GRINDING WHEEL ASSEMBLY

Abstract

An abrasive article is disclosed and can include a core comprising a polymer material. The core can include an upper surface, an outer peripheral surface, an upper recessed portion extending into the core from the upper surface and a peripheral recess extending into the outer peripheral surface. The abrasive article can also include a bonded abrasive body disposed within the peripheral recess of the outer peripheral surface of the core and a cover plate having an upper surface. The cover plate can fit into the upper recessed portion of the upper surface the core so that the upper surface of the cover plate is substantially coplanar with the upper surface of the core.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 62/671,534, entitled “GRINDING WHEEL ASSEMBLY”, by Cecile O. MEJEAN et al., filed May 15, 2018, which is assigned to the current assignees hereof and incorporated herein by reference in its entirety.

FIELD OF THE DISCLOSURE

The present invention relates, in general, to grinding wheels and multi-piece grinding wheel assemblies.

BACKGROUND

Abrasive grinding wheels can be used to smooth and contour the edges of certain flat materials, e.g., sheets of glass, for safety and cosmetic reasons. Such abrasive grinding wheels may include diamond-containing abrasive wheels and may be used to shape the edges of materials for various industries, including but not limited to automotive, architectural, furniture, and appliance industries.

The industry continues to demand improved grinding wheel assemblies, particularly for applications of grinding the edges of flat materials.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure may be better understood, and its numerous features and advantages made apparent to those skilled in the art by referencing the accompanying drawings.

FIG. 1 includes an illustration of a side plan view of a grinding wheel assembly in accordance with an embodiment.

FIG. 2 includes an illustration of an exploded side plan view of a grinding wheel assembly in accordance with an embodiment.

FIG. 3 includes an illustration of a top plan view of an abrasive article for a grinding wheel assembly in accordance with an embodiment.

FIG. 4 includes an illustration of a bottom plan view of an abrasive article for a grinding wheel assembly in accordance with an embodiment.

FIG. 5 includes an illustration of a side plan view of an abrasive article for a grinding wheel assembly in accordance with an embodiment.

FIG. 6 includes an illustration of a side plan view of a core for an abrasive article for a grinding wheel assembly in accordance with an embodiment.

FIG. 7 includes an illustration of a cross-section view, taken along Line 7-7 in FIG. 3, of an abrasive article for a grinding wheel assembly in accordance with an embodiment.

FIG. 8 includes an illustration of a top plan view of a cover plate for a grinding wheel assembly in accordance with an embodiment.

FIG. 9 includes an illustration of a bottom plan view of a cover plate for a grinding wheel assembly in accordance with an embodiment.

FIG. 10 includes an illustration of a side plan view of a cover plate for a grinding wheel assembly in accordance with an embodiment.

FIG. 11 includes an illustration of a cross-section view, taken along Line 11-11 in FIG. 8, of a cover plate for a grinding wheel assembly in accordance with an embodiment.

FIG. 12 includes an illustration of a cross-section view of a cover plate fitted into an abrasive article for a grinding wheel assembly in accordance with an embodiment.

FIG. 13 includes an illustration of a side plan view of a grinding wheel assembly in accordance with an embodiment.

FIG. 14 includes an illustration of an exploded side plan view of a grinding wheel assembly in accordance with an embodiment.

FIG. 15 includes an illustration of a top plan view of an abrasive article for a grinding wheel assembly in accordance with an embodiment.

FIG. 16 includes an illustration of a bottom plan view of an abrasive article for a grinding wheel assembly in accordance with an embodiment.

FIG. 17 includes an illustration of a side plan view of an abrasive article for a grinding wheel assembly in accordance with an embodiment.

FIG. 18 includes an illustration of a side plan view of a core for an abrasive article for a grinding wheel assembly in accordance with an embodiment.

FIG. 19 includes an illustration of a cross-section view, taken along Line 19-19 in FIG. 15, of an abrasive article for a grinding wheel assembly in accordance with an embodiment.

FIG. 20 includes an illustration of a top plan view of a cover plate for a grinding wheel assembly in accordance with an embodiment.

FIG. 21 includes an illustration of a bottom plan view of a cover plate for a grinding wheel assembly in accordance with an embodiment.

FIG. 22 includes an illustration of a side plan view of a cover plate for a grinding wheel assembly in accordance with an embodiment.

FIG. 23 includes an illustration of a cross-section view, taken along Line 23-23 in FIG. 20, of a cover plate for a grinding wheel assembly in accordance with an embodiment.

FIG. 24 includes an illustration of a cross-section view of a cover plate fitted into an abrasive article for a grinding wheel assembly in accordance with an embodiment.

DETAILED DESCRIPTION

The following is generally directed to grinding wheel assemblies that are particularly suitable for grinding and smoothing the edges of brittle materials, such as glass.

Embodiments are directed to abrasive articles which may be in the form of grinding wheels. In one aspect, a grinding wheel assembly can include an abrasive body mounted in a head assembly that can be easily removed and replaced after the abrasive body is no longer providing sufficient abrasion during use. The grinding wheel assembly can include an arbor in which a pull stud can be installed. The arbor can further provide support for an abrasive body. In one aspect, the arbor can include a mounting plate and the abrasive body can be held between the mounting plate and a cover plate. The grinding wheel assembly can be particular suitable for operations of grinding the edges of glass, such as automobile glass and flat glass. Further, the grinding wheel assembly can allow for relatively quicker removal and replacement of the abrasive article after the abrasive article is no longer useful. The pull stud, the arbor, and the cover plate need not be replaced after the abrasive body is no longer useful.

Grinding Wheel Assembly

Referring initially to FIG. 1 through FIG. 2, a grinding wheel assembly is illustrated and is generally designated 100. As shown, the grinding wheel assembly 100 can include a pull stud 102, an arbor 104, an abrasive article 106, a cover plate 108, and at least one fastener 110, e.g., a threaded fastener. A threaded fastener with a socket head is depicted in the FIGs., but it is to be understood that any other type of threaded fastener may be used. For example, socket head cap screws may be used. In particular, standard grade 12.9 M8 socket head cap screws may be used to fasten the cover plate to the arbor 104. Alternatively, standard grade 12.9 M10 socket head cap screws or standard grade 12.9 M12 socket head cap screws may be used. FIG. 2 also indicates that three threaded fasteners 110 can be used to mount the cover plate 108 and the abrasive article 106 to the arbor 104. However, in an alternative embodiment, a single, centrally located threaded fastener can be used to mount the cover plate 108 and the abrasive article 106 to the arbor 104. In such a case, the single, centrally located threaded fastener can pass through a center of the cover plate 108, a center of the abrasive article 106, and engage threads formed in the center of the arbor 104.

The pull stud 102, the arbor 104, and the cover plate 108 can include a metal or a metal alloy. For example, the metal can be stainless steel or titanium. Further, the metal can include a hardened metal, such as hardened steel. It is to be understood that the material utilized for the pull stud 102, the arbor 104, and the cover plate 108 will minimize wearing of these elements during use. The abrasive article 106, however, will wear during grinding operations performed on the edges of various workpieces. After the abrasive article 106 is sufficiently worn, the abrasive article 106 may be removed and replace with a new abrasive body. Alternatively, the abrasive article 106 may be removed and the outer periphery of the abrasive article 106 may be reground. Thereafter, the abrasive article 106 may be reinstalled and used to perform further grinding operations.

Arbor

As shown in FIG. 2, the arbor 104 can include a body 200 that can define a proximal end 202 and a distal end 204. The body 200 of the arbor 104 can include a generally frustoconical drive shaft 206 that can extend from the proximal end 202 of the body 200 to a central flange 208 that extends outwardly from the body 130. Further, the body 200 of the arbor 104 can include a mounting plate 210 that can extend radially outward from the body 200 at, or near, the distal end 204 of the body 130 of the arbor 104. As illustrated, the mounting plate 210 can include at least one threaded bore 212 radially offset from a central axis 214. The at least one threaded bore 212 can be configured to receive the at least one fastener 110. In a particular aspect, the arbor 104 can include a central bore 216. The central bore can be formed with threads (not shown). Further, the central bore 216 of the arbor 104 can be configured to threadably engage a portion of the pull stud 102 when it is inserted in the central bore 216 of the arbor 104.

Abrasive Article

Referring now to FIG. 3 through FIG. 7, details regarding the abrasive article 106 are shown. The abrasive article 106 can include a core 300 that can include an upper surface 302, a lower surface 304, and an outer peripheral surface 306. In particular, as shown in FIG. 6, the abrasive article 106 can include a peripheral recess 308 formed in the outer peripheral surface 306 of the core 300. As shown, the peripheral recess 308 can extend radially inwardly from the outer peripheral surface 304.

