Abrasive tools and methods of forming the same

Abstract

An abrasive tool is provided that may include a body, which may include abrasive particles contained within a bond material. The abrasive particles may be a super abrasive material. The body may further include at least one of a break-in length of not greater than about 1000 linear meters, a maximum initial speed character of at least about 10 m/min, a life span of at least about 1000 linear meters, a dressing frequency of at least about 25 parts/dress, an edge quality of at least about 25% of a workpiece free from defects and a combination thereof.

What is claimed is: 
     
         1 . An abrasive tool comprising:
 a body including:
 abrasive particles comprising a super abrasive material contained within a bond material; and 
 at least one high material removal rate character selected from the group consisting of:
 a break-in length of not greater than about 1000 linear meters; 
 a maximum initial speed character of at least about 10 m/min; 
 a life span of at least about 1000 linear meters; 
 a dressing frequency of at least about 25 parts/dress; 
 an edge quality of at least about 25% of a workpiece free from defects; and 
 a combination thereof. 
 
   
     
     
         2 . The abrasive tool of  claim 1 , wherein the body comprises substantially no break-in period. 
     
     
         3 . The abrasive tool of  claim 1 , further comprising at least one of:
 a ratio of tungsten to cast iron [W/CI] of not greater than about 1;   a ratio of copper-containing compositions to cast iron [CCC/CI] of not greater than about 1;   a ratio of titanium-containing compositions to cast iron [TiCC/CI] of not greater than about 1;   a ratio of tungsten carbide to cast iron [WC/CI] of not greater than about 1;   a ratio of tungsten carbide to copper-containing compositions [WC/CCC] of not greater than about 1;   a ratio of copper-containing compositions and titanium-containing compositions to cast iron [(CCC+TiC)/CI] of not greater than about 1.5; and   a combination thereof.   
     
     
         4 . The abrasive tool of  claim 3 , wherein the body further comprises comprising a ratio of nickel to cast iron [Ni/CI] of not greater than about 1. 
     
     
         5 . The abrasive tool of  claim 3 , wherein the body further comprises a ratio of chromium to cast iron [Cr/CI] of not greater than about 1. 
     
     
         6 . The abrasive tool of  claim 3 , wherein the body further comprises a ratio of titanium-containing compositions to abrasive particles [TiCC/AP] of not greater than about 1. 
     
     
         7 . The abrasive tool of  claim 3 , wherein the body further comprises a ratio of cast iron to abrasive particles [CI/AP] of not greater than about 1. 
     
     
         8 . The abrasive tool of  claim 3 , wherein the body comprises not greater than about 10 wt. % titanium-containing compositions for a total weight of the bond material. 
     
     
         9 . The abrasive tool of  claim 3 , wherein the body comprises not greater than about 10 wt. % tungsten for a total weight of the bond material. 
     
     
         10 . The abrasive tool of  claim 3 , wherein the body comprises not greater than about 50 wt. % copper-containing compound for a total weight of the bond material. 
     
     
         11 . The abrasive tool of  claim 3 , wherein the copper-containing compound comprises elemental copper. 
     
     
         12 . The abrasive tool of  claim 11 , wherein the body comprises not greater than about 50 wt. % elemental copper for a total weight of the bond material. 
     
     
         13 . The abrasive tool of  claim 3 , wherein the body comprises not greater than about 20 wt. % tin for a total weight of the bond material. 
     
     
         14 . The abrasive tool of  claim 3 , wherein the cast iron comprises not greater than about 5 wt. % chromium for a total weight of the cast iron. 
     
     
         15 . A method of forming an abrasive tool comprising:
 providing a mixture comprising:
 a bond material; 
 abrasive particles comprising a superabrasive material; 
 an active bonding agent comprising a titanium-containing compositions; and 
 at least one of:
 at least one high material removal rate character selected from the group consisting of:
 a break-in length of not greater than about 1000 linear meters; 
 a maximum initial speed character of at least about 10 m/min; 
 a life span of at least about 1000 linear meters; 
 a dressing frequency of at least about 25 parts/dress; 
 an edge quality of at least about 25% of a workpiece free from defects; and 
 a combination thereof; and 
 
 
   forming the mixture into the abrasive tool.   
     
     
         16 . The method of forming an abrasive tool of  claim 15 , wherein the body comprises substantially no break-in period. 
     
     
         17 . The method of forming an abrasive tool of  claim 15 , further comprising at least one of:
 a ratio of tungsten to cast iron [W/CI] of not greater than about 1;   a ratio of copper-containing compositions to cast iron [CCC/CI] of not greater than about 1;   a ratio of titanium-containing compositions to cast iron [TiCC/CI] of not greater than about 1;   a ratio of tungsten carbide to cast iron [WC/CI] of not greater than about 1;   a ratio of tungsten carbide to copper-containing compositions [WC/CCC] of not greater than about 1;   a ratio of copper-containing compositions and titanium-containing compositions to cast iron [(CCC+TiC)/CI] of not greater than about 1.5; and   a combination thereof.   
     
     
         18 . The method of forming an abrasive tool of  claim 17 , wherein the body further comprises a ratio of titanium-containing compositions to abrasive particles [TiCC/AP] of not greater than about 1. 
     
     
         19 . The method of forming an abrasive tool of  claim 17 , wherein the body further comprises a ratio of cast iron to abrasive particles [CI/AP] of not greater than about 1. 
     
     
         20 . The method of forming an abrasive tool of  claim 17 , wherein the copper-containing compound comprises elemental copper.