An abrasive article comprises a porous substrate having openings extending through the porous substrate between first and second opposed major surfaces. An abrasive coating is disposed on only a portion of a first major surface of the porous substrate. The abrasive coating comprises a functional layer disposed on only a portion of a first major surface of the porous substrate, a make layer disposed on at least a portion of the functional layer opposite the porous substrate, and abrasive particles. The functional layer and the make layer independently comprise chemically crosslinked binders. The functional layer fully occludes a first portion the openings and does not fully occlude a second portion of the openings, which permits passage of abraded swarf through the abrasive article. Methods of making the abrasive article are also disclosed.

A method for producing a high-porosity vitrified grinding stone that has a plurality of pores communicating with each other. The method includes: (a) a grinding-stone-material preparing step of obtaining a grinding-stone raw material slurry that is a mixture fluid of abrasive grains, a vitrified bond, a gellable water-soluble polymer and a water; (b) a molding step of obtaining a molded body, by gelling the grinding-stone raw material slurry with use of a molding mold; (c) a freeze vacuum drying step of generating a plurality of frozen particles inside the molded body by freezing the molded body, and placing the molded body under a vacuum state, so as to sublimate the frozen particles generated inside the molded body for thereby drying the molded body; and (d) a firing step of obtaining the high-porosity vitrified grinding stone, by binding the abrasive grains with the vitrified bond by firing the molded body.

A method of processing a polycrystalline diamond element includes forming a protective layer over a selected portion of a polycrystalline diamond element, the polycrystalline diamond element having a polycrystalline diamond table that includes a superabrasive face, a superabrasive side surface, and a chamfer extending between the superabrasive face and the superabrasive side surface. A portion of the superabrasive side surface is covered by the protective layer and the protective layer is not formed over the chamfer. The method includes exposing at least a portion of the polycrystalline diamond element to a leaching solution. A polycrystalline diamond element has a polycrystalline diamond table that includes a leached volume extending from the superabrasive face to a portion of the chamfer proximate to the superabrasive side surface, and the leached volume does not substantially extend along the superabrasive side surface.

Various embodiments disclosed relate to an abrasive article. The abrasive article includes a nonwoven web. The non-woven web includes a first irregular major surface and an opposite second irregular major surface. The nonwoven web further includes a fiber component comprising staple fibers having a linear density ranging from about 50 denier to about 2000 denier and a crimp index value ranging from about 15% to about 60%. The nonwoven web further includes a binder dispensed on the fiber component and abrasive particles dispersed throughout the nonwoven web.

The present invention is an abrasive composite including a first crosslinkable binder component, wherein when polymerized, has a glass transition temperature (T.sub.g) below room temperature and a modulus of less than about 150 MPa: a second crosslinkable binder component having a T.sub.g above room temperature; a material capable of initiating addition polymerization; and particulate grains having a Mohs hardness value of less than or equal to about 3.

An abrasive tool has an abrasive grain layer comprising a plurality of hard abrasive grains bonded by a binder, with a plurality of the hard abrasive grains each having a working surface formed to contact a workpiece, a ratio of a total area of a plurality of such working surfaces to an area of an imaginary plane smoothly connecting the plurality of working surfaces being 5% or more and 30% or less.

An abrasive tool has an abrasive grain layer comprising a plurality of hard abrasive grains bonded by a binder, with a plurality of the hard abrasive grains each having a working surface formed to contact a workpiece, a ratio of a total area of a plurality of such working surfaces to an area of an imaginary plane smoothly connecting the plurality of working surfaces being 5% or more and 30% or less.

A method of processing a polycrystalline diamond element includes forming a protective layer over a selected portion of a polycrystalline diamond element, the polycrystalline diamond element having a polycrystalline diamond table that includes a superabrasive face, a superabrasive side surface, and a chamfer extending between the superabrasive face and the superabrasive side surface. A portion of the superabrasive side surface is covered by the protective layer and the protective layer is not formed over the chamfer. The method includes exposing at least a portion of the polycrystalline diamond element to a leaching solution. A polycrystalline diamond element has a polycrystalline diamond table that includes a leached volume extending from the superabrasive face to a portion of the chamfer proximate to the superabrasive side surface, and the leached volume does not substantially extend along the superabrasive side surface.

This method for manufacturing a cutting blade includes: a mixing step of adding a liquid dispersion medium to a mixed powder containing a resin powder of a thermocompression-bondable resin, abrasive grains and fibrous fillers; a compression step of cold pressing, in a forming die, the mixed powder to which the dispersion medium has been added to form an original plate of a blade main body; and a sintering step of hot pressing and sintering the original plate.

This method for manufacturing a cutting blade includes: a mixing step of adding a liquid dispersion medium to a mixed powder containing a resin powder of a thermocompression-bondable resin, abrasive grains and fibrous fillers; a compression step of cold pressing, in a forming die, the mixed powder to which the dispersion medium has been added to form an original plate of a blade main body; and a sintering step of hot pressing and sintering the original plate.