As further shown in FIG. 7, the core 300 of the abrasive article 106 can further include an upper recessed portion 310 that can extend inwardly from the upper surface 302 of the core 300 along a central axis 312. The upper recessed portion 310 can include a recessed surface 314 and a sidewall 316. In a particular aspect, the upper recessed portion 310 can be bound by the sidewall 316 and can extend between the upper surface 302 and the recessed surface 314. In a particular aspect, the recessed surface 314 can form an angle, α, with respect to the upper surface 302, or an axis or plane that is parallel to the upper surface 302. In a particular aspect, α can be greater than or equal to 5°. In another aspect, a can be greater than or equal to 7.5°, such as greater than or equal to 10°, greater than or equal to 12.5°, or greater than or equal to 15°. In still another aspect, α can be less than or equal to 30°, such as less than or equal to 27.5°, less than or equal to 25°, less than or equal to 22.5°, or less than or equal to 22°.

FIG. 3, FIG. 4, and FIG. 7 indicate that the core 300 can further include a central bore 318. In a particular aspect, the central bore 318 can be concentric with the central axis 312. Further, the central bore 318 can extend from the upper recessed portion 310 to the lower surface 304 of the core 300. In particular, the central bore 318 can extend from the recessed surface 314 of the upper recessed portion 310 to the lower surface 304 of the core 300. The central bore 318 can be bound an inner surface 320 of the core 300.

As indicated in FIG. 3, the upper recessed portion 310, or the recessed surface 314 of the upper recessed portion 310, can have a radial width, W_RP, measured from the inner surface 320 of the core 300 to the sidewall 316 of the upper recessed portion 310. Further, the core 300 can have a radial width, W_C, measured from the inner surface 320 of the core 300 to the outer surface 306 of the core 300. In a particular aspect, W_RP can be greater than or equal to 40% W_C. Further, W_RP can be greater than or equal to 45% W_C, such as greater than or equal to 50% W_C, or greater than or equal to 55% W_C. In another aspect, W_RP can be less than or equal to 75% W_C, such as less than or equal to 70% W_C, less than or equal to 65% W_C, or less than or equal to 60% W_C.

FIG. 4 and FIG. 7 further indicate that the core 300 of the abrasive article 106 can also include a central mounting hub 322 that circumscribes, or surrounds, the central bore 318 formed in the core 300. The central mounting hub 322 and the lower surface 304 of the core 300 can abut, or engage, the mounting plate 210 on the arbor 104 when the abrasive article 106 is installed on the arbor 104 as illustrated in FIG. 1. The central mounting hub 322 can include a plurality of fastener bores 324 equally spaced around the central axis 312. Each fastener bore 324 can receive one of the fasteners 110 therethrough when the grinding wheel assembly 100 is assembled as shown in FIG. 1.

As shown in FIG. 3, FIG. 4, FIG. 5, and FIG. 7, the abrasive article 106 can further include a bonded abrasive body 330 disposed within the core 300. In particular, the bonded abrasive body 330 can be disposed within the peripheral recess 308 formed in the outer peripheral surface 306 of the core 300. In particular, the core 300 can be molded around the abrasive body 330 and the core 300 can include a plurality of manufacturing holes 332 that are formed by a tool configured to hold the abrasive body 330 within a mold during the molding process.

In a particular aspect, each manufacturing hole 332 can extends axially into the core 300 in a direction parallel to the central axis 312. Further, each manufacturing hole 332 can at least partially radially overlaps a portion of the bonded abrasive body 330. In a particular aspect, the core 300 can also include a plug (not shown) that can be fitted into each manufacturing hole 332. Further, the core 300 can include at least two plugs (not shown) and each of the plugs can be fitted into a respective manufacturing hole 332. Each of the at least two plugs can be substantially identical. On the other hand, each of the at least two plugs can be different. For example, each of the at least two plugs can have different densities. Moreover, each of the at least two plugs can have different masses.

In a particular aspect, the core 300 may include a particular polymer material that facilitates improved performance of the bonded abrasive body, including but not limited to, aspects of strength, wearability, vibration damping, and manufacturability.

In one embodiment, the core 300 of the abrasive article 106 of the present disclosure may have a particular heat deflection temperature (HDT) at 0.45 MPa of at least about 130° C., such as at least about 140° C., at least about 150° C., at least about 160° C., at least about 180° C., at least about 200° C.; at least about 230° C., at least about 250° C., or at least about 260° C. In another non-limiting embodiment, the HDT of the core at 0.45 MPa may not be not greater than 400° C., such as not greater than 380° C., or not greater than 360° C. It will be appreciated that the HDT at 0.45 MPa of the core 300 can be within a range between any of the minimum and maximum values noted above, such as from about 130° C. to about 400° C., from about 200° C. to about 350° C., or from about 250° C. to about 330° C.

In another embodiment, the core 300 of the abrasive article 106 may have a shrinkage ratio of not greater than 3%, such as not greater than 2%, not greater than 1.5%, not 1.0%, not greater than 0.8%, not greater than 0.5%, not greater than 0.3%, not greater than 0.1%, or not greater than 0.05%. In a particular embodiment, the shrinkage ratio may be not greater than 0.1%. In another embodiment, the shrinkage ratio of the core 300 is at least 0.001% or at least 0.005%. It will be appreciated that the shrinkage ratio of the core 300 can be within a range between and including any of the minimum and maximum values noted above, such as from 0.001% to 3%, from 0.005% to 1%, or from 0.001% to 0.1%.

In a further embodiment, the core 300 of the abrasive article can have a Charpy impact of at least 45 kJ/m2, such as at least 50 kJ/m2, at least 55 KJ/m2, at least 60 kJ/m2, at least 80 kJ/m2, at least 100 kJ/m2, or at least 150 kJ/m2; in another aspect, the Charpy impact may be not greater than 300 kJ/m2 or not greater than 250 kJ/m2. It will be appreciated that the Charpy impact can be within a range from any of the minimum and maximum values noted above, such as from 45 kJ/m2 to 300 kJ/m2, from 50 kJ/m2 to 250 kJ/m2, or from 100 KJ/m2 to 180 kJ/m2.

In one embodiment the core 300 can include a polymer material selected from the group of a polyamide (PA), a polybutylene terephthalate (PBT), a polyphenylene sulfide (PPS), ethylene tetrafluoroethylene (ETFE), a polyetherketone (PEEK), a polyester (PE), a polyethyleneimine (PEI), a polyethersulfone (PESU), a polyethylene terephthalate (PET), a polyphthalamide (PPA), a poly (p-phenylene sulfide), a polycarbonate (PC), acrylonitrile-butadiene-styrene (ABS), PC-ABS, or any combination thereof. In an aspect, the polymer material may be a nylon, a PBT, a PPS, or a PC-ABS. The nylon may be, for example, nylon 6, nylon 66, nylon 610, nylon 612, nylon 66/6, nylon 410, or nylon 46. In a particular embodiment, the polymer material of the core 300 may consist essentially of PPS. In another particular embodiment, the polymer material of the core 300 may consist essentially of PC-ABS. In another embodiment, the polymer material of the core 300 may be essentially free of nylon.

In another embodiment, the core 300 may further contain reinforcing fibers and/or a powder distributed within the polymer material. The reinforcing fibers may include, for example, glass fibers, carbon fibers, ceramic fibers, organic fibers, mineral fibers, or combinations thereof. Suitable powders may be, for example, calcium carbonate, glass powder, mineral powder, or talc.

In a particular embodiment, the reinforcing fibers of the core 300 may consist essentially of carbon fibers. In another particular embodiment, the reinforcing fibers of the core 300 can consist essentially of glass fibers. Consisting essentially should be understood only one specific type of fibers containing only unavoidable impurities.

The amount of reinforcing fibers and/or powder contained in the core 300 may be at least about 1 wt %, such as at least about 5 wt %, at least about 10 wt %, at least about 15 wt %, at least about 20 wt %, at least about 25 wt %, or at least about 30 wt %, based on the total weight of the core. In another aspect, the amount of reinforcing fibers and/or powder may be not greater than 60 wt %, such as not greater than 55 wt %, not greater than 50 wt %, not greater than 45 wt %, or not greater than 40 wt %. It will be appreciated that the amount of reinforcing fibers and/or powder contained in the core 300 can be within a range between any of the minimum and maximum values noted above, such as from about 5 wt % to about 50 wt %, from about 15 wt % to about 40 wt %, from about 20 wt % to about 50 wt %, or from about 30 wt % to about 50 wt % based on the total weight of the core.

In one embodiment, the reinforcing fibers can have an average aspect ratio of length to width of at least about 3, such as at least about 5, at least about 10, at least about 30, at least about 50, at least about 100, at least about 500, or at least about 800. In another embodiment the primary aspect ratio of the reinforcing fibers may be not greater than 5000, such as not greater than 3500, not greater than 2000, not greater than 1200, not greater than 1100, or not greater than 1000. It will be appreciated that the average aspect ratio of the reinforcing fibers can be within a range between any of the minimum and maximum values note above, such as from about 3 to about 5000, from about 3 to about 1300, from about 10 to about 1200, from about 100 to about 1200, from about 500 to about 1200, from about 700 to 1200, or from about 800 to about 1200.

In one embodiment, the core 300 of the abrasive article 106 of the present disclosure may consist essentially of the polymer material and the reinforcing fibers, the reinforcing fibers being present in an amount of 30 to 50 wt % based on the total weight of the core and having an average aspect ratio of length to width of 500 to 1200.

