Patent Application
20170266782
Field of the Disclosure
The following is generally directed to abrasive tools and processes for forming same, and more particularly, to abrasive tools utilizing abrasive segments attached to a base and methods of assembling such tools.
Description of the Related Art
Tools necessary for furthering infrastructure improvements, such as building additional roads and buildings, are vital to the continued economic expansion of developing regions. Additionally, developed regions have a continuing need to replacing aging infrastructure with new and expanded roads and buildings.
The construction industry utilizes a variety of tools for cutting and grinding of construction materials. Cutting and grinding tools are required for to remove or refinish old sections of roads. Additionally, quarrying and preparing finishing materials, such as stone slabs used for floors and building facades, require tools for drilling, cutting, and polishing. Typically, these tools include abrasive segments bonded to a base element or core, such as a plate or a wheel. As with other industries, improvements to these abrasive tools are always sought.
The present disclosure may be better understood, and its numerous features and advantages made apparent to those skilled in the art by referencing the accompanying drawings.
The use of the same reference symbols in different drawings indicates similar or identical items.
According to an embodiment, the abrasive article herein can include a core and a plurality of abrasive segments affixed to the core. The abrasive article can be a grinding tool for grinding metal, concrete, or natural stone.
In general, the abrasive article can include multiple Z-shaped segments affixed to a core.
A generally frusto-conical sidewall 112 can extend radially outward and axially from the central hub 106 at an angle with respect to the central hub 106. The sidewall 112 can include a distal end 114 and a generally ring-shaped segment support flange 116 can extend radially outward from the distal end 114 of the frusto-conical sidewall 112. The segment support flange 116 can include a face 118 perpendicular to a direction of rotation of the abrasive article 100 around a central axis passing perpendicularly through the center 110 of the abrasive article 100.
A plurality of abrasive segments 120 can be affixed to the face 118 of the segment support flange 116 can extend axially away from the segment support flange 116 in a direction parallel to the central axis. The segments 120 can be formed separately from the core 102, as described herein, and affixed to the core via a brazing procedure, a welding procedure, a mechanical coupling, etc. In a particular aspect, each adjacent pair of segments 120 can be separated by a gap 122.
In a particular aspect, the inner segment portion 132 can include an inner circumferential wall 140 and an outer circumferential wall 142. The inner segment portion 132 can also include a leading radial sidewall 144 extending between the inner circumferential wall 140 and the outer circumferential wall 142 and a trailing radial sidewall 146 extending between the inner circumferential wall 140 and the outer circumferential wall 142 opposite the leading radial sidewall 144. The terms leading and trailing, as used herein, can be defined based on a direction of rotation of the abrasive article 100, which is counter-clockwise in the view illustrated in
As illustrated, the inner segment portion 132 can further include a first grinding face 148 that can extend between the inner and outer circumferential walls 140, 142 and the leading and trailing radial sidewalls 144, 146. Moreover, a first serrated portion 150 can extend at least partially over the first grinding face 148. In a particular aspect, the first grinding face 148 can include an area, AGF1, and the first serrated portion 150 can include an area, ASP1. ASP1 can be ≦AGF1. For example, ASP1 can be ≦80% AGF1, such as ≦75% AGF1, ≦70% AGF1, ≦65% AGF1, or ≦60% AGF1. Further, ASP1 can be ≧30% AGF1, such as ≧35% AGF1, ≧40% AGF1, ≧45% AGF1, or ≧50% AGF1. In another aspect, ASP1 can be within a range between and including any of the maximum and minimum values of ASP1 described herein.
For example, ASP1 can be ≦80% AGF1 and ≧30% AGF1, such as ≦80% AGF1 and ≧35% AGF1, ≦80% AGF1 and ≧40% AGF1, ≦80% AGF1 and ≧45% AGF1, or ≦80% AGF1 and ≧50% AGF1. ASP1 can be ≦75% AGF1 and ≧30% AGF1, such as ≦75% AGF1 and ≧35% AGF1, ≦75% AGF1 and ≧40% AGF1, ≦75% AGF1 and ≧45% AGF1, or ≦75% AGF1 and ≧50% AGF1. ASP1 can be ≦70% AGF1 and ≧30% AGF1, such as ≦70% AGF1 and ≧35% AGF1, ≦70% AGF1 and ≧40% AGF1, ≦70% AGF1 and ≧45% AGF1, or ≦70% AGF1 and ≧50% AGF1. Further, ASP1 can be ≦65% AGF1 and ≧30% AGF1, such as ≦65% AGF1 and ≧35% AGF1, ≦65% AGF1 and ≧40% AGF1, ≦65% AGF1 and ≧45% AGF1, or ≦65% AGF1 and ≧50% AGF1. Still further, ASP1 can be ≦60% AGF1 and ≧30% AGF1, such as ≦60% AGF1 and ≧35% AGF1, ≦60% AGF1 and ≧40% AGF1, ≦60% AGF1 and ≧45% AGF1, or ≦60% AGF1 and ≧50% AGF1.
