinding. The grinding force (Hp or Hp / in) for grinding a workpiece with a main body is shown. In some other grinding operations, the bonded abrasive body may be about 8% or less, for example about 6% or less, about 4% or less, or even about 2% or less, for a grinding time of at least 400 seconds at a minimum feed rate of about 3 inches / minute. May have an increase in the initial grinding force. In certain grinding applications, the bonded abrasive body is between about 0.1% to about 10%, such as between about 0.1% to about 8%, about 0.1% to about 6, for a grinding time of at least 400 seconds at a minimum feed rate of 3 inches / minute. An increase in initial grinding force between% or within a range from about 0.1% to about 4%.

에 의해 정의될 수 있는데, 여기서 P_o는 제1 연삭 사이클에서 접합된 연마 본체로 가공물을 처음으로 연삭하기 위한 처음 연삭력(Hp 또는 Hp/in)을 나타내고 P₈₀₀은 800 초의 연삭 후에 접합된 연마 본체로 가공물을 연삭하기 위한 연삭력(Hp 또는 Hp/in)을 나타낸다. 또한, 본원에서 실시예들의 어떤 접합된 연마 물품들에 대해, 처음 연마력에서 증가는 3 인치/분의 최소 공급속도로 적어도 약 800 초의 시간에 대해 더 작을 수 있어서, 예컨대 약 15% 이하, 약 10% 이하, 또는 심지어 약 8% 이하일 수 있다. 본원에서의 접합된 연마 본체는 약 3 인치/분의 최소 공급속도로 적어도 약 800 초의 연삭 시간에 대해, 약 0.1% 내지 약 20% 사이, 예컨대 약 0.1% 내지 약 18% 사이, 예컨대 약 0.1% 내지 약 15% 사이, 또는 심지어 약 0.1% 내지 약 8% 사이의 범위 내에서 처음 연삭력에서의 증가를 가질 수 있다. 이러한 특성들은 경질 또는 초경질 가공물을 연삭할 때 접합된 연마 본체의 작동을 위해 특히 적합할 수 있다.The bonded abrasive bodies of the embodiments herein may have a specific grinding capability such that the increase in initial grinding force is less than or equal to about 20% for a grinding time of at least about 800 seconds at a minimum feed rate of at least 3 inches / minute. For these applications the increase in initial grinding force is

Where P _o represents the initial grinding force (Hp or Hp / in) for the first grinding of the workpiece into the bonded body bonded in the first grinding cycle and P ₈₀₀ represents the bonded polishing after 800 seconds of grinding. The grinding force (Hp or Hp / in) for grinding a workpiece with a main body is shown. In addition, for certain bonded abrasive articles of the embodiments herein, the increase in initial polishing force may be smaller for a time of at least about 800 seconds at a minimum feed rate of 3 inches / minute, such as about 15% or less, about 10 Up to%, or even up to about 8%. The bonded abrasive body herein herein is between about 0.1% and about 20%, such as between about 0.1% and about 18%, such as about 0.1%, for a grinding time of at least about 800 seconds at a minimum feed rate of about 3 inches / minute. It may have an increase in initial grinding force within a range from about 15%, or even between about 0.1% to about 8%. These properties may be particularly suitable for the operation of the bonded abrasive body when grinding hard or ultrahard workpieces.

According to another embodiment, the bonded abrasive body may have a limited increase in initial grinding force for a grinding time of at least 800 seconds at a minimum feed rate of at least 6 inches / minute. For example, the increase in initial grinding force may be about 20% or less, such as about 15% or less, about 12% or less, or even about 10% or less for a grinding time of at least about 800 seconds at a minimum feed rate of about 6 inches / minute. Can be. These properties may be particularly suitable for the operation of the bonded abrasive body when grinding hard or ultrahard workpieces.

The bonded abrasive bodies of the embodiments herein may be suitable for grinding certain workpieces, particularly hard workpieces. For example, the workpiece can have an average Vickers hardness of at least 5 GPa. In other examples, the average Vickers hardness of the workpiece may be at least about 10 GPa or even at least about 15 GPa.

The workpiece can be made of metal, metal alloy, nitride, boride, carbide, oxide, oxynitride, oxyboride, oxycarbide, combinations thereof. In certain examples, the workpiece can be a metal carbide, including, for example, tungsten carbide. In exemplary conditions where grinding is performed in a workpiece made of tungsten carbide, the amount of cobalt in the tungsten carbide workpiece may be in the range between about 5% and about 12% by weight.

In performing certain grinding operations, for example, in certain hard materials, the bonded abrasive body can be operated at a speed of at least 1800 sfpm. In other examples, the bonded abrasive body may be rotated at a speed of at least 1900 sfpm, at least 2200 sfpm, or even at least 2350 sfpm. In certain examples, the bonded abrasive body may be rotated during grinding operations at a speed within a range between about 1800 sfpm and about 3100 sfpm, more particularly between about 1900 sfpm and about 2350 sfpm.

In addition, the bonded abrasive articles of the embodiments herein are suitable for certain grinding operations, such as, for example, in a workpiece that is particularly hard at any feed rate. For example, the feed rate may be at least about 2 inches / minute. In other examples, the feed rate may be greater, such as at least about 3 inches / minute, at least about 3.5 inches / minute, or at least about 4 inches / minute. Certain embodiments may utilize a bonded abrasive body in a grinding operation, wherein the feed rate is within a range from about 2 inches / minute to about 10 inches / minute, such as between about 3 inches / minute and about 8 inches / minute. .

In another embodiment, the bonded abrasive body can be used in a grinding operation, where after truing the bonded abrasive body with the abrasive truing wheel, the bonded abrasive body does not exceed the maximum spindle power of the grinding machine. Workpieces with an average Vickers hardness of at least 5 GPa can be ground for at least 17 consecutive grinding cycles. As such, the bonded abrasive body exhibits particularly improved processing life in grinding workpieces of hard materials. In fact, the bonded abrasive body may perform at least about 20 consecutive grinding cycles, at least about 25 consecutive grinding cycles, or at least about 30 consecutive grinding cycles before the truing operation is utilized. Reference to a continuous grinding cycle should be understood as referring to a grinding cycle performed in a continuous manner without truing or dressing of the abrasive body bonded between the grinding cycles.

In comparison of the bonded abrasive bodies of the embodiments herein to conventional bonded abrasive bodies, in general, conventional bonded abrasive articles are required before the truing operation for sharpening and resurfacing again is required. Up to about 16 consecutive grinding cycles are performed on relatively hard workpieces. As such, the bonded abrasive bodies of the embodiments herein are conventional metals, as measured by the number of consecutive grinding cycles that are required before the truing operation is required or the grinding force exceeds the power capacity of the grinding machine. -An improvement in the grinding time operable for the bonded, bonded abrasives.

Another notable improvement in grinding performance as measured in the industry is the parts / dress, which is a measure of the number of parts that can be processed by a particular abrasive article before the abrasive article requires dressing to maintain performance. According to one embodiment, the bonded abrasive bodies of the embodiments herein increase in grinding efficiency at a workpiece of at least about 10% compared to a conventional metal bonded abrasive article, as measured by the parts / dresses. It can have According to another embodiment, the increase in grinding efficiency is at least about 20%, such as at least about 30%, at least about 40%, or even at least about 50% compared to conventional metal bonded abrasive articles. In particular, such conventional metal-bonded abrasive articles may include state-of-the-art articles such as G-Force and Spector brand abrasive articles available from Saint-Gobain. In certain examples, the increase in grinding efficiency as measured by the parts / dresses may be between about 10% and about 200%, such as between about 20% and about 200%, between about 50% and about 200%, Or even between about 50% and about 150%. It is to be understood that this improvement can be achieved in the workpieces described herein under the grinding conditions described herein.