In a particular embodiment, the core 300 may comprise PPS and carbon fibers, the carbon fibers having an average aspect ratio from about 800 to about 1200, wherein the core can have a shrinkage ratio of not greater than 0.1% and a tensile modulus of at least about 20.0 GPa.

In another particular embodiment, the core 300 can comprise PC-ABS and glass fibers, the glass fibers having an average aspect ratio from about 800 to about 1200, wherein the core can have a shrinkage ratio of not greater than 0.1% and a tensile modulus of at least about 20.0 GPa.

According to one embodiment, the core 300 of the abrasive article can represent a majority of the total volume of the abrasive article. For example, in one embodiment, the core 300 can be at least about 60 vol % based on the total volume of the abrasive article, such as at least about 70 vol %, at least about 75 vol %, at least 80 vol % or at least 85 vol %. Still, in another non-limiting embodiment, the core 300 may be not greater than about 99 vol % of the abrasive article, such as at not greater than about 97 vol %, not greater than about 95 vol %, or not greater than about 90 vol %. It will be appreciated that the volume percentage of the core 300 of the abrasive article based on the total volume of the abrasive article can be within a range between any of the minimum and maximum values noted above, such as from about 65 vol % to about 99 vol %, from about 70° vol % to about 95 vol %, or from about 80 vol % to about 95 vol %.

The bonded abrasive body 330 can be disposed in the 306 recess at the peripheral surface 304 of the core 300 and can include abrasive particles fixed in a bond material. Suitable abrasive particles can include, for example, oxides, carbides, nitrides, borides, diamond, cubic boron nitride, silicon carbide, boron carbide, alumina, silicon nitride, tungsten carbide, zirconia, or a combination thereof. In a particular aspect, the abrasive particles of the bonded abrasive body 330 are diamond particles. In at least one embodiment, the abrasive particles can consist essentially of diamond.

The abrasive particles contained in the bonded abrasive body 330 can have an average particle size suitable to facilitate particular grinding performance. For example, the abrasive particles can have a size less than about 2000 μm, such as less than about 1000 μm, less than about 500 μm, or less than about 300 μm. In another aspect, the abrasive particles can have a size of at least 0.01 μm, such as at least 0.1 μm, at least about 1 μm, at least 5 μm or at least 10 μm. It will be appreciated that the size of the abrasive particles contained in the bonded abrasive body 330 can be within a range between any of the minimum and maximum values noted above, such as from about 0.01 μm to about 2000 μm, from about 1 μm to about 500 μm, from about 5 μm to about 300 μm or from about 50 μm to about 150 μm.

The bond material of the bonded abrasive body 330 an include an inorganic material, an organic material, and a combination thereof. Suitable inorganic materials for the use as bond material may include metals, glass, glass-ceramics, and a combination thereof. For example, an inorganic bond material can include one or more metal compositions or elements such as Cu, Sn, Fe, W, WC, Co, and a combination thereof. Organic materials may include resins, for example thermosets, thermoplastics, and a combination thereof. For example, some suitable resins can include phenolic resins, epoxies, polyesters, cyanate esters, shellacs, polyurethanes, rubber, polyimides and a combination thereof.

The abrasive article 106 of the present disclosure may be selected from a range of suitable sizes to facilitate efficient grinding depending upon the workpiece. In one embodiment, the abrasive article 106 can include an abrasive wheel having a diameter of at least about 25 mm, such as at least about 30 mm or at least about 50 mm. In another embodiment, the wheel diameter may be not greater than 500 mm, such as not greater than 450 mm, not greater than 300 mm or not greater than 200 mm. It will be appreciated that the wheel diameter can be within a range between any of the minimum and maximum values noted above, such as from about 25 mm to about 500 mm, from about 50 mm to about 250 mm, or from about 25 mm to about 150 mm.

As illustrated in FIG. 5, the abrasive body 330 of the abrasive article 106 can have an outer peripheral surface 334 that may have a profile ground therein. As shown, the profile may be concave, or U-shaped. However, in other aspects, the profile may be angular, or V-shaped. The profile of the outer peripheral surface 334 of the abrasive body 330 of the abrasive article 106 will be reproduced in reverse on the material to be shaped by the grinding wheel assembly 100.

The abrasive article 106 of the present disclosure may be selected from a range of suitable sizes to facilitate efficient grinding depending upon the workpiece. In one embodiment, the abrasive article 106 can include a diameter of at least about 25 mm, such as at least about 30 mm or at least about 50 mm. In another embodiment, the diameter may be not greater than 500 mm, such as not greater than 450 mm, not greater than 300 mm or not greater than 200 mm. It will be appreciated that the diameter can be within a range between any of the minimum and maximum values noted above, such as from about 25 mm to about 500 mm, from about 50 mm to about 250 mm, or from about 25 mm to about 150 mm.

The abrasive article 106 of the present disclosure can be designed for shaping the edges of a workpiece. The workpiece can be an inorganic or organic material, such as, for example, glass, plastic, ceramic, or metal. In a particular embodiment, the workpiece can include glass, including but not limited to automotive glass, architectural glass, furniture glass, optical glass, and glass used in displays and/or to cover electronic devices (e.g., a phone). The workpiece can further be crystalline, such as monocrystalline or polycrystalline, including but not limited to sapphire.

In a particular embodiment, the abrasive article 106 of the present disclosure can be an abrasive wheel. In one aspect, the burst strength of the abrasive wheel may be at least 135 m/s, such as at least 150 m/s, at least 160 m/s or at least 180 m/s. In another embodiment, the burst strength may be not larger than 300 m/s, such as not larger than 280 m/s, or not larger than 250 m/s.

Cover Plate

FIG. 8 through FIG. 11 illustrate the details concerning the construction of the cover plate 108. The cover plate 108 can include a body 800 that is generally disk-shaped. Further, the body 800 of the cover plate 108 can include an upper surface 802 and a lower surface 804. The body 800 of the cover plate 108 can also include an outer wall 806 extending between the upper surface 802 and the lower surface 804. The lower surface 804 and outer wall 806 of the cover plate 108 are configured to be complimentary in size and shape to the recessed surface 314 and the sidewall 316 of the core 300 of the abrasive article 106. As depicted in FIG. 12, this shape allows the cover plate 108 to fit into the upper recessed portion 310 of the core 300 of the abrasive article 106 and engage the recessed surface 314 and the sidewall 316. Specifically, the lower surface 804 of the body 800 of the cover plate 108 can abut and engage the recessed surface 314 of the upper recessed portion 310 of the core 300 of the abrasive article 106. Moreover, the outer wall 806 of the body 800 of the cover plate 108 can abut and engage the sidewall 316 of the core 300 of the abrasive article 106 the surrounds, or circumscribes, the recessed surface 314 of the upper recessed portion 310 of the core 300 of the abrasive article 106. Accordingly, the upper recessed portion 310 of the core 300 of the abrasive article 106 is sized and shaped to receive the complimentary sized and shaped cover plate 108 therein. Further, the cover plate 108 fits into the upper recessed portion 310 of the upper surface 302 of the core 300 of the abrasive article 106, so that the upper surface 802 of the cover plate 108, i.e., the body 800 of the cover plate 108, is substantially coplanar with the upper surface 302 of the core 300 of the abrasive article 106.

As illustrated in FIG. 10 and FIG. 11, a generally cylindrical hub 808 can extend outwardly from the lower surface 804 of the body 800 of the cover plate 108 along a central axis 810. The cylindrical hub 808 is configured to extend into the central bore 318 of the core 300 of the abrasive article 106 when the cover plate 108 is fitted into the upper recessed portion 310 of the core 300 of the abrasive article 106. Moreover, FIG. 12 shows that the central bore 318 of the core 300 of the abrasive article 106 can have a bore depth, D_B, and the cover plate 108, i.e., the cylindrical hug 808 of the body 800 of the cover plate 108, can extend at least partially into the central bore 318 at a depth, D_E, and D_E can be less than or equal to 50% D_B. In another aspect, D_E can be less than or equal to 45% D_B, such as less than or equal to 40% D_B, less than or equal to 35% D_B, less than or equal to 30% D_B, less than or equal to 25% D_B, less than or equal to 20% D_B, or less than or equal to 15% D_B. In another aspect, D_E can be greater than or equal to 2.5% D_B, such as greater than or equal to 5% D_B, greater than or equal to 7.5% D_B, or greater than or equal to 10% D_B. It is to be understood that D_E can be within a range between, and including, any of the maximum and minimum values of D_E described herein.

In a particular aspect, the cover plate 108, i.e., the body 800 of the cover plate 108, has a diameter, D_CP, and W_RP of the core 300 of the abrasive article 106 can be greater than or equal to 10% D_CP. Moreover, W_RP can be greater than or equal to 12.5% D_CP, such as greater than or equal to 15% D_CP, greater than or equal to 17.5% D_CP, or greater than or equal to 20% D_CP. In another aspect, W_RP can be less than or equal to 30.0% D_CP, such as less than or equal to 27.5% D_CP, less than or equal to 25% D_CP, or less than or equal to 22.5% D_CP. It is to be understood that W_RP can be within a range between and including any of the maximum and minimum % D_CP values described herein.