In a particular aspect, the inner segment portion 132 can have a first radial width, W1, measured from the inner circumferential wall 140 to the outer circumferential wall 142. W1 can be ≧d, described above. For example, W1 can be ≧105% d, such as ≧110% d, or ≧125% d. In another aspect, W1 can be ≦200% d, such as ≦175% d, or ≦150% d. W1 can also be within a range between and including any of the maximum and minimum values of W1 described herein.
For example, W1 can be ≧105% d and ≦200% d, such as ≧105% d and ≦175% d, or ≧105% d and ≦150% d. Further, W1 can be ≧110% d and ≦200% d, such as ≧110% d and ≦175% d, or ≧110% d and ≦150% d. Still further, W1 can be ≧125% d and ≦200% d, such as ≧125% d and ≦175% d, or ≧125% d and ≦150% d.
As illustrated, the outer segment portion 134 can include an inner circumferential wall 160 and an outer circumferential wall 162. The outer segment portion 134 can also include a leading radial sidewall 164 extending between the inner circumferential wall 160 and the outer circumferential wall 162 and a trailing radial sidewall 166 extending between the inner circumferential wall 160 and the outer circumferential wall 162 opposite the leading radial sidewall 164.
As illustrated, the outer segment portion 134 can further include a second grinding face 168 that can extend between the inner and outer circumferential walls 160, 162 and the leading and trailing radial sidewalls 164, 166. Moreover, a second serrated portion 170 can extend at least partially over the second grinding face 168. In a particular aspect, the second grinding face 168 can include an area, AGF2, and the second serrated portion 170 can include an area, ASP2. ASP2 can be ≦AGF2. For example, ASP2 can be ≦80% AGF2, such as ≦75% AGF2, 70% AGF2, ≦65% AGF2, or ≦60% AGF2. Further, ASP2 can be ≧30% AGF2, such as ≧35% AGF2, ≧40% AGF2, ≧45% AGF2, or ≧50% AGF2. In another aspect, ASP2 can be within a range between and including any of the maximum and minimum values of ASP2 described herein.
For example, ASP2 can be ≦80% AGF2 and ≧30% AGF2, such as ≦80% AGF2 and ≧35% AGF2, ≦80% AGF2 and ≧40% AGF2, ≦80% AGF2 and ≧45% AGF2, or ≦80% AGF2 and ≧50% AGF2. ASP2 can be ≦75% AGF2 and ≧30% AGF2, such as ≦75% AGF2 and ≧35% AGF2, ≦75% AGF2 and ≧40% AGF2, ≦75% AGF2 and ≧45% AGF2, or ≦75% AGF2 and ≧50% AGF2. ASP2 can be ≦70% AGF2 and ≧30% AGF2, such as ≦70% AGF2 and ≧35% AGF2, ≦70% AGF2 and ≧40% AGF2, ≦70% AGF2 and ≧45% AGF2, or ≦70% AGF2 and ≧50% AGF2. Further, ASP2 can be ≦65% AGF2 and ≧30% AGF2, such as ≦65% AGF2 and ≧35% AGF2, ≦65% AGF2 and ≧40% AGF2, ≦65% AGF2 and ≧45% AGF2, or ≦65% AGF2 and ≧50% AGF2. Still further, ASP2 can be ≦60% AGF2 and ≧30% AGF2, such as ≦60% AGF2 and ≧35% AGF2, ≦60% AGF2 and ≧40% AGF2, ≦60% AGF2 and ≧45% AGF2, or ≦60% AGF2 and ≧50% AGF2.
In a particular aspect, the outer segment portion 134 can have a second radial width, W2, measured from the inner circumferential wall 160 to the outer circumferential wall 162. W2 can be ≧d, described above. For example, W2 can be ≧105% d, such as ≧110% d, or ≧125% d. In another aspect, W2 can be ≦200% d, such as ≦175% d, or ≦150% d. W2 can also be within a range between and including any of the maximum and minimum values of W2 described herein.
For example, W2 can be ≧105% d and ≦200% d, such as ≧105% d and ≦175% d, or ≧105% d and ≦150% d. Further, W2 can be ≧110% d and ≦200% d, such as ≧110% d and ≦175% d, or ≧110% d and ≦150% d. Still further, W2 can be ≧125% d and ≦200% d, such as ≧125% d and ≦175% d, or ≧125% d and ≦150% d.
In another aspect, ASP1 can be ≦ASP2. For example, ASP1 can be ≦95% ASP2, such as ≦90% ASP2, ≦85% ASP2, or ≦80% ASP2. Further, ASP1≧50% ASP2, such as ≧55% ASP2, or ≧60% ASP2. In another aspect, ASP1 can be within a range between and including any of the maximum and minimum values of ASP1 described herein.
