Composite resinoid bonded abrasive wheels
United States Patent 3867795
Reinforced resin bonded abrasive depressed and straight center wheels for portable snagging grinders in which the thickness of each wheel comprises a primary abrading portion containing a superior, expensive, premium, fast cutting and durable cofused alumina-zirconia abrasive particles and an adjoining secondary abrading portion containing different, less costly, slower cutting abrasive particles which, it has been discovered, does not materially reduce the grinding performance of the wheel from one made entirely with alumina-zirconia abrasive throughout the thickness of the wheel.
US Patent References:
Vitrified bonded grinding wheel with fine hard sides
Smith - March 1959 - 2877105
Organic bond abrasive wheel
Skoog - August 1961 - 2997820
Grinding wheel
Robertson - June 1964 - 3136100
Grinding wheel
Caserta - May 1966 - 3250045
ABRASIVE DISC AND METHOD OF MAKING IT
Shoemaker - April 1971 - 3576090
Vitrified bonded grinding wheel with fine hard sides
Smith - March 1959 - 2877105
Organic bond abrasive wheel
Skoog - August 1961 - 2997820
Grinding wheel
Robertson - June 1964 - 3136100
Grinding wheel
Caserta - May 1966 - 3250045
ABRASIVE DISC AND METHOD OF MAKING IT
Shoemaker - April 1971 - 3576090
Application Number:
05/406918
Publication Date:
02/25/1975
Filing Date:
10/16/1973
View Patent Images:
Export Citation:
Assignee:
Norton Company (Worcester, MA)
Primary Class:
Other Classes:
451/546, 451/544
International Classes:
B24D7/04; C09K3/14; B24D7/00; B24D7/04
Field of Search:
51/26R,26NF,29R,207,358,376-379,401,204,29DL
Primary Examiner:
Kelly, Donald G.
Attorney, Agent or Firm:
Fred, Walter
Claims:
What is claimed is
1. A reinforced resin bonded abrasive grinding wheel of predetermined thickness having a relatively narrow peripheral grinding face usually presented and worn at an angle during grinding, extending between a top and a bottom side, reinforcing material bonded thereto and means for mounting the wheel for rotstion about its axis, wherein the improvement comprises:
2. A reinforced resin bonded abrasive grinding wheel according to claim 1 wherein the primary abrading portion further comprises:
3. A reinforced resin bonded abrasive grinding wheel according to claim 2 wherein the diluent abrasive particles are made of garnet.
4. A reinforced resin bonded abrasive grinding wheel according to claim 1 wherein the secondary abrasive particles are made of an abrasive material selected from a group consisting of aluminum oxide, silicon carbide, garnet, silica, quartz, emery, flint and mixtures thereof and wherein the primary abrading portion occupies at least about one-half the thickness of the wheel.
5. A reinforced resin bonded abrasive grinding wheel according to claim 1 wherein the secondary abrasive particles are no larger than 16 grit size and wherein the alumina-zirconia particles are from 16 to 60 grit size.
6. A reinforced resin bonded abrasive grinding wheel according to claim 1 wherein the alumina-zirconia particles are of larger and coarser grit size than the secondary abrasive particles.
7. A reinforced resin bonded abrasive grinding wheel according to claim 4 wherein the secondary abrasive material is aluminum oxide.
8. A reinforced resin bonded abrasive grinding wheel according to claim 1 wherein the reinforcing material comprises:
9. A reinforced resin bonded abrasive grinding wheel according to claim 8 wherein the reinforcing material further comprises:
1. A reinforced resin bonded abrasive grinding wheel of predetermined thickness having a relatively narrow peripheral grinding face usually presented and worn at an angle during grinding, extending between a top and a bottom side, reinforcing material bonded thereto and means for mounting the wheel for rotstion about its axis, wherein the improvement comprises:
2. A reinforced resin bonded abrasive grinding wheel according to claim 1 wherein the primary abrading portion further comprises:
3. A reinforced resin bonded abrasive grinding wheel according to claim 2 wherein the diluent abrasive particles are made of garnet.
4. A reinforced resin bonded abrasive grinding wheel according to claim 1 wherein the secondary abrasive particles are made of an abrasive material selected from a group consisting of aluminum oxide, silicon carbide, garnet, silica, quartz, emery, flint and mixtures thereof and wherein the primary abrading portion occupies at least about one-half the thickness of the wheel.
5. A reinforced resin bonded abrasive grinding wheel according to claim 1 wherein the secondary abrasive particles are no larger than 16 grit size and wherein the alumina-zirconia particles are from 16 to 60 grit size.
6. A reinforced resin bonded abrasive grinding wheel according to claim 1 wherein the alumina-zirconia particles are of larger and coarser grit size than the secondary abrasive particles.
7. A reinforced resin bonded abrasive grinding wheel according to claim 4 wherein the secondary abrasive material is aluminum oxide.
8. A reinforced resin bonded abrasive grinding wheel according to claim 1 wherein the reinforcing material comprises:
9. A reinforced resin bonded abrasive grinding wheel according to claim 8 wherein the reinforcing material further comprises:
Description:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to resin bonded abrasive grinding wheels and particularly to relatively thin reinforced raised hub or depressed center and straight center snagging wheels for portable grinders.
2. Description of the Prior Art
Heretofore grinding wheels have been made with inner and outer layers, sides and zones varying either in density, hardness, type of abrasive, bond, and in the grit size of the abrasive particles as disclosed in the following publications U.S. Pat. Nos. 1,403,416, 1,616,531, 2,479,078, 2,877,105 and German Gebrauchsmuster No. 7,306,787 dated May 24, 1973. In use straight and depressed center or raised hub wheels of various shapes are usually attached and driven by hand operated portable grinders, and held at a slight angle to grind welding beads, flash, gates and risers off castings. During grinding the peripheral grinding face or edge of the wheel wears at an angle to the axis of rotation and the opposite sides of the wheel. As a result a sharp and relatively thin fragile peripheral edge is formed at the junction of the grinding face and the back or top side of the wheel. The fragile edge has a tendency to break away and contributes very little to removing the unwanted material. Also known, are wheels having various types of backing materials for reinforcing the fragile edge and for supporting the primary cutting or abrading portion of the wheel.
For many years and up to the present time depressed center also known as raised hub grinding wheels have been made in the United States with a backing layer of bonded abrasive particles of relatively fine grit size bonded between a layer of coarser primary abrasive particles of substantially uniform grit size and a fiber glass backing. The finer abrasive being of the same type as the coarser and usually include what are known in the art as abrasive fines which vary in grit size. When mixed and bonded together the fines tend to occupy the spaces between the larger particles and thereby densify and strengthen the backing layer of finer abrasive particles.
The Applicant's invention differs from the prior art in that abrasive particles of a tough, superior, more durable, faster cutting and more expensive alumina-zirconia abrasive material such as disclosed in U.S. Pat. No. 3,181,939 and a commonly owned prior copending application Ser. No. 386,718 filed Aug. 8, 1973 and to which reference may be had for details not disclosed herein, is used in the primary abrading portion and differs from the abrasive used in the secondary abrading portion of the wheel. U.S. Pat. No. 3,181,939 discloses rapidly cooled co-fused alumina-zirconia containing 10 to 60% zirconia. The preferred abrasive for this invention is the 35 to 50% zirconia, very rapidly cooled material of Ser. No. 386,718.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional veiw through the center of a typical depressed center or raised hub wheel made according to the invention;
FIG. 2 is a sectional view through the center of a straight center wheel made according to the invention; and
FIG. 3 is a partial sectional view through a peripheral portion of a wheel showing the wheel inclined and the grinding edge thereof worn at an angle during grinding.
