Abrasive article and method of making

Abstract

An abrasive article includes a bonded abrasive having a body made of abrasive grains contained within a composite bond material. The composite bond material can include an organic material and a metal material. The body can also include a filler material made of a superabrasive material. In an embodiment, the filler material can have an average particle size at least about 10 times less than an average particle size of the abrasive grains.

What is claimed is: 
     
         1 . An abrasive article comprising:
 a bonded abrasive having a body comprising abrasive grains contained within a composite bond material including an organic material and a metal material, wherein the body further includes a filler material comprising a superabrasive material, the filler material having an average particle size at least about 10 times less than an average particle size of the abrasive grains, wherein the body comprises a ratio of filler material to abrasive grains (FM/AG) not greater than about 0.30, wherein FM is the volume percent of the filler material based on the total volume of the body and AG is the volume percent of the abrasive grains based on the total volume of the body.   
     
     
         2 . The abrasive article of  claim 1 , wherein the composite bond material has a fracture toughness of not greater than about 3.0 MPa m 0.5 . 
     
     
         3 . The abrasive article of  claim 1 , wherein the organic material comprises a material selected from the group of materials consisting of polyimides, polyamides, epoxies, resins, aramids, polyesters, polyurethanes, and a combination thereof. 
     
     
         4 . The abrasive article of  claim 1 , wherein the organic material comprises between about 1 vol % and about 20 vol % for the total volume of the bond material. 
     
     
         5 . The abrasive article of  claim 1 , wherein the metal material comprises a metal alloy. 
     
     
         6 . The abrasive article of  claim 5 , wherein the metal material consists essentially of bronze. 
     
     
         7 . The abrasive article of  claim 1 , wherein the metal material comprises at least about 20 vol % of the total volume of the bond material. 
     
     
         8 . The abrasive article of  claim 1 , wherein the bond material comprise a ratio (OM/MM) of organic material by volume (OM) to metal material by volume (MM) of not greater than about 0.25. 
     
     
         9 . The abrasive article of  claim 1 , wherein the body comprises between about 10 vol % and about 80 vol % bond material for the total volume of the body. 
     
     
         10 . The abrasive article of  claim 1 , wherein the abrasive grains have an average particle size of less than about 400 microns. 
     
     
         11 . The abrasive article of  claim 1 , wherein the body comprises a porosity of not greater than about 10 vol % for the total volume of the body. 
     
     
         12 . The abrasive article of  claim 1 , wherein the filler material has an average particle size at least about 12 times less than an average particle size of the abrasive grains. 
     
     
         13 . The abrasive article of  claim 1 , wherein the filler material has an average particle size not greater than about 40 times less than an average particle size of the abrasive grains. 
     
     
         14 . The abrasive article of  claim 1 , wherein the body comprises at least about 2 vol % filler material for the total volume of the body. 
     
     
         15 . The abrasive article of  claim 14 , wherein the body comprises not greater than about 16 vol % filler material for the total volume of the body. 
     
     
         16 . The abrasive article of  claim 1 , wherein the filler material comprises an average particle size of not greater than about 25 microns. 
     
     
         17 . The abrasive article of  claim 1 , wherein the filler material comprises an average particle size of at least about 0.5 microns. 
     
     
         18 . The abrasive article of  claim 1 , wherein the filler material comprises diamond. 
     
     
         19 . The abrasive article of  claim 1 , wherein the average particle size of the filler material and the average particle size of the abrasive grains define a bimodal particle size distribution. 
     
     
         20 . The abrasive article of  claim 1 , wherein the body comprises an average wear of not greater than about 0.25 mm.