For example, ASP1 can be ≦95% ASP2 and ≧50% ASP2, such as ≦95% ASP2 and ≧55% ASP2, or ≦95% ASP2 and ≧60% ASP2. ASP1 can be ≦90% ASP2 and ≧50% ASP2, such as ≦90% ASP2 and ≧55% ASP2, or ≦90% ASP2 and ≧60% ASP2. Further, ASP1 can be ≦85% ASP2 and ≧50% ASP2, such as ≦85% ASP2 and ≧55% ASP2, or ≦85% ASP2 and ≧60% ASP2. Moreover, ASP1 can be ≦80% ASP2 and ≧50% ASP2, such as ≦80% ASP2 and ≧55% ASP2, or ≦80% ASP2 and ≧60% ASP2.
As further depicted in
In a particular aspect, the outer circumferential wall 162 have a circumferential length, LOCW, and the sinusoidal wave structure can includes a wavelength, WLSWS. WLSWS can be ≦0.2 LOCW, such as ≦0.175 LOCW, ≦0.15 LOCW, or ≦0.125 LOCW. Further, WLSWS can be ≧0.05 LOCW, such as ≧0.06 LOCW, ≧0.07 LOCW, ≧0.08 LOCW, or ≧0.09 LOCW. WLSWS can be within a range between and including any of the maximum and minimum values of WLSWS described herein.
For example, WLSWS can be ≦0.2 LOCW and ≧0.05 LOCW, such as ≦0.2 LOCW and ≧0.06 LOCW, ≦0.2 LOCW and ≧0.07 LOCW, ≦0.2 LOCW and ≧0.08 LOCW, or ≦0.2 LOCW and ≧0.09 LOCW. In another aspect, WLSWS can be ≦0.175 LOCW and ≧0.05 LOCW, such as ≦0.175 LOCW and ≧0.06 LOCW, ≦0.175 LOCW and ≧0.07 LOCW, ≦0.175 LOCW and ≧0.08 LOCW, or ≦0.175 LOCW and ≧0.09 LOCW. Further, WLSWS can be ≦0.15 LOCW and ≧0.05 LOCW, such as ≦0.15 LOCW and ≧0.06 LOCW, ≦0.15 LOCW and ≧0.07 LOCW, ≦0.15 LOCW and ≧0.08 LOCW, or ≦0.15 LOCW and ≧0.09 LOCW. Further still, WLSWS can be ≦0.125 LOCW and ≧0.05 LOCW, such as ≦0.125 LOCW and ≧0.06 LOCW, ≦0.125 LOCW and ≧0.07 LOCW, ≦0.125 LOCW and ≧0.08 LOCW, or ≦0.125 LOCW and ≧0.09 LOCW.
As illustrated in
In a particular aspect, α can be <90°, such as ≦75°, ≦70°, ≦65°, or ≦60°. Moreover, a can be ≧40°, such as ≧45°, ≧50°, or ≧55°. Further, a can be within a range between and including any of the values of a described herein. For example, a can be ≦90° and ≧40°, such as ≦90° and ≧45°, ≦90° and ≧50°, or ≦90° and ≧55°. Further, a can be ≦75° and ≧40°, such as ≦75° and ≧45°, ≦75° and ≧50°, or ≦75° and ≧55°. Additionally, a can be ≦70° and ≧40°, such as ≦70° and ≧45°, ≦70° and ≧50°, or ≦70° and ≧55°. In another aspect, a can be ≦65° and ≧40°, such as ≦65° and ≧45°, ≦65° and ≧50°, or ≦65° and ≧55°. Still further, α can be ≦60° and ≧40°, such as ≦60° and ≧45°, ≦60° and ≧50°, or ≦60° and ≧55°.
In another aspect, β can be >90°, such as ≧115°, ≧120°, ≧125°, or ≧130°. Moreover, β can be ≦150°, such as ≦145°, ≦140°, or ≦135°. In another aspect, β can be within a range between and including any of the maximum and minimum values of β described herein. For example, β can be ≧90° and ≦150°, such as ≧90° and ≦145°, ≧90° and ≦140°, or ≧90° and ≦135°. Additionally, β can be ≧115° and ≦150°, such as ≧115° and ≦145°, ≧115° and ≦140°, or ≧115° and ≦135°. Further, β can be ≧120° and ≦150°, such as ≧120° and ≦145°, ≧120° and ≦140°, or ≧120° and ≦135°. Further still, β can be ≧125° and ≦150°, such as ≧125° and ≦145°, ≧125° and ≦140°, or ≧125° and ≦135°. Even further, β can be ≧130° and ≦150°, such as ≧130° and ≦145°, ≧130° and ≦140°, or ≧130° and ≦135°.