SUMMARY OF THE INVENTION
Depressed and straight center reinforced resin bonded abrasive grinding wheels comprising a primary abrading portion or layer containing tough, durable, fast cutting and relatively expensive bonded alumina-zirconia abrasive particles occupying a portion of the thickness of the wheel situated on the working or bottom side of the wheel. A secondary abrading portion or layer containing different, less expensive, less durable abrasive particles is bonded to the primary abrading portion and situated on the back or top side of the wheel. If desired and preferably there is a backing consisting of at least one layer of reinforcing material molded in and bonded to the back or top side of the secondary abrading portion of the wheel.
The reinforced wheel may have one or more additional layers or discs of fiber glass reinforcing material integrally molded and bonded therein. One layer of reinforcement is preferably bonded to and situated in between the secondary and primary abrading layers of the wheel. The central hub portion of the wheel is preferably further reinforced with a disc of fiber glass cloth molded in and bonded to the bottom side of the primary abrading layer or portion.
Therefore it is the primary object of the invention to provide reinforced resin bonded abrasive grinding wheels having a primary abrading portion comprising particles of co-fused alumina-zirconia abrasive material and a secondary abrading portion containing particles of different abrasive material.
DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
Referring to the drawings wherein there is shown a depressed center or raised hub grinding wheel 10 and a straight center or hub wheel 10'. The wheels are shown in only one of the many possible conventional shapes to which they may be made and known to those skilled in the art. For example, they may be molded to the shape of a shallow dish or saucer with curved or straight flaring sides and still have either a straight or depressed center portion about the mounting hole. As used herein the term straight center is meant to include wheels other than depressed center or raised hub and those having top and bottom surfaces which continue without any deviation or sharp bends to the center mounting hole. The construction of each of the wheels 10 and 10' being substantially the same except for the configuration of the central hub mounting portion around the center mounting hole which may be adapted to receive any suitable mounting, such as shown in FIG. 3, for attaching the wheel to the drive spindle or shaft of a portable grinder. In U.S. Pat. Nos. 3,081,584; 3,136,100; 3,500,592; and 3,596,415 there are disclosed wheel mountings which may be attached to the wheels disclosed herein and to which reference may be had for details not disclosed herein. Obviously, there are many other types of suitable mountings known to those skilled in the art which may be attached in various ways to the wheels. The mounting forms no part of the invention and therefor is not shown but merely incorporated by reference herein.
As shown both of the wheels 10 and 10' have a bottom or working side 12, a top or back side 14, a peripheral grinding edge or face 16 and a center hole 18 for mounting the wheel. Adjacent the bottom side 12 is a primary abrading portion or layer 20 containing resin bonded primary abrasive particles of a premium co-fused alumina-zirconia abrasive material of the type disclosed in U.S. Pat. No. 3,181,939 and the copending application disclosed above to which reference may be had for details not disclosed herein and which preferably occupies about one-half the thickness of the wheel and at least two particles deep. Embedded in and bonded to the bottom side of the primary abrading layer in the central hub portion of the wheel about center hole 18 is a layer or disc 22 of reinforcing material. The disc or layer 22 of reinforcing material is preferably a disc 4 inches in diameter of resin coated, open 14 × 14 mesh, plain woven, fiber glass cloth having approximately 14 openings to the inch and commercially available as number 196 from Eli Sandman Company, Worcester, Mass. Molded within the wheel and bonded to the inner side of the primary abrading portion 20 is another disc 24 of reinforcing material which extends radially out from the center hole to the peripheral grinding edge 16 of the wheel. The disc 24 is preferably made of resin coated, open 7 × 7 mesh, plain woven fiber glass cloth having approximately 7 openings to the inch and commercially available as number RC717 from Eli Sandman Company, Worcester, Mass.
Adjacent to and resin bonded to both the reinforcement 24 and the primary abrading layer 20 is a secondary abrading portion or layer 26 of resin bonded secondary abrasive particles which differ from and are preferably less costly than the co-fused alumina-zirconia abrasive particles in the primary abrading layer 20. The secondary abrading layer 26 extends axially to the back or top side 14 and occupies approximately the upper half or remaining portion of the thickness of the wheel.
Integrally bonded to and molded into the secondary abrading layer 26 at the back or top side 14 of the wheel is a third or composite disc or layer 28 of backing material extending to the peripheral edge 16 of the wheel. The disc 28 of backing material is preferably a composite disc consisting of a thin layer of paper adhered to a layer of fiber glass cloth and designated as a number 955 paper stick resin coated 5 × 5 open mesh, low twist woven fiber glass cloth with approximately five openings per inch available from Eli Sandman Company, Worcester, Mass.
The secondary abrasive may be any of the well known abrasive materials selected from a group consisting of aluminum oxide, garnet, silicon carbide, silica, emery, flint and quartz and mixtures thereof which are less costly, not as durable and less efficient than the primary co-fused alumina-zirconia abrasive material. Preferably, for most grinding applications, the secondary abrasive material comprises particles of aluminum oxide of either 24 or 46 grit size. However, for other applications the size of the secondary abrasive particles may be in a range of 16 to 60 grit size and if desired no larger than 16 grit size and include what is known as abrasive fines. When bonded together both the fines and smaller grit size particles provide a denser and stronger secondary abrading portion which backs up and supports the primary abrading portion.
The primary co-fused alumina-zirconia abrasive particles are preferably rolls crushed elongated particles of substantially uniform grit size of from 16 to 60, of high purity fine crystalline structure containing 10 - 60 percent by weight of zirconium oxide. However, in the grinding wheels of this invention elongated particles of co-fused alumina-zirconia of 24 grit size having about 43% of zirconia by weight, a specific gravity of 4.66 and a bulk density of 129 to 137 pounds per cubic feet are preferred for most foundry snagging operations while in other operations particles having a content of 25% zirconia and a specific gravity of 4.35 will suffice.
The alumina-zirconia abrasive particles are preferably of the type disclosed in a prior copending application Ser. No. 386,718 filed Aug. 8, 1973 to which reference may be had for details not disclosed herein. It is made by rapidly crystallizing and solidifying a eutectic or near eutectic molten mixture of aluminum oxide and 35 to 50%, but preferably around 40%, by weight of zirconium oxide. One of the various methods of rapidly crystallizing the molten mixture is to pour it between a plurality of three-fourths inch thick plates spaced about three-sixteenths of an inch apart which quickly cool and solidify the mixture into a product with a microcrystalline structure having the following typical analysis of ingredients by weight percent.
______________________________________ SiO 2 0.21% Fe 2 O 3 0.15% TiO 2 0.15% Na 2 O 0.04% ZrO 2 40.56% Al 2 O 3 58.89 (by difference) ______________________________________
No analysis was made for the small amounts of lime or magnesia which were present. However, the analysis shows that the fine crystalline alumina-zirconia abrasive product was of high purity with less than 1% by weight of impurities therein.
The solidified alumina-zirconia product has very high strength combined with high desirable microfracture properties. Also, the zirconia is in the form of rods (or platelets) which average less than 3,000 angstroms in diameter and preferably at least 25% by weight of the zirconia is in the tetragonal crystal form. The solidified product is made up of eutectic cells or colonies typically 40 microns or less in width. Groups of cells having idential orientation of microstructure, form grains each of which typically include from 2 to 100 or more cells or colonies. During crushing, the material fractures along grain boundaries and cell boundaries and is first jaws crushed and then rolls crushed to form elongated abrasive particles which are separated and screened to obtain the desired grit size particles thereof. As used above, the term "grain" is not synonymous with the word "grit. " Typically an abrasive grit will contain a large number of grains, in the sense used above.
