Abstract: A method for making an abrasive product comprising forming a structure of a sinterable retaining matrix having at least one first region containing a plurality of abrasive particles embedded therein and at least one second region containing substantially less or no abrasive particles adjacent the first region, at least one of the regions substantially surrounding the other of the regions, sintering the structure to form a unitary structure, wherein the first and second regions are integrated along a border between the regions, and extracting at least the first region from the unitary structure to form an abrasive product.

Abstract: A method for making an abrasive material comprising a plurality of hard particles providing the abrasive quality distributed in a retaining matrix for holding the particles in place, the method comprising the steps of placing a mask having openings therein against a carrier capable of supporting a plurality of the particles, providing an affixing capability to an outer side of the mask remote from the carrier to which hard particles will adhere, applying a plurality of hard particles to the outer side of the mask so that a portion of the particles pass through the openings of the mask and form a pattern of the particles on the carrier corresponding to the openings of the mask and another portion of the particles adhere to the mask, separating the mask containing the hard particles adhered to it from the carrier leaving the pattern of the particles on the carrier, at least partially surrounding the particles on the carrier with a retaining matrix material, and heating the retaining matrix material to cause the

Abstract: A method for making a sintered article comprising providing a plurality of individual blocks of sinterable matrix material, arranging said blocks in abutting relationship to form an assembly of said blocks in a sinter mold wherein said assembly comprises a plurality of said blocks extending in at least one direction thereof and sintering said assembly under pressure in the mold to form an integrated sintered article. The blocks may contain abrasive particles to provide a sintered abrasive article and individual abrasive segments may be extracted from the article.

Abstract: Structurally independent cutting members are formed with abrasive material comprising a plurality of particles protruding through a surface of the retaining material comprising a mesh material for durable cutting members; and, the structurally independent cutting members are selectively continuous or discontinuous and spatially mounted along the working edge of a core. Some of the cutting members or portions of the cutting members are arranged for stock removal, and some are arranged for gauge keeping. Since the individual portions of the cutting portions are separate, more stock removal portions can be included, with fewer gauge keeping portions as may be required. The structurally independent cutting members may have a variety of profile shapes, such as contoured configurations to provide stock removal using high pressure cutting forces applied normal to the cutting face of the workpiece and gauge keeping functions using low pressure cutting forces applied laterally to the cutting face to the workpiece.

Abstract: A composite abrasive material is formed by coating a mesh-type material substrate with an adhesive, contacting the substrate with a quantity of hard, abrasive particles, then removing all particles not held by the adhesive within the openings of the mesh-type material. The particles are surrounded with a sinterable matrix material while the particles are temporarily held by the adhesive. The substrate can have the adhesive applied in a pattern, or covering uniformly to cause the particles to adhere in certain areas to achieve a desired pattern. While the particles are held on the substrate, physical force can be applied to orient the particles uniformly; then, a powder can be applied, or the substrate can be applied to a preform. Subsequent treatment with heat and pressure will complete the composite abrasive material.

Abstract: A composite abrasive material is formed by coating a mesh-type material substrate with an adhesive, contacting the substrate with a quantity of hard, abrasive particles, then removing all particles not held by the adhesive within the openings of the mesh-type material. The particles are surrounded with a sinterable matrix material while the particles are temporarily held by the adhesive. The substrate can have the adhesive applied in a pattern, or covering uniformly to cause the particles to adhere in certain areas to achieve a desired pattern. While the particles are held on the substrate, physical force can be applied to orient the particles uniformly; then, a powder can be applied, or the substrate can be applied to a preform. Subsequent treatment with heat and pressure will complete the composite abrasive material.

Abstract: Structurally independent cutting members are formed with abrasive material comprising a plurality of particles protruding through a surface of the retaining material comprising a mesh material for durable cutting members; and, the structurally independent cutting members are selectively continuous or discontinuous and spatially mounted along the working edge of a core. Some of the cutting members or portions of the cutting members are arranged for stock removal, and some are arranged for gauge keeping. Since the individual portions of the cutting portions are separate, more stock removal portions can be included, with fewer gauge keeping portions as may be required. The structurally independent cutting members may have a variety of profile shapes, such as contoured configurations to provide stock removal using high pressure cutting forces applied normal to the cutting face of the workpiece and gauge keeping functions using low pressure cutting forces applied laterally to the cutting face to the workpiece.

Abstract: A method for making abrasive articles uses a soft, easily deformable and flexible preform having a high binder content. The binder gives the preform its integrity, and is present in greater quantity than the retaining powder. The preform can have superabrasive particles mixed therein, or added later. The preform allows even distribution of a small quantity of retaining powder for thin superabrasive articles. A porous layer may be added to the assembly for making an abrasive article, the porous layer absorbing the liquid binder, supporting the retaining powder and superabrasive particles to prevent lateral movement, and perhaps giving strength to the preform. The final assembly to be heated or sintered (preferably under pressure) for making the abrasive article, which may include any number of layers of superabrasive particles, porous layers and preforms.