In still another aspect, the upper recessed portion 310, or the recessed surface 314 of the upper recessed portion 310, can have a surface area, A_RP. Further, the cover plate 310, e.g., the upper surface 302 of the body 300 of the cover plate, can have a surface area, A_CP, and A_RP can less than or equal to 75.0% A_CP. In another aspect, A_RP can be less than or equal to 72.5% A_CP, such as less than or equal to 70.0% A_CP, less than or equal to 67.5% A_CP, less than or equal to 65.0% Au), less than or equal to 62.5% A_CP, less than or equal to 60.0% A_CP, or less than or equal to 57.5% A_CP. In yet another aspect, A_RP can be greater than or equal to 40.0% A_CP, such as greater than or equal to 42.5% A_CP, greater than or equal to 45.0% A_CP, greater than or equal to 47.5% A_CP, greater than or equal to 50.0% A_CP, greater than or equal to 52.5% A_CP, or greater than or equal to 55.0% A_CP. It is to be understood that A_RP can be within a range between and including any of the maximum and minimum % A_CP values described herein.

In another aspect, the core 300 of the abrasive article 106 can have an internal volume, V_C, that is the combined volume of the upper recessed portion 310 of the core 300 of the abrasive article 106 and the central bore 318 of the core 300 of the abrasive article 106. It is to be understood that V_C is the volume within the core 300 of the abrasive article 106, i.e., between the upper surface 302 of the core 300 and the lower surface 304 of the core 300, that is bound by the sidewall 316 of the upper recessed portion 310 of the core 300, the recessed surface 314 of the upper recessed portion 310 of the core 300, and the inner wall 320 of the core 300. Further, a displaced volume, V_D, which is the volume displaced, or filled, by the body 800 of the cover plate 108 when the cover plate 108 is installed within the abrasive article 106, e.g. within the upper recessed portion 310 and the central bore 318 of the core 300, can be greater than or equal to 60.0% V_C. In another aspect, V_D can be greater than or equal to 62.5% V_C, such as greater than or equal to 65.0% V_C, greater than or equal to 67.5% V_C, greater than or equal to 70.0% V_C, greater than or equal to 72.5% V_C, greater than or equal to 75.0% V_C, greater than or equal to 77.5% V_C, greater than or equal to 80.0% V_C, or greater than or equal to 82.5% V_C. In another aspect, V_D can be less than or equal to 100.0% V_C, such as less than or equal to 97.5% V_C, less than or equal to 95.0% V_C, less than or equal to 92.5% V_C, less than or equal to 90.0% V_C, less than or equal to 87.5% V_C, or less than or equal to 85.0% V_C. It is to be understood that V_D can be within a range between, and including, any of the minimum and maximum values of V_D described herein.

As shown in FIG. 8, FIG. 9, FIG. 11, and FIG. 12, the body 800 of the cover plate 108 can include at least one bore 812 extending through the cover plate 108, i.e., between the upper surface 802 and the lower surface 804. The at least one bore 812 can be radially offset from the central axis 810. The at least one bore 812 can be a smooth walled bore and may be sized and shaped to allow the at least one fastener 110, shown in FIG. 1, to extend through the at least one bore 812 and engage the at least one bore 812 in a slip fit arrangement. Further, the body 800 of the cover plate 108 can include at least one generally semi-circular cutout 814 that can be aligned with a manufacturing hole 332 on the core 300 of the abrasive article 106 when the cover plate 108 is installed within the abrasive article 106 as shown in FIG. 12.

In a particular embodiment, the cover plate 108 can be made from a metal, a metal alloy, or a combination thereof. Further, the cover plate 108 can be from a non-ferrous metal. For example, the cover plate 108 can be made from aluminum, an aluminum alloy, or a combination thereof. Moreover, the cover plate 108 can be made from copper, brass, or a combination thereof. Further still, the cover plate 108 can be made from tin, bronze, or a combination thereof.

Grinding Wheel Assembly

Referring initially to FIG. 13 through FIG. 14, a grinding wheel assembly is illustrated and is generally designated 1300. As shown, the grinding wheel assembly 1300 can include a pull stud 1302, an arbor 1304, an abrasive article 1306, a cover plate 1308, and at least one fastener 1310, e.g., a threaded fastener. As shown, the threaded fasteners 1310 can include countersunk socket fasteners that will not extend beyond an upper surface of the cover plate 1308 or abrasive article 1306 when installed and assembled as shown in FIG. 13. FIG. 14 indicates that three threaded fasteners 1310 can be used to mount the cover plate 1308 and the abrasive article 1306 to the arbor 1304. However, in an alternative embodiment, a single, centrally located threaded fastener can be used to mount the cover plate 1308 and the abrasive article 1306 to the arbor 1304. In such a case, the single, centrally located threaded fastener can pass through a center of the cover plate 1308, a center of the abrasive article 1306, and engage threads formed in the center of the arbor 1304.

The pull stud 1302, the arbor 1304, and the cover plate 1308 can include a metal or a metal alloy. For example, the metal can be stainless steel or titanium. Further, the metal can include a hardened metal, such as hardened steel. It is to be understood that the material utilized for the pull stud 1302, the arbor 1304, and the cover plate 1308 will minimize wearing of these elements during use. The abrasive article 1306, however, will wear during grinding operations performed on the edges of various workpieces. After the abrasive article 1306 is sufficiently worn, the abrasive article 1306 may be removed and replace with a new abrasive body. Alternatively, the abrasive article 1306 may be removed and the outer periphery of the abrasive article 1306 may be reground. Thereafter, the abrasive article 1306 may be reinstalled and used to perform further grinding operations.

Arbor

As shown in FIG. 14, the arbor 1304 can include a body 1400 that can define a proximal end 1402 and a distal end 1404. The body 1400 of the arbor 1304 can include a generally frustoconical drive shaft 1406 that can extend from the proximal end 1402 of the body 1400 to a central flange 1408 that extends outwardly from the body 1330. Further, the body 1400 of the arbor 1304 can include a mounting plate 1410 that can extend radially outward from the body 1400 at, or near, the distal end 1404 of the body 1330 of the arbor 1304. As illustrated, the mounting plate 1410 can include at least one threaded bore 1412 radially offset from a central axis 1414. The at least one threaded bore 1412 can be configured to receive the at least one fastener 1310. In a particular aspect, the arbor 1304 can include a central bore 1416. The central bore can be formed with threads (not shown). Further, the central bore 1416 of the arbor 1304 can be configured to threadably engage a portion of the pull stud 1302 when it is inserted in the central bore 1416 of the arbor 1304.

Abrasive Article

Referring now to FIG. 15 through FIG. 19, details regarding the abrasive article 1306 are shown. The abrasive article 1306 can include a core 1500 that can include an upper surface 1502, a lower surface 1504, and an outer peripheral surface 1506. In particular, as shown in FIG. 18, the abrasive article 1506 can include a peripheral recess 1508 formed in the outer peripheral surface 1506 of the core 1500. As shown, the peripheral recess 1508 can extend radially inwardly from the outer peripheral surface 1504.

As further shown in FIG. 19, the core 1500 of the abrasive article 1506 can further include an upper recessed portion 1510 that can extend inwardly from the upper surface 1502 of the core 1500 along a central axis 1512. The upper recessed portion 1510 can include a recessed surface 1514 and a sidewall 1516. In a particular aspect, the upper recessed portion 1510 can be bound by the sidewall 1516 and can extend between the upper surface 1502 and the recessed surface 1514. In a particular aspect, the recessed surface 1514 is substantially parallel to the upper surface 1502.

FIG. 15, FIG. 16, and FIG. 19 indicate that the core 1500 can further include a central bore 1518. In a particular aspect, the central bore 1518 can be concentric with the central axis 1512. Further, the central bore 1518 can extend from the upper recessed portion 1510 to the lower surface 1504 of the core 1500. In particular, the central bore 1518 can extend from the recessed surface 1514 of the upper recessed portion 1510 to the lower surface 1504 of the core 1500. The central bore 1518 can be bound an inner surface 1520 of the core 1500.

As indicated in FIG. 15, the upper recessed portion 1510, or the recessed surface 1514 of the upper recessed portion 1510, can have a radial width, W_RP, measured from the inner surface 1520 of the core 1500 to the sidewall 1516 of the upper recessed portion 1510. Further, the core 1500 can have a radial width, W_C, measured from the inner surface 1520 of the core 1500 to the outer surface 1506 of the core 1500. In a particular aspect, W_RP can be greater than or equal to 40% W_C. Further, W_RP can be greater than or equal to 45% W_C, such as greater than or equal to 50% W_C, or greater than or equal to 55% W_C. In another aspect, W_RP can be less than or equal to 75% W_C, such as less than or equal to 70% W_C, less than or equal to 65% W_C, or less than or equal to 60% W_C.