The wheels 10 and 10'to may be molded either by hot or cold pressing in any suitable manner well known to those skilled in the art. A mold having a center hole forming arbor surrounded by a circular cavity in which the center is depressed can be used to mold the depressed center or raised hub wheel 10 and a mold also having a hole arbor but a straight cylindrical cavity may be used to mold the straight hub or center wheel 10'. The wheels may be molded by first placing the paper side of the paper stick fiber glass disc 28 of composite backing material with a center hole around the arbor and in contact with the bottom of the mold. Then, spreading a uniform layer of a prepared abrasive mixture containing a suitable resin bond and the secondary abrasive particles on top of the fiber glass backing disc 28. Thereafter, placing the disc 24 of fiber glass reinforcing material with a center hole about the arbor and onto the layer of secondary abrasive mix followed by spreading a uniform layer of a prepared mixture comprising a suitable and compatible resin bond and the primary abrasive containing particles of alumina-zirconia abrasive material thereon. Lastly, laying the hub reinforcing disc 22 with a center hole therein around the arbor and onto the layer of primary abrasive and placing a top mold plate of the desired shape to either produce the depressed center or the straight center hub portion of the wheels, on top of the layers. The mold assembly is then placed between the platens of either a conventional cold or hot press. Then the press is actuated to force the mold plate downwardly and compress the discs and abrasive mixtures together, at a pressure of 1 to 4 tons per square inch, into a self supporting structure of predetermined thickness, diameter and density. After molding the wheel is stripped from the mold and placed in an oven heated to a temperature of approximately 175°C for approximately 6 hours to fully cure the resin bond.
The resin bond may comprise any one of a number of the conventional and well known thermosetting or infusible resins, such as, phenol-aldehyde, epoxy, polyester, polyimides, and polybenzimadazole in either liquid for powder form. Preferably the resin bond comprises a phenolic (phenol-aldehyde) resin in powder form which is premixed with other fillers and coloring materials and then mixed with predetermined amounts of the secondary and primary abrasive particles.
A suitable primary abrasive mixture of primary abrasive particles and resin bond for a snagging operation may comprise the following percentage of ingredients by weight:
% by Ingredients Weight ______________________________________ Abrasive-24 grit alumina-zirconia abrasive 78.54 particles Resin Bond % by Weight 21.46 100.00 VARCUM Chemical Co. No. 29-345 40.9 powdered phenolic resin Wallastonite - (Grade C-6 53.0 Interface Corp., Willsboro, New York) Calcium Oxide (CaO) 5.1 Carbon Black 1.0 100.0 ______________________________________
The secondary abrasive mixture of secondary abrasive and resin bond may comprise the following percentage of ingredients by weight:
% by Ingredients Weight ______________________________________ Abrasive-24 grit aluminum oxide abrasive 75.62 particles Resin Bond % by Weight 24.38 100.00 VARCUM Chemical Co. No. 29-345 40.9 powdered phenolic resin Wallastonite - (Grade C-6 53.0 Interface Corp.) Calcium Oxide (CaO) 5.1 Carbon Black 1.0 100.00 ______________________________________
In addition there was added to each of the primary and secondary abrasive mixtures of abrasive and resin bond 45 cc of furfural plasticizer and 25 cc of CARBOSOTA (creosote oil) for each pound of powdered phenolic resin. The CARBOSOTA being mixed separately with the resin bond and the furfural being mixed with and wetting the abrasive particles prior to mixing the wetted abrasive particle with the resin bond. Thereafter, to the entire mixture of wetted abrasive and resin bond there is added and mixed therewith 4 cc of a mixture of 60% by weight of furfural and 40% by weight of castor oil and lastly, 0.0005 of a pound (lb.) or 0.23 grams of dry colloidal silica (CAB-O-SIL) for each pound (lb.) of the entire abrasive mixture.
Referring to FIG. 3 there is shown a sectional view through a portion of a grinding wheel of the invention mounted on a shaft and positioned at an angle to the surface of the workpiece W being worked upon to show how in normal use the initial grinding face or edge 16 is worn at an angle to the back or top side 14 and bottom or working side 12. It can be seen that when the wheel is used at an angle that the length of the grinding face 16 is increased and that the thinnest, weakest and most fragile part of the wheel is at and adjacent the outer tip or edge 16a located at the junction of the grinding face 16 and the back side 14. When grinding pressure is applied, the edge 16a and the adjacent tapered portions of the secondary abrading portion have a tendency to break away because they are only supported by the fiber glass backing layer 28. As a result, the secondary abrading portion 26 does much less grinding or cutting of unwanted material. In contrast, the primary abrading portion 20 does not have as fragile an edge or corner as the edge 16a and is more rigidly supported and backed up by the secondary abrading portion of the wheel. Therefore, the primary abrading portion 20 with the more durable faster cutting and more efficient alumina-zirconia abrasive therein does most of the grinding or cutting away of material without the tendency to break away.
Wheels 7 inches in diameter, one-quarter of an inch thick each with a seven-eighths inch diameter center hole were made according to the invention with the 24 grit size alumina-zirconia abrasive resin mixtures, and 24 grit aluminum oxide abrasive resin mixtures disclosed above. The wheels were tested and compared with a variety of other wheels all of comparable size and shape, 24 grit size particles and resin bond disclosed above but with variations in the type, amount by volume and location of abrasive particles in the wheel. Some of the wheels were made with aluminum oxide or the alumina-zirconia throughout, with the alumina-zirconia abrasive in the secondary portion and alumina in the primary portion, and with a mixture containing by volume 50% of alumina-zirconia and 50% alumina in both portions of the wheel. Another wheel had a mixture containing by volume 75% of alumina-zirconia and 25% garnet in the primary portion and alumina in the secondary portion. The alumina-zirconia abrasive used in all the wheels tested contained about 43% zirconia by weight.
The grinding tests were performed by mounting each wheel on an automated apparatus adapted to transverse and manipulate a Chicago Pneumatic 360 cycle right angle portable grinder rotatable at 5,200 RPM and inclined so the bottom side of the wheel was at an angle of 25° from a horizontal plane to simulate the position, applied force and movements of a hand operated portable grinder.
Each wheel tested was run four times during each of which the grinding wheels ground into the annular edge of a 12 inch O.D. × 103/4 inch I.D. ring of cast steel, mounted on a reversible rotary table rotated at 15 RPM in reversed directions every one-half minute. Each run lasted for a period of 15 minutes while a constant downward force of 20 pounds was applied to the wheel reciprocated 13/8 inches across the annular edge. After each run the ring of cast steel was weighed and the wheel measured to determine the number of pounds of metal removed per hour and the number of cubic inches of wheel wear per hour. The "grinding ratio" of the wheel is the ratio of metal removed to wheel wear.
In the following Tables I and II, RGR refers to the "Relative Grinding Ratio" in percent which is determined by dividing the grinding ratio × 100 of the wheel being tested by the grinding ratio of a conventional standard wheel with 24 grit aluminum oxide abrasive throughout the wheel given an RGR rating of 100%. The "Relative Rate of Cut" in percent is indicated by RRC in the table and is determined by dividing the rate of cut × 100 of the wheel being tested with that of a comparable conventional standard wheel rated at 100% and made with aluminum oxide abrasive throughout. The results of one of the tests are shown in Table I below.
