Method of abrading a zirconium-based alloy workpiece

Abstract

A method of abrading a zirconium-based alloy workpiece including the steps of contacting a zirconium-based alloy workpiece with an abrasive article, wherein the abrasive article includes a flexible waterproof backing having a first surface bearing a cured primer coating; and a plurality of shaped structures, each structure having a distal end spaced from said backing and an attachment end attached to the primer coating on the backing, said shaped structures comprising a mixture of abrasive particles having a Knoop hardness greater than 2,200 kg/mm 2 and cured particulate binder, wherein the metal workpiece is contacted with the distal ends of the shaped structures to form an abrading interface; moving the abrasive article relative to the metal workpiece while providing sufficient force between the metal workpiece and the distal ends of the shaped structures of the abrasive article to abrade the metal workpiece; and applying liquid coolant proximate the abrading interface.

1 . A method of abrading a zirconium-based alloy workpiece comprising:
 contacting a zirconium-based alloy workpiece with an abrasive article, wherein the abrasive article comprises:
 a flexible waterproof backing having a first surface bearing a cured primer coating; and 
 a plurality of shaped structures, each structure having a distal end spaced from said backing and an attachment end attached to the primer coating on the backing, said shaped structures comprising a mixture of abrasive particles having a Knoop hardness greater than 2,200 kg/mm 2  and cured particulate binder, 
 wherein the metal workpiece is contacted with the distal ends of the shaped structures to form an abrading interface; 
   moving the abrasive article relative to the metal workpiece while providing sufficient force between the metal workpiece and the distal ends of the shaped structures of the abrasive article to abrade the metal workpiece; and   applying liquid coolant proximate the abrading interface.   
   
   
       2 . The method of  claim 1  wherein the abrasive particles comprise silicon carbide. 
   
   
       3 . The method of  claim 1  wherein the flexible waterproof backing comprises treated woven polyester fabric. 
   
   
       4 . The method of  claim 1  wherein the liquid coolant comprises water and oil. 
   
   
       5 . The method of  claim 1  further comprising rotating the workpiece is being abraded. 
   
   
       6 . The method of  claim 1 , wherein the abrasive article is an abrasive belt. 
   
   
       7 . The method of  claim 6  wherein the abrasive belt is mounted on a centerless grinding machine. 
   
   
       8 . The method of  claim 6  wherein the abrasive belt is mounted on a fixed center roll grinding machine. 
   
   
       9 . The method of  claim 1  wherein at least a portion of the shaped structures of the abrasive article comprise a cross-section selected from the group consisting of square, circular, rectangular, hexagonal, and triangular. 
   
   
       10 . The method of  claim 9  wherein the shaped structures are arranged in a tessellated pattern. 
   
   
       11 . The method of  claim 9  wherein the shaped structured are formed by an embossing process. 
   
   
       12 . The method of  claim 9 , wherein the zirconium-based alloy workpiece is cylindrical. 
   
   
       13 . A method of abrading a cylindrical zirconium-based alloy workpiece comprising:
 contacting a cylindrical zirconium-based alloy workpiece with an abrasive article, wherein the abrasive article comprises:
 a flexible waterproof backing having a first surface bearing a cured primer coating; and 
 a plurality of shaped structures, each structure having a distal end spaced from said backing and an attachment end attached to the primer coating on the backing, said shaped structures comprising a mixture of silicon carbide abrasive particles and a cured thermoset particulate binder, 
 wherein the metal workpiece is contacted with the distal ends of the shaped structures to form an abrading interface; 
   moving the abrasive article relative to the metal workpiece while providing sufficient force between the metal workpiece and the distal ends of the shaped structures of the abrasive article to abrade the metal workpiece; and   applying liquid coolant proximate the abrading interface.   
   
   
       14 . The method of  claim 13  wherein the silicon carbide abrasive particles have an average particle size in the range of 4 to 40 micrometers. 
   
   
       15 . The method of  claim 13  wherein the flexible waterproof backing comprises treated woven polyester fabric. 
   
   
       16 . The method of  claim 13  wherein the liquid coolant comprises water and oil. 
   
   
       17 . The method of  claim 13  further comprising rotating the workpiece is being abraded. 
   
   
       18 . The method of  claim 13 , wherein the abrasive article is an abrasive belt. 
   
   
       19 . The method of  claim 18  wherein the abrasive belt is mounted on a centerless grinding machine. 
   
   
       20 . The method of  claim 18  wherein the abrasive belt is mounted on a fixed center roll grinding machine. 
   
   
       21 . The method of  claim 13  wherein at least a portion of the shaped structures of the abrasive article comprise a cross-section selected from the group consisting of square, circular, rectangular, hexagonal, and triangular. 
   
   
       22 . The method of  claim 21  wherein the shaped structured are formed by an embossing process. 
   
   
       23 . The method of  claim 18  wherein at least 0.3 grams of material is removed from the workpiece per 25.4 millimeter of belt width per minute, and a surface finish no greater than 0.22 micrometers Ra is obtained. 
   
   
       24 . A method of abrading a zirconium-based alloy cylindrical workpiece comprising:
 contacting a cylindrical zirconium-based alloy workpiece with an abrasive article, wherein the abrasive article comprises:
 a flexible waterproof backing having a first surface bearing a cured primer coating; and 
 a plurality of shaped structures, each structure having a distal end spaced from said backing and an attachment end attached to the primer coating on the backing, said shaped structures comprising a mixture of abrasive particles having a Knoop hardness greater than 2,200 kg/mm 2  and a mixture of cured thermoplastic and thermoset particulate binder, 
 wherein the metal workpiece is contacted with the distal ends of the shaped structures to form an abrading interface; 
   moving the abrasive article relative to the metal workpiece while providing sufficient force between the metal workpiece and the distal ends of the shaped structures of the abrasive article to abrade the metal workpiece; and   applying liquid coolant proximate the abrading interface.   
   
   
       25 . The method of  claim 24  wherein the abrasive article is an abrasive belt. 
   
   
       26 . The method of  claim 25  wherein at least 0.3 grams of material is removed from the workpiece per 25.4 millimeter of belt width per minute, and a surface finish no greater than 0.22 micrometers Ra is obtained. 
   
   
       27 . The method of  claim 25  wherein at least 0.3 grams of material is removed from the workpiece per 25.4 millimeter of belt width per minute, and a surface finish no greater than 0.20 micrometers Ra is obtained. 
   
   
       28 . The method of  claim 25  wherein at least 0.3 grams of material is removed from the workpiece per 25.4 millimeter of belt width per minute, and a surface finish no greater than 0.13 micrometers Ra is obtained.