Abrasive article having shaped segments

An abrasive segment can include an inner segment portion, an outer segment portion, and a central segment portion connected thereto. The inner segment portion can include an inner circumferential wall and an outer circumferential wall. Leading and trailing radial sidewalls can extend between the inner circumferential wall and the outer circumferential wall opposite each other. The outer segment portion can include an inner circumferential wall and an outer circumferential wall. Leading and trailing radial sidewalls can extend between the inner circumferential wall and the outer circumferential wall opposite each other. The central segment portion can include a leading radial sidewall and a trailing radial sidewall. The leading radial sidewall of the central segment portion can establish an acute angle, α, with respect to the outer circumferential wall of the inner segment portion and an obtuse angle, β, with respect the inner circumferential wall of the outer segment portion.

BACKGROUND

1. Field of the Disclosure

The following is generally directed to abrasive tools and processes for forming same, and more particularly, to abrasive tools utilizing abrasive segments attached to a base and methods of assembling such tools.

2. Description of the Related Art

Tools necessary for furthering infrastructure improvements, such as building additional roads and buildings, are vital to the continued economic expansion of developing regions. Additionally, developed regions have a continuing need to replacing aging infrastructure with new and expanded roads and buildings.

The construction industry utilizes a variety of tools for cutting and grinding of construction materials. Cutting and grinding tools are required for to remove or refinish old sections of roads. Additionally, quarrying and preparing finishing materials, such as stone slabs used for floors and building facades, require tools for drilling, cutting, and polishing. Typically, these tools include abrasive segments bonded to a base element or core, such as a plate or a wheel. As with other industries, improvements to these abrasive tools are always sought.

DETAILED DESCRIPTION

According to an embodiment, the abrasive article herein can include a core and a plurality of abrasive segments affixed to the core. The abrasive article can be a grinding tool for grinding metal, concrete, or natural stone.

In general, the abrasive article can include multiple Z-shaped segments affixed to a core.FIG. 1andFIG. 2illustrate an exemplary abrasive article designated100.FIG. 1includes a front plan view of the abrasive article100.FIG. 2includes a rear plan view of the abrasive article100.FIG. 3throughFIG. 8include various views of a shaped segment that can be installed on the core. Specifically,FIG. 3includes a front plan view of the segment.FIG. 4includes a rear plan view of the segment.FIG. 5includes a left side plan view.FIG. 6includes a right side plan view.FIG. 7includes a top plan view andFIG. 8includes a bottom plan view of the segment.FIG. 8includes an enlarged bottom plan view of the segment.

FIG. 1 and 2illustrates an exemplary abrasive article designated100. As depicted, the abrasive article100can include a generally cup-shaped core102. The core102can include a body104having a generally disc-shaped central hub106formed with a central bore108along a center110of the core102. The center110of the core102is also the center110of the abrasive article100.

A generally frusto-conical sidewall112can extend radially outward and axially from the central hub106at an angle with respect to the central hub106. The sidewall112can include a distal end114and a generally ring-shaped segment support flange116can extend radially outward from the distal end114of the frusto-conical sidewall112. The segment support flange116can include a face118perpendicular to a direction of rotation of the abrasive article100around a central axis passing perpendicularly through the center110of the abrasive article100.

A plurality of abrasive segments120can be affixed to the face118of the segment support flange116can extend axially away from the segment support flange116in a direction parallel to the central axis. The segments120can be formed separately from the core102, as described herein, and affixed to the core via a brazing procedure, a welding procedure, a mechanical coupling, etc. In a particular aspect, each adjacent pair of segments120can be separated by a gap122.

FIG. 3throughFIG. 8illustrate the details of one of the segments120. As illustrated, the segment120can include a body130that can include a generally curved inner segment portion132and a generally curved outer segment portion134spaced a radial distance, d, from the inner segment portion132. The body132of the segment130can also include a central segment portion136connected to the inner segment portion132and the outer segment portion134.

In a particular aspect, the inner segment portion132can include an inner circumferential wall140and an outer circumferential wall142. The inner segment portion132can also include a leading radial sidewall144extending between the inner circumferential wall140and the outer circumferential wall142and a trailing radial sidewall146extending between the inner circumferential wall140and the outer circumferential wall142opposite the leading radial sidewall144. The terms leading and trailing, as used herein, can be defined based on a direction of rotation of the abrasive article100, which is counter-clockwise in the view illustrated inFIG. 1.