In addition, the bonded abrasive articles of the embodiments herein may have an improvement in grinding performance as measured in the industry by the wear rate, which is a measure of the wear experienced by the abrasive article during grinding. According to one embodiment, the bonded abrasive bodies of the embodiments herein can have an improvement in the wear rate, such that the abrasive article wears at a rate at least 5% less than the wear rate of a conventional metal bonded abrasive article. According to another embodiment, the wear rate is at least about 8% smaller, such as at least about 10%, at least about 12%, or even at least about 15% smaller compared to conventional metal bonded abrasive articles. In certain examples, the improvement in wear rate ranges from about 5% to about 100%, such as between about 5% to about 75%, about 5% to about 0%, or even about 5% to about 50% Can be in. It is to be understood that such improvements can be achieved in the workpieces described herein under the grinding conditions described herein.

Another notable improvement in grinding performance as measured in the industry is wear rate, which is a measure of the wear experienced by abrasive articles during grinding. According to one embodiment, the bonded abrasive bodies of the embodiments herein may result in an improvement in the wear rate as the abrasive article wears at a rate at least 5% less than the wear rate of a conventional metal bonded abrasive article. have. According to another embodiment, the wear rate is at least about 8% smaller, such as at least about 10%, at least about 12%, or even at least about 15% smaller compared to conventional metal bonded abrasive articles. In certain examples, the improvement in wear rate is between about 5% and about 100%, such as between about 5% and about 75%, between about 5% and about 60%, or even between about 5% and about 50% May be in range. It is to be understood that such improvements can be achieved in the workpieces described herein under the polishing conditions described herein.

Another notable improvement in the grinding performance exhibited by the abrasive articles of the embodiments herein includes an increase in the available grinding speeds. Grinding speed is the speed at which a workpiece can be molded without sacrificing surface finish or exceeding the grinding force of a machined or bonded abrasive article. According to one embodiment, the bonded abrasive bodies of the embodiments herein may have an improvement in the grinding speed, such that the abrasive article may be grinding at least 5% faster than conventional metal bonded abrasive articles. have. In other examples, the grinding speed is for example at least about 8%, at least about 10%, at least about 12%, at least about 15%, at least about 20% or even at least about 25% or less compared to conventional metal bonded abrasive articles. Can be larger. For certain bonded abrasive articles herein, the increase in grinding speed may be between about 5% and about 100%, such as between about 5% and about 75%, between about 5% and about 60%, or even about 5%. It may be in the range between% and about 50%. It is to be understood that such improvements can be achieved in the workpieces described herein under the polishing conditions described herein.

In particular, these improvements in grinding speed can be achieved while maintaining other grinding conditions. For example, improvements in grinding speed may be achieved while having a limited increase in initial grinding force as mentioned herein, limited deviation in surface finish as mentioned herein, and limited wear rate as mentioned herein. have.

12 includes an enlarged image of a bonded abrasive body according to an embodiment. As shown, the bonded abrasive body includes abrasive particles 1201 surrounded by and in a bonding material 1202 comprising a metal or metal alloy material. As also shown, the bonded abrasive body has a substantially open structure, including pores 1203 extending between abrasive particles 1201 and bonding material 1202. As is apparent from FIG. 12, the bonded abrasive body comprises a significant amount (vol%) of abrasive particles 1201, mainly comprising abrasive particles 1201 whose structure is bonded together by the bonding material 1202. It will contain. In addition, abrasive particles 1201 are in close proximity to each other, and a small amount of bonding material 1202 separates abrasive particles 1201, resulting in a high ratio of abrasive particles 1201 to bonding material 1202. Indicates.

Yes

Example 1

The first bonded abrasive sample is made into a 4 "diameter with a 1A1 shape as understood in the industry. The fabrication of the sample was obtained from Connecticut Engineering Associate of 27 Philo Curtis Road, Sandy Hook, CT 06482, USA. Making a mixture comprising 45.96 grams of bronze (ie copper: tin 60:40 by weight) powder in mesh size, the same bronze purchased from Chemetall Chemical Products in New Providence New Jersey, USA Dry blended with 5.11 grams of titanium hydride in size Cubic boron nitride abrasive particles with US mesh size -120 / + 140 are mixed with bronze powder and titanium hydride The abrasive grains are Saint-Gobain Ceramics in Worcester, MA. and commercially available as CBN-V from and Plastics.

After adding abrasive particles, 8.15 grams of organic binder is added to the mixture and the mixture is sheared to mud concentration. Organic binders include thermoplastic resins sold under the trade names S-binder by Wall Company and K424 binder by Vitta. The mixture is dried in an oven to remove moisture. The dried mixture is ground and sieved to give agglomerates. The aggregate is placed in a steel mold having a ring shape and defining a nominal outside diameter of 4 inches and an inside diameter of 3.2 inches. The aggregate is pressed at 2.4 ton / in ² to form a green article. The green article is sintered at 950 ° C. for 30 minutes in a reduced pressure atmosphere having a pressure of about 10 ⁻⁴ Torr. The resulting bonded abrasive has a ratio of 3.0 (V _AG / V _BM ) and an amount of pores (100% interconnected pores) which is 34 volume percent of the total volume of the body.

A steel core is attached to the polished bonded body using epoxy and further finished, balanced and speed tested to complete the wheel manufacturing process. The wheel is labeled Sample 1 for identification.

Sample 1 is used for grinding workpieces that are 52100 bearing steel, originally cured to 58-62 HRC, in an external cylindrical plunge grinding mode in a Byrant OD / ID grinder. The workpieces are in the form of 52100 steel discs 4 inches in diameter, and the grinding operation is external cylindrical plunge grinding. Initially, prior to grinding, sample 1 is installed on the machine spindle and is trued with a BPR diamond roll, commercially available from Saint-Gobain Abrasives in Arden, NC, as a BPR roll. The truing coefficients are shown in Table 1.

Wheel diameter, in 4 Wheel rpm 12675 Wheel speed, fpm 13273 Dresser Type BPR Dresser diameter, in 5.93 Dresser rpm 5482 Dressing direction One-way (+) Speed or crushing ratio + 0.64 Depth of cut per pass, in 0.000080 Dresser width, in 0.012 Dresser Crossing Supply, in / sec 1.106 Dresser lead, in / rev 0.005 Overlap ratio 2

Sample 1 is not dressed with an abrasive stick after truing, resulting in reading the polishing bodies for a grinding operation that is not dressed when the abrasive grit is sufficiently exposed. In Table 2 the grinding factors are given.