As best indicated in
For example, γ can be ≧10° and ≦30°, such as ≧10° and ≦25°, or ≧10° and ≦20°. Further, γ can be ≧12.5° and ≦30°, such as ≧12.5° and ≦25°, or ≧12.5° and ≦20°. Still further, γ can be ≧15° and ≦30°, such as ≧15° and ≦25°, or ≧15° and ≦20°.
In a particular aspect, the abrasive segment 120 can include a thickness, TAS, measured from a rear face to a front face, e.g., the first grinding face 148 or the second grinding face 168. The trailing edge 194 of each serration 190 can extend a distance, DTES, out from the first grinding face 148 or the second grinding face 168 and measured perpendicular to the first grinding face 148 or the second grinding face 168 and DTES can be ≦0.125 TAS, such as ≦0.1 TAS, ≦0.075 TAS, or ≦0.05 TAS. Moreover, DTES can be ≧0.0075 TAS, such as ≧0.01 TAS, ≧0.0125 TAS, or ≧0.015 TAS. In another aspect, DTES can be within a range between and including any of the maximum or minimum values of DTES described herein.
For example, DTES can be ≦0.125 TAS and ≧0.0075 TAS, such as ≦0.125 TAS and ≧0.01 TAS, ≦0.125 TAS and ≧0.0125 TAS, or ≦0.125 TAS and ≧0.015 TAS. Further, DTES can be ≦0.1 TAS and ≧0.0075 TAS, such as ≦0.1 TAS and ≧0.01 TAS, ≦0.1 TAS and ≧0.0125 TAS, or ≦0.1 TAS and ≧0.015 TAS. Further still, DTES can be ≦0.075 TAS and ≧0.0075 TAS, such as ≦0.075 TAS and ≧0.01 TAS, ≦0.075 TAS and ≧0.0125 TAS, or ≦0.075 TAS and ≧0.015 TAS. Even further, DTES can be ≦0.05 TAS and ≧0.0075 TAS, such as ≦0.05 TAS and ≧0.01 TAS, ≦0.05 TAS and ≧0.0125 TAS, or ≦0.05 TAS and ≧0.015 TAS.
The leading edge 192 of each serration 190 can extend a distance, DLES, into the first grinding face 148 or the second grinding face 168 and measured perpendicular to the first grinding face 148 or the second grinding face 168, and DLES can be ≦0.125 TAS, such as ≦0.1 TAS, ≦0.075 TAS, or ≦0.05 TAS. Moreover, DLES can be ≧0.0075 TAS, such as ≧0.01 TAS, ≧0.0125 TAS, or ≧0.015 TAS. In another aspect, DLES can be within a range between and including any of the maximum or minimum values of DLES described herein.
For example, DLES can be ≦0.125 TAS and ≧0.0075 TAS, such as ≦0.125 TAS and ≧0.01 TAS, ≦0.125 TAS and ≧0.0125 TAS, or ≦0.125 TAS and ≧0.015 TAS. Further, DLES can be ≦0.1 TAS and ≧0.0075 TAS, such as ≦0.1 TAS and ≧0.01 TAS, ≦0.1 TAS and ≧0.0125 TAS, or ≦0.1 TAS and ≧0.015 TAS. Further still, DLES can be ≦0.075 TAS and ≧0.0075 TAS, such as ≦0.075 TAS and ≧0.01 TAS, ≦0.075 TAS and ≧0.0125 TAS, or ≦0.075 TAS and ≧0.015 TAS. Even further, DLES can be ≦0.05 TAS and ≧0.0075 TAS, such as ≦0.05 TAS and ≧0.01 TAS, ≦0.05 TAS and ≧0.0125 TAS, or ≦0.05 TAS and ≧0.015 TAS.
In another particular aspect, the abrasive segment 120 can include a central axis 200 that can extend through a center 202 of curvature of the abrasive segment and bisect the leading radial sidewall 180 of the central segment portion 136 of the abrasive segment 120. In this aspect, the first serrated portion 150 on the first segment portion 132 can lie entirely behind the central axis 200 with respect to a direction of rotation of the abrasive segment 120. Further, the second serrated portion 170 on the second segment portion 134 can lie entirely ahead of the central axis 200 with respect to a direction of rotation of the abrasive segment 120.
Further, in a particular aspect, a portion of the inner segment portion 132 can extend ahead of the leading radial sidewall 180 of the central segment portion 136 with respect to the direction of rotation. Moreover, a portion of the outer segment portion 134 can extend behind the trailing radial sidewall 182 of the central segment portion 136 with respect to the direction of rotation.
In a particular aspect, the core 102 of the abrasive article 100 described herein can be in the form of a cup, a ring, a ring section, a plate, or a disc depending upon the intended application of the abrasive article. The core 102 can be made of a metal or metal alloy. For instance, the core 102 can be made of steel, and particularly, a heat treatable steel alloys, such as 25CrMo4, 75Cr1, C60, or similar steel alloys for a core having a thin cross section or simple construction steel like St 60 or similar for a thick core. The core 102 can have a tensile strength of at least about 600 N/mm2. The core 102 can be formed by a variety of metallurgical techniques known in the art.