As illustrated, the inner segment portion132can further include a first grinding face148that can extend between the inner and outer circumferential walls140,142and the leading and trailing radial sidewalls144,146. Moreover, a first serrated portion150can extend at least partially over the first grinding face148. In a particular aspect, the first grinding face148can include an area, AGF1, and the first serrated portion150can include an area, ASP1. ASP1can be <AGF1. For example, ASP1can be ≦80% AGF1, such as ≦75% AGF1, ≦70% AGF1, ≦65% AGF1, or ≦60% AGF1. Further, ASP1can be ≦30% AGF1, such as ≧35% AGF1, ≧40% AGF1, ≧45% AGF1, or ≧50% AGF1. In another aspect, ASP1can be within a range between and including any of the maximum and minimum values of ASP1described herein.

In a particular aspect, the inner segment portion132can have a first radial width, W1, measured from the inner circumferential wall140to the outer circumferential wall142. W1can be ≧d, described above. For example, W1can be ≧105% d, such as ≧110% d, or ≧125% d. In another aspect, W1can be ≦200% d, such as ≦175% d, or ≦150% d. W1can also be within a range between and including any of the maximum and minimum values of W1described herein.

For example, W1can be ≧105% d and ≦200% d, such as ≧105% d and ≦175% d, or ≧105% d and ≦150% d. Further, W1can be ≧110% d and ≦200% d, such as ≧110% d and ≦175% d, or ≧110% d and ≦150% d. Still further, W1can be ≧125% d and ≦200% d, such as ≧125% d and ≦175% d, or ≧125% d and ≦150% d.

As illustrated, the outer segment portion134can include an inner circumferential wall160and an outer circumferential wall162. The outer segment portion134can also include a leading radial sidewall164extending between the inner circumferential wall160and the outer circumferential wall162and a trailing radial sidewall166extending between the inner circumferential wall160and the outer circumferential wall162opposite the leading radial sidewall164.

As illustrated, the outer segment portion134can further include a second grinding face168that can extend between the inner and outer circumferential walls160,162and the leading and trailing radial sidewalls164,166. Moreover, a second serrated portion170can extend at least partially over the second grinding face168. In a particular aspect, the second grinding face168can include an area, AGF2, and the second serrated portion170can include an area, ASP2. ASP2can be <AGF2. For example, ASP2can be ≦80% AGF2, such as ≦75% AGF2, ≦70% AGF2, ≦65% AGF2, or ≦60% AGF2. Further, ASP2can be ≧30% AGF2, such as ≧35% AGF2, ≧40% AGF2, ≧45% AGF2, or ≧50% AGF2. In another aspect, ASP2can be within a range between and including any of the maximum and minimum values of ASP2described herein.

In a particular aspect, the outer segment portion134can have a second radial width, W2, measured from the inner circumferential wall160to the outer circumferential wall162. W2can be ≧d, described above. For example, W2can be ≧105% d, such as ≧110% d, or ≧125% d. In another aspect, W2can be ≦200% d, such as ≦175% d, or ≦150% d. W2can also be within a range between and including any of the maximum and minimum values of W2described herein.

For example, W2can be ≧105% d and ≦200% d, such as ≧105% d and ≦175% d, or ≧105% d and ≦150% d. Further, W2can be ≧110% d and ≦200% d, such as ≧110% d and ≦175% d, or ≧110% d and ≦150% d. Still further, W2can be ≧125% d and ≦200% d, such as ≧125% d and ≦175% d, or ≧125% d and ≦150% d.

In another aspect, ASP1can be ≦ASP2. For example, ASP1can be ≦95% ASP2, such as ≦90% ASP2, ≦85% ASP2, or ≦80% ASP2. Further, ASP1≧50% ASP2, such as ≧55% ASP2, or ≧60% ASP2. In another aspect, ASP1can be within a range between and including any of the maximum and minimum values of ASP1described herein.