Wheel diameter, in 4 Wheel rpm 13051 Wheel speed, fpm 13743 Working diameter, in 3.7 Working rpm 168 Work speed, fpm 163 Wheel ratio to working speed 84 Equivalent diameter, in 1.92 Wheel width, in 0.5 Working width, in 0.25 Grinding width, in 1.106 Grinding mode Plunge Total amount of infeed 0.015 Infeed rate, in / sec (Q '= 0.5) 0.00071 Infeed rate, in / sec (Q '= 1.0) 0.00143 Infeed rate, in / sec (Q '= 2.0) 0.00286

1 shows the number of grinding cycles for sample 1 under the grinding conditions provided in Table 2 at two different material removal rates (MRR ′) (ie, 1 in ³ / min / in and 2 in ³ / min / in). Include a plot of grinding force (HP / in). As indicated, table 101 is for grinding the workpiece with MRR 'of 1 in ³ / min / in at the first grinding force of sample 1 of 11 Hp / in and of the grinding force after 5 consecutive grinding cycles of 10 Hp / in. It can be done. Table 103 shows that sample 1 can be ground with MRR 'of 2 in ³ / min / in at the initial grinding force of 19 Hp / in and at the grinding force after 5 consecutive grinding cycles of 16 Hp / in. Indicates. The power deviation for sample 1 was 9% for grinding workpieces with MRR 'of 1 in ³ / min / in, and the power deviation for sample 1 for grinding workpieces with MRR' for 2 in ³ / min / in 16%. Thus, Sample 1 shows a very small deviation between the initial grinding force and the steady state grinding force after five consecutive grinding operations. The workpiece was about 0.25 inches wide and the abrasive wheel samples were made to be 0.5 inches wide. The width (width of the workpiece) used to calculate MRR 'was 0.25 inches.

FIG. 1 shows two more plots of grinding force (Hp / in) versus number of grinding cycles for a commonly available metal bonded abrasive article (Sample MBS1) such as G-Force wheel B181-75UP061 from Saint-Gobain. Include. As shown, table 103 shows that it is possible to grind the workpiece with a grinding force of 40 Hp / in at MRR 'where sample MBS1 is 1 in ³ / min / in. After five consecutive grinding cycles, the sample MBS1 is ground with a force of 10 Hp / in for MRR 'which is 1 in ³ / min / in. Sample MBS1 shows a 75% power deviation in the undressed grinding operation.

Plot 104 shows that the sample MBS1 can grind the workpiece with an initial grinding force of 50 Hp / in at MRR 'with 2 in ³ / min / in. After five consecutive grinding cycles, the sample MBS1 is ground with a force of 10 Hp / in for MRR 'which is 2 in ³ / min / in. Sample MBS1 shows a power deviation of 84% in the grinding operation without dressing. Clearly, in an undressed grinding operation, the bonded abrasive articles of the embodiments herein exhibit a significantly improved performance of grinding force variation compared to state-of-the-art abrasive wheels.

FIG. 2 shows the number of grinding cycles for Sample 1 under the grinding conditions provided in Table 2 at two different material removal rates (MRR ′) (ie, 1 in ³ / min / in and 2 in ³ / min / in). and a diagram of surface finish or surface roughness (R _a). As shown, the sample indicated by diagrams 201 and 202 provides the workpiece with a surface finish Ra of about 30 microinches or less after successive grinding cycles at both material removal rates. In addition, the deviation of all measured surface finish values (ie, the standard deviation of all measurements) between the first grinding operation and the fifth grinding cycle does not change by more than two.

2 shows the number of grinding cycles for sample BMS1 under the grinding conditions provided in Table 2 at two different material removal rates (MRR ') (ie, 1 in ³ / min / in and 2 in ³ / min / in). It further comprises _a surface finish (R _a ). As indicated by plots 203 and 204, representing the surface finish obtained by sample MBS1 at both material removal rates was initially 30 microinches at both material removal rates and 1 in ³ / min for further continuous grinding. At material removal rates of / in and 2 in ³ / min / in, they rise significantly to values of 50 microinches and about 60 microinches, respectively. The average surface finish for sample MBS1 at both material removal rates was about 40 microinches and the deviation (standard deviation) at surface finish was about 10 at both material removal rates. Clearly, sample 1 can provide a better surface finish to the workpiece after a continuous grinding cycle compared to sample MBS1.

Example 2

Sample 2 is made using the same process as Sample 1 provided herein. Sample 2 included fused silica filler material in an amount that replaced 25% of the abrasive particle material. Fused silica was -120 / + 140 US mesh size and was available from Washington Mills. The resulting bonded abrasive has a ratio of 2.3 (V _P / V _BM ) and an amount of pores (100% interconnected pores) which is 29% volume percent of the total volume of the body.

For comparison, vitrified CBN wheels of specification B126-M160VT2B were also included in the same test as sample C1. Such grinding wheels are readily available from Saint-Gobin, such as the B126-M160VT2B grinding wheels.

FIG. 3 includes a plot of grinding force (Hp / in) versus the number of grinding cycles for Sample 1, Sample 2, and Sample C1 under the grinding conditions provided in Table 2. FIG. A material removal rate of 2 in ³ / min / in was used during grinding. As shown by diagram 301, Sample 1 was grinding the workpiece for a power deviation of about 16% with an initial grinding force of 18 Hp / in and a grinding force of 16 Hp / in after five consecutive grinding cycles. can do. Table 103 can grind the workpiece for a power deviation of about 12% with the first grinding force of sample 2 being 17 Hp / in, and the grinding force of 15 Hp / in after five consecutive grinding cycles. By comparison, a typical vitrified bonded abrasive sample had the same change in power as Sample 2 and a power variation of about 12%. As such and unexpectedly, despite being metal bonded abrasive articles, Samples 1 and 2 behave more similarly to vitrified bonded abrasive articles having brittle bonding components and low power variations.

Example 3

The third sample (sample 3) was made using the same manufacturing process as sample 1. The initial mixture was 372 grams of 60/40 copper / tin metal bonding composition, 41 grams of active bonding composition precursor, titanium hydride, 359 grams of CBN-V abrasive particles of size B181, 38 mesh size 100A from Saint-Gobain Grains and Powders. It is made using 131 grams of commercially available filler as alumina and 58 grams of binder used in Example 1. Sample 3 has a ratio of 2.5 (V _P / V _BM ) and pores of about 29 vol%.

Sample 3 was used as a peel grinding operation on the outer diameter of a workpiece made of 4140 steel in a round rod shape having a diameter of 5 inches and a length of 11 inches. The workpiece was cured to 40 to 45 HRC. Sample 3 is compared to a conventional, vitrified CBN wheel (Sample C2) commercially available from Saint-Gobin Abrasives as B150-M150-VT2B.

Sample 3 is made of a large bonded abrasive wheel, installed in the periphery of the steel disk forming a 20 inch diameter wheel. Sample 3 was used to grind the workpiece without any subsequent dressing to be trued with a diamond roll and to expose the grit. Truing conditions are shown in Table 3 below. Grinding conditions are shown in Table 4.

