Abrasive particles and methods of forming same

Abstract

An abrasive particle having a body including a first major surface, a second major surface opposite the first major surface, and a side surface extending between the first major surface and the second major surface, such that a majority of the side surface comprises a plurality of microridges.

What is claimed is: 
     
         1 . A method for making abrasive particles comprising:
 forming a mixture into a body, wherein the mixture comprises a ceramic;   modifying the body to change the stress within the body; and   drying the body to induce cracking of the body and formation of a plurality of precursor abrasive particles.   
     
     
         2 . The method of  claim 1 , wherein modifying the body includes deforming at least a portion of the body. 
     
     
         3 . The method of  claim 1 , wherein forming is conducted without the use of a production tool. 
     
     
         4 . The method of  claim 1 , wherein modifying includes changing a physical feature of the body. 
     
     
         5 . The method of  claim 1 , wherein modifying includes forming a controlled distribution of features in at least a portion of the body. 
     
     
         6 . The method of  claim 5 , wherein the controlled distribution of features includes an array of features having at least one repeating unit. 
     
     
         7 . The method of  claim 1 , wherein drying includes creating controlled cracking conditions in the body by controlling at least one of:
 a drying temperature within a range of at least 20° C. and not greater than 250° C.;   a relative humidity within a range of at least 10% and not greater than 90%;   a flow rate within a range of at least 0.1 m/s and not greater than 5 m/s; or   any combination thereof.   
     
     
         8 . The method of  claim 1 , wherein the body is in the form of a layer having a first major surface, a second major surface, and a side surface, and wherein the first major surface defines a width (w), the side surface defines a height (h), and wherein the layer has an aspect ratio (w:h) of at least 10:1, and wherein the first major surface has a surface area of at least 10 cm 2 . 
     
     
         9 . The method of  claim 1 , wherein the plurality of precursor abrasive particle is formed without comminution of the body or intentional vibration of the body to induce cracking of the body. 
     
     
         10 . The method of  claim 1 , wherein the body of at least one of the abrasive particles includes a side surface portion having an irregular contour. 
     
     
         11 . The method of  claim 4 , wherein the controlled distribution of features includes at least one protrusion or depression within the body. 
     
     
         12 . The method of  claim 4 , wherein the controlled distribution of features includes an interconnected network of depressions formed in at least a portion of the body. 
     
     
         13 . The method of  claim 4 , wherein the controlled distribution of features includes a discontinuous distribution of depressions extending partially into the body. 
     
     
         14 . The method of  claim 1 , further comprising sintering the plurality of precursor abrasive particles to form abrasive particles. 
     
     
         15 . The method of  claim 14 , wherein the abrasive particles comprise alpha alumina. 
     
     
         16 . The method of  claim 14 , wherein the abrasive particles comprise a polycrystalline material having an average grain size of not greater than 20 microns. 
     
     
         17 . The method of  claim 14 , further comprising incorporating the abrasive particles into a fixed abrasive article. 
     
     
         18 . The method of  claim 1 , wherein drying includes forming a plurality of precursor abrasive particles, wherein a majority of the precursory abrasive particles have a substantially polygonal two-dimensional shape. 
     
     
         19 . The method of  claim 1 , wherein drying includes forming a plurality of precursor abrasive particles, wherein a minority of the precursory abrasive particles have an irregular two-dimensional shape. 
     
     
         20 . The method of  claim 1 , wherein the ceramic includes alumina.