As further depicted inFIG. 3, the outer segment portion134can further include a plurality of outer peripheral serrations172formed in the outer circumferential wall162of the outer segment portion134. The outer peripheral serrations172can extend along the entire outer circumferential wall162from the leading radial sidewall164to the trailing radial sidewall166of the outer segment portion134. Moreover, the outer peripheral serrations172can form a sinusoidal wave structure along the outer circumferential wall162.

In a particular aspect, the outer circumferential wall162have a circumferential length, LOCW, and the sinusoidal wave structure can includes a wavelength, WLSWS. WLSWScan be ≦0.2 LOCW, such as ≦0.175 LOCW, ≦0.15 LOCW, or ≦0.125 LOCW. Further, WLSWScan be ≧0.05 LOCW, such as ≧0.06 LOCW, ≧0.07 LOCW, ≧0.08 LOCW, or ≧0.09 LOCW. WLSWScan be within a range between and including any of the maximum and minimum values of WLSWSdescribed herein.

As illustrated inFIG. 3, the central segment portion136can include a leading radial sidewall180that can extend from the outer circumferential wall142of the inner segment portion132to the inner circumferential wall160of the outer segment portion134. The central segment portion136can also include a trailing radial sidewall182that can extend from the outer circumferential wall142of the inner segment portion132to the inner circumferential wall160of the outer segment portion134. In a particular aspect, the leading radial sidewall180of the central segment portion136can establish an acute angle, α, with respect to the outer circumferential wall142of the inner segment portion132and an obtuse angle, β, with respect the inner circumferential wall160of the outer segment portion136.

In a particular aspect, α can be <90°, such as ≦75°, ≦70°, ≦65°, or ≦60°. Moreover, α can be ≧40°, such as ≧45°, ≧50°, or ≧55°. Further, α can be within a range between and including any of the values of a described herein. For example, α can be <90° and ≧40°, such as <90° and ≧45°, <90° and ≧50°, or <90° and ≧55°. Further, α can be ≦75° and ≧40°, such as ≦75° and ≧45°, ≦75° and ≧50°, or ≦75° and ≧55°. Additionally, α can be ≦70° and ≧40°, such as ≦70° and ≧45°, ≦70° and ≧50°, or ≦70° and ≧55°. In another aspect, α can be ≦65° and ≧40°, such as ≦65° and ≧45°, ≦65° and ≧50°, or ≦65° and ≧55°. Still further, α can be ≦60° and ≧40°, such as ≦60° and ≧45°, ≦60° and ≧50°, or ≦60° and ≧55°.

In another aspect, β can be >90°, such as ≧115°, ≧120°, ≧125°, or ≧130°. Moreover, β can be ≦150°, such as ≦145°, ≦140°, or ≦135°. In another aspect, β can be within a range between and including any of the maximum and minimum values of β described herein. For example, β can be >90° and ≦150°, such as >90° and ≦145°, >90° and ≦140°, or >90° and ≦135°. Additionally, β can be ≧115° and ≦150°, such as ≧115° and ≦145°, ≧115° and ≦140°, or ≧115° and ≦135°. Further, β can be ≧120° and ≦150°, such as ≧120° and ≦145°, ≧120° and ≦140°, or ≧120° and ≦135°. Further still, β can be ≧125° and ≦150°, such as ≧125° and ≦145°, ≧125° and ≦140°, or ≧125° and ≦135°. Even further, β can be ≧130° and ≦150°, such as ≧130° and ≦145°, ≧130° and ≦140°, or ≧130° and ≦135°.

As best indicated inFIG. 9, each serrated portion150,170can include a plurality of serrations190. Each serration includes a leading edge192, a trailing edge194, and a ramped surface196extending there between. In particular, each ramped surface196can extend at an angle, γ, into the first grinding face148or the second grinding face168from the trailing edge194to the leading edge192. In a particular aspect, γ can be ≧10°, such as ≧12.5°, or ≧15°. Further, γ can be ≦30°, such as ≦25°, or ≦20°. In another aspect, γ can be within a range between and including any of the maximum and minimum values described herein.

For example, γ can be ≧10° and ≦30°, such as ≧10° and ≦25°, or ≧10° and ≦20°. Further, γ can be ≧12.5° and ≦30°, such as ≧12.5° and ≦25°, or ≧12.5° and ≦20°. Still further, γ can be ≧15° and ≦30°, such as ≧15° and ≦25°, or ≧15° and ≦20°.