TABLE I ____________________________________________________________ ______________ TYPE AND LOCATION OF 24 GRIT SIZE ABRASIVE PARTICLES WHEEL METAL TYPE OF PRIMARY SECONDARY WEAR REMOVED RGR RRC WHEEL PORTION PORTION IN. 3 /HR. LBS./HR. IN. % IN. % ____________________________________________________________ ______________ STANDARD aluminum aluminum 3.43 2.91 100 100 PRIOR ART oxide oxide WHEEL VARIATION alumina- alumina- 1.46 3.00 243 103 OF zirconia zirconia WHEELS 50% alumina- 50% alumina- 2.32 3.13 159 108 zirconia zirconia % BY VOLUME mixed with mixed with 50% aluminum 50% aluminum oxide oxide aluminum alumina- 3.58 3.08 102 106 oxide zirconia WHEELS alumina- aluminum 1.34 2.82 2.47 97 OF zirconia oxide INVENTION 75% alumina- aluminum 1.78 2.91 193 100 % BY VOLUME zirconia oxide 25% garnet ____________________________________________________________ ______________
As can be seen from the test data, the wheel with alumina-zirconia in both the primary and secondary portions with a 243% RGR and 103% RRC was far superior to the standard wheel with aluminum oxide in both the primary and secondary portions. The wheel having a mixture of one-half (50%) alumina-zirconia and one-half (50 %) aluminum oxide by volume in both the primary and secondary portions gave as expected a 159% RGR and 108% RRC which is an improvement over the standard wheel with aluminum oxide throughout but not equal to the wheel with alumina-zirconia in both portions of the wheel. However, the wheel of the invention with all of alumina-zirconia in the primary abrading portion of the wheel and aluminum oxide in the secondary portion gave a result of 247% RGR and 97% RRC which is very nearly equal to the wheel with alumina-zirconia throughout the wheel. In contrast, the wheel with the aluminum oxide in the primary portion and alumina-zirconia in the secondary portion gave a result of 102% RGR and 106% RRC which shows a performance equal to that of the standard wheel with aluminum oxide throughout the wheel. The data shows that the wheels made according to the invention with approximately one-half as much of the more costly alumina-zirconia located in the primary portion of the wheel and a less costly abrasive in the secondary portion performs very nearly as well as the wheel with alumina-zirconia throughout the wheel. Hence, only one-half as much of the premium abrasive is required with no apparent loss in performance.
In another embodiment of the invention the primary abrading portion may contain a primary abrasive mixture consisting of the superior co-fused primary alumina-zirconia abrasive particles and up to one-fourth or 25% by volume of the primary abrasive particles therein of a different, less costly, less efficient and less durable diluent or filler abrasive particles of material such as, garnet, flint, silica, emery, silicon, carbide, alumina and quartz and mixtures thereof which it has been discovered does not materially reduce the performance of the wheel below one without the 25% of diluent abrasive therein. As shown in Table I wheels were made and tested in which the primary and secondary abrading portions were comprised of abrasive and resin bond mixtures consisting of the following percentage of ingredients by weights.
______________________________________ Primary Abrading Portion ______________________________________ % by Ingredients Weight ______________________________________ Primary Abrasive Mixture % by Volume 78.54 24 grit size particles of 75 alumina-zirconia 12 thru 28 grit size particles 25 of garnet 100 Resin Bond % by Weight 21.46 100.00 VARCUM Chemical Co. No. 29-345 40.9 powdered phenolic resin Wallastonite - (Grade C-6 53.0 Interface Corp.) Calcium Oxide (CaO) 5.1 Carbon Black 1.0 100.0 Secondary Abrading Portion ______________________________________ % by Ingredients Weight ______________________________________ Abrasive-24 grit aluminum oxide abrasive 75.62 particles Resin Bond % by Weight 24.38 100.00 VARCUM Chemical Co. No. 29-345 40.9 powdered phenolic resin Wallastonite (Grade C-6 53.0 Interface Corp.) Calcium Oxide (CaO) 5.1 Carbon Black 1.0 100.0 ______________________________________
The 25% mixture of garnet particles in the primary abrading portion had a particle grit size break down which was the sizing as prepared by the manufacture of the garnet, as follows:
Screen Size Percent ______________________________________ thru 12 on 16 1/2- 3 thru 16 on 18 8 - 30 thru 18 on 24 50 - 65 thru 24 on 28 12 - 25 ______________________________________
In addition there was added to each of the primary and secondary abrasive mixtures of abrasive and resin bond 45 cc of furfural plasticizer and 25 cc of CARBOSOTA (creosote oil) for each pound of powdered phenolic resin. The CARBOSOTA being mixed separately with the resin bond and the furfural being mixed with and wetting the abrasive particles prior to mixing the wetted abrasive particle with the resin bond. Thereafter, to the entire mixture of wetted abrasive and resin bond there is added and mixed therewith 4 cc of a mixture of 60% by weight of furfural and 40% by weight of castor oil and lastly, 0.0005 of a pound (lb.) or 0.23 grams of dry colloidal silica (CAB-O-SIL) for each pound (lb.) of the entire abrasive mixture.
The data in Table I discloses that the wheel with alumina-zirconia abrasive blended with 25% garnet abrasive particles in the primary abrading portion and 24 grit size aluminum oxide in the secondary portion gave a RGR of 193% and RRC of 100% and a performance nearly equal to the wheels with alumina-zirconia in only the primary portion and throughout the wheel.
In another embodiment a wheel of comparable size and shape was made according to the invention with finer 46 grit size alumina particles in the secondary portion and with a mixture of alumina-zirconia and 25% garnet in the primary portion. The wheel consisted of the following percentages by weight of ingredients.
______________________________________ Primary Abrading Portion ______________________________________ % by Ingredients Weight ______________________________________ Primary Abrasive Mixture % by Volume 79.6 20 thru 30 grit size alumina- 75 zirconia 12 thru 28 grit size garnet 25 100 Resin Bond % by Weight 20.4 100.0 Union Carbide BRP5417 phenolic 42 resin powder VARCUM 29-390 liquid resin 14 (plasticizer) Wallastonite (Grade C-6 42.9 Interface Corp.) Carbon Black 1.1 100.0 Secondary Abrading Portion ______________________________________ % by Ingredients Weight ______________________________________ Abrasive-46 grit size aluminum oxide 77.8 Resin Bond % by Weight 22.2 100.0 Union Carbide BRP5417 phenolic 42 powdered resin VARCUM 29-390 liquid resin 14 (plasticizer). Wallastonite (Grade C-6 42.9 Interface Corp.) Carbon Black 1.1 100.0 ______________________________________
Of the total volume of the 20 thru 30 grit alumina-zirconia abrasive particles, one-third (331/3 %) were 20 grit, 1/3 were 24 grit and 1/3were 30 grit size particles. The garnet of 12 thru 28 grit size was of the same sizes disclosed before in the table above.
In addition there was added to each of the primary and secondary resin bonds 25 cc of CARBOSOTA (creosote oil) for each pound of dry powdered phenolic resin. The CARBOSOTA being mixed separately with the resin bond prior to mixing the abrasive particles therewith. Then, to each of the primary and secondary abrasive mixtures of abrasive and resin bond is added 4 cc of a mixture containing by weight 60% of furfural and 40% castor oil and lastly, 0.0005 pounds or 0.23 grams of colloidal silica (CAB-O-SIL) for each pound of the entire abrasive mixture.