Truing of wheels for delamination grinding of 4140 steel Wheel speed, sfpm 26,000 Truing direction Cross roll, diamond roll perpendicular to the wheel axis Truing wheel Diamond roll, BPR Roll speed, sfpm 10,200 Depth of cut per pass, in. 0.0002 Traverse speed, in / rev 0.015 Roll diameter, in 4.7

Grinding factors for delamination grinding of 4140 steel Wheel speed, sfpm 26,000 Working speed, sfpm 250 Centrifugal Depth of Cutting, in / pass 0.008 Roll speed, sfpm 10,200 Feed rate, in / rev 0.04 Pass count 10 equipment Weldon 1632 Gold grinder

The results are summarized in FIGS. 4 and 5. 4 includes a bar graph of the grinding force (Hp) versus two different material removal rates (ie, 9.6 in ³ / min / in and 12 in ³ / min / in). Bar 401 represents the grinding force used during grinding of the workpiece by Sample 3 after the first pass at a material removal rate of 9.6 in ³ / min / in. Bar 402 represents the grinding force of Sample 3 during the grinding of the workpiece after 25 consecutive grinding cycles (ie, passes) in the workpiece at a material removal rate of 9.6 in ³ / min / in. As shown, Sample 3 shows a very small change in grinding force for 25 consecutive grinding cycles without performing the truing operation. In practice, the change in grinding force is estimated to be less than about 12%.

The bars 403 and 404 represent the grinding force used during grinding of sample C2 in the workpiece and after 25 consecutive grinding cycles (ie, passes) at a material removal rate of 9.6 in ³ / min / in. In comparing Sample 3 with Sample 2, it should be noted that Sample 3 behaves more like vitrified bonded abrasive articles than conventional metal bonded abrasive articles.

Bar 405 represents the grinding force used during grinding of the workpiece by Sample 3 after the first pass at a material removal rate of 12 in ³ / min / in. Bar 406 represents the grinding force of Sample 3 during the grinding of the workpiece after 25 consecutive grinding cycles (ie, passes) in the workpiece at a material removal rate of 12 in ³ / min / in. Again, sample 3 shows very small changes in grinding force for 25 consecutive grinding cycles without performing the truing operation. In practice, the change in grinding force is estimated to be about 10% or less.

Rods 407 and 408 represent the grinding force used by sample C2 during grinding of the workpiece and after the first and 25 consecutive grinding cycles (ie, passes) in the workpiece at a material removal rate of 12 in ³ / min / in. . In comparing Sample 3 with Sample C2, it should be noted that Sample 3 behaves more like vitrified bonded abrasive articles than conventional metal bonded abrasive articles.

FIG. 5 includes a bar graph of the grinding ratio (G-ratio) versus two different material removal rates (ie, 9.6 in ³ / min / in and 12 in ³ / min / in) for Sample 3 and Sample C2. . As shown, at both material removal rates, Sample 3 has a significantly higher G-ratio compared to Sample C2. In fact, although the spindle power and surface finish were virtually the same for Sample 3 compared to Sample C2, the G-ratio of Sample 3 was 35% to 50% higher than the G-ratio of Sample C1 at both material removal rates.

Example 4

A fourth sample (Sample 4) is made according to the processes provided in Example 1. The first mixture was 138 grams of 60/40 copper / tin metal bonding composition, 15 grams of titanium hydride as the active bonding composition precursor, 20 grams of the organic binder of Example 1 and Saint-Gobain Ceramics and Diamond Grits as RB 270/325 US mesh. Made from 164 grams of diamonds available from Plastics. Sample 4 has a ratio of 2.3 (V _AG / V _BM ) and pores of about 36 vol%.

Grinding operations involve fluting tungsten carbide with a diameter of 1 inch and cobalt 10% by weight as binder. The grinding performance of sample 4 was the latest metal bonded wheels with 18.75 vol% abrasive particles, 71.25 vol% binder, RB 270/325 US mesh diamond abrasive particles (G-Force abrasive available from Saint-Gobain). Was tested against.

Both samples were true and dressing without running before use. Samples are installed and balanced in steel arbors. The sample is trued with a 100 grit silicon carbide wheel and vitrified adhesive, commonly used in these processes. The sample is spun at about 1/10 surface velocity of silicon carbide operating at about 5000 sfpm. While the sample wheel is rotating, it is trued at a cutting depth of 0.001 "and at a crossover speed of 10 inches / minute until the wheel is considered true. Each sample is also dressed with a 200 mesh silicon carbide wheel for grinding. The grit is exposed The dressing with the stick is completed at all grinding points to start from the same reference point.

The results of the grinding test are provided in FIG. 6. FIG. 6 includes a plot of spindle power (Hp) versus grinding time (seconds) for sample 1 under three different conditions and for sample C2 under one condition. Sample C2 is indicated by plot 601 and grinding was performed at a wheel speed of 3000 rpm and a grinding speed of 3.75 inches / minute. As shown, sample C2 has experienced a significant increase in the grinding force required for continuous grinding cycles. The initial grinding force is about 1.8 Hp and dramatically increases to 3 Hp for 16 grinding cycles for a duration of about 1200 seconds. Sample C2 experienced an increase in grinding force from a marginal grinding force of at least 40%.

In contrast, Sample 4 showed a markedly small increase in initial grinding force for various grinding conditions. Plot 602 shows the grinding force of Sample 4 on the workpiece at 3000 rpm and at a grinding speed of 3.75 inches / minute. The conditions are the same as the grinding conditions used to test sample C2. As shown by diagram 602, Sample 4 has an initial grinding force of about 1.5 Hp and a final grinding force of 2 Hp after 16 consecutive grinding cycles in nearly 1200 seconds. Sample 4 shows an increase in limit power that is only 25%. Sample 4 exhibits significantly improved operable grinding life compared to sample C2.

Plot 603 shows the grinding force of Sample 4 on the workpiece at 2500 rpm and at a grinding speed of 3.75 inches / minute. As shown by diagram 603, Sample 4 has an initial grinding force of about 1.8 Hp and a final grinding force of 3 Hp for 16 grinding cycles for a duration of 1200 seconds. Sample 4 appears to have no substantial increase in grinding force for all grinding cycles, indicating a significantly improved operable life compared to sample C2.

Plot 604 shows the grinding force of Sample 4 on the workpiece at 2500 rpm and at a grinding speed of 6.5 inches / minute. As shown by diagram 604, Sample 4 has an initial grinding force of about 2.8 Hp and a final grinding force of 1.9 Hp after 16 consecutive grinding cycles in about 800 seconds. Sample 4 appears to have no substantial increase in the limit power for all grinding cycles, indicating a significantly improved operable grinding life compared to sample C2.

In addition to the above noted differences in grinding performance, the bonded abrasive bodies of Sample 4 (Figures 602 and 603) can continue grinding 40 flutes of a total of 10 parts before dressing. there was. On the other hand, sample C2 was able to grind a total of 16 flutes, corresponding to a total of 4 parts before dressing was needed. As such, sample 4 shows an increase in grinding efficiency, as measured by about 125% parts / dress relative to conventional sample C2.

In addition, in the comparison of charts 601 and 604, Sample 4 showed that improved grinding speeds were possible for conventional Sample C2. Under the grinding conditions of Table 604, Sample 4 exhibited the ability to grind the same number of parts (four parts) in about 700 seconds compared to Sample C2, which required about 1100 seconds. Thus, Sample 4 shows an improvement of 300 seconds in grinding time, which corresponds to an improvement of about 36% over conventional Sample C2. In addition, based on the feed rate conditions for the plots 601 and 604, Sample 4 showed an increase at a grinding speed (using inches / minute) of 73% compared to conventional sample C2. In addition, Sample 4 obtained an improved grinding speed while maintaining substantially the same grinding force, while Sample C2 showed a short and unsatisfactory increase in grinding force.

