Abrasive article with improved grain retention and performance

Abstract

An abrasive article with improved grain retention and performance and method of making are disclosed. The abrasive article with improved grain retention results in an article with improved performance and longer article life.

1 . An ultra-thin, small diameter cutoff wheel, comprising: a plurality of abrasive grains, an organic bond material and an active filler material, wherein the active filler material comprises an effective amount of an active endothermic filler material that provides an endothermic reaction at normal dry cutting conditions. 
     
     
         2 . The cutoff wheel according to  claim 1 , wherein the plurality of abrasive grains are selected from the group consisting of seeded or unseeded sol gel alumina grain and Al 2 O 3 —ZrO 2  grain and combinations thereof. 
     
     
         3 . The cutoff wheel according to  claim 1 , wherein the plurality of abrasive grains are selected from the group consisting of SG, NQ, 3M321, 3M324, NZ Plus, ZF, ZS, ZK40, ZR25B, ZR25R, and combinations thereof. 
     
     
         4 . The cutoff wheel according to  claim 1 , wherein the plurality of abrasive grains is present in a range of about 35 to about 55 percent by volume/total mix. 
     
     
         5 . The cutoff wheel according to  claim 1 , wherein the plurality of abrasive grains comprise a primary abrasive grain and a secondary abrasive grain, the primary abrasive grain being selected from the group consisting of seeded or unseeded sol gel alumina grains, Al 2 O 3 —ZrO 2  grains and combinations thereof, and the primary grain comprises between about 20 to about 100 percent of the total amount of abrasive grain by volume. 
     
     
         6 . The cutoff wheel according to  claim 1 , wherein the active endothermic filler material is selected from the group of filler types consisting of sulfides and low melting point oxides. 
     
     
         7 . The cutoff wheel according to  claim 6 , wherein the active endothermic filler material is selected from the group consisting of pyrite, zinc sulfide, copper sulfide, lead oxide, tin oxide, bismuth oxide and combinations thereof. 
     
     
         8 . The cutoff wheel according to  claim 1 , wherein the active filler material comprises Cryolite, PAF, KBF 4 , K 2 SO 4 , and NaCl/KCl and combinations thereof. 
     
     
         9 . An ultra-thin, small diameter cutoff wheel, comprising: a plurality of abrasive grains and an organic bond material comprising an active endothermic filler material providing an endothermic reaction added thereto, the amount of active endothermic filler material is in a range of about 12 to about 50 percent by volume of the bond. 
     
     
         10 . The cutoff wheel according to  claim 9 , wherein the plurality of abrasive grains are selected from the group consisting of seeded or unseeded sol gel alumina grain and Al 2 O 3 —ZrO 2  grain and combinations thereof. 
     
     
         11 . The cutoff wheel according to  claim 9 , wherein the plurality of abrasive grains are selected from the group consisting of SG, NQ, 3M321, 3M324, NZ Plus, ZF, ZS, ZK40, ZR25B, ZR25R, and combinations thereof. 
     
     
         12 . The cutoff wheel according to  claim 9 , wherein the plurality of abrasive grains comprise a primary abrasive grain and a secondary abrasive grain, the primary abrasive grain being selected from the group consisting of seeded or unseeded sol gel alumina grain, Al 2 O 3 —ZrO 2  grain and combinations thereof, and the primary grain comprises between about 20 to about 100 percent of the total amount of abrasive grain by volume. 
     
     
         13 . The cutoff wheel according to  claim 9 , wherein the organic bond material comprises a dry resin material. 
     
     
         14 . The cutoff wheel according to  claim 9 , wherein the organic bond material is present in a range of about 25 to about 45 percent by volume/total mix. 
     
     
         15 . The cutoff wheel according to  claim 9 , wherein the active endothermic filler material is selected from the group of filler types consisting of sulfides and low melting point oxides. 
     
     
         16 . The cutoff wheel according to  claim 9 , wherein the cutoff wheel comprises a diameter that ranges from about 75 mm to about 250 mm. 
     
     
         17 . The cutoff wheel according to  claim 9 , wherein the cutoff wheel comprises an aspect ratio that ranges from about 40 to about 160. 
     
     
         18 . The cutoff wheel according to  claim 9 , wherein the cutoff wheel comprises an abrasive wheel. 
     
     
         19 . The cutoff wheel according to  claim 18 , wherein the abrasive wheel is used for dry cutting applications, where thermal degradation is a primary product wear mechanism. 
     
     
         20 . An ultra-thin, small diameter cutoff wheel, comprising: a plurality of abrasive grains and an organic bond material with an active endothermic filler material added thereto to provide an endothermic reaction that improves grain retention, wherein the plurality of abrasive grains are selected from the group consisting of seeded or unseeded sol gel alumina grain, Al 2 O 3 —ZrO 2  grain and combinations thereof and wherein the active endothermic filler material is selected from the group consisting of sulfides, low melting point oxides and combinations thereof.