Functionally graded abrasive structure and methods of using and making same

Abstract

A functionally graded abrasive structure with controlled variation in abrasive content in one or more directions ranging from 5% to 60% by volume, together with variation in porosity content ranging from 5% to 50% within the structure, wherein the variation in abrasive content is achieved through packing efficiencies, mixture of different nominal size abrasives.

What is claimed is: 
     
         1 . A functionally graded abrasive structure with controlled variation in abrasive content in one or more directions ranging from 5% to 60% by volume, together with variation in porosity content ranging from 5% to 50% within the structure, wherein the variation in abrasive content is achieved through packing efficiencies, mixture of different nominal size abrasives. 
     
     
         2 . The abrasive article of  claim 1 , wherein the graded structure could also be achieved through the use of fillers and abrasives at different content levels. 
     
     
         3 . The abrasive article of  claim 1 , wherein the abrasive type could comprise of superabrasives such as diamond or cubic boron nitride or conventional abrasives such as aluminum oxide, silicon carbide, boron carbide, tungsten carbide, and zirconium oxide. 
     
     
         4 . The abrasive article of  claim 1 , wherein the abrasive type could be a mixture of two different abrasive types. 
     
     
         5 . The abrasive article of  claim 1 , wherein the abrasive size could vary from 1200 microns down to 5 microns. 
     
     
         6 . The abrasive article of  claim 2 , wherein a filler when present could comprise of an oxide, nitride, boride, oxynitride, silicide or carbide. 
     
     
         7 . The abrasive article of  claim 1 , wherein the bond holding the structure could be a metal or metal alloy. 
     
     
         8 . The abrasive article of  claim 1 , wherein the bond holding the structure could be a glass or glass ceramic. 
     
     
         9 . The abrasive article of  claim 1 , wherein the abrasive comprises of a finite number of layers such as 10 layers, optionally 5 layers, or optionally 2 layers.