The grinding wheel was tested and compared with a comparable standard wheel. The grinding test was performed on the annular edge of a rotating ring of cast steel of the same type, in the same manner and with the same apparatus disclosed above except that the wheel was reciprocated and traversed 31/8inches across the edge instead of 11/8 inches disclosed above. Results of the test are shown for comparison in Table II below.
TABLE II ____________________________________________________________ ______________ TYPE AND LOCATION OF ABRASIVE PARTICLES WHEEL METAL TYPE OF PRIMARY SECONDARY WEAR REMOVED RGR RRC WHEEL PORTION PORTION IN. 3 /HR. LBS./HR. IN. % IN. % ____________________________________________________________ ______________ STANDARD aluminum aluminum 9.75 4.70 100 100 PRIOR ART oxide oxide WHEEL 24 grit 46 grit WHEEL OF 75% alumina- aluminum 5.12 5.28 214 113 INVENTION zirconia oxide 20 thru 30 46 grit grit % BY VOLUME 25% garnet 12 thru 28 grit ____________________________________________________________ ______________
As can be seen the standard comparable wheel in Table II has a higher wheel wear and metal removal rate than the standard wheel shown in Table I above. This is due to the fact that the wheel forced downwardly by the 20 pounds of force had a longer transverse across the annular edge than those recited in Table I. As a result it cut more severely into the ring of cast steel. However, comparing the relative grinding ratio (RGR) and the relative rate of cut (RRC) discloses that the wheel with three-fourths (75%) alumina-zirconia, one-fourth (25%) garnet, and 46 grit aluminum oxide gave an RGR twice as good and an RRC slightly better than the 100 given the standard wheel and substantially equal to the 2.47 RGR and 97 RRC for the other wheel of the invention with all alumina-zirconia in the primary portion and 24 grit aluminum oxide in the secondary portion.
All of the wheels tested, including those of the invention, had substantially a volume percent composition of about 46% abrasive, 34% resin bond and 20% pores and a density of about 2.7.
It will thus be seen that there has been provided by the invention raised hub or depressed center and straight center portable grinding wheels in which the object hereinabove set forth together with the many thoroughly practical advantages are successfully achieved. As many possible embodiments may be made of the invention and as many changes might be made in the embodiments set forth above, it is to be understood that all matter hereinbefore set forth is to be interpreted as illustrative only and includes all embodiments and modifications coming within the scope of the appended claims.
1. Field of the Invention
The invention relates to resin bonded abrasive grinding wheels and particularly to relatively thin reinforced raised hub or depressed center and straight center snagging wheels for portable grinders.
2. Description of the Prior Art
Heretofore grinding wheels have been made with inner and outer layers, sides and zones varying either in density, hardness, type of abrasive, bond, and in the grit size of the abrasive particles as disclosed in the following publications U.S. Pat. Nos. 1,403,416, 1,616,531, 2,479,078, 2,877,105 and German Gebrauchsmuster No. 7,306,787 dated May 24, 1973. In use straight and depressed center or raised hub wheels of various shapes are usually attached and driven by hand operated portable grinders, and held at a slight angle to grind welding beads, flash, gates and risers off castings. During grinding the peripheral grinding face or edge of the wheel wears at an angle to the axis of rotation and the opposite sides of the wheel. As a result a sharp and relatively thin fragile peripheral edge is formed at the junction of the grinding face and the back or top side of the wheel. The fragile edge has a tendency to break away and contributes very little to removing the unwanted material. Also known, are wheels having various types of backing materials for reinforcing the fragile edge and for supporting the primary cutting or abrading portion of the wheel.
For many years and up to the present time depressed center also known as raised hub grinding wheels have been made in the United States with a backing layer of bonded abrasive particles of relatively fine grit size bonded between a layer of coarser primary abrasive particles of substantially uniform grit size and a fiber glass backing. The finer abrasive being of the same type as the coarser and usually include what are known in the art as abrasive fines which vary in grit size. When mixed and bonded together the fines tend to occupy the spaces between the larger particles and thereby densify and strengthen the backing layer of finer abrasive particles.
The Applicant's invention differs from the prior art in that abrasive particles of a tough, superior, more durable, faster cutting and more expensive alumina-zirconia abrasive material such as disclosed in U.S. Pat. No. 3,181,939 and a commonly owned prior copending application Ser. No. 386,718 filed Aug. 8, 1973 and to which reference may be had for details not disclosed herein, is used in the primary abrading portion and differs from the abrasive used in the secondary abrading portion of the wheel. U.S. Pat. No. 3,181,939 discloses rapidly cooled co-fused alumina-zirconia containing 10 to 60% zirconia. The preferred abrasive for this invention is the 35 to 50% zirconia, very rapidly cooled material of Ser. No. 386,718.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional veiw through the center of a typical depressed center or raised hub wheel made according to the invention;
FIG. 2 is a sectional view through the center of a straight center wheel made according to the invention; and
FIG. 3 is a partial sectional view through a peripheral portion of a wheel showing the wheel inclined and the grinding edge thereof worn at an angle during grinding.
SUMMARY OF THE INVENTION
Depressed and straight center reinforced resin bonded abrasive grinding wheels comprising a primary abrading portion or layer containing tough, durable, fast cutting and relatively expensive bonded alumina-zirconia abrasive particles occupying a portion of the thickness of the wheel situated on the working or bottom side of the wheel. A secondary abrading portion or layer containing different, less expensive, less durable abrasive particles is bonded to the primary abrading portion and situated on the back or top side of the wheel. If desired and preferably there is a backing consisting of at least one layer of reinforcing material molded in and bonded to the back or top side of the secondary abrading portion of the wheel.
The reinforced wheel may have one or more additional layers or discs of fiber glass reinforcing material integrally molded and bonded therein. One layer of reinforcement is preferably bonded to and situated in between the secondary and primary abrading layers of the wheel. The central hub portion of the wheel is preferably further reinforced with a disc of fiber glass cloth molded in and bonded to the bottom side of the primary abrading layer or portion.
Therefore it is the primary object of the invention to provide reinforced resin bonded abrasive grinding wheels having a primary abrading portion comprising particles of co-fused alumina-zirconia abrasive material and a secondary abrading portion containing particles of different abrasive material.
DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
Referring to the drawings wherein there is shown a depressed center or raised hub grinding wheel 10 and a straight center or hub wheel 10'. The wheels are shown in only one of the many possible conventional shapes to which they may be made and known to those skilled in the art. For example, they may be molded to the shape of a shallow dish or saucer with curved or straight flaring sides and still have either a straight or depressed center portion about the mounting hole. As used herein the term straight center is meant to include wheels other than depressed center or raised hub and those having top and bottom surfaces which continue without any deviation or sharp bends to the center mounting hole. The construction of each of the wheels 10 and 10' being substantially the same except for the configuration of the central hub mounting portion around the center mounting hole which may be adapted to receive any suitable mounting, such as shown in FIG. 3, for attaching the wheel to the drive spindle or shaft of a portable grinder. In U.S. Pat. Nos. 3,081,584; 3,136,100; 3,500,592; and 3,596,415 there are disclosed wheel mountings which may be attached to the wheels disclosed herein and to which reference may be had for details not disclosed herein. Obviously, there are many other types of suitable mountings known to those skilled in the art which may be attached in various ways to the wheels. The mounting forms no part of the invention and therefor is not shown but merely incorporated by reference herein.