FIG. 16 and FIG. 19 further indicate that the core 1500 of the abrasive article 1506 can also include a central mounting hub 1522 that circumscribes, or surrounds, the central bore 1518 formed in the core 1500. The central mounting hub 1522 and the lower surface 1504 of the core 1500 can abut, or engage, the mounting plate 210 on the arbor 1504 when the abrasive article 1506 is installed on the arbor 1304 as illustrated in FIG. 13. The central mounting hub 1522 can include a plurality of fastener bores 1524 equally spaced around the central axis 1512. Each fastener bore 1524 can receive one of the fasteners 1310 therethrough when the grinding wheel assembly 1300 is assembled as shown in FIG. 13.

As shown in FIG. 15, FIG. 16, FIG. 17, and FIG. 19, the abrasive article 1306 can further include a bonded abrasive body 1530 disposed within the core 1500. In particular, the bonded abrasive body 1530 can be disposed within the peripheral recess 1508 formed in the outer peripheral surface 1506 of the core 1500. In particular, the core 1500 can be molded around the abrasive body 1530 and the core 1500 can include a plurality of manufacturing holes 1532 that are formed by a tool configured to hold the abrasive body 1530 within a mold during the molding process.

In a particular aspect, each manufacturing hole 1532 can extends axially into the core 1500 in a direction parallel to the central axis 1512. Further, each manufacturing hole 1532 can at least partially radially overlaps a portion of the bonded abrasive body 1530. In a particular aspect, the core 1500 can also include a plug (not shown) that can be fitted into each manufacturing hole 1532. Further, the core 1500 can include at least two plugs (not shown) and each of the plugs can be fitted into a respective manufacturing hole 1532. Each of the at least two plugs can be substantially identical. On the other hand, each of the at least two plugs can be different. For example, each of the at least two plugs can have different densities. Moreover, each of the at least two plugs can have different masses.

In a particular aspect, the core 1500 may include a particular polymer material that facilitates improved performance of the bonded abrasive body, including but not limited to, aspects of strength, wearability, vibration damping, and manufacturability.

In one embodiment, the core 1500 of the abrasive article 1506 of the present disclosure may have a particular heat deflection temperature (HDT) at 0.45 MPa of at least about 130° C., such as at least about 140° C., at least about 150° C., at least about 160° C., at least about 180° C., at least about 200° C.; at least about 230° C., at least about 250° C., or at least about 260° C. In another non-limiting embodiment, the HDT of the core at 0.45 MPa may not be not greater than 400° C., such as not greater than 380° C., or not greater than 360° C. It will be appreciated that the HDT at 0.45 MPa of the core 1500 can be within a range between any of the minimum and maximum values noted above, such as from about 130° C. to about 400° C., from about 200° C. to about 350° C., or from about 250° C. to about 330° C.

In another embodiment, the core 1500 of the abrasive article 1306 may have a shrinkage ratio of not greater than 3%, such as not greater than 2%, not greater than 1.5%, not 1.0%, not greater than 0.8%, not greater than 0.5%, not greater than 0.3%, not greater than 0.1%, or not greater than 0.05%. In a particular embodiment, the shrinkage ratio may be not greater than 0.1%. In another embodiment, the shrinkage ratio of the core 1500 is at least 0.001% or at least 0.005%. It will be appreciated that the shrinkage ratio of the core 1500 can be within a range between and including any of the minimum and maximum values noted above, such as from 0.001% to 3%, from 0.005% to 1%, or from 0.001% to 0.1%.

In a further embodiment, the core 1500 of the abrasive article can have a Charpy impact of at least 45 kJ/m2, such as at least 50 kJ/m2, at least 55 KJ/m2, at least 60 kJ/m2, at least 80 kJ/m2, at least 100 kJ/m2, or at least 150 kJ/m2; in another aspect, the Charpy impact may be not greater than 300 kJ/m2 or not greater than 250 kJ/m2. It will be appreciated that the Charpy impact can be within a range from any of the minimum and maximum values noted above, such as from 45 kJ/m2 to 300 kJ/m2, from 50 kJ/m2 to 250 kJ/m2, or from 100 KJ/m2 to 180 kJ/m2.

In one embodiment the core 1500 can include a polymer material selected from the group of a polyamide (PA), a polybutylene terephthalate (PBT), a polyphenylene sulfide (PPS), ethylene tetrafluoroethylene (ETFE), a polyetherketone (PEEK), a polyester (PE), a polyethyleneimine (PEI), a polyethersulfone (PESU), a polyethylene terephthalate (PET), a polyphthalamide (PPA), a poly (p-phenylene sulfide), a polycarbonate (PC), acrylonitrile-butadiene-styrene (ABS), PC-ABS, or any combination thereof. In an aspect, the polymer material may be a nylon, a PBT, a PPS, or a PC-ABS. The nylon may be, for example, nylon 6, nylon 66, nylon 610, nylon 612, nylon 66/6, nylon 410, or nylon 46. In a particular embodiment, the polymer material of the core 1500 may consist essentially of PPS. In another particular embodiment, the polymer material of the core 1500 may consist essentially of PC-ABS. In another embodiment, the polymer material of the core 1500 may be essentially free of nylon.

In another embodiment, the core 1500 may further contain reinforcing fibers and/or a powder distributed within the polymer material. The reinforcing fibers may include, for example, glass fibers, carbon fibers, ceramic fibers, organic fibers, mineral fibers, or combinations thereof. Suitable powders may be, for example, calcium carbonate, glass powder, mineral powder, or talc.

In a particular embodiment, the reinforcing fibers of the core 1500 may consist essentially of carbon fibers. In another particular embodiment, the reinforcing fibers of the core 1500 can consist essentially of glass fibers. Consisting essentially should be understood only one specific type of fibers containing only unavoidable impurities.

The amount of reinforcing fibers and/or powder contained in the core 1500 may be at least about 1 wt %, such as at least about 5 wt %, at least about 10 wt %, at least about 15 wt %, at least about 20 wt %, at least about 25 wt %, or at least about 30 wt %, based on the total weight of the core. In another aspect, the amount of reinforcing fibers and/or powder may be not greater than 60 wt %, such as not greater than 55 wt %, not greater than 50 wt %, not greater than 45 wt %, or not greater than 40 wt %. It will be appreciated that the amount of reinforcing fibers and/or powder contained in the core 1500 can be within a range between any of the minimum and maximum values noted above, such as from about 5 wt % to about 50 wt %, from about 15 wt % to about 40 wt %, from about 20 wt % to about 50 wt %, or from about 30 wt % to about 50 wt % based on the total weight of the core.

In one embodiment, the reinforcing fibers can have an average aspect ratio of length to width of at least about 3, such as at least about 5, at least about 10, at least about 30, at least about 50, at least about 100, at least about 500, or at least about 800. In another embodiment the primary aspect ratio of the reinforcing fibers may be not greater than 5000, such as not greater than 3500, not greater than 2000, not greater than 1200, not greater than 1100, or not greater than 1000. It will be appreciated that the average aspect ratio of the reinforcing fibers can be within a range between any of the minimum and maximum values note above, such as from about 3 to about 5000, from about 3 to about 1300, from about 10 to about 1200, from about 100 to about 1200, from about 500 to about 1200, from about 700 to 1200, or from about 2000 to about 1200.

In one embodiment, the core 1500 of the abrasive article 1306 of the present disclosure may consist essentially of the polymer material and the reinforcing fibers, the reinforcing fibers being present in an amount of 30 to 50 wt % based on the total weight of the core and having an average aspect ratio of length to width of 500 to 13200.

In a particular embodiment, the core 1500 may comprise PPS and carbon fibers, the carbon fibers having an average aspect ratio from about 800 to about 1200, wherein the core can have a shrinkage ratio of not greater than 0.1% and a tensile modulus of at least about 20.0 GPa.

In another particular embodiment, the core 1500 can comprise PC-ABS and glass fibers, the glass fibers having an average aspect ratio from about 800 to about 1200, wherein the core can have a shrinkage ratio of not greater than 0.1% and a tensile modulus of at least about 20.0 GPa.

According to one embodiment, the core 1500 of the abrasive article can represent a majority of the total volume of the abrasive article. For example, in one embodiment, the core 1500 can be at least about 60 vol % based on the total volume of the abrasive article, such as at least about 70 vol %, at least about 75 vol %, at least 80 vol % or at least 85 vol %. Still, in another non-limiting embodiment, the core 1500 may be not greater than about 99 vol % of the abrasive article, such as at not greater than about 97 vol %, not greater than about 95 vol %, or not greater than about 90 vol %. It will be appreciated that the volume percentage of the core 1500 of the abrasive article based on the total volume of the abrasive article can be within a range between any of the minimum and maximum values noted above, such as from about 65 vol % to about 99 vol %, from about 70° vol % to about 95 vol %, or from about 80 vol % to about 95 vol %.