In an exemplary embodiment, the abrasive segments 104 can include abrasive particles embedded in a bond matrix. In a particular aspect, the bond matrix can include a metal matrix having a network of interconnected pores. The abrasive particles can include an abrasive material having a Mohs hardness of at least about 7. In particular instances, the abrasive particles can include a superabrasive material, such as diamond or cubic boron nitride. The abrasive particles can have a particle size of not less than about 400 US mesh, such as not less than about 100 US mesh, such as between about 25 and 80 US mesh. Depending on the application, the size can be between about 30 and 60 US mesh.
The abrasive particles can be present in an amount between about 2 vol % to about 50 vol %. Additionally, the amount of abrasive particles may depend on the application. For example, an abrasive segment for a grinding or polishing tool can include between about 3.75 and about 50 vol % abrasive particles of the total volume of the abrasive segment. Alternatively, an abrasive segment for a cutting-off tool can include between about 2 vol % and about 6.25 vol % abrasive particles of the total volume of the abrasive segment. Further, an abrasive segment for core drilling can include between about 6.25 vol % and about 20 vol % abrasive particles of the total volume of the abrasive segment.
The metal matrix can include a metal element or metal alloy including a plurality of metal elements. For certain abrasive segments, the metal matrix can include metal elements such as iron, tungsten, cobalt, nickel, chromium, titanium, silver, and a combination thereof. In particular instances, the metal matrix can include a rare earth element such as cerium, lanthanum, neodymium, and a combination thereof.
In one particular example, the metal matrix can include a wear resistant component. For example, in one embodiment, the metal matrix can include tungsten carbide, and more particularly, may consist essentially of tungsten carbide.
In certain designs, the metal matrix can include particles of individual components or pre-alloyed particles. The particles can be between about 1.0 microns and about 250 microns.
In a particular aspect, the abrasive segments 104 can be formed such that an infiltrant is present within the interconnected network of pores within the body of the abrasive segment 104. The infiltrant can partially fill, substantially fill, or even completely fill the volume of the pores extending through the volume of the abrasive segment 104. In accordance with one particular design, the infiltrant can be a metal or metal alloy material. For example, some suitable metal elements can include copper, tin, zinc, and a combination thereof.
In particular instances, the infiltrant can be a bronzing material made of a metal alloy, and particular a copper-tin metal alloy, such that it is particularly suited for welding according to embodiments herein. For example, the bronzing material can consist essentially of copper and tin. Certain bronzing materials can incorporate particular contents of tin greater than about 5% by weight, such as greater than about 6% by weight, greater than about 7% by weight, or even greater than about 8% by weight. Further, certain bronzing materials can incorporate particular contents of tin less than about 20% by weight, such as less than about 15% by weight, less than about 12% by weight, or even less than about 10% by weight of the total amount of materials within the composition.
In accordance with an embodiment, the bronzing material can include an amount of tin within a range between and including about 5% by weight and about 20% by weight, such as between and including about 5% by weight and about 15% by weight, between and including about 5% by weight and about 12% by weight, or between and including about 5% by weight and about 10% by weight.
In another embodiment, the bronzing material can include an amount of tin within a range between and including about 6% by weight and about 20% by weight, such as between and including about 6% by weight and about 15% by weight, between and including about 6% by weight and about 12% by weight, or between and including about 6% by weight and about 10% by weight.
Further, in yet another embodiment, the bronzing material can include an amount of tin within a range between and including about 7% by weight and about 20% by weight, such as between and including about 7% by weight and about 15% by weight, between and including about 7% by weight and about 12% by weight, or between and including about 7% by weight and about 10% by weight.
Still further, in accordance with another embodiment, the bronzing material can include an amount of tin within a range between and including about 8% by weight and about 20% by weight, such as between and including about 8% by weight and about 15% by weight, between and including about 8% by weight and about 12% by weight, or between and including about 8% by weight and about 10% by weight.
Moreover, certain bronzing materials can be used as infiltrant material, and can have an amount of copper of at least about 80%, at least about 85%, or even at least about 88% by weight of the total amount of materials within the composition. Some bronzing materials can utilize an amount of copper within a range between about 80% and about 95%, such as between about 85% and about 95%, or even between about 88% and about 93% by weight of the total amount of materials within the composition.
Additionally, the bronzing material may contain a particularly low content of other elements, such as zinc to facilitate proper formation of the abrasive article according to the forming methods of the embodiments herein. For example, the bronzing material may utilize not greater than about 10%, such as not greater than about 5%, or even not greater than about 2% zinc. In fact, certain bronzing materials can be essentially free of zinc.