In a particular aspect, the abrasive segment120can include a thickness, TAS, measured from a rear face to a front face, e.g., the first grinding face148or the second grinding face168. The trailing edge194of each serration190can extend a distance, DTES, out from the first grinding face148or the second grinding face168and measured perpendicular to the first grinding face148or the second grinding face168and DTEScan be ≦0.125 TAS, such as ≦0.1 TAS, ≦0.075 TAS, or ≦0.05 TAS. Moreover, DTEScan be ≧0.0075 TAS, such as ≧0.01 TAS, ≧0.0125 TAS, or ≧0.015 TAS. In another aspect, DTEScan be within a range between and including any of the maximum or minimum values of DTESdescribed herein.

The leading edge192of each serration190can extend a distance, DLES, into the first grinding face148or the second grinding face168and measured perpendicular to the first grinding face148or the second grinding face168, and DLEScan be ≦0.125 TAS, such as ≦0.1 TAS, ≦0.075 TAS, or ≦0.05 TAS. Moreover, DLEScan be ≧0.0075 TAS, such as ≧0.01 TAS, ≧0.0125 TAS, or ≧0.015 TAS. In another aspect, DLEScan be within a range between and including any of the maximum or minimum values of DLESdescribed herein.

In another particular aspect, the abrasive segment120can include a central axis200that can extend through a center202of curvature of the abrasive segment and bisect the leading radial sidewall180of the central segment portion136of the abrasive segment120. In this aspect, the first serrated portion150on the first segment portion132can lie entirely behind the central axis200with respect to a direction of rotation of the abrasive segment120. Further, the second serrated portion170on the second segment portion134can lie entirely ahead of the central axis200with respect to a direction of rotation of the abrasive segment120.

Further, in a particular aspect, a portion of the inner segment portion132can extend ahead of the leading radial sidewall180of the central segment portion136with respect to the direction of rotation. Moreover, a portion of the outer segment portion134can extend behind the trailing radial sidewall182of the central segment portion136with respect to the direction of rotation.

In a particular aspect, the core102of the abrasive article100described herein can be in the form of a cup, a ring, a ring section, a plate, or a disc depending upon the intended application of the abrasive article. The core102can be made of a metal or metal alloy. For instance, the core102can be made of steel, and particularly, a heat treatable steel alloys, such as 25CrMo4, 75Cr1, C60, or similar steel alloys for a core having a thin cross section or simple construction steel like St 60 or similar for a thick core. The core102can have a tensile strength of at least about 600 N/mm2. The core102can be formed by a variety of metallurgical techniques known in the art.

In an exemplary embodiment, the abrasive segments104can include abrasive particles embedded in a bond matrix. In a particular aspect, the bond matrix can include a metal matrix having a network of interconnected pores. The abrasive particles can include an abrasive material having a Mohs hardness of at least about 7. In particular instances, the abrasive particles can include a superabrasive material, such as diamond or cubic boron nitride. The abrasive particles can have a particle size of not less than about 400 US mesh, such as not less than about 100 US mesh, such as between about 25 and 80 US mesh. Depending on the application, the size can be between about 30 and 60 US mesh.

The abrasive particles can be present in an amount between about 2 vol % to about 50 vol %. Additionally, the amount of abrasive particles may depend on the application. For example, an abrasive segment for a grinding or polishing tool can include between about 3.75 and about 50 vol % abrasive particles of the total volume of the abrasive segment. Alternatively, an abrasive segment for a cutting-off tool can include between about 2 vol % and about 6.25 vol % abrasive particles of the total volume of the abrasive segment. Further, an abrasive segment for core drilling can include between about 6.25 vol % and about 20 vol % abrasive particles of the total volume of the abrasive segment.

The metal matrix can include a metal element or metal alloy including a plurality of metal elements. For certain abrasive segments, the metal matrix can include metal elements such as iron, tungsten, cobalt, nickel, chromium, titanium, silver, and a combination thereof. In particular instances, the metal matrix can include a rare earth element such as cerium, lanthanum, neodymium, and a combination thereof.