The bonded abrasive body 1530 can be disposed in the 1506 recess at the peripheral surface 1504 of the core 1500 and can include abrasive particles fixed in a bond material. Suitable abrasive particles can include, for example, oxides, carbides, nitrides, borides, diamond, cubic boron nitride, silicon carbide, boron carbide, alumina, silicon nitride, tungsten carbide, zirconia, or a combination thereof. In a particular aspect, the abrasive particles of the bonded abrasive body 1530 are diamond particles. In at least one embodiment, the abrasive particles can consist essentially of diamond.

The abrasive particles contained in the bonded abrasive body 1530 can have an average particle size suitable to facilitate particular grinding performance. For example, the abrasive particles can have a size less than about 2000 μm, such as less than about 1000 μm, less than about 500 μm, or less than about 300 μm. In another aspect, the abrasive particles can have a size of at least 0.01 μm, such as at least 0.1 μm, at least about 1 μm, at least 5 μm or at least 10 μm. It will be appreciated that the size of the abrasive particles contained in the bonded abrasive body 1330 can be within a range between any of the minimum and maximum values noted above, such as from about 0.01 μm to about 2000 μm, from about 1 μm to about 500 μm, from about 5 μm to about 300 μm or from about 50 μm to about 150 μm.

The bond material of the bonded abrasive body 1530 an include an inorganic material, an organic material, and a combination thereof. Suitable inorganic materials for the use as bond material may include metals, glass, glass-ceramics, and a combination thereof. For example, an inorganic bond material can include one or more metal compositions or elements such as Cu, Sn, Fe, W, WC, Co, and a combination thereof. Organic materials may include resins, for example thermosets, thermoplastics, and a combination thereof. For example, some suitable resins can include phenolic resins, epoxies, polyesters, cyanate esters, shellacs, polyurethanes, rubber, polyimides and a combination thereof.

The abrasive article 1306 of the present disclosure may be selected from a range of suitable sizes to facilitate efficient grinding depending upon the workpiece. In one embodiment, the abrasive article 1306 can include an abrasive wheel having a diameter of at least about 25 mm, such as at least about 30 mm or at least about 50 mm. In another embodiment, the wheel diameter may be not greater than 500 mm, such as not greater than 450 mm, not greater than 300 mm or not greater than 200 mm. It will be appreciated that the wheel diameter can be within a range between any of the minimum and maximum values noted above, such as from about 25 mm to about 500 mm, from about 50 mm to about 250 mm, or from about 25 mm to about 150 mm.

As illustrated in FIG. 17, the abrasive body 1530 of the abrasive article 1306 can have an outer peripheral surface 1534 that may have a profile ground therein. As shown, the profile may be concave, or U-shaped. However, in other aspects, the profile may be angular, or V-shaped. The profile of the outer peripheral surface 1534 of the abrasive body 1530 of the abrasive article 1506 will be reproduced in reverse on the material to be shaped by the grinding wheel assembly 1500.

The abrasive article 1506 of the present disclosure may be selected from a range of suitable sizes to facilitate efficient grinding depending upon the workpiece. In one embodiment, the abrasive article 1506 can include a diameter of at least about 25 mm, such as at least about 30 mm or at least about 50 mm. In another embodiment, the diameter may be not greater than 500 mm, such as not greater than 450 mm, not greater than 300 mm or not greater than 200 mm. It will be appreciated that the diameter can be within a range between any of the minimum and maximum values noted above, such as from about 25 mm to about 500 mm, from about 50 mm to about 250 mm, or from about 25 mm to about 150 mm.

The abrasive article 1306 of the present disclosure can be designed for shaping the edges of a workpiece. The workpiece can be an inorganic or organic material, such as, for example, glass, plastic, ceramic, or metal. In a particular embodiment, the workpiece can include glass, including but not limited to automotive glass, architectural glass, furniture glass, optical glass, and glass used in displays and/or to cover electronic devices (e.g., a phone). The workpiece can further be crystalline, such as monocrystalline or polycrystalline, including but not limited to sapphire.

In a particular embodiment, the abrasive article 1306 of the present disclosure can be an abrasive wheel. In one aspect, the burst strength of the abrasive wheel may be at least 135 m/s, such as at least 135 m/s, at least 160 m/s or at least 180 m/s. In another embodiment, the burst strength may be not larger than 300 m/s, such as not larger than 280 m/s, or not larger than 250 m/s.

Cover Plate

FIG. 20 through FIG. 23 illustrate the details concerning the construction of the cover plate 1308. The cover plate 1308 can include a body 2000 that is generally disk-shaped. Further, the body 2000 of the cover plate 1308 can include an upper surface 2002 and a lower surface 2004. The body 2000 of the cover plate 1308 can also include an outer wall 2006 extending between the upper surface 2002 and the lower surface 2004. The lower surface 2004 and outer wall 2006 of the cover plate 1308 are configured to be complimentary in size and shape to the recessed surface 1514 and the sidewall 1516 of the core 1500 of the abrasive article 1306. As depicted in FIG. 24, this shape allows the cover plate 1308 to fit into the upper recessed portion 1510 of the core 1500 of the abrasive article 1306 and engage the recessed surface 1514 and the sidewall 1516. Specifically, the lower surface 2004 of the body 2000 of the cover plate 108 can abut and engage the recessed surface 1514 of the upper recessed portion 1510 of the core 1500 of the abrasive article 1306. Moreover, the outer wall 2006 of the body 2000 of the cover plate 1308 can abut and engage the sidewall 1516 of the core 1500 of the abrasive article 1306 the surrounds, or circumscribes, the recessed surface 1514 of the upper recessed portion 1510 of the core 1500 of the abrasive article 1306. Accordingly, the upper recessed portion 1510 of the core 1500 of the abrasive article 1306 is sized and shaped to receive the complimentary sized and shaped cover plate 1308 therein. Further, the cover plate 1308 fits into the upper recessed portion 1510 of the upper surface 1502 of the core 1500 of the abrasive article 1306, so that the upper surface 2002 of the cover plate 1308, i.e., the body 2000 of the cover plate 1308, is substantially coplanar with the upper surface 1502 of the core 1500 of the abrasive article 1306.

As illustrated in FIG. 22 and FIG. 23, a generally cylindrical hub 2008 can extend outwardly from the lower surface 2004 of the body 2000 of the cover plate 1308 along a central axis 2010. The cylindrical hub 2008 is configured to extend into the central bore 1518 of the core 1500 of the abrasive article 1306 when the cover plate 1308 is fitted into the upper recessed portion 1510 of the core 1500 of the abrasive article 1306. Moreover, FIG. 24 shows that the central bore 1518 of the core 1500 of the abrasive article 1306 can have a bore depth, D_B, and the cover plate 1308, i.e., the cylindrical hug 2008 of the body 2000 of the cover plate 1308, can extend at least partially into the central bore 1518 at a depth, D_E, and D_E can be less than or equal to 50% D_B. In another aspect, D_E can be less than or equal to 45% D_B, such as less than or equal to 40% D_B, less than or equal to 35% D_B, less than or equal to 30% D_B, less than or equal to 25% D_B, less than or equal to 20% D_B, or less than or equal to 10% D_B. In another aspect, D_E can be greater than or equal to 2.5% D_B, such as greater than or equal to 5% D_B, greater than or equal to 7.5% D_B, or greater than or equal to 10% D_B. It is to be understood that D_E can be within a range between, and including, any of the maximum and minimum values of D_E described herein.

In a particular aspect, the cover plate 1308, i.e., the body 2000 of the cover plate 1308, has a diameter, D_CP, and W_RP of the core 1500 of the abrasive article 1306 can be greater than or equal to 10% D_CP. Moreover, W_RP can be greater than or equal to 12.5% D_CP, such as greater than or equal to 15% D_CP, greater than or equal to 17.5% D_CP, or greater than or equal to 20% D_CP. In another aspect, W_RP can be less than or equal to 30.0% D_CP, such as less than or equal to 27.5% D_CP, less than or equal to 25% D_CP, or less than or equal to 22.5% D_CP. It is to be understood that W_RP can be within a range between and including any of the maximum and minimum % D_CP values described herein.

In still another aspect, the upper recessed portion 1510, or the recessed surface 1514 of the upper recessed portion 1510, can have a surface area, A_RP. Further, the cover plate 1510, e.g., the upper surface 1502 of the body 1500 of the cover plate, can have a surface area, A_CP, and A_RP can less than or equal to 75.0% A_CP. In another aspect, A_RP can be less than or equal to 72.5% A_CP, such as less than or equal to 70.0% A_CP, less than or equal to 67.5% A_CP, less than or equal to 65.0% A_CP, less than or equal to 62.5% A_CP, less than or equal to 60.0% A_CP, or less than or equal to 57.5% A_CP. In yet another aspect, A_RP can be greater than or equal to 40.0% A_CP, such as greater than or equal to 42.5% A_CP, greater than or equal to 45.0% A_CP, greater than or equal to 47.5% A_CP, greater than or equal to 50.0% A_CP, greater than or equal to 52.5% A_CP, or greater than or equal to 55.0% A_CP. It is to be understood that A_RP can be within a range between and including any of the maximum and minimum % A_CP values described herein.