The abrasive segment 104 may be manufactured, such that abrasive particles can be combined with a metal matrix to form a mixture. The metal matrix can include a blend of particles of the components of the metal matrix or can be pre-alloyed particles of the metal matrix. In an embodiment, the metal matrix can conform to the formula (WC)wWxFeyCrzX(1-w-x-y-z), wherein 0≦w≦0.8, 0≦x≦0.7, 0≦y≦0.8, 0≦z≦0.05, w+x+y+z≦1, and X can include other metals such as cobalt and nickel. In another embodiment, the metal matrix can conform to the formula (WC)wWxFeyCrzAgvX(1-v-w-x-y-z), wherein 0≦w≦0.5, 0≦x≦0.4, 0≦y≦1.0, 0≦z≦0.05, 0≦v≦0.1, v+w+x+y+z≦1, and X can include other metals such as cobalt and nickel.
The mixture of metal matrix and abrasive particles can be formed into an abrasive preform by a pressing operation, particularly a cold pressing operation, to form a porous abrasive segment. The cold pressing can be carried out at a pressure within a range between and including about 50 kN/cm2 (500 MPa) to about 250 kN/cm2 (2500 MPa). The resulting porous abrasive segment can have a network of interconnected pores. In an example, the porous abrasive segment can have a porosity between about 25 and 50 vol %.
The resulting porous abrasive segment 104 can then be subject to an infiltration process, wherein the infiltrant material is disposed within the body of the abrasive segment, and particularly, disposed within the interconnected network of pores within the body of the abrasive segment. The infiltrant may be drawn into the pores of the cold pressed abrasive segment via capillary action. After the infiltration process, the resulting densified abrasive segment can be not less than about 96% dense. The amount of infiltrant that infiltrates the abrasive segment can be between about 20 wt % and 45 wt % of the densified abrasive segment.
The abrasive segment 104 can include a backing region, disposed between the abrasive segment and the base, i.e., the core 102, which facilitates the joining of the abrasive segment and the core 102. According to one embodiment, the backing region can be a distinct region from the abrasive segment 104 and the core 102. Still, the backing region can be initially formed as part of the abrasive segment 104, and particularly may be a distinct region of the abrasive segment 104 along a bottom surface of the abrasive segment 104 that has particular characteristics facilitating the joining of the abrasive segment 104 and the core 102. For example, according to one embodiment, the backing region can have a lesser percentage (vol %) of abrasive particles as compared to the amount of abrasive particles within the abrasive segment 104. In fact, in certain instances, the backing region can be essentially free of abrasive particles. This may be particularly suitable for forming methods utilizing a beam of energy (e.g., a laser) used to weld the abrasive segment 104 to the core 102.
At least a portion of the backing region can include a bonding composition. The bonding composition can include a metal or metal alloy. Some suitable metal materials can include transition metal elements, including for example, titanium, silver, manganese, phosphorus, aluminum, magnesium, chromium, iron, lead, copper, tin, and a combination thereof.
In particular instances, the bonding composition can be similar to the infiltrant, such that the bonding composition and the infiltrant are different from each other by not greater than a single elemental species. In even more particular instances, the bonding composition can be the same as the infiltrant. According to embodiments herein, the bonding composition can be related to the infiltrant composition in having a certain degree of commonality of elemental species. Quantitatively, an elemental weight percent difference between the bonding composition and the infiltrant composition does not exceed 20 weight percent. Elemental weight percent difference is defined as the absolute value of the difference in weight content of each element contained in the bonding composition relative to the infiltrant composition. Other embodiments have closer compositional relationships between the bonding composition and the composition of the infiltrant. The elemental weight percent difference between the bonding composition and the infiltrant composition may, for example, not exceed 15 weight percent, 10 weight percent, 5 weight percent, or may not exceed 2 weight percent. An elemental weight percent difference of about zero represents the same composition making up the backing region and the infiltrant. The foregoing elemental values may be measured by any suitable analytical means, including microprobe elemental analysis, and ignores alloying that might take place along areas in which the infiltrant contacts the metal matrix.
The backing region can include at least about 90 wt % infiltrant, such as at least about 95 wt % infiltrant, such as at least about 98 wt % infiltrant. The infiltrant can be continuous throughout the backing region and the densified abrasive segment. In certain instances, the backing region can be formed primarily of the infiltrant material, and in more particular instances, can consist essentially of the infiltrant material. Still, in other embodiments, the backing region can be an infiltrated region, like the abrasive segment. Accordingly, the backing region can include a network of interconnected pores formed between a matrix metal, and wherein the infiltrant material substantially fills the interconnected pores. The backing region can contain similar amounts of matrix metal and infiltrant. Notably, the backing region may be essentially free of abrasive particles. In such embodiments wherein the backing region includes interconnected pores substantially filled with the infiltrant, the infiltrant material can act as a bronzing material in forming a joint (e.g., a welded joint) between the base and the abrasive segment.
In one embodiment, the backing region can be formed of the bronzing material described herein. In fact, certain backing regions can consist essentially of a copper-tin bronzing material having about 88% copper and 12% tin or 90% copper and 10% tin.