In one particular example, the metal matrix can include a wear resistant component. For example, in one embodiment, the metal matrix can include tungsten carbide, and more particularly, may consist essentially of tungsten carbide.

In certain designs, the metal matrix can include particles of individual components or pre-alloyed particles. The particles can be between about 1.0 microns and about 250 microns.

In a particular aspect, the abrasive segments104can be formed such that an infiltrant is present within the interconnected network of pores within the body of the abrasive segment104. The infiltrant can partially fill, substantially fill, or even completely fill the volume of the pores extending through the volume of the abrasive segment104. In accordance with one particular design, the infiltrant can be a metal or metal alloy material. For example, some suitable metal elements can include copper, tin, zinc, and a combination thereof.

In particular instances, the infiltrant can be a bronzing material made of a metal alloy, and particular a copper-tin metal alloy, such that it is particularly suited for welding according to embodiments herein. For example, the bronzing material can consist essentially of copper and tin. Certain bronzing materials can incorporate particular contents of tin greater than about 5% by weight, such as greater than about 6% by weight, greater than about 7% by weight, or even greater than about 8% by weight. Further, certain bronzing materials can incorporate particular contents of tin less than about 20% by weight, such as less than about 15% by weight, less than about 12% by weight, or even less than about 10% by weight of the total amount of materials within the composition.

In accordance with an embodiment, the bronzing material can include an amount of tin within a range between and including about 5% by weight and about 20% by weight, such as between and including about 5% by weight and about 15% by weight, between and including about 5% by weight and about 12% by weight, or between and including about 5% by weight and about 10% by weight.

In another embodiment, the bronzing material can include an amount of tin within a range between and including about 6% by weight and about 20% by weight, such as between and including about 6% by weight and about 15% by weight, between and including about 6% by weight and about 12% by weight, or between and including about 6% by weight and about 10% by weight.

Further, in yet another embodiment, the bronzing material can include an amount of tin within a range between and including about 7% by weight and about 20% by weight, such as between and including about 7% by weight and about 15% by weight, between and including about 7% by weight and about 12% by weight, or between and including about 7% by weight and about 10% by weight.

Still further, in accordance with another embodiment, the bronzing material can include an amount of tin within a range between and including about 8% by weight and about 20% by weight, such as between and including about 8% by weight and about 15% by weight, between and including about 8% by weight and about 12% by weight, or between and including about 8% by weight and about 10% by weight.

Moreover, certain bronzing materials can be used as infiltrant material, and can have an amount of copper of at least about 80%, at least about 85%, or even at least about 88% by weight of the total amount of materials within the composition. Some bronzing materials can utilize an amount of copper within a range between about 80% and about 95%, such as between about 85% and about 95%, or even between about 88% and about 93% by weight of the total amount of materials within the composition.

Additionally, the bronzing material may contain a particularly low content of other elements, such as zinc to facilitate proper formation of the abrasive article according to the forming methods of the embodiments herein. For example, the bronzing material may utilize not greater than about 10%, such as not greater than about 5%, or even not greater than about 2% zinc. In fact, certain bronzing materials can be essentially free of zinc.

The abrasive segment104may be manufactured, such that abrasive particles can be combined with a metal matrix to form a mixture. The metal matrix can include a blend of particles of the components of the metal matrix or can be pre-alloyed particles of the metal matrix. In an embodiment, the metal matrix can conform to the formula (WC)wWxFeyCrzX(l−w−x−y−z), wherein 0≦w≦0.8, 0≦x≦0.7, 0≦y≦0.8, 0≦z≦0.05, w+x+y+z≦1, and X can include other metals such as cobalt and nickel. In another embodiment, the metal matrix can conform to the formula (WC)wWxFeyCrzAgvX(l−v−w−x−y−z), wherein 0≦w≦0.5, 0≦x≦0.4, 0≦y≦1.0, 0≦z≦0.05, 0≦v≦0.1, v+w+x+y+z≦1, and X can include other metals such as cobalt and nickel.

The mixture of metal matrix and abrasive particles can be formed into an abrasive preform by a pressing operation, particularly a cold pressing operation, to form a porous abrasive segment. The cold pressing can be carried out at a pressure within a range between and including about 50 kN/cm2(500 MPa) to about 250 kN/cm2(2500 MPa). The resulting porous abrasive segment can have a network of interconnected pores. In an example, the porous abrasive segment can have a porosity between about 25 and 50 vol %.