Example 5

Sample 4 and Sample C2 are used for flute grinding operations on tungsten carbide workpieces of 0.5 inch diameter with 6% cobalt. This form of processing material is harder to grind than the workpiece of Example 4 due to the higher tungsten carbide content (94 vs. 90%) as evidenced by the difference between the diagrams 701 and 702. Plot 701 shows the grinding force for sample C2 in a tungsten carbide workpiece with 10% cobalt binder at 3000 rpm and at a grinding speed of 6 inches / minute for a grinding time of 800 seconds. In fact, diagram 701 is identical to diagram 601 of FIG. 6. Plot 702 shows the grinding force for sample C2 in a tungsten carbide workpiece with 6% cobalt binder at 3000 rpm and at a grinding speed of 6 inches / minute for a grinding time of 800 seconds. As shown, the power required for grinding the workpiece with 10% cobalt for sample C2 is significantly less than the power required for grinding a workpiece made of tungsten carbide with only 6% cobalt.

By comparison, table 703 shows the grinding of sample 4 which performs a grinding operation at a speed of 2500 rpm at a grinding speed of 8 inches / minute for a grinding time of less than 600 seconds in a workpiece of tungsten carbide with only 6% cobalt. Power. As shown, in the comparison of the diagrams 703 and 702, sample 4 can more effectively grind a large amount of tungsten carbide workpiece at a high speed. That is, Sample 4 will experience significantly smaller changes in grinding force through successive grinding cycles as compared to Sample C2.

In further comparison of the plots 702 and 703 showing the grinding performance of Sample 4 and Sample C2, respectively, it should be noted that Sample 4 also shows an improvement in the grinding speed. In particular, without an increase in grinding power, Sample 4 only required about 500 seconds to grind the same number of parts as required by Sample C2, which required about 800 seconds. Thus, Sample 4 obtained an increase in grinding speed which is about 31% compared to conventional Sample C2. It is also faster than the time required to grind the same number of parts by sample C2.

The bonded abrasive bodies herein exhibit compositions and abrasive properties that distinguish them from conventional metal bonded abrasive articles. The abrasive properties of the abrasive articles of the embodiments herein are more similar to bonded abrasive articles that are glassy than state of the art metal bonded abrasive articles. The bonded abrasive bodies of the embodiments herein exhibit improved effective grinding life, require significantly less dressing than other conventional metal bonded abrasive bodies, and improved wear characteristics compared to modern metal bonded abrasive bodies. Have them. In particular, the bonded abrasive body may not require a separate dressing operation after performing the truing operation, which is distinguished from the taming operations of conventional metal bonded, bonded abrasive articles. That is, using a truing wheel combined with a dressing stick to regrind and sharpen bonded abrasive bodies utilizing metal bonding materials is a typical procedure within the industry. Thus, the bonded abrasive bodies of the embodiments herein can grind a larger number of parts per dress, resulting in a more efficient and longer life compared to modern metal bonded abrasive articles.

In addition, certain aspects of the manufacturing process for bonded abrasive bodies herein are believed to be due to certain compositions and microstructure properties. The bonded abrasive bodies of the embodiments herein include a combination of properties, which combination may be due to manufacturing processes, for example, an active bonding composition, a particular phase of the active bonding composition, and a particular of these phases. Positions, shape and amount of pores, shape and amount of abrasive particles, shape and amount of fillers, ratios of particles to bonding, polishing ratios to bonding, and mechanical properties of certain components (eg, fracture toughness) ), Which promotes improved grinding performance.

In the foregoing, the connection of certain components and reference to specific embodiments are exemplary. It is to be understood that the description of the joined or connected parts is intended to initiate a direct connection between the parts or an indirect connection through one or more intermediate parts to perform the methods as described herein. As such, the subject matter described above is intended to be illustrative, and not restrictive, and the appended claims are intended to cover all such modifications, enhancements, and other embodiments that fall within the true scope of the present invention. Thus, to the maximum extent permitted by law, the scope of the present invention is defined by the broadest acceptable interpretation of the appended claims and their equivalents, and shall not be limited or limited by the foregoing detailed description.

The disclosure will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, various features can be grouped together and described in a single embodiment to simplify the description. This disclosure is not intended to reflect the intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the appended claims reflect, inventive subject matter may be directed to less than all features of any disclosed embodiments.

Claims (124)

A bonded abrasive body having abrasive particles contained in a bonding material comprising a metal, wherein
The bonded abrasive body during the undressing grinding operation is about 40% or less

Where P _o represents the grinding force for grinding the workpiece with the bonded abrasive body in the first grinding cycle and P _n is for grinding the workpiece for the n th grinding cycle with n> 4. Abrasive tool, indicating force. A bonded abrasive body having abrasive particles contained in a bonding material comprising a metal, wherein
The body comprises a ratio of V _AG / V _{BM that} is at least about 1.3, where V _AG is a volume percentage of the abrasive particles in the total volume of the body, and V _BM is the bond in the total volume of the body The volume percentage of the material
During the grinding operation of a metal workpiece, the bonded abrasive body has a G-ratio of at least about 1200 at a material removal rate of at least about 1.0 in ³ / min / in, wherein the G-ratio is from the workpiece. An abrasive tool, defined as the volume of material removed is divided by the volume of material lost through wear from the bonded abrasive body. A bonded abrasive body having abrasive particles contained in a bonding material comprising a metal, wherein
During the grinding operation of a workpiece having an average Vickers hardness of at least about 5 GPa, the bonded abrasive body is

With an increase in the initial grinding force of 40% or less, as defined by P _o , where P _o represents the initial grinding force for grinding the workpiece with the bonded abrasive body in the first grinding cycle and P _n is n> 16 An abrasive tool exhibiting a grinding force for grinding a workpiece with an abrasive body joined in an nth grinding cycle. A bonded abrasive body having abrasive particles contained in a bonding material comprising a metal, wherein
The body comprises a ratio of V _AG / V _{BM that} is at least about 1.3, where V _AG is a volume percentage of the abrasive particles in the total volume of the body, and V _BM is the bond in the total volume of the body Volume percentage of the material,
During a grinding operation of a workpiece having an average Vickers hardness of at least about 5 GPa, the bonded abrasive body exhibits an increase in initial grinding force of 10% or less for a grinding time of at least about 400 seconds at a minimum feed rate of at least about 3 inches / minute. Where the increase in the initial grinding force is

P _o is the initial grinding force for initially grinding the workpiece with the bonded abrasive body in the first grinding cycle and P _n is the grinding force for grinding the workpiece with the bonded abrasive body after 400 seconds of grinding. Indicating, abrasive tools. A bonded abrasive body having abrasive particles contained in a bonding material comprising a metal or metal alloy,
Wherein the bonded abrasive body performs a grinding operation and has an increase in grinding efficiency in a workpiece that is at least about 10%, as measured by parts / dress, as compared to conventional metal bonded abrasive articles. A bonded abrasive body having abrasive particles contained in a bonding material comprising a metal or metal alloy,
The bonded abrasive body performs an abrasive operation and has an increase in grinding efficiency in workpieces that are at least less than about 5% wear, as measured by the grinding wear rate, as compared to conventional metal bonded abrasive articles. . A bonded abrasive body having abrasive particles contained in a bonding material comprising a metal or metal alloy,
And the bonded abrasive body performs the grinding operation on the workpiece at a speed of at least about 5% faster than conventional metal bonded abrasive articles. The method according to any one of claims 1, 3, 5, 6 or 7,
The body comprises a ratio of V _AG / V _{BM that} is at least about 1.3, wherein V _AG is a volume percentage of the abrasive particles in the total volume of the body, and V _BM is the bonding material in the total volume of the body. Abrasive article, by volume percent. The method of claim 1,
The power deviation

Is up to 30%, up to 20%, up to 15%, or up to 12%. 8. The method according to any one of claims 2 to 7,
The bonded abrasive body has a power deviation of about 40% or less, about 30% or less, about 20% or less, about 15% or less, or about 12% or less.