In a particular aspect, a method of making the abrasive article 100 can include stamping, cutting, drilling, or otherwise forming a core 102 having vibration reducing gullets 140 and segment support structures 130. The method can include affixing the segments 104 to the core 102 such that each segment 104 is affixed to a segment support structure 130. Affixing the segments 104 to the core 102 can include welding the abrasive segments 104 to the core 102. In particular, the welding process can include impinging a beam of energy at the base of each segment 104. More particularly, in the instance of a segment 104 having a backing region, welding can include impinging a beam of energy at the backing region between the abrasive segment 104 and the core 102. In particular instances, the beam of energy can be a laser, such that each abrasive segment 104 is attached to the core 102 via a laser welded bond joint. The laser may be a Roffin laser source commonly available from Dr. Fritsch, GmbH.
In one aspect, each segment 104 can be formed by pressing a green segment in a mold and curing the green segment. The pressing can include hot pressing or cold pressing. In another aspect, forming each segment 104 can include sintering a green segment, e.g., using an electro-discharge sintering process. In yet another aspect, forming each segment 104 can include the infiltration method described herein.
In another aspect, each segment 104 can be include a single layer metal bond (“SLMB”) segment having a core and a single layer of abrasive electro-plated, or otherwise deposited, on a cutting, or grinding surface of the core.
According to an embodiment, each abrasive article 100 can include a carrier element, e.g., a core 102, and an abrasive component, e.g., a segment 104. The abrasive article 100 can be a cutting tool for cutting construction materials, such as a saw for cutting concrete. Alternatively, the abrasive article 100 can be a grinding tool such as for grinding concrete or fired clay or removing asphalt.
Items.
Item 1. An abrasive segment, comprising:
Item 2. An abrasive article, comprising:
Item 3. An abrasive article, comprising:
Item 4. The abrasive article according to item 3, wherein each serrated portion includes a plurality of serrations and each serration includes a leading edge, a trailing edge, and a ramped surface that extends at an angle, γ, into the first grinding face or the second grinding face from the trailing edge to the leading edge.
Item 5. The abrasive article according to item 4, wherein γ≧10°, such as ≧12.5°, or ≧15°.
Item 6. The abrasive article according to item 5, wherein γ≦30°, such as ≦25°, or ≦20°.
Item 7. The abrasive segment or article according to item 4, wherein the abrasive segment includes a thickness, TAS, and the trailing edge of each serration extends a distance, DTES, outward from the first grinding face or the second grinding face, wherein DTES≦0.125 TAS, such as ≦0.1 TAS, ≦0.075 TAS, or ≦0.05 TAS.
Item 8. The abrasive segment or article according to claim 7, wherein DTES≧0.0075 TAS, such as ≧0.01 TAS, ≧0.0125 TAS, or ≧0.015 TAS.
Item 9. The abrasive segment or article according to item 4, wherein the abrasive segment includes a thickness, TAS, and the trailing edge of each serration extends a distance, DLES, inward from the first grinding face or the second grinding face, wherein DLES≦0.125 TAS, such as ≦0.1 TAS, ≦0.075 TAS, or ≦0.05 TAS.
Item 10. The abrasive segment or article according to item 9, wherein DLES≧0.0075 TAS, such as ≧0.01 TAS, ≧0.0125 TAS, or ≧0.015 TAS.
Item 11. The abrasive segment or article according to of item 1, wherein α is ≦90°, such as ≦75°, ≦70°, ≦65°, or ≦60°.
Item 12. The abrasive segment or article according to item 11, wherein α is ≧40°, such as ≧45°, ≧50°, or ≧55°.
Item 13. The abrasive segment or article according to any of item 1, wherein β≧90°, such as ≧115°, ≧120°, ≧125°, or ≧130°.
Item 14. The abrasive segment or article according to item 13, wherein α is ≦150°, such as ≦145°, ≦140°, or ≦135°.
Item 15. The abrasive segment or article according to any of items 1 or 2, wherein the inner segment portion further comprises a grinding face extending between the inner and outer circumferential walls, the leading radial sidewall, and the trailing radial sidewall wherein the first grinding face includes a first serrated portion extending at least partially over the first grinding face.
Item 16. The abrasive segment or article according to item 15, wherein the first grinding face includes an area, AGF1, and the first serrated portion includes an area, ASP1, and ASP1≦AGF1.
Item 17. The abrasive segment or article according to item 16, wherein ASP1≦80% AGF1, such as ≦75% AGF1, ≦70% AGF1, ≦65% AGF1, or ≦60% AGF1.
Item 18. The abrasive segment or article according to item 17, wherein ASP1≧30% AGF1, such as ≧35% AGF1, ≧40% AGF1, ≧45% AGF1, or ≧50% AGF1.