As shown both of the wheels 10 and 10' have a bottom or working side 12, a top or back side 14, a peripheral grinding edge or face 16 and a center hole 18 for mounting the wheel. Adjacent the bottom side 12 is a primary abrading portion or layer 20 containing resin bonded primary abrasive particles of a premium co-fused alumina-zirconia abrasive material of the type disclosed in U.S. Pat. No. 3,181,939 and the copending application disclosed above to which reference may be had for details not disclosed herein and which preferably occupies about one-half the thickness of the wheel and at least two particles deep. Embedded in and bonded to the bottom side of the primary abrading layer in the central hub portion of the wheel about center hole 18 is a layer or disc 22 of reinforcing material. The disc or layer 22 of reinforcing material is preferably a disc 4 inches in diameter of resin coated, open 14 × 14 mesh, plain woven, fiber glass cloth having approximately 14 openings to the inch and commercially available as number 196 from Eli Sandman Company, Worcester, Mass. Molded within the wheel and bonded to the inner side of the primary abrading portion 20 is another disc 24 of reinforcing material which extends radially out from the center hole to the peripheral grinding edge 16 of the wheel. The disc 24 is preferably made of resin coated, open 7 × 7 mesh, plain woven fiber glass cloth having approximately 7 openings to the inch and commercially available as number RC717 from Eli Sandman Company, Worcester, Mass.
Adjacent to and resin bonded to both the reinforcement 24 and the primary abrading layer 20 is a secondary abrading portion or layer 26 of resin bonded secondary abrasive particles which differ from and are preferably less costly than the co-fused alumina-zirconia abrasive particles in the primary abrading layer 20. The secondary abrading layer 26 extends axially to the back or top side 14 and occupies approximately the upper half or remaining portion of the thickness of the wheel.
Integrally bonded to and molded into the secondary abrading layer 26 at the back or top side 14 of the wheel is a third or composite disc or layer 28 of backing material extending to the peripheral edge 16 of the wheel. The disc 28 of backing material is preferably a composite disc consisting of a thin layer of paper adhered to a layer of fiber glass cloth and designated as a number 955 paper stick resin coated 5 × 5 open mesh, low twist woven fiber glass cloth with approximately five openings per inch available from Eli Sandman Company, Worcester, Mass.
The secondary abrasive may be any of the well known abrasive materials selected from a group consisting of aluminum oxide, garnet, silicon carbide, silica, emery, flint and quartz and mixtures thereof which are less costly, not as durable and less efficient than the primary co-fused alumina-zirconia abrasive material. Preferably, for most grinding applications, the secondary abrasive material comprises particles of aluminum oxide of either 24 or 46 grit size. However, for other applications the size of the secondary abrasive particles may be in a range of 16 to 60 grit size and if desired no larger than 16 grit size and include what is known as abrasive fines. When bonded together both the fines and smaller grit size particles provide a denser and stronger secondary abrading portion which backs up and supports the primary abrading portion.
The primary co-fused alumina-zirconia abrasive particles are preferably rolls crushed elongated particles of substantially uniform grit size of from 16 to 60, of high purity fine crystalline structure containing 10 - 60 percent by weight of zirconium oxide. However, in the grinding wheels of this invention elongated particles of co-fused alumina-zirconia of 24 grit size having about 43% of zirconia by weight, a specific gravity of 4.66 and a bulk density of 129 to 137 pounds per cubic feet are preferred for most foundry snagging operations while in other operations particles having a content of 25% zirconia and a specific gravity of 4.35 will suffice.
The alumina-zirconia abrasive particles are preferably of the type disclosed in a prior copending application Ser. No. 386,718 filed Aug. 8, 1973 to which reference may be had for details not disclosed herein. It is made by rapidly crystallizing and solidifying a eutectic or near eutectic molten mixture of aluminum oxide and 35 to 50%, but preferably around 40%, by weight of zirconium oxide. One of the various methods of rapidly crystallizing the molten mixture is to pour it between a plurality of three-fourths inch thick plates spaced about three-sixteenths of an inch apart which quickly cool and solidify the mixture into a product with a microcrystalline structure having the following typical analysis of ingredients by weight percent.
______________________________________ SiO 2 0.21% Fe 2 O 3 0.15% TiO 2 0.15% Na 2 O 0.04% ZrO 2 40.56% Al 2 O 3 58.89 (by difference) ______________________________________
No analysis was made for the small amounts of lime or magnesia which were present. However, the analysis shows that the fine crystalline alumina-zirconia abrasive product was of high purity with less than 1% by weight of impurities therein.
The solidified alumina-zirconia product has very high strength combined with high desirable microfracture properties. Also, the zirconia is in the form of rods (or platelets) which average less than 3,000 angstroms in diameter and preferably at least 25% by weight of the zirconia is in the tetragonal crystal form. The solidified product is made up of eutectic cells or colonies typically 40 microns or less in width. Groups of cells having idential orientation of microstructure, form grains each of which typically include from 2 to 100 or more cells or colonies. During crushing, the material fractures along grain boundaries and cell boundaries and is first jaws crushed and then rolls crushed to form elongated abrasive particles which are separated and screened to obtain the desired grit size particles thereof. As used above, the term "grain" is not synonymous with the word "grit. " Typically an abrasive grit will contain a large number of grains, in the sense used above.
The wheels 10 and 10'to may be molded either by hot or cold pressing in any suitable manner well known to those skilled in the art. A mold having a center hole forming arbor surrounded by a circular cavity in which the center is depressed can be used to mold the depressed center or raised hub wheel 10 and a mold also having a hole arbor but a straight cylindrical cavity may be used to mold the straight hub or center wheel 10'. The wheels may be molded by first placing the paper side of the paper stick fiber glass disc 28 of composite backing material with a center hole around the arbor and in contact with the bottom of the mold. Then, spreading a uniform layer of a prepared abrasive mixture containing a suitable resin bond and the secondary abrasive particles on top of the fiber glass backing disc 28. Thereafter, placing the disc 24 of fiber glass reinforcing material with a center hole about the arbor and onto the layer of secondary abrasive mix followed by spreading a uniform layer of a prepared mixture comprising a suitable and compatible resin bond and the primary abrasive containing particles of alumina-zirconia abrasive material thereon. Lastly, laying the hub reinforcing disc 22 with a center hole therein around the arbor and onto the layer of primary abrasive and placing a top mold plate of the desired shape to either produce the depressed center or the straight center hub portion of the wheels, on top of the layers. The mold assembly is then placed between the platens of either a conventional cold or hot press. Then the press is actuated to force the mold plate downwardly and compress the discs and abrasive mixtures together, at a pressure of 1 to 4 tons per square inch, into a self supporting structure of predetermined thickness, diameter and density. After molding the wheel is stripped from the mold and placed in an oven heated to a temperature of approximately 175°C for approximately 6 hours to fully cure the resin bond.
The resin bond may comprise any one of a number of the conventional and well known thermosetting or infusible resins, such as, phenol-aldehyde, epoxy, polyester, polyimides, and polybenzimadazole in either liquid for powder form. Preferably the resin bond comprises a phenolic (phenol-aldehyde) resin in powder form which is premixed with other fillers and coloring materials and then mixed with predetermined amounts of the secondary and primary abrasive particles.