Where P _o represents the grinding force for grinding the workpiece with the bonded abrasive body in the first grinding cycle and P _n represents the grinding force for grinding the workpiece for the n th grinding cycle with n> 4, Abrasive articles. The method of claim 1,
abrasive article, wherein n> 6 or n> 10. The method of claim 10,
abrasive article, wherein n> 6 or n> 10. 8. The method according to any one of claims 1 to 7,
And the grinding operation comprises at least five consecutive grinding cycles without truing the bonded abrasive body. 8. The method according to any one of claims 1 to 7,
The grinding operation is at least about 1.0 in ³ / min / in, at least about 4.0 in ³ / min / in, at least about 5.0 in ³ / min / in, at least about 6.0 in ³ / min / in, or The abrasive article is performed at a material removal rate (MRR ') that is at least about 7.0 in ³ / min / in. 15. The method of claim 14,
The grinding operation may be carried out at a material removal rate within a range from about 1.0 in ³ / min / in to about 20 in ³ / min / in or from about 5.0 in ³ / min / in to about 18 in ³ / min / in MRR '). 8. The method according to any one of claims 1 to 7,
The bonded abrasive body during grinding is operated at a speed of at least about 1500 sfpm, at least about 2000 sfpm, at least about 5000 sfpm, or at least about 10000 sfpm. 8. The method according to any one of claims 1 to 7,
And the grinding operation is a plunge grinding operation. 8. The method according to any one of claims 1 to 7,
The abrasive article during grinding is at least about 0.1 mm. 8. The method according to any one of claims 1 to 7,
And the workpiece includes an average surface roughness (R _a ) that is about 50 microinches or less or about 40 microinches or less after performing n grinding cycles. 8. The method according to any one of claims 1 to 7,
The workpiece, the abrasive article comprising about 35% or less, the average surface less than or equal to about 25% or about 10% roughness deviation (R _a) for at least three successive grinding operations. The method of claim 2,
And the G-ratio is at least about 1300, at least about 1400, at least about 1500, at least about 1600, or at least about 1700. The method according to any one of claims 1, 3, 4, 5, 6, or 7,
The bonded abrasive body during the grinding operation is at least about 1200, at least about 1300, at least about 1400, at least about 1500, at least about 1600 or at least about 1700 at a material removal rate of at least about 1.0 in ³ / min / in. And wherein the G-ratio is defined as the volume of material removed from the workpiece divided by the volume of material lost through wear from the bonded abrasive body. The method of claim 2,
And the G-ratio is in a range between about 1200 and about 2500, between about 1200 and about 2300 or between about 1400 and about 2300. The method according to any one of claims 1, 3, 4, 5, 6, or 7,
The bonded abrasive body during the grinding operation has a G-ratio between about 1200 and about 2500, between about 1200 and about 2300, or between about 1400 and about 2300, wherein the G-ratio is the volume of material removed from the workpiece. And divided by the volume of material lost through abrasion from the bonded abrasive body. 8. The method according to any one of claims 1 to 7,
And the bonded abrasive body comprises at least about 5 vol% of pores, wherein a majority of the pores are interconnected pores defining a network of interconnected pores extending through the volume of the body. 8. The method according to any one of claims 1 to 7,
And the workpiece comprises steel. The method of claim 3,
Wherein the bonded abrasive body has an increase in initial grinding force that is 35% or less, 30% or less, 25% or less, 20% or less, or 15% or less. The method according to any one of claims 1, 2, 4, 5, 6, or 7,
Wherein the bonded abrasive body has an increase in initial grinding force that is 35% or less, 30% or less, 25% or less, 20% or less, or 15% or less. The method of claim 3,
And the bonded abrasive body has an increase in initial grinding force in the range of between about 0.1% and about 40%, between about 0.1% and about 30%, or between about 1% and about 15%. The method according to any one of claims 1, 2, 4, 5, 6, or 7,
Wherein the bonded abrasive body has an increase in initial grinding force that is within a range between about 0.1% and about 40%, between about 0.1% and about 30%, or between about 1% and about 15%. The method according to claim 3 or 4,
And the average Vickers hardness is at least about 10 GPa or at least about 15 GPa. The method according to any one of claims 1, 2, 5, 6, and 7,
And the workpiece includes an average Vickers hardness that is at least about 5 GPa, at least about 10 GPa, or at least about 15 GPa. 8. The method according to any one of claims 1 to 7,
And the workpiece comprises a material selected from the group of materials consisting of metals, metal alloys, nitrides, borides, carbides, oxides, oxynitrides, oxyborides, oxynitrides and combinations thereof. 34. The method of claim 33,
And the workpiece comprises metal carbide. 34. The method of claim 33,
And the workpiece comprises tungsten carbide. 36. The method of claim 35,
And the workpiece includes an amount of cobalt in the range between about 5% and about 12%. 8. The method according to any one of claims 1 to 7,
And the bonded abrasive body is operated at a speed of at least about 1800 sfpm during grinding or at least about 2000 sfpm during grinding or at least about 2200 sfpm during grinding. 39. The method of claim 37,
Wherein the bonded abrasive body is rotated at a speed within a range between about 2000 sfpm to about 15000 sfpm during grinding or about 2000 sfpm to about 12000 sfpm during grinding. 5. The method of claim 4,
And the feed rate is at least 3.5 inches / minute. The method according to any one of claims 1, 2, 3, 5, 6, or 7,
The abrasive article is at least about 2 inches / minute, at least about 3 inches / minute or at least about 3.5 inches / minute during the grinding operation. 5. The method of claim 4,
And the feed rate is in a range between about 3 inches / minute and about 10 inches / minute. The method according to any one of claims 1, 2, 3, 5, 6, or 7,
Wherein the feed rate during the grinding operation is within a range from about 2 inches / minute to about 10 inches / minute or between about 3 inches / minute and about 10 inches / minute. 8. The method according to any one of claims 1 to 7,
And the workpiece is an end mill. 5. The method of claim 4,
And the bonded abrasive body has an increase in initial grinding force of 8% or less, 6% or less, 4% or less, or 2% or less. The method according to any one of claims 1, 2, 3, 5, 6, or 7,
And the bonded abrasive body has an increase in initial grinding force of 10% or less, 8% or less, 6% or less, 4% or less, or 2% or less. 5. The method of claim 4,
The bonded abrasive body increases in initial grinding force within a range between about 0.1% and about 10%, between about 0.1% and about 8%, between about 0.1% and about 6%, or between about 0.1% and about 4%. Having an abrasive article. The method according to any one of claims 1, 2, 3, 5, 6, or 7,
The bonded abrasive body increases in initial grinding force within a range between about 0.1% and about 10%, between about 0.1% and about 8%, between about 0.1% and about 6%, or between about 0.1% and about 4%. Having an abrasive article. 5. The method of claim 4,
Wherein the bonded abrasive body has an increase in initial grinding force of 20% or less, 15% or less, or 10% or less for a grinding time of at least about 800 seconds at a minimum feed rate of at least about 3 inches / minute. The method according to any one of claims 1, 2, 3, 5, 6, or 7,
Wherein the bonded abrasive body has an increase in initial grinding force of 20% or less, 15% or less, or 10% or less for a grinding time of at least about 800 seconds at a minimum feed rate of at least about 3 inches / minute. 5. The method of claim 4,
The bonded abrasive body has an increase in initial grinding force of 20% or less or 15% or less for a grinding time of at least about 800 seconds at a minimum feed rate of at least about 6 inches / minute. The method according to any one of claims 1, 2, 3, 5, 6, or 7,
Wherein the bonded abrasive body has an increase in initial grinding force of 20% or less or 15% or less for a grinding time of at least about 800 seconds at a minimum feed rate of at least about 6 inches / minute. 8. The method according to any one of claims 1 to 7,