Item 19. The abrasive segment or article according to item 15, wherein the outer segment portion further comprises a second grinding face extending between the inner and outer circumferential walls, the leading radial sidewall, and the trailing radial sidewall wherein the second grinding face includes a second serrated portion extending at least partially over the second grinding face.
Item 20. The abrasive segment or article according to item 19, wherein the second grinding face includes an area, AGF2, and the second serrated portion includes an area, ASP2, and ASP2≦AGF2.
Item 21. The abrasive segment or article according to item 20, wherein ASP2≦80% AGF2, such as ≦75% AGF2, ≦70% AGF2, ≦65% AGF2, or ≦60% AGF2.
Item 22. The abrasive segment or article according to item 21, wherein ASP2≧30% AGF2, such as ≧35% AGF2, ≧40% AGF2, ≧45% AGF2, or ≧50% AGF2.
Item 23. The abrasive segment or article according to item 19, wherein the first serrated portion includes an area, ASP1, and the second serrated portion includes an area ASP2, wherein ASP1≦ASP2.
Item 24. The abrasive segment or article according to item 23, wherein ASP1≦95% ASP2, such as ≦90% ASP2, ≦85% ASP2, ≦80% ASP2, or ≦75% ASP2.
Item 25. The abrasive segment or article according to item 24, wherein ASP1≧50% ASP2, such as ≧55% ASP2, or ≧60% ASP2.
Item 26. The abrasive segment or article according to item 19, wherein the abrasive segment includes a central axis extending through a center of curvature of the abrasive segment and bisecting the leading radial sidewall of the central segment portion of the abrasive segment and wherein the first serrated portion lies entirely behind the central axis with respect to a direction of rotation of the abrasive segment.
Item 27. The abrasive segment or article according to item 26, wherein the second serrated portion lies entirely ahead of the central axis with respect to a direction of rotation of the abrasive segment.
Item 28. The abrasive segment or article according to any of items 1, 2, or 3, wherein the outer segment portion further comprises a plurality of outer peripheral serrations formed in the outer circumferential wall of the outer segment portion.
Item 29. The abrasive segment or article according to item 28, wherein the outer peripheral serrations extend along the entire outer circumferential wall from the leading radial sidewall to the trailing radial sidewall.
Item 30. The abrasive segment or article according to item 29, wherein the outer peripheral serrations form a sinusoidal wave structure along the outer circumferential wall.
Item 31. The abrasive segment or article according to item 30, wherein the outer circumferential wall has a length, LOCW, and the sinusoidal wave structure includes a wavelength, WLSWS, wherein WLSWS≦0.2 LOCW, such as ≦0.175 LOCW, ≦0.15 LOCW, or ≦0.125 LOCW.
Item 32. The abrasive segment or article according to item 30, wherein WLSWS≧0.05 LOCW, such as ≧0.06 LOCW, ≧0.07 LOCW, ≧0.08 LOCW, or ≧0.09 LOCW.
In the foregoing, reference to specific embodiments and the connections of certain components is illustrative. It will be appreciated that reference to components as being coupled or connected is intended to disclose either direct connection between said components or indirect connection through one or more intervening components as will be appreciated to carry out the methods as discussed herein. As such, the above-disclosed subject matter is to be considered illustrative, and not restrictive, and the appended claims are intended to cover all such modifications, enhancements, and other embodiments, which fall within the true scope of the present invention. Thus, to the maximum extent allowed by law, the scope of the present invention is to be determined by the broadest permissible interpretation of the following claims and their equivalents, and shall not be restricted or limited by the foregoing detailed description.
The Abstract of the Disclosure is provided to comply with Patent Law and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description of the Drawings, various features may be grouped together or described in a single embodiment for the purpose of streamlining the disclosure. This disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter may be directed to less than all features of any of the disclosed embodiments. Thus, the following claims are incorporated into the Detailed Description of the Drawings, with each claim standing on its own as defining separately claimed subject matter.
This application is a continuation and claims priority to U.S. patent application Ser. No. 14/843,755, entitled ABRASIVE ARTICLE HAVING SHAPED SEGMENTS, by Ignazio Gosamo, filed Sep. 2, 2015, which application is a continuation and claims priority to U.S. patent application Ser. No. 14/132,140, now U.S. Pat. No. 9,149,913, entitled ABRASIVE ARTICLE HAVING SHAPED SEGMENTS, by Ignazio Gosamo, filed Dec. 18, 2013, which application claims priority under 35 U.S.C. §119(e) to U.S. Patent Application No. 61/747,965 entitled ABRASIVE ARTICLE HAVING SHAPED SEGMENTS, by Ignazio Gosamo, filed Dec. 31, 2012, all of which applications are assigned to the current assignee hereof and incorporated herein by reference in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| 61747965 | Dec 2012 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 14843755 | Sep 2015 | US |
| Child | 15613868 | US | |
| Parent | 14132140 | Dec 2013 | US |
| Child | 14843755 | US |