In another aspect, the core 1500 of the abrasive article 1306 can have an internal volume, V_C, that is the combined volume of the upper recessed portion 1510 of the core 1500 of the abrasive article 1306 and the central bore 1518 of the core 1500 of the abrasive article 1306. It is to be understood that V_C is the volume within the core 1500 of the abrasive article 1306, i.e., between the upper surface 1502 of the core 1500 and the lower surface 1504 of the core 1500, that is bound by the sidewall 1516 of the upper recessed portion 1510 of the core 1500, the recessed surface 1514 of the upper recessed portion 1510 of the core 1500, and the inner wall 1520 of the core 1500. Further, a displaced volume, V_D, which is the volume displaced, or filled, by the body 2000 of the cover plate 1308 when the cover plate 1308 is installed within the abrasive article 1306, e.g. within the upper recessed portion 1510 and the central bore 1518 of the core 1500, can be greater than or equal to 60.0% V_C. In another aspect, V_D can be greater than or equal to 62.5% V_C, such as greater than or equal to 65.0% V_C, greater than or equal to 67.5% V_C, greater than or equal to 70.0% V_C, greater than or equal to 72.5% V_C, greater than or equal to 75.0% V_C, greater than or equal to 77.5% V_C, greater than or equal to 80.0% V_C, or greater than or equal to 82.5% V_C. In another aspect, V_D can be less than or equal to 100.0% V_C, such as less than or equal to 97.5% V_C, less than or equal to 95.0% V_C, less than or equal to 92.5% V_C, less than or equal to 90.0% V_C, less than or equal to 87.5% V_C, or less than or equal to 85.0% V_C. It is to be understood that V_D can be within a range between, and including, any of the minimum and maximum values of V_D described herein.

As shown in FIG. 20, FIG. 21, FIG. 23, and FIG. 24, the body 2000 of the cover plate 1308 can include at least one bore 2012 extending through the cover plate 1308, i.e., between the upper surface 2002 and the lower surface 2004. The at least one bore 2012 can be radially offset from the central axis 2010. The at least one bore 2012 can be a smooth walled bore and may be sized and shaped to allow the at least one fastener 1510, shown in FIG. 15, to extend through the at least one bore 2012 and engage the at least one bore 2012 in a slip fit arrangement. Further, the body 2000 of the cover plate 1308 can include at least one generally semi-circular cutout 2014 that can be aligned with a manufacturing hole 1532 on the core 1500 of the abrasive article 1306 when the cover plate 1308 is installed within the abrasive article 1306 as shown in FIG. 24.

In a particular embodiment, the cover plate 1308 can be made from a metal, a metal alloy, or a combination thereof. Further, the cover plate 1308 can be from a non-ferrous metal. For example, the cover plate 1308 can be made from aluminum, an aluminum alloy, or a combination thereof. Moreover, the cover plate 1308 can be made from copper, brass, or a combination thereof. Further still, the cover plate 1308 can be made from tin, bronze, or a combination thereof.

It is to be understood that the configuration of structure described herein provides a grinding wheel assembly that substantially minimizes the splashing of cutting fluid, or coolant, on a workpiece during an edge grinding operation. This substantially minimizes swarf and debris from collecting on the workpiece and potentially causing scratches or other damage to the workpiece. Specifically, the manner in which the cover plate fits into the abrasive article and forms an enclosed surface at the top of the grinding wheel assembly can substantially minimize the splashing of coolant and swarf. Further, the shape of the cover plate relative to the upper recessed portion of the abrasive article, e.g., the complimentary shape of the lower surface of the cover plate with respect to the recessed surface, provides a structure that evenly distributes the compressive forces on the recessed surface of the abrasive article from the threaded fasteners when the grinding wheel assembly is properly assembled. This distribution of the compressive forces substantially minimizes, or eliminates, the cracking, or breaking, of the polymeric core of the abrasive article during assembly of the grinding wheel assembly. Moreover, the close fit of the cover plate within the upper recessed portion of the abrasive article can substantially minimize vibration of the abrasive article during edge grinding operations.

Many different aspects and embodiments are possible. Some of those aspects and embodiments are described herein. After reading this specification, skilled artisans will appreciate that those aspects and embodiments are only illustrative and do not limit the scope of the present invention. Embodiments may be in accordance with any one or more of the items as listed below.

EMBODIMENTS

Embodiment 1

An abrasive article, comprising:

a core comprising a polymer material, the core having an upper surface, an outer peripheral surface, an upper recessed portion extending into the core from the upper surface and a peripheral recess extending into the outer peripheral surface;

a bonded abrasive body disposed within the peripheral recess of the outer peripheral surface of the core; and

a cover plate having an upper surface, wherein the cover plate fits into the upper recessed portion of the upper surface the core so that the upper surface of the cover plate is substantially coplanar with the upper surface of the core.

Embodiment 2

An abrasive article, comprising:

a core, the core having an upper surface, an outer peripheral surface, an upper recessed portion extending into the core from the upper surface and an peripheral recess extending into the outer peripheral surface, wherein the upper recessed portion includes a recessed surface;

a bonded abrasive body disposed within the peripheral recess of the outer peripheral surface of the core; and

a cover plate, wherein the cover plate fits entirely within the upper recessed portion of the core and mates with the recessed surface.

Embodiment 3

An abrasive article, comprising:

a core, the core having an upper surface, an outer peripheral surface, an upper recessed portion extending into the core from the upper surface and a peripheral recess extending into the outer peripheral surface, wherein the upper recessed portion is sized and shaped to receive a complimentary sized and shaped cover plate therein; and

a bonded abrasive body disposed within the peripheral recess of the outer peripheral surface of the core.

Embodiment 4

The abrasive article of any of embodiments 1, 2, or 3, wherein the core further comprises a central bore and the cover plate extends at least partially into the central bore.

Embodiment 5

The abrasive article according to embodiment 4, wherein the bore has a depth, D_B, and the cover plate extends into the bore at a depth, D_E, and D_E is less than or equal to 50% D_B.

Embodiment 6

The abrasive article according to embodiment 5, wherein D_E is less than or equal to 45% D_B, such as less than or equal to 40% D_B, less than or equal to 35% D_B, less than or equal to 30% D_B, less than or equal to 25% D_B, less than or equal to 20% D_B, or less than or equal to 15% D_B.

Embodiment 7

The abrasive article according to embodiment 6, wherein D_E is greater than or equal to 2.5% D_B, such as greater than or equal to 5% D_B, greater than or equal to 7.5% D_B, or greater than or equal to 10% D_B.

Embodiment 8

The abrasive article according to any of embodiments 1, 2, or 3, wherein the recessed portion has a radial width, W_RP, and the core has a radial width, W_C, and W_RP is greater than or equal to 40% W_C.

Embodiment 9

The abrasive article according to embodiment 8, wherein W_RP is greater than or equal to 45% W_C, such as greater than or equal to 50% W_C, or greater than or equal to 55% W_C.

Embodiment 10

The abrasive article according to embodiment 9, wherein W_RP is less than or equal to 75% W_C, such as less than or equal to 70% W_C, less than or equal to 65% W_C, or less than or equal to 60% W_C.

Embodiment 11

The abrasive article according to any of embodiments 1, 2, or 3 wherein the recessed portion has a radial width, W_RP, and the cover plate has a diameter, D_CP, and W_RP is greater than or equal to 10% D_CP.

Embodiment 12

The abrasive article according to embodiment 11, wherein W_RP is greater than or equal to 12.5% D_CP, such as greater than or equal to 15% D_CP, greater than or equal to 17.5% D_CP, or greater than or equal to 20% D_CP.

Embodiment 13

The abrasive article according to embodiment 12, wherein W_RP is less than or equal to 30.0% D_CP, such as less than or equal to 27.5% D_CP, less than or equal to 25% D_CP, or less than or equal to 22.5% D_CP.

Embodiment 14

The abrasive article according to any of embodiments 1, 2, or 3, wherein the recessed portion has a recessed surface formed at an angle, a, with respect to the upper surface and a is greater than or equal to 5°.

Embodiment 15

The abrasive article according to embodiment 14, wherein a is greater than or equal to 7.5°, such as greater than or equal to 10°, greater than or equal to 12.5°, or greater than or equal to 15°.

Embodiment 16

The abrasive article according to embodiment 15, wherein a is less than or equal to 30°, such as less than or equal to 27.5°, less than or equal to 25°, less than or equal to 22.5°, or less than or equal to 22°.

Embodiment 17

The abrasive article according to any of embodiments 1, 2, or 3, wherein the recessed portion has a surface area, A_RP, and the cover plate has a surface area, A_CP, and A_RP is less than or equal to 75.0% A_CP.

Embodiment 18

The abrasive article according to embodiment 17, wherein A_RP is less than or equal to 72.5% A_CP, such as less than or equal to 70.0% A_CP, less than or equal to 67.5% A_CP, less than or equal to 65.0% A_CP, less than or equal to 62.5% A_CP, less than or equal to 60.0% A_CP, or less than or equal to 57.5% A_CP.

