Sintered polycrystalline flat-shaped geometrically structured ceramic abrasive element, method of making and use thereof

Abstract

The present invention relates to sintered polycrystalline flat-shaped geometrically structured ceramic abrasive elements designed for the use in resin bonded wheels, particularly in cut-off wheels. The present invention also relates to a method of making such sintered polycrystalline flat-shaped geometrically structured ceramic abrasive elements and the use thereof.

Claims

1. An abrasive element comprising a sintered shaped ceramic body having; a homogeneous microstructure, a consistent chemical composition across the whole sintered body, and a uniformly structured geometry, and a center, wherein the sintered ceramic body has a first surface and a second surface opposite the first surface and parallel to it, the first and second surfaces are separated by a sidewall having a thickness (t) between 50 and 2000 μm, and the diameter-to thickness ratio of the abrasive element is greater than 30, an average diameter of the crystals which form the microstructure of the sintered body is less than 10 μm, and the ceramic body includes a plurality of recesses or perforations, wherein a first distance measured across a first one of the plurality of recesses or perforations is greater than a second distance measured across a second one of the recesses or perforations, the first distance is measured further from the center of the sintered ceramic body than the second distance, and a volume ratio of the plurality of the recesses or perforations to the massive parts of the ceramic body is constant over the whole usable diameter of the abrasive element.

2. The abrasive element according to claim 1, wherein the chemical composition of the abrasive element is based on aluminum oxide and/or other chemical compounds selected from the group consisting of carbides, oxides, nitrides, oxy-carbides, oxy-nitrides and carbo-nitrides of at least one of the elements selected from the group consisting of Al, B, Si, Zr and Ti.

3. The abrasive element according to claim 1, wherein the abrasive element is a circular disk or a segment of a circle.

4. The abrasive element according to claim 1, wherein the perforation of the ceramic body features a homogeneous geometrical structure of geometric shaped openings.

5. The abrasive element according to claim 1, wherein the abrasive element is a porous ceramic body.

6. The abrasive element according to claim 1, wherein the chemical composition of the abrasive element comprises at least 50 wt.-% alumina and one or more oxides selected from the group consisting of SiO.sub.2, MgO, TiO.sub.2, Cr.sub.2O.sub.3, MnO.sub.2, Co.sub.2O.sub.3, Fe.sub.2O.sub.3, NiO, Cu.sub.2O, ZnO, ZrO.sub.2, and rare earth oxides.

7. A method of manufacturing a ceramic abrasive elements according to claim 1, comprising the steps of: preparing a ductile ceramic precursor mass; forming precursors of flat-shaped geometrically structured ceramic abrasive elements from said ductile ceramic precursor mass; and calcining and sintering said precursors of flat-shaped geometrically structured ceramic abrasive elements to obtain sintered flat-shaped geometrically structured ceramic abrasive elements.

8. A method according of manufacturing a ceramic abrasive elements comprising preparing a ductile ceramic precursor mass; forming precursors of flat-shaped geometrically structured ceramic abrasive elements from said ductile ceramic precursor mass; and calcining and sintering said precursors of flat-shaped geometrically structured ceramic abrasive elements to obtain sintered flat-shaped geometrically structured ceramic abrasive elements; preparing a dispersion of α-alumina in water by ball-milling α-alumina having an average particle size of less than 1 μm in presence of a dispersant; adding an organic binder and optionally a plasticizer and/or an antifoaming agent to the dispersion; mixing the dispersion for several hours to obtain a stable colloidal dispersion; tape casting the stable colloidal dispersion to a film having a thickness up to 3 mm; drying the tape cast film; cutting-out precursors of flat-shaped geometrically structured ceramic abrasive elements; and calcining and sintering the precursors of the ceramic abrasive elements; wherein each of the ceramic abrasive elements includes a sintered shaped ceramic body having a homogeneous microstructure, a consistent chemical composition across the whole sintered body, and a uniformly structured geometry, wherein the sintered ceramic body has a first surface and a second surface opposite the first surface and parallel to it, the first and second surfaces are separated by a sidewall having a thickness (t) between 50 and 2000 μm, and the diameter-to thickness ratio of the abrasive element is greater than 30, an average diameter of the crystals which form the microstructure of the sintered body is less than 10 μm.

9. A method comprising the use of a ceramic abrasive element according to claim 1 for making resin-bonded grinding wheels.

10. A cut-off wheel comprising a ceramic abrasive element according to claim 1.

11. The abrasive element according to claim 1, wherein the ceramic body comprises perforations.

12. The abrasive element according to claim 1, wherein the first one of the plurality of recesses or perforations is located further from the center of the sintered ceramic body than the second one of the plurality of recesses or perforations.

13. The abrasive element according to claim 1, wherein the plurality of recesses or perforations are round openings.

14. The abrasive element according to claim 1, wherein the plurality of recesses or perforations are trapezoidal openings.

15. The abrasive element according to claim 1, wherein the plurality of recesses or perforations are rhombic openings.

16. The abrasive element according to claim 1, wherein the plurality of recesses or perforations are hexagonal honeycomb-shaped openings.