The resulting porous abrasive segment104can then be subject to an infiltration process, wherein the infiltrant material is disposed within the body of the abrasive segment, and particularly, disposed within the interconnected network of pores within the body of the abrasive segment. The infiltrant may be drawn into the pores of the cold pressed abrasive segment via capillary action. After the infiltration process, the resulting densified abrasive segment can be not less than about 96% dense. The amount of infiltrant that infiltrates the abrasive segment can be between about 20 wt % and 45 wt % of the densified abrasive segment.

The abrasive segment104can include a backing region, disposed between the abrasive segment and the base, i.e., the core102, which facilitates the joining of the abrasive segment and the core102. According to one embodiment, the backing region can be a distinct region from the abrasive segment104and the core102. Still, the backing region can be initially formed as part of the abrasive segment104, and particularly may be a distinct region of the abrasive segment104along a bottom surface of the abrasive segment104that has particular characteristics facilitating the joining of the abrasive segment104and the core102. For example, according to one embodiment, the backing region can have a lesser percentage (vol %) of abrasive particles as compared to the amount of abrasive particles within the abrasive segment104. In fact, in certain instances, the backing region can be essentially free of abrasive particles. This may be particularly suitable for forming methods utilizing a beam of energy (e.g., a laser) used to weld the abrasive segment104to the core102.

At least a portion of the backing region can include a bonding composition. The bonding composition can include a metal or metal alloy. Some suitable metal materials can include transition metal elements, including for example, titanium, silver, manganese, phosphorus, aluminum, magnesium, chromium, iron, lead, copper, tin, and a combination thereof.

In particular instances, the bonding composition can be similar to the infiltrant, such that the bonding composition and the infiltrant are different from each other by not greater than a single elemental species. In even more particular instances, the bonding composition can be the same as the infiltrant. According to embodiments herein, the bonding composition can be related to the infiltrant composition in having a certain degree of commonality of elemental species. Quantitatively, an elemental weight percent difference between the bonding composition and the infiltrant composition does not exceed 20 weight percent. Elemental weight percent difference is defined as the absolute value of the difference in weight content of each element contained in the bonding composition relative to the infiltrant composition. Other embodiments have closer compositional relationships between the bonding composition and the composition of the infiltrant. The elemental weight percent difference between the bonding composition and the infiltrant composition may, for example, not exceed 15 weight percent, 10 weight percent, 5 weight percent, or may not exceed 2 weight percent. An elemental weight percent difference of about zero represents the same composition making up the backing region and the infiltrant. The foregoing elemental values may be measured by any suitable analytical means, including microprobe elemental analysis, and ignores alloying that might take place along areas in which the infiltrant contacts the metal matrix.

The backing region can include at least about 90 wt % infiltrant, such as at least about 95 wt % infiltrant, such as at least about 98 wt % infiltrant. The infiltrant can be continuous throughout the backing region and the densified abrasive segment. In certain instances, the backing region can be formed primarily of the infiltrant material, and in more particular instances, can consist essentially of the infiltrant material. Still, in other embodiments, the backing region can be an infiltrated region, like the abrasive segment. Accordingly, the backing region can include a network of interconnected pores formed between a matrix metal, and wherein the infiltrant material substantially fills the interconnected pores. The backing region can contain similar amounts of matrix metal and infiltrant. Notably, the backing region may be essentially free of abrasive particles. In such embodiments wherein the backing region includes interconnected pores substantially filled with the infiltrant, the infiltrant material can act as a bronzing material in forming a joint (e.g., a welded joint) between the base and the abrasive segment.

In one embodiment, the backing region can be formed of the bronzing material described herein. In fact, certain backing regions can consist essentially of a copper-tin bronzing material having about 88% copper and 12% tin or 90% copper and 10% tin.