Wherein the bonding material comprises an active bonding composition that is at least 10 vol% of the total volume of the bonding material. 53. The method of claim 52,
And the active bonding composition comprises a compound comprising a metal. 54. The method of claim 53,
And the active bonding composition comprises a metal element selected from the group of metal elements consisting of titanium, vanadium, chromium and combinations thereof. 54. The method of claim 53,
Wherein the active bonding composition consists essentially of titanium. 53. The method of claim 52,
And the active bonding composition comprises a compound selected from the group consisting of carbides, nitrides, oxides, and combinations thereof. 8. The method according to any one of claims 1 to 7,
And the abrasive particles comprise a superabrasive material. 8. The method according to any one of claims 1 to 7,
And the bonding material comprises at least one transition metal element. 8. The method according to any one of claims 1 to 7,
And the bonding material comprises a metal selected from the group of metals consisting of copper, tin, silver, molybdenum, zinc, tungsten, iron and combinations thereof. 8. The method according to any one of claims 1 to 7,
And the bonding material comprises a bronze material. The method according to claim 2 or 4,
And the ratio of V _AG / V _BM is at least about 1.5. The method according to any one of claims 1, 3, 5, 6 or 7,
The body comprises a ratio of V _AG / V _{BM that} is at least about 1.3 or at least about 1.5, wherein V _AG is a volume percentage of the abrasive particles within the total volume of the body, and V _BM is within the total volume of the body Abrasive percent by volume of the bonding material. 5. The method of claim 4,
And the ratio of V _AG / V _BM is in a range between about 1.3 to about 9.0. The method according to any one of claims 1, 2, 3, 5, 6, or 7,
The body comprises a ratio of V _AG / V _BM in the range between about 1.3 and about 9.0, where V _AG is the volume percentage of the abrasive particles within the total volume of the body, and V _BM is the total of the body And a volume percentage of the bonding material in the volume. 8. The method according to any one of claims 1 to 7,
And the bonding material has an average fracture toughness (K _1C ) of about 4.0 MPa m ^0.5 or less or about 3.0 MPa m ^0.5 or less. 66. The method of claim 65,
And the bonding material has an average fracture toughness (K _1C ) in the range between about 1.0 MPa m ^0.5 and about 4.0 MPa m ^0.5 . 8. The method according to any one of claims 1 to 7,
And the body comprises at least about 5 vol% pores of the total volume of the body. 68. The method of claim 67,
Wherein the majority of the pores are interconnected pores defining a network of interconnected voids extending through the volume of the body. The method of claim 5,
The increase in polishing efficiency is at least about 20%, at least about 30%, at least about 40% or at least about 50%. 8. The method according to claim 6 or 7,
The increase in grinding efficiency during the grinding operation, as measured in parts / dresses, is at least about 10%, at least about 20%, at least about 30%, at least about 40% or at least compared to conventional metal bonded abrasive articles. Abrasive article about 50%. 5. The method according to any one of claims 1 to 4,
The increase in grinding efficiency during the grinding operation, as measured in parts / dresses, is at least about 10%, at least about 20%, at least about 30%, at least about 40% or at least compared to conventional metal bonded abrasive articles. Abrasive article about 50%. The method of claim 5,
The increase in grinding efficiency is in the range between about 10% and about 200%, between about 20% and about 200%, between about 50% and about 200% or between about 50% and about 150%. 8. The method according to claim 6 or 7,
The increase in grinding efficiency during the grinding operation, as measured in parts / dresses, is between about 10% and about 200%, between about 20% and about 200%, about 50% compared to conventional metal bonded abrasive articles. And the abrasive article in the range of about 50% to about 150%. 5. The method according to any one of claims 1 to 4,
The increase in grinding efficiency during the grinding operation, as measured in parts / dresses, is between about 10% and about 200%, between about 20% and about 200%, about 50% compared to conventional metal bonded abrasive articles. And the abrasive article in the range of about 50% to about 150%. 8. The method according to any one of claims 1 to 7,
Wherein the grinding is completed using a grinding operation selected from the group of operations consisting of peel grinding, flute grinding, creepfeed grinding and plunge grinding. 8. The method according to any one of claims 1 to 7,
Grinding is completed at the number of parts / dresses at a rate at least about 5% greater than the speed of a conventional metal bonded abrasive article. 8. The method according to any one of claims 1 to 7,
And the body comprises a G-ratio at least about 5% greater than the G-ratio of conventional metal bonded abrasive articles. The method according to claim 6,
Wherein the abrasive wear rate is wear of at least less than 8%, at least less than 10%, at least less than 12%, or at least less than 15% compared to conventional metal bonded abrasive articles. The method according to claim 5 or 7,
The abrasive wear rate during the grinding operation is at least about 5%, at least about 8%, at least 10%, at least 12%, or at least 15% less wear compared to conventional metal bonded abrasive articles. . 5. The method according to any one of claims 1 to 4,
The abrasive wear rate during the grinding operation is at least 5%, at least 8%, at least 10%, at least 12% or at least 12% or at least 15% less wear compared to conventional metal bonded abrasive articles. The method according to claim 6,
Wherein the abrasive wear rate is wear in the range of between about 5% and less than about 100% or between about 5% and less than about 75% compared to conventional metal bonded abrasive articles. The method according to claim 5 or 7,
Wherein the abrasive wear rate during the grinding operation is wear in the range of between about 5% and less than about 100% or between about 5% and less than about 75% compared to conventional metal bonded abrasive articles. 5. The method according to any one of claims 1 to 4,
Wherein the abrasive wear rate during the grinding operation is wear that is in the range of between about 5% and less than about 100% or between about 5% and less than about 75% compared to conventional metal bonded abrasive articles. 8. The method according to any one of claims 5 to 7,
During grinding, the body has an increase in efficiency for the workpiece, as measured in parts / dresses, which is at least about 10% or at least 20% compared to conventional metal bonded abrasive articles. 5. The method according to any one of claims 1 to 4,
During grinding, the body has an increase in efficiency for the workpiece, as measured in parts / dress, which is at least about 10% or at least 20% compared to conventional metal bonded abrasive articles. The method of claim 7, wherein
Wherein the grinding speed is at least about 10% faster, at least about 15% faster or at least about 20% faster compared to conventional metal bonded abrasive articles. The method according to claim 5 or 6,
The grinding speed during the grinding operation is at least about 5% faster, at least about 10% faster, at least about 15% faster or at least about 20% faster compared to traditional metal bonded abrasive articles. 5. The method according to any one of claims 1 to 4,
The grinding speed during the grinding operation is at least about 5% faster, at least about 10% faster, at least about 15% faster or at least about 20% faster compared to conventional metal bonded abrasive articles. The method of claim 7, wherein
Wherein the grinding speed is within a range from about 5% to about 100% or from about 5% to about 75% compared to conventional metal bonded abrasive articles. The method according to claim 5 or 6,
The grinding speed during the grinding operation is in the range of about 5% to about 100% or between about 5% to about 75% compared to conventional metal bonded abrasive articles. 5. The method according to any one of claims 1 to 4,
The grinding speed during the grinding operation is in the range of about 5% to about 100% or between about 5% to about 75% compared to conventional metal bonded abrasive articles. 8. The method according to any one of claims 1 to 7,
The bonded abrasive body is a formula