17. The abrasive element according to claim 1, wherein the plurality of recesses or perforations are triangular openings.

18. The abrasive element according to claim 1, wherein the first and second ones of the plurality of recesses or perforations are openings that extend radially outward from the center of the sintered ceramic body.

Description

SHORT DESCRIPTION OF THE FIGURES

(1) The present invention is additionally described by means of figures. Thereby,

(2) FIGS. 1 to 8 show two dimensional plan views of different geometrically structured ceramic abrasive elements;

(3) FIG. 9 shows a summary of different geometrical recesses; and

(4) FIGS. 10a-10c schematically show different rake angles.

(5) The selection of the geometric structures described in the figures above should not be construed to unduly limit this invention. Beside the above illustrated structures, numerous other structures are possible and suitable to solve the problem according to this invention.

DESCRIPTION OF PREFERRED EMBODIMENTS

(6) FIG. 1 shows a plan view of a radially shaped round ceramic abrasive element. In the middle of the element one can see a center hole 1 corresponding to the hub of the grinding wheel for which the element is designed. The body 2 of the abrasive element is star-shaped whereby the ends of the beams 3 perpendicularly stand to the center hole 1 while forming a circle whereof the diameter corresponds to the diameter of the wheel for which the abrasive element is designed. Between the beams 3 one can see the openings 4 which are suitable to provide the required porosity for the grinding wheel. The dimensions of the openings 4 are such that the volume ratio of the openings 4 to the massive parts of the grinding wheel is constant during machining over the whole diameter of the usable wheel. Thus, it is guaranteed that the porosity of the grinding wheel and with it the abrasion conditions are constant during radial wear of the whole grinding process. This ratio is illustrated in FIG. 1 by the ratio of the distances A B and A′/B′, relating to the circumferences U and U″, respectively, at a defined wheel diameter.

(7) The FIGS. 2 and 3 also show plan views of radially shaped abrasive elements, whereby the beams 3 in FIG. 2 are angled with regard to the center hole 1. In FIG. 3, the beams 3 are additionally curved. Also in these cases, the openings 4 are designed in a manner that the volume ratio of the openings to the massive parts of the abrasive element is constant over the whole abraded diameter of the wheel, which is illustrated by the ratio of the distances A/B and A′/B′, respectively, relating to the circumference.

(8) Another feature for characterizing the flat-shaped geometrically structured ceramic abrasive elements is the rake angle γ which corresponds to the angle of inclination of the rake surface (surface of attack) from the reference plane which is orthogonal to the tangent of the disk. Three different types of rake angles are possible: positive, negative or even zero. A positive rake angle γ helps to reduce the cutting force and thus cutting power requirement, whereas a negative rake angle γ increases the edge-strength and the life of the abrasive element or the grinding wheel. The rake angle γ is additionally explained by means of FIGS. 3, 4, 8, 10a, 10b, and 10c.

(9) The abrasive element according to FIG. 3 has a positive rake angle γ of 18°. During the grinding process the rake angle γ falls off to zero with increasing wear (decreasing radius) of the grinding wheel.

(10) FIG. 4 shows a circular disk-shaped abrasive element. The body 2 of the abrasive element has a center hole 1 corresponding to the hub of the grinding wheel. In this case, the porosity of the grinding wheel is guaranteed by round holes 4 becoming greater with increasing radius of the wheel so that the volume ratio of openings 4 to the massive parts of the abrasive element here also is constant over the diameter used during the grinding process, which is once more illustrated by the ratio of the distances A/B and A′/B′ in relation to the circumference. The rake angle γ of the abrasive element starts with +29° and with reduced abrasive wheel radius switches by passing zero into the negative range down to −90°. With the next line of round holes 4 the rake angle γ starts with +90′, falls off to zero and switches subsequently into negative range down to −90°. This run is repeated with every new row of holes.

(11) The FIGS. 5 to 8 also show circular disk-shaped abrasive elements having openings 4 with other geometrical structures, Trapezoidal openings 4 are shown in FIG. 5, rhombic openings 4 in FIG. 6, hexagonal honeycomb-shaped openings 4 in FIG. 7, and triangular openings 4 in FIG. 8. In all cases, the volume ratio of the openings 4 to the massive parts of the abrasive elements is constant over the whole diameter of the wheel used during the grinding process, which is illustrated once more by the ratio of the distances A/B and A′/B′ in relation to the circumference. The rake angle γ of the abrasive element according to FIG. 8 is 32° and stays constant over the whole grinding process.

(12) The rake angle γ is generally illustrated by means of FIGS. 10a to 10c, whereby FIG. 10a shows a positive rake angle γ, the rake angle γ according to FIG. 10b is zero, and FIG. 10c shows a negative rake angle γ. During cutting, the abrasive element 7 generates a chip 6 from the workpiece 5, whereby a positive rake angle γ helps to reduce the cutting force and thus cutting power requirement, whereas a negative rake angle γ increases the edge-strength and the life of the abrasive element 7.