In a particular aspect, a method of making the abrasive article100can include stamping, cutting, drilling, or otherwise forming a core102having vibration reducing gullets140and segment support structures130. The method can include affixing the segments104to the core102such that each segment104is affixed to a segment support structure130. Affixing the segments104to the core102can include welding the abrasive segments104to the core102. In particular, the welding process can include impinging a beam of energy at the base of each segment104. More particularly, in the instance of a segment104having a backing region, welding can include impinging a beam of energy at the backing region between the abrasive segment104and the core102. In particular instances, the beam of energy can be a laser, such that each abrasive segment104is attached to the core102via a laser welded bond joint. The laser may be a Roffin laser source commonly available from Dr. Fritsch, GmbH.

In one aspect, each segment104can be formed by pressing a green segment in a mold and curing the green segment. The pressing can include hot pressing or cold pressing. In another aspect, forming each segment104can include sintering a green segment, e.g., using an electro-discharge sintering process. In yet another aspect, forming each segment104can include the infiltration method described herein.

In another aspect, each segment104can be include a single layer metal bond (“SLMB”) segment having a core and a single layer of abrasive electro-plated, or otherwise deposited, on a cutting, or grinding surface of the core.

According to an embodiment, each abrasive article100can include a carrier element, e.g., a core102, and an abrasive component, e.g., a segment104. The abrasive article100can be a cutting tool for cutting construction materials, such as a saw for cutting concrete. Alternatively, the abrasive article100can be a grinding tool such as for grinding concrete or fired clay or removing asphalt.

Item 1. An abrasive segment, comprising:an inner segment portion comprising an inner circumferential wall, an outer circumferential wall, a leading radial sidewall extending between the inner circumferential wall and the outer circumferential wall, and a trailing radial sidewall extending between the inner circumferential wall and the outer circumferential wall opposite the leading radial sidewall;an outer segment portion spaced a radial distance, d, from the inner segment portion, the outer segment portion comprising an inner circumferential wall, an outer circumferential wall, a leading radial sidewall extending between the inner circumferential wall and the outer circumferential wall, and a trailing radial sidewall extending between the outer circumferential wall and the inner circumferential wall opposite the leading radial sidewall; anda central segment portion connected to the inner segment portion and the outer segment portion, the central segment portion including a leading radial sidewall and a trailing radial sidewall, wherein the leading radial sidewall of the central segment portion establishes an acute angle, α, with respect to the outer circumferential wall of the inner segment portion and an obtuse angle, β, with respect the inner circumferential wall of the outer segment portion.

a body;

a plurality of Z-shaped abrasive segments extending from a face of the body, wherein each Z-shaped abrasive segment comprises:an inner segment;an outer segment portion spaced a radial distance, d, from the inner segment portion; anda central segment portion connected to the inner segment portion and the outer segment portion.

Item 3. An abrasive article, comprising:a body;a plurality of Z-shaped abrasive segments extending from a face of the body, wherein each abrasive segment comprises:an inner segment portion comprising a first grinding face and a first serrated portion extending at least partially over the first grinding face;an outer segment portion spaced a radial distance, d, from the inner segment portion, the outer segment portion comprising a second grinding face and a second serrated portion extending at least partially over the second grinding face; anda central segment portion connected to the inner segment portion and the outer segment portion.

Item 4. The abrasive article according to claim 3, wherein each serrated portion includes a plurality of serrations and each serration includes a leading edge, a trailing edge, and a ramped surface that extends at an angle, γ, into the first grinding face or the second grinding face from the trailing edge to the leading edge.

Item 5. The abrasive article according to claim 4, wherein γ≧10°, such as ≧12.5°, or ≧15°.

Item 6. The abrasive article according to claim 5, wherein γ≦30°, such as ≦25°, or ≦20°.

Item 7. The abrasive segment or article according to claim 4, wherein the abrasive segment includes a thickness, TAS, and the trailing edge of each serration extends a distance, DTES, outward from the first grinding face or the second grinding face, wherein DTES≦0.125 TAS, such as ≦0.1 TAS, ≦0.075 TAS, or ≦0.05 TAS.

Item 8. The abrasive segment or article according to claim 7, wherein DTES>0.0075 TAS, such as ≧0.01 TAS, ≧0.0125 TAS, or ≧0.015 TAS.

