Abrasive article and method of forming same

Abstract

An abrasive article may be configured to work titanium and may comprise a body including a bond material comprising an organic material. A first type of abrasive particles may be contained within the bond material and comprise fused alumina. The body may comprise a burnout modulus of rupture (MOR) of at least about 1.6 MPa.

What is claimed is: 
     
         1 . An abrasive article configured to work titanium comprising:
 a body including:
 a bond material comprising a resin having a high temperature flexure modulus of at least 1.05; and 
 a first type of abrasive particles contained within the bond material comprising fused alumina. 
   
     
     
         2 . The abrasive article of  claim 1 , wherein the first type abrasive particles consist essentially of fused alumina. 
     
     
         3 . The abrasive article of  claim 1 , wherein the first type of abrasive particle comprises an average particle size of at least about 200 microns. 
     
     
         4 . The abrasive article of  claim 1 , further comprising a second type of abrasive particle different than the first type of abrasive particle. 
     
     
         5 . The abrasive article of  claim 4 , wherein the second type of abrasive particle comprises an average particle size of at least about 200 microns. 
     
     
         6 . The abrasive article of  claim 4 , wherein the second type of abrasive particle comprises at least about 60% and not greater than about 95% alumina, and at least about 5% and not greater than about 40% zirconia. 
     
     
         7 . The abrasive article of  claim 1 , wherein the body comprise a blend of the first type of abrasive particles and a second type of abrasive particles different than the first type of abrasive particles, wherein the blend comprises a different amount (vol %) of the first type of abrasive particle than an amount (vol %) of the second type of abrasive particle. 
     
     
         8 . The abrasive article of  claim 7 , wherein the blend comprises a ratio (AP1/AP2) of at least about 0.01 and not greater than about 4, wherein AP1 represents the weight of first type of abrasive particles in the blend and AP2 represents the weight of the second type of abrasive particles in the blend. 
     
     
         9 . The abrasive article of  claim 1 , wherein the body comprises a total content of abrasive particles of not greater than about 75 vol % and at least about 30 vol % for a total volume of the body. 
     
     
         10 . The abrasive article of  claim 1 , wherein the body comprises a total content of bond material of not greater than about 70 vol % and at least about 25 vol % for the total volume of the body. 
     
     
         11 . The abrasive article of  claim 1 , wherein the body comprises a total content of porosity of not greater than about 10 vol % and at least about 0.05 vol % porosity for a total volume of the body. 
     
     
         12 . The abrasive article of  claim 1 , wherein the bond material comprises an organic material selected from the group consisting of epoxy resins, polyester resins, polyurethanes, polyester, rubber, polyimide, polybenzimidazole, aromatic polyamide, modified phenolic resins, and a combination thereof. 
     
     
         13 . The abrasive article of  claim 1 , wherein the body further comprises a filler comprising a material selected from the group consisting of powders, granules, spheres, fibers, sand, bubble alumina, bauxite, chromites, magnesite, dolomites, bubble mullite, borides, titanium dioxide, carbon products (e.g., carbon black, coke or graphite), wood flour, clay, talc, hexagonal boron nitride, molybdenum disulfide, feldspar, nepheline syenite, glass spheres, glass fibers, CaF 2 , KBF 4 , Cryolite (Na 3 AlF 6 ), potassium Cryolite (K 3 AlF 6 ), pyrites, ZnS, copper sulfide, mineral oil, fluorides, carbonates, calcium carbonate, and a combination thereof. 
     
     
         14 . The abrasive article of  claim 1 , wherein the body is configured to conduct a material removal operation on a workpiece comprising titanium. 
     
     
         15 . The abrasive article of  claim 1 , wherein the body comprises a burnout modulus of rupture (MOR) of at least about 1.6 MPa and not greater than about 10 MPa. 
     
     
         16 . The abrasive article of  claim 1 , wherein the body comprises a burnout elastic modulus (EMOD) of at least about 250 MPa and not greater than about 1000 MPa. 
     
     
         17 . The abrasive article of  claim 1 , wherein the body comprises a relative material removal rate (MRR) improvement of at least about 5% and not greater than about 80% for a standard titanium grinding test as compared to a conventional abrasive article. 
     
     
         18 . The abrasive article of  claim 1 , further comprising a second type of abrasive particle different than the first type of abrasive particle, wherein the first type of abrasive particle is at least about 50% more friable than the second type of abrasive particle. 
     
     
         19 . The abrasive article of  claim 1 , wherein to break 90% of the first type of abrasive particles, at least about 300 N and no greater than about 1500 N is required. 
     
     
         20 . The abrasive article of  claim 1 , further comprising a second type of abrasive particle different than the first type of abrasive particle, wherein to break 90% of the second type of abrasive particles, at least about 500 N and greater than about 3300 N is required.