(13) As mentioned above, the embodiments of the abrasive elements shown in FIGS. 1 to 8 are an arbitrary selection which should not be construed to unduly limit the scope of the invention. Examples of further geometrical surfaces being suitable shapes of openings or holes are shown in FIG. 9. Also this summary should not be construed to unduly limit the invention.

(14) Beside the full circular abrasive elements shown in FIGS. 1 to 8, it is also possible to accordingly make and use segments of a circle having analogous structures. It is an advantage of the segments that their making and handling is easier with a minor risk of breakage during processing. Appropriate segments of a circle are fractions having the half, one third, a quarter, or one eighth of a full circular abrasive element.

(15) Finally, the geometric configuration of the abrasive elements primarily depends on the field of application of the grinding wheel. A person skilled in the art will choose a simply producible geometric shape wherewith the grinding conditions are most suitably adjustable.

EXAMPLES

(16) An 80% α-aluminum oxide suspension having a mean particle size d.sub.50 of 0.144 μm was obtained by wet milling α-aluminum oxide starting powder having a mean particle size d.sub.50 of less than 1 μm, whereby the suspension was stabilized by addition of 0.75 wt.-% polymethacrylate (KV5182, Zschimmer & Schwarz). Then, a latex binder (B-100, Dow Chemicals) was added to the stabilized suspension.

(17) Subsequently, 5 wt.-% of 1.25% aqueous cellulose solution (Methocel K15M) was added to the liquid suspension to increase its viscosity. In this stage, films with differing thicknesses between 200 μm and 500 μm were cast using the above ceramic precursor having an aluminum oxide content of 72.6% by weight and a viscosity of about 1,300 mPa*s, wherefrom precursors of the flat-shaped geometrically structured ceramic abrasive elements were stamped according to the structures of FIGS. 1 to 8.

(18) The precursors were dried whereby, due to the high aluminum oxide content, only small shrinkage and no crack formation was observed. The dried precursors were heated to 600° C. using a heating rate of 1° C./min to remove the binder, and subsequently sintered up to a maximum temperature of 1600° C. using a heating rate of 5° C./min. The holding time at 1600° C. was 30 minutes. The flat-shaped geometrically structured ceramic abrasive elements such obtained have a density of 3.94 g/cm.sup.3 (98.3% of the theoretical density), a Vickers hardness Hv of 18.4 GPa, and a crystallite size of less than 2 μm.

(19) Cutoff Test

(20) For making a resin bonded cut-off wheel with a diameter of 125 mm, a flat-shaped geometrically structured ceramic abrasive element according to FIG. 1 having a thickness of 300 μm was used. The resin was additionally mixed with a corundum filler to ensure the stability of the wheel. For comparison, a wheel comprising monocrystalline corundum (TSCTSK, Imerys Fused Minerals) grit size F46/F60 was used as standard.

(21) Round CrNi stainless-steel bars having a diameter of 20 mm were used as workpieces for cut-off tests and the cutting operation was carried out using a wheel speed of 8,800 revolutions per minute and a cutting rate of 6,000 μm/s. For each test, 3 pre-cuts and 12 cuts were performed. Then, the wheel wear was determined based on the reduction of the wheel diameter. The G-ratio was calculated from the ratio of material removal and wheel wear.

(22) The results are summarized in table 1 as follows:

(23) TABLE-US-00001 TABLE 1 Example G-ratio cm.sup.2/cm.sup.2 performance (%) According to FIG. 1 3.41 112 300 μm Standard 3.04 100 TSCTSK 46/60

(24) The above example illustrates the potential of the abrasive elements according to the present invention. By varying the geometric structure, the thickness and their own porosity, customized abrasive elements may be provided for any number of applications. Porous alumina based oxide ceramics are suitable abrasive elements with high proper porosity. The porosity of such ceramics can be adjusted to a pore volume between 10% and 90% by means of well-known ceramic technologies.

(25) Another optimization potential results from applying several abrasive elements incorporated in parallel to each other in one grinding wheel, whereby the hole patterns of the abrasive elements are advantageously staggered with respect to each other, such that the grinding wheel possesses a homogeneous porosity distribution over the whole width of the wheel. An example for such a wheel is a double layered staggered cut-off wheel comprising two flat-shaped geometrically structured ceramic abrasive elements each having a thickness of 150 μm.

(26) Additionally, the physical properties of the abrasive elements may be varied by introducing dopants. For example, the toughness and breaking strength of the abrasive elements can be improved by introducing zirconia. The variations of the raw materials and the production methods are further possibilities for varying and optimizing the abrasive elements according to the present invention. Particular fine crystalline abrasive elements having a crystal size in the range of 100 nm may be obtained by means of well-known technologies via the sol-gel route. Such ceramic abrasive elements have a high toughness and hardness and are particular suitable for machining high-alloy steels.

(27) Additional applications of particular interest are thin resin bonded wheels having a thickness between 100 μM and 200 μm and a minor diameter between 1 cm and 4 cm which are used for dental technologies.