Item 9. The abrasive segment or article according to claim 4, wherein the abrasive segment includes a thickness, TAS, and the trailing edge of each serration extends a distance, DLES, inward from the first grinding face or the second grinding face, wherein DLES≦0.125 TAS, such as ≦0.1 TAS, ≦0.075 TAS, or ≦0.05 TAS.

Item 10. The abrasive segment or article according to claim 9, wherein DLES>0.0075 TAS, such as ≧0.01 TAS, ≧0.0125 TAS, or ≧0.015 TAS.

Item 11. The abrasive segment or article according to of claim 1, wherein α is <90°, such as ≦75°, ≦70°, ≦65°, or ≦60°.

Item 12. The abrasive segment or article according to claim 11, wherein α is ≧40°, such as ≧45°, ≧50°, or ≧55°.

Item 13. The abrasive segment or article according to any of claims 1, wherein β>90°, such as ≧115°, ≧120°, ≧125°, or ≧130°.

Item 14. The abrasive segment or article according to claim 13, wherein α is ≦150°, such as ≦145°, ≦140°, or ≦135°.

Item 15. The abrasive segment or article according to any of claim 1 or 2, wherein the inner segment portion further comprises a grinding face extending between the inner and outer circumferential walls, the leading radial sidewall, and the trailing radial sidewall wherein the first grinding face includes a first serrated portion extending at least partially over the first grinding face.

Item 16. The abrasive segment or article according to claim 15, wherein the first grinding face includes an area, AGF1, and the first serrated portion includes an area, ASP1, and ASP1<AGF1.

Item 19. The abrasive segment or article according to claim 15, wherein the outer segment portion further comprises a second grinding face extending between the inner and outer circumferential walls, the leading radial sidewall, and the trailing radial sidewall wherein the second grinding face includes a second serrated portion extending at least partially over the second grinding face.

Item 20. The abrasive segment or article according to claim 19, wherein the second grinding face includes an area, AGF2, and the second serrated portion includes an area, ASP2, and ASP2<AGF2.

Item 23. The abrasive segment or article according to claim 19, wherein the first serrated portion includes an area, ASP1, and the second serrated portion includes an area ASP2, wherein ASP1≦ASP2.

Item 25. The abrasive segment or article according to claim 24, wherein ASP1≧50% ASP2, such as ≧55% ASP2, or ≧60% ASP2.

Item 26. The abrasive segment or article according to claim 19, wherein the abrasive segment includes a central axis extending through a center of curvature of the abrasive segment and bisecting the leading radial sidewall of the central segment portion of the abrasive segment and wherein the first serrated portion lies entirely behind the central axis with respect to a direction of rotation of the abrasive segment.

Item 27. The abrasive segment or article according to claim 26, wherein the second serrated portion lies entirely ahead of the central axis with respect to a direction of rotation of the abrasive segment.

Item 28. The abrasive segment or article according to any of claim 1, 2, or 3, wherein the outer segment portion further comprises a plurality of outer peripheral serrations formed in the outer circumferential wall of the outer segment portion.

Item 29. The abrasive segment or article according to claim 28, wherein the outer peripheral serrations extend along the entire outer circumferential wall from the leading radial sidewall to the trailing radial sidewall.

Item 30. The abrasive segment or article according to claim 29, wherein the outer peripheral serrations form a sinusoidal wave structure along the outer circumferential wall.

Item 31. The abrasive segment or article according to claim 30, wherein the outer circumferential wall has a length, LOCW, and the sinusoidal wave structure includes a wavelength, WLSWS, wherein WLSWS≦0.2 LOCW, such as ≦0.175 LOCW, ≦0.15 LOCW, or ≦0.125 LOCW.

In the foregoing, reference to specific embodiments and the connections of certain components is illustrative. It will be appreciated that reference to components as being coupled or connected is intended to disclose either direct connection between said components or indirect connection through one or more intervening components as will be appreciated to carry out the methods as discussed herein. As such, the above-disclosed subject matter is to be considered illustrative, and not restrictive, and the appended claims are intended to cover all such modifications, enhancements, and other embodiments, which fall within the true scope of the present invention. Thus, to the maximum extent allowed by law, the scope of the present invention is to be determined by the broadest permissible interpretation of the following claims and their equivalents, and shall not be restricted or limited by the foregoing detailed description.