A suitable primary abrasive mixture of primary abrasive particles and resin bond for a snagging operation may comprise the following percentage of ingredients by weight:
% by Ingredients Weight ______________________________________ Abrasive-24 grit alumina-zirconia abrasive 78.54 particles Resin Bond % by Weight 21.46 100.00 VARCUM Chemical Co. No. 29-345 40.9 powdered phenolic resin Wallastonite - (Grade C-6 53.0 Interface Corp., Willsboro, New York) Calcium Oxide (CaO) 5.1 Carbon Black 1.0 100.0 ______________________________________
The secondary abrasive mixture of secondary abrasive and resin bond may comprise the following percentage of ingredients by weight:
% by Ingredients Weight ______________________________________ Abrasive-24 grit aluminum oxide abrasive 75.62 particles Resin Bond % by Weight 24.38 100.00 VARCUM Chemical Co. No. 29-345 40.9 powdered phenolic resin Wallastonite - (Grade C-6 53.0 Interface Corp.) Calcium Oxide (CaO) 5.1 Carbon Black 1.0 100.00 ______________________________________
In addition there was added to each of the primary and secondary abrasive mixtures of abrasive and resin bond 45 cc of furfural plasticizer and 25 cc of CARBOSOTA (creosote oil) for each pound of powdered phenolic resin. The CARBOSOTA being mixed separately with the resin bond and the furfural being mixed with and wetting the abrasive particles prior to mixing the wetted abrasive particle with the resin bond. Thereafter, to the entire mixture of wetted abrasive and resin bond there is added and mixed therewith 4 cc of a mixture of 60% by weight of furfural and 40% by weight of castor oil and lastly, 0.0005 of a pound (lb.) or 0.23 grams of dry colloidal silica (CAB-O-SIL) for each pound (lb.) of the entire abrasive mixture.
Referring to FIG. 3 there is shown a sectional view through a portion of a grinding wheel of the invention mounted on a shaft and positioned at an angle to the surface of the workpiece W being worked upon to show how in normal use the initial grinding face or edge 16 is worn at an angle to the back or top side 14 and bottom or working side 12. It can be seen that when the wheel is used at an angle that the length of the grinding face 16 is increased and that the thinnest, weakest and most fragile part of the wheel is at and adjacent the outer tip or edge 16a located at the junction of the grinding face 16 and the back side 14. When grinding pressure is applied, the edge 16a and the adjacent tapered portions of the secondary abrading portion have a tendency to break away because they are only supported by the fiber glass backing layer 28. As a result, the secondary abrading portion 26 does much less grinding or cutting of unwanted material. In contrast, the primary abrading portion 20 does not have as fragile an edge or corner as the edge 16a and is more rigidly supported and backed up by the secondary abrading portion of the wheel. Therefore, the primary abrading portion 20 with the more durable faster cutting and more efficient alumina-zirconia abrasive therein does most of the grinding or cutting away of material without the tendency to break away.
Wheels 7 inches in diameter, one-quarter of an inch thick each with a seven-eighths inch diameter center hole were made according to the invention with the 24 grit size alumina-zirconia abrasive resin mixtures, and 24 grit aluminum oxide abrasive resin mixtures disclosed above. The wheels were tested and compared with a variety of other wheels all of comparable size and shape, 24 grit size particles and resin bond disclosed above but with variations in the type, amount by volume and location of abrasive particles in the wheel. Some of the wheels were made with aluminum oxide or the alumina-zirconia throughout, with the alumina-zirconia abrasive in the secondary portion and alumina in the primary portion, and with a mixture containing by volume 50% of alumina-zirconia and 50% alumina in both portions of the wheel. Another wheel had a mixture containing by volume 75% of alumina-zirconia and 25% garnet in the primary portion and alumina in the secondary portion. The alumina-zirconia abrasive used in all the wheels tested contained about 43% zirconia by weight.
The grinding tests were performed by mounting each wheel on an automated apparatus adapted to transverse and manipulate a Chicago Pneumatic 360 cycle right angle portable grinder rotatable at 5,200 RPM and inclined so the bottom side of the wheel was at an angle of 25° from a horizontal plane to simulate the position, applied force and movements of a hand operated portable grinder.
Each wheel tested was run four times during each of which the grinding wheels ground into the annular edge of a 12 inch O.D. × 103/4 inch I.D. ring of cast steel, mounted on a reversible rotary table rotated at 15 RPM in reversed directions every one-half minute. Each run lasted for a period of 15 minutes while a constant downward force of 20 pounds was applied to the wheel reciprocated 13/8 inches across the annular edge. After each run the ring of cast steel was weighed and the wheel measured to determine the number of pounds of metal removed per hour and the number of cubic inches of wheel wear per hour. The "grinding ratio" of the wheel is the ratio of metal removed to wheel wear.
In the following Tables I and II, RGR refers to the "Relative Grinding Ratio" in percent which is determined by dividing the grinding ratio × 100 of the wheel being tested by the grinding ratio of a conventional standard wheel with 24 grit aluminum oxide abrasive throughout the wheel given an RGR rating of 100%. The "Relative Rate of Cut" in percent is indicated by RRC in the table and is determined by dividing the rate of cut × 100 of the wheel being tested with that of a comparable conventional standard wheel rated at 100% and made with aluminum oxide abrasive throughout. The results of one of the tests are shown in Table I below.
TABLE I ____________________________________________________________ ______________ TYPE AND LOCATION OF 24 GRIT SIZE ABRASIVE PARTICLES WHEEL METAL TYPE OF PRIMARY SECONDARY WEAR REMOVED RGR RRC WHEEL PORTION PORTION IN. 3 /HR. LBS./HR. IN. % IN. % ____________________________________________________________ ______________ STANDARD aluminum aluminum 3.43 2.91 100 100 PRIOR ART oxide oxide WHEEL VARIATION alumina- alumina- 1.46 3.00 243 103 OF zirconia zirconia WHEELS 50% alumina- 50% alumina- 2.32 3.13 159 108 zirconia zirconia % BY VOLUME mixed with mixed with 50% aluminum 50% aluminum oxide oxide aluminum alumina- 3.58 3.08 102 106 oxide zirconia WHEELS alumina- aluminum 1.34 2.82 2.47 97 OF zirconia oxide INVENTION 75% alumina- aluminum 1.78 2.91 193 100 % BY VOLUME zirconia oxide 25% garnet ____________________________________________________________ ______________
As can be seen from the test data, the wheel with alumina-zirconia in both the primary and secondary portions with a 243% RGR and 103% RRC was far superior to the standard wheel with aluminum oxide in both the primary and secondary portions. The wheel having a mixture of one-half (50%) alumina-zirconia and one-half (50 %) aluminum oxide by volume in both the primary and secondary portions gave as expected a 159% RGR and 108% RRC which is an improvement over the standard wheel with aluminum oxide throughout but not equal to the wheel with alumina-zirconia in both portions of the wheel. However, the wheel of the invention with all of alumina-zirconia in the primary abrading portion of the wheel and aluminum oxide in the secondary portion gave a result of 247% RGR and 97% RRC which is very nearly equal to the wheel with alumina-zirconia throughout the wheel. In contrast, the wheel with the aluminum oxide in the primary portion and alumina-zirconia in the secondary portion gave a result of 102% RGR and 106% RRC which shows a performance equal to that of the standard wheel with aluminum oxide throughout the wheel. The data shows that the wheels made according to the invention with approximately one-half as much of the more costly alumina-zirconia located in the primary portion of the wheel and a less costly abrasive in the secondary portion performs very nearly as well as the wheel with alumina-zirconia throughout the wheel. Hence, only one-half as much of the premium abrasive is required with no apparent loss in performance.
