Large diameter cutting tool

Abstract

An abrasive cutting tool has a body in the shape of a large diameter disk having an outer diameter of at least about 60 centimeters, and an aspect ratio defined as a ratio between the outer diameter to an axial thickness of the body of at least about 10:1. The body includes an abrasive portion having a bond material and abrasive particles contained within the bond material. The abrasive particles comprise brown fused alumina. A first filler is contained within the abrasive portion comprising iron and sulfur having an average particle size of not greater than about 40 microns.

1 . An abrasive cutting tool, comprising:
 a body in a shape of a large diameter disk having an outer diameter of at least about 60 centimeters, and an aspect ratio defined as a ratio (D:T) between the outer diameter to an axial thickness of the body of at least about 10:1, and the body including an abrasive portion having:
 a bond material; 
   abrasive particles contained within the bond material, the abrasive particles comprising brown fused alumina (BFA); and   a first filler contained within the abrasive portion comprising iron and sulfur having an average particle size of not greater than about 40 microns.   
     
     
         2 .- 3 . (canceled) 
     
     
         4 . The abrasive cutting tool of  claim 1 , wherein the first filler comprises pyrite (FeS 2 ). 
     
     
         5 . The abrasive cutting tool of  claim 1 , wherein the first filler is at least about 30 vol % of a total volume of fillers and not greater than about 80 vol %. 
     
     
         6 . The abrasive cutting tool of  claim 1 , wherein the average particle size of the first filler is not greater than about 30 microns. 
     
     
         7 . The abrasive cutting tool of  claim 1 , wherein the abrasive portion comprises a second filler comprising a compound including potassium, aluminum, and fluoride. 
     
     
         8 . The abrasive cutting tool of  claim 7 , wherein the abrasive portion comprises a greater content of the first filler (vol %) as compared to a content of the second filler (vol %). 
     
     
         9 . The abrasive cutting tool of  claim 7 , wherein the abrasive portion comprises at least about 20 vol % of the second filler for a total volume of fillers, and not greater than about 70 vol %. 
     
     
         10 . The abrasive cutting tool of  claim 7 , wherein the second filler comprises an average particle size of not greater than about 75 microns, and at least about 25 microns. 
     
     
         11 . The abrasive cutting tool of  claim 1 , wherein the abrasive portion comprises a third filler different than the first filler, wherein the third filler comprises a compound including calcium and oxygen. 
     
     
         12 . The abrasive cutting tool of  claim 11 , wherein the third filler comprises an average particle size of not greater than about 75 microns, and at least about 15 microns. 
     
     
         13 .- 14 . (canceled) 
     
     
         15 . The abrasive cutting tool of  claim 1 , wherein the abrasive portion comprises a third filler different than the first filler, the abrasive portion comprises at least about 0.5 vol % of the third filler for a total volume of fillers, and not greater than about 5 vol %. 
     
     
         16 . The abrasive cutting tool of  claim 1 , wherein the abrasive portion comprises a fourth filler, and the fourth filler comprises calcium silicates. 
     
     
         17 . The abrasive cutting tool of  claim 16 , wherein the fourth filler comprises an average particle size of not greater than about 40 microns, and at least about 1 micron. 
     
     
         18 .- 20 . (canceled) 
     
     
         21 . The abrasive cutting tool of  claim 1 , wherein the abrasive portion comprises a fourth filler (vol %), and the abrasive portion comprises at least about 1 vol % of the fourth filler of a total volume of fillers, and not greater than about 5 vol %. 
     
     
         22 . The abrasive cutting tool of  claim 1 , wherein the abrasive portion comprises a combination of the first filler, a second filler, a third filler, and a fourth filler, the abrasive portion comprises a total content of the first filler, second filler, third filler, and fourth filler of at least about 15 vol % for a total volume of the abrasive portion, and not greater than about 40 vol %. 
     
     
         23 . The abrasive cutting tool of  claim 1 , wherein the abrasive portion comprises a wetting liquid remnant including at least one of an aliphatic chain, and cyclic organic molecules. 
     
     
         24 .- 33 . (canceled) 
     
     
         34 . The abrasive cutting tool of  claim 1 , wherein the abrasive portion comprises at least about 30 vol % abrasive grains of the total volume of the abrasive portion, and not greater than about 65 vol %. 
     
     
         35 . The abrasive cutting tool of  claim 1 , wherein the BFA comprises not greater than about 99 vol % Al 2 O 3 , and at least about 80 vol % Al 2 O 3 . 
     
     
         36 . The abrasive cutting tool of  claim 1 , wherein the BFA comprises not greater than about 20 vol % ZrO 2 , and at least about 0.01 vol % ZrO 2 . 
     
     
         37 .- 38 . (canceled) 
     
     
         39 . The abrasive cutting tool of  claim 1 , wherein the abrasive portion comprises a second type of abrasive particle having not greater than about 90 vol % Al 2 O 3 , and at least about 70 vol % Al 2 O 3 . 
     
     
         40 . The abrasive cutting tool of  claim 39 , wherein the second type of abrasive particle comprises not greater than about 40 vol % ZrO 2 , at least about 15 vol % ZrO 2 . 
     
     
         41 .- 43 . (canceled) 
     
     
         44 . The abrasive cutting tool of  claim 1 , wherein the bond material comprises a resin having a normalized heat soak modulus of at least about 1.05. 
     
     
         45 . An abrasive cutting tool, comprising:
 a body in a shape of a large diameter disk having an outer diameter of at least about 60 centimeters, the body also having an aspect ratio defined as a ratio between diameter to thickness of at least about 10:1, and the body including an abrasive portion having:
 a bond material comprising a resin having a normalized heat soak modulus of at least about 1.05; 
 abrasive particles contained within the bond material. 
   
     
     
         46 . An abrasive cutting tool, comprising:
 a body in a shape of a large diameter disk having an outer diameter of at least about 60 centimeters, the body also having an aspect ratio defined as a ratio between diameter to thickness of at least about 10:1, and the body including an abrasive portion having:
 a bond material: 
 abrasive particles contained within the bond material; and 
   wherein the body comprises a CVR index of at least about 1% greater than a body of a conventional abrasive cutting tool, wherein the CVR Index comprises [(CVR1−CVR2)/CVR1]×100%, wherein CVR1 is a CVR surface coverage of the body, and CVR2 is a CVR surface coverage of the body of the conventional abrasive cutting tool.   
     
     
         47 . The abrasive cutting tool of  claim 46 , wherein the CVR index of the body is at least about 10% greater than the body of the conventional abrasive cutting tool, and not greater than about 90% greater than the body of the conventional abrasive cutting tool. 
     
     
         48 .- 49 . (canceled)