Embodiment 19

The abrasive article according to embodiment 18, wherein A_RP is greater than or equal to 40.0% A_CP, such as greater than or equal to 42.5% A_CP, greater than or equal to 45.0% A_CP, greater than or equal to 47.5% A_CP, greater than or equal to 50.0% A_CP, greater than or equal to 52.5% A_CP, or greater than or equal to 55.0% A_CP.

Embodiment 20

The abrasive article according to any of embodiments 1, 2, or 3, wherein the cover plate is made from a metal, a metal alloy, or a combination thereof.

Embodiment 21

The abrasive article according to embodiment 20, wherein the cover plate is made from non-ferrous metal.

Embodiment 22

The abrasive article according to embodiment 21, wherein the cover plate is made from aluminum, an aluminum alloy, or a combination thereof.

Embodiment 23

The abrasive article according to embodiment 21, wherein the cover plate is made from copper, brass, or a combination thereof.

Embodiment 24

The abrasive article according to embodiment 23, wherein the cover plate is made from tin, bronze, or a combination thereof.

Embodiment 25

The abrasive article according to any of embodiments 1, 2, or 3, wherein no part of the abrasive article extends above the upper surface of the core.

Embodiment 26

The abrasive article according to any of embodiments 1, 2, or 3, wherein no part of the abrasive article or the cover plate extends above the upper surface of the core.

Embodiment 27

The abrasive article according to any of embodiments 1, 2, or 3, wherein the core comprises and an inner volume, V_C; the cover plate can displace a volume, V_D, when the cover plate is installed within the core; and V_D is greater than or equal to 60.0% V_C.

Embodiment 28

The abrasive article according to embodiment 27, wherein V_D is greater than or equal to 62.5% V_C, such as greater than or equal to 65.0% V_C, greater than or equal to 67.5% V_C, greater than or equal to 70.0% V_C, greater than or equal to 72.5% V_C, greater than or equal to 75.0% V_C, greater than or equal to 77.5% V_C, greater than or equal to 80.0% V_C, or greater than or equal to 82.5% V_C.

Embodiment 29

The abrasive article according to embodiment 28, wherein V_D is less than or equal to 100.0% V_C, such as less than or equal to 97.5% V_C, less than or equal to 95.0% V_C, less than or equal to 92.5% V_C, less than or equal to 90.0% V_C, less than or equal to 87.5% V_C, or less than or equal to 85.0% V_C.

Embodiment 30

The abrasive article according to any of embodiments 1, 2, and 3, wherein the core comprises a polymer material.

Embodiment 31

The abrasive article according to embodiment 30, wherein the polymer material includes at least one of a polyamide (PA), a polybutylene terephthalate (PBT), a polyphenylene sulfide (PPS), ethylene tetrafluoroethylene (ETFE), a polyetherketone (PEEK), a polyester (PE), a polyethyleneimine (PEI), a polyethersulfone (PESU), a polyethylene terephthalate (PET), a polyphthalamide (PPA), a poly (p-phenylene sulfide), a polycarbonate (PC), an acrylonitrile-butadiene-styrene (ABS), a PC-ABS, or any combination thereof.

Embodiment 32

The abrasive article according to embodiment 30, wherein the core further comprises reinforcing fibers.

Embodiment 33

The abrasive article according to embodiment 32, wherein the reinforcing fibers include at least one of glass fibers, carbon fibers, ceramic fibers, organic fibers, mineral fibers, or any combination thereof.

The specification and illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The specification and illustrations are not intended to serve as an exhaustive and comprehensive description of all of the elements and features of apparatus and systems that use the structures or methods described herein. Separate embodiments may also be provided in combination in a single embodiment, and conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any subcombination. Further, reference to values stated in ranges includes each and every value within that range. Many other embodiments may be apparent to skilled artisans only after reading this specification. Other embodiments may be used and derived from the disclosure, such that a structural substitution, logical substitution, or another change may be made without departing from the scope of the disclosure. Accordingly, the disclosure is to be regarded as illustrative rather than restrictive. Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims.

The description in combination with the figures is provided to assist in understanding the teachings disclosed herein. The following discussion will focus on specific implementations and embodiments of the teachings. This focus is provided to assist in describing the teachings and should not be interpreted as a limitation on the scope or applicability of the teachings. However, other teachings can certainly be used in this application.

As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

Also, the use of “a” or “an” is employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be read to include one or at least one and the singular also includes the plural, or vice versa, unless it is clear that it is meant otherwise. For example, when a single item is described herein, more than one item may be used in place of a single item. Similarly, where more than one item is described herein, a single item may be substituted for that more than one item.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The materials, methods, and examples are illustrative only and not intended to be limiting. To the extent not described herein, many details regarding specific materials and processing acts are conventional and may be found in reference books and other sources within the structural arts and corresponding manufacturing arts.

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.

Claims

1. An abrasive article, comprising:

a core comprising a polymer material, the core having an upper surface, an outer peripheral surface, an upper recessed portion extending into the core from the upper surface and a peripheral recess extending into the outer peripheral surface;

a bonded abrasive body disposed within the peripheral recess of the outer peripheral surface of the core; and

a cover plate having an upper surface, wherein the cover plate fits into the upper recessed portion of the upper surface the core so that the upper surface of the cover plate is substantially coplanar with the upper surface of the core.

2. The abrasive article of claim 1, wherein the core further comprises a central bore and the cover plate extends at least partially into the central bore.

3. The abrasive article of claim 2, wherein the bore has a depth, DB, and the cover plate extends into the bore at a depth, DE, and DE is less than or equal to 50% DB.

4. The abrasive article of claim 3, wherein DE is greater than or equal to 2.5% DB, such as greater than or equal to 5% DB, greater than or equal to 7.5% DB, or greater than or equal to 10% DB.

5. The abrasive article of claim 1, wherein the recessed portion has a radial width, WRP, and the core has a radial width, WC, and WRP is greater than or equal to 40% WC.

6. The abrasive article of claim 5, wherein WRP is less than or equal to 75% WC, such as less than or equal to 70% WC, less than or equal to 65% WC, or less than or equal to 60% WC.

7. The abrasive article of claim 1, wherein the recessed portion has a radial width, WRP, and the cover plate has a diameter, DCP, and WRP is greater than or equal to 10% DCP.

8. The abrasive article of claim 7, wherein WRP is less than or equal to 30.0% DCP, such as less than or equal to 27.5% DCP, less than or equal to 25% DCP, or less than or equal to 22.5% DCP.

9. An abrasive article, comprising:

a core, the core having an upper surface, an outer peripheral surface, an upper recessed portion extending into the core from the upper surface and an peripheral recess extending into the outer peripheral surface, wherein the upper recessed portion includes a recessed surface;

a bonded abrasive body disposed within the peripheral recess of the outer peripheral surface of the core; and

a cover plate, wherein the cover plate fits entirely within the upper recessed portion of the core and mates with the recessed surface.

10. The abrasive article of claim 9, wherein the recessed portion has a recessed surface formed at an angle, a, with respect to the upper surface and a is greater than or equal to 5°.

11. The abrasive article of claim 10, wherein a is less than or equal to 30°, such as less than or equal to 27.5°, less than or equal to 25°, less than or equal to 22.5°, or less than or equal to 22°.

12. The abrasive article of claim 9, wherein the recessed portion has a surface area, ARP, and the cover plate has a surface area, ACP, and ARP is less than or equal to 75.0% ACP.

13. The abrasive article of claim 12, wherein ARP is greater than or equal to 40.0% ACP, such as greater than or equal to 42.5% ACP, greater than or equal to 45.0% ACP, greater than or equal to 47.5% ACP, greater than or equal to 50.0% ACP, greater than or equal to 52.5% ACP, or greater than or equal to 55.0% ACP.

14. An abrasive article, comprising:

a core, the core having an upper surface, an outer peripheral surface, an upper recessed portion extending into the core from the upper surface and a peripheral recess extending into the outer peripheral surface, wherein the upper recessed portion is sized and shaped to receive a complimentary sized and shaped cover plate therein; and

a bonded abrasive body disposed within the peripheral recess of the outer peripheral surface of the core.

15. The abrasive article of claim 14, wherein the cover plate is made from a metal, a metal alloy, or a combination thereof.

16. The abrasive article of claim 15, wherein the cover plate is made from non-ferrous metal.

17. The abrasive article of claim 14, wherein no part of the abrasive article extends above the upper surface of the core.

18. The abrasive article of claim 14, wherein no part of the abrasive article or the cover plate extends above the upper surface of the core.

19. The abrasive article of claim 14, wherein the core comprises and an inner volume, VC; the cover plate can displace a volume, VD, when the cover plate is installed within the core; and VD is greater than or equal to 60.0% VC.

20. The abrasive article of claim 19, wherein VD is less than or equal to 100.0% VC, such as less than or equal to 97.5% VC, less than or equal to 95.0% VC, less than or equal to 92.5% VC, less than or equal to 90.0% VC, less than or equal to 87.5% VC, or less than or equal to 85.0% VC.