Has an increase in the initial grinding force of 40% or less, as defined by P _o , where P _o represents the initial grinding force for grinding the workpiece into the bonded body bonded in the first grinding cycle and P _n is n> 17 An abrasive article exhibiting a grinding force for grinding a workpiece with an abrasive body joined in an nth grinding cycle. Truing a bonded abrasive body comprising abrasive particles contained in the metal bonding material, with an abrasive truing wheel; And
After truing, the workpiece is ground with the bonded abrasive body without stick dressing the bonded abrasive body, and during grinding, the bonded abrasive body has a power deviation of about 40% or less.

Wherein P _o represents the grinding force for grinding the workpiece with the abrasive body bonded in the first grinding cycle and P _n represents the grinding force for grinding the workpiece in the n th grinding cycle with n> 4. To operate the polishing tool. With an abrasive truing wheel, truing a bonded abrasive body comprising abrasive particles contained in the metal bonding material, wherein the bonding material has an average fracture toughness (K _1C ) of about 4.0 MPa m ^0.5 or less; And
Grinding the workpiece directly into the bonded abrasive body after truing, wherein during the grinding operation of the metal workpiece the bonded abrasive body has a G-ratio of at least about 1200 at a material removal rate of at least about 1.0 in ³ / min / in. (G-ratio), wherein the G-ratio is defined as the volume of material removed from the workpiece divided by the volume of material lost through wear from the bonded abrasive body. . Grinding the workpiece with the bonded bonded body after truing the bonded abrasive body with a diamond roll wheel, wherein during grinding, the workpiece has an average Vickers hardness of at least about 5 GPa and the bonded abrasive body expression

An increase in the initial grinding force of 40% or less as defined by P _o , where P _o represents the initial grinding force for grinding the workpiece into the abrasive body bonded in the first grinding cycle and P _n is n> 16 10. A method of operating an abrasive tool, wherein the abrasive tool exhibits a grinding force for grinding a workpiece with a bonded body bonded in a first successive grinding cycle. Grinding a workpiece comprising a carbide material having an average Vickers hardness of at least about 5 GPa with a bonded abrasive body comprising abrasive particles contained within the metal bonding material, the bonded abrasive workpiece comprising the maximum spindle power of the grinding machine. At least 17 consecutive grinding cycles without exceeding. A method according to any one of claims 93 to 96,
The body comprises a ratio of V _AG / V _{BM that} is at least about 1.3, where V _AG is the volume percentage of abrasive particles in the total volume of the body, and V _BM is the volume of bonding material in the total volume of the body. Method, which is a percentage. A method according to any one of claims 93 to 95,
The truing is performed with a diamond roll wheel. 97. The method of claim 96,
Truing the abrasive body bonded with a diamond roll wheel prior to grinding the workpiece. A method according to any one of claims 93 to 96,
And the bonded abrasive body has a power deviation [(P _o P _n ) / P _o ] x 100% that is about 30% or less or about 12% or less. A method according to any one of claims 93 to 96,
The grinding operation comprises at least five consecutive grinding cycles without truing of the bonded abrasive body. A method according to any one of claims 93 to 96,
Wherein the grinding operation is performed at a material removal rate (MRR ′) of at least about 1.0 in ³ / min / in. A method according to any one of claims 93 to 96,
Wherein the bonded abrasive body during grinding is operated at a speed of at least about 1800 sfpm. A method according to any one of claims 93 to 96,
And said grinding operation is a plunge grinding operation. A method according to any one of claims 93 to 96,
And the workpiece includes an average surface roughness (R _a ) of about 50 microinches or less after performing n grinding cycles. 95. The method of claim 94,
And the G-ratio is at least about 1700. 97. The method of any of claims 93, 95 or 96,
The body comprises a G-ratio of at least about 1200 or at least about 1700, wherein the G-ratio is defined as the volume of material removed from the workpiece divided by the volume of material lost through wear from the bonded abrasive body. Way. 95. The method of claim 94,
And the G-ratio is in a range between about 1400 and about 2300. 97. The method of any of claims 93, 95 or 96,
The body includes a G-ratio within a range between about 1400 and about 2300, wherein the G-ratio is defined as the volume of material removed from the workpiece divided by the volume of material lost through wear from the bonded abrasive body. How. A method according to any one of claims 93 to 96,
Wherein the grinding operation is performed at a material removal rate (MRR ') that is within a range between about 1.0 in ³ / min / in and about 20 in ³ / min / in. A method according to any one of claims 93 to 96,
The bonded abrasive body comprises at least about 5 vol% of pores, the majority of the pores being interconnected pores defining a network of interconnected pores extending through the volume of the body. A method according to any one of claims 93 to 96,
And the workpiece comprises steel. A method according to any one of claims 93 to 96,
The method wherein grinding is a peel grinding operation. A method according to any one of claims 93 to 96,
And the bonded abrasive body is not dressed between successive grinding cycles. 97. The method of claim 96,
And the maximum spindle power is about 3 Hp or less. A method according to any one of claims 94 to 96,
During grinding, the bonded abrasive body has a power deviation of about 40% or less.

Where P _o represents the grinding force for grinding the workpiece with the abrasive body bonded in the first grinding cycle and P _n is the grinding force for grinding the workpiece with the abrasive body bonded in the nth grinding cycle with n> 17. Representing the method. 93. The method of claim 93,
n> 17. 97. The method of any of claims 93, 94 or 96,
During grinding, the bonded abrasive body is

Has an increase in the initial grinding force of 30% or less, as defined by P _o , where P _o represents the initial grinding force for grinding the workpiece into the bonded abrasive body in the first grinding cycle and P _n is n> 17 and a grinding force for grinding the workpiece with the abrasive body joined in the nth grinding cycle. 95. The method of claim 95,
n> 17. A method according to any one of claims 93 to 96,
And the bonded abrasive body has an increase in initial grinding force that is within a range between about 0.1% and about 40%. A method according to any one of claims 93 to 96,
And the workpiece comprises tungsten carbide. A method according to any one of claims 93 to 96,
Wherein the bonded abrasive body is rotated at a speed that is within a range between about 1800 sfpm and about 3100 sfpm during grinding. A method according to any one of claims 93 to 96,
Wherein the grinding operation is performed at a feed rate of at least about 2 inches / minute. A method according to any one of claims 93 to 96,
And the workpiece is an end mill.

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