In another embodiment of the invention the primary abrading portion may contain a primary abrasive mixture consisting of the superior co-fused primary alumina-zirconia abrasive particles and up to one-fourth or 25% by volume of the primary abrasive particles therein of a different, less costly, less efficient and less durable diluent or filler abrasive particles of material such as, garnet, flint, silica, emery, silicon, carbide, alumina and quartz and mixtures thereof which it has been discovered does not materially reduce the performance of the wheel below one without the 25% of diluent abrasive therein. As shown in Table I wheels were made and tested in which the primary and secondary abrading portions were comprised of abrasive and resin bond mixtures consisting of the following percentage of ingredients by weights.
______________________________________ Primary Abrading Portion ______________________________________ % by Ingredients Weight ______________________________________ Primary Abrasive Mixture % by Volume 78.54 24 grit size particles of 75 alumina-zirconia 12 thru 28 grit size particles 25 of garnet 100 Resin Bond % by Weight 21.46 100.00 VARCUM Chemical Co. No. 29-345 40.9 powdered phenolic resin Wallastonite - (Grade C-6 53.0 Interface Corp.) Calcium Oxide (CaO) 5.1 Carbon Black 1.0 100.0 Secondary Abrading Portion ______________________________________ % by Ingredients Weight ______________________________________ Abrasive-24 grit aluminum oxide abrasive 75.62 particles Resin Bond % by Weight 24.38 100.00 VARCUM Chemical Co. No. 29-345 40.9 powdered phenolic resin Wallastonite (Grade C-6 53.0 Interface Corp.) Calcium Oxide (CaO) 5.1 Carbon Black 1.0 100.0 ______________________________________
The 25% mixture of garnet particles in the primary abrading portion had a particle grit size break down which was the sizing as prepared by the manufacture of the garnet, as follows:
Screen Size Percent ______________________________________ thru 12 on 16 1/2- 3 thru 16 on 18 8 - 30 thru 18 on 24 50 - 65 thru 24 on 28 12 - 25 ______________________________________
In addition there was added to each of the primary and secondary abrasive mixtures of abrasive and resin bond 45 cc of furfural plasticizer and 25 cc of CARBOSOTA (creosote oil) for each pound of powdered phenolic resin. The CARBOSOTA being mixed separately with the resin bond and the furfural being mixed with and wetting the abrasive particles prior to mixing the wetted abrasive particle with the resin bond. Thereafter, to the entire mixture of wetted abrasive and resin bond there is added and mixed therewith 4 cc of a mixture of 60% by weight of furfural and 40% by weight of castor oil and lastly, 0.0005 of a pound (lb.) or 0.23 grams of dry colloidal silica (CAB-O-SIL) for each pound (lb.) of the entire abrasive mixture.
The data in Table I discloses that the wheel with alumina-zirconia abrasive blended with 25% garnet abrasive particles in the primary abrading portion and 24 grit size aluminum oxide in the secondary portion gave a RGR of 193% and RRC of 100% and a performance nearly equal to the wheels with alumina-zirconia in only the primary portion and throughout the wheel.
In another embodiment a wheel of comparable size and shape was made according to the invention with finer 46 grit size alumina particles in the secondary portion and with a mixture of alumina-zirconia and 25% garnet in the primary portion. The wheel consisted of the following percentages by weight of ingredients.
______________________________________ Primary Abrading Portion ______________________________________ % by Ingredients Weight ______________________________________ Primary Abrasive Mixture % by Volume 79.6 20 thru 30 grit size alumina- 75 zirconia 12 thru 28 grit size garnet 25 100 Resin Bond % by Weight 20.4 100.0 Union Carbide BRP5417 phenolic 42 resin powder VARCUM 29-390 liquid resin 14 (plasticizer) Wallastonite (Grade C-6 42.9 Interface Corp.) Carbon Black 1.1 100.0 Secondary Abrading Portion ______________________________________ % by Ingredients Weight ______________________________________ Abrasive-46 grit size aluminum oxide 77.8 Resin Bond % by Weight 22.2 100.0 Union Carbide BRP5417 phenolic 42 powdered resin VARCUM 29-390 liquid resin 14 (plasticizer). Wallastonite (Grade C-6 42.9 Interface Corp.) Carbon Black 1.1 100.0 ______________________________________
Of the total volume of the 20 thru 30 grit alumina-zirconia abrasive particles, one-third (331/3 %) were 20 grit, 1/3 were 24 grit and 1/3were 30 grit size particles. The garnet of 12 thru 28 grit size was of the same sizes disclosed before in the table above.
In addition there was added to each of the primary and secondary resin bonds 25 cc of CARBOSOTA (creosote oil) for each pound of dry powdered phenolic resin. The CARBOSOTA being mixed separately with the resin bond prior to mixing the abrasive particles therewith. Then, to each of the primary and secondary abrasive mixtures of abrasive and resin bond is added 4 cc of a mixture containing by weight 60% of furfural and 40% castor oil and lastly, 0.0005 pounds or 0.23 grams of colloidal silica (CAB-O-SIL) for each pound of the entire abrasive mixture.
The grinding wheel was tested and compared with a comparable standard wheel. The grinding test was performed on the annular edge of a rotating ring of cast steel of the same type, in the same manner and with the same apparatus disclosed above except that the wheel was reciprocated and traversed 31/8inches across the edge instead of 11/8 inches disclosed above. Results of the test are shown for comparison in Table II below.
TABLE II ____________________________________________________________ ______________ TYPE AND LOCATION OF ABRASIVE PARTICLES WHEEL METAL TYPE OF PRIMARY SECONDARY WEAR REMOVED RGR RRC WHEEL PORTION PORTION IN. 3 /HR. LBS./HR. IN. % IN. % ____________________________________________________________ ______________ STANDARD aluminum aluminum 9.75 4.70 100 100 PRIOR ART oxide oxide WHEEL 24 grit 46 grit WHEEL OF 75% alumina- aluminum 5.12 5.28 214 113 INVENTION zirconia oxide 20 thru 30 46 grit grit % BY VOLUME 25% garnet 12 thru 28 grit ____________________________________________________________ ______________
As can be seen the standard comparable wheel in Table II has a higher wheel wear and metal removal rate than the standard wheel shown in Table I above. This is due to the fact that the wheel forced downwardly by the 20 pounds of force had a longer transverse across the annular edge than those recited in Table I. As a result it cut more severely into the ring of cast steel. However, comparing the relative grinding ratio (RGR) and the relative rate of cut (RRC) discloses that the wheel with three-fourths (75%) alumina-zirconia, one-fourth (25%) garnet, and 46 grit aluminum oxide gave an RGR twice as good and an RRC slightly better than the 100 given the standard wheel and substantially equal to the 2.47 RGR and 97 RRC for the other wheel of the invention with all alumina-zirconia in the primary portion and 24 grit aluminum oxide in the secondary portion.
All of the wheels tested, including those of the invention, had substantially a volume percent composition of about 46% abrasive, 34% resin bond and 20% pores and a density of about 2.7.
It will thus be seen that there has been provided by the invention raised hub or depressed center and straight center portable grinding wheels in which the object hereinabove set forth together with the many thoroughly practical advantages are successfully achieved. As many possible embodiments may be made of the invention and as many changes might be made in the embodiments set forth above, it is to be understood that all matter hereinbefore set forth is to be interpreted as illustrative only and includes all embodiments and modifications coming within the scope of the appended claims.