Coated Abrasive Products Containing Aggregates

Abstract

A coated abrasive product includes a particulate material containing green, unfired abrasive aggregates having a generally spheroidal or toroidal shape, the aggregates formed from a composition comprising abrasive grit particles and a nanoparticle binder. Free abrasive products, bonded abrasive products, and the particulate material also contain aggregates.

1 - 38 . (canceled) 
     
     
         39 . An abrasive slurry, comprising:
 green, unfired abrasive aggregates provided in suspension, the aggregates having a generally spheroidal or toroidal shape, the aggregates formed from a composition comprising abrasive grit particles and a nanoparticle binder,   wherein the nanoparticle binder forms a continuous matrix phase in which the abrasive grit particles are uniformly distributed.   
     
     
         40 . (canceled) 
     
     
         41 . A bonded abrasive product comprising:
 aggregates having a generally spheroidal or toroidal shape, the aggregates comprising abrasive grit particles and a nanoparticle binder, wherein the nanoparticle binder forms a continuous matrix phase in which the abrasive grit particles are uniformly distributed; and   an inter-aggregate bond material fixing position of the aggregates with respect to each other.   
     
     
         42 . (canceled) 
     
     
         43 . A method for forming abrasive particulate material, comprising:
 forming a slurry comprising a liquid carrier, abrasive grit particles and a nanoparticle binder;   spray drying the slurry to form green, unfired aggregates containing the abrasive grit particles and the nanoparticle binder, wherein the nanoparticle binder forms a continuous matrix phase in which the abrasive grit particles are uniformly distributed; and   classifying the aggregates for use in an abrasive product,   
     
     
         44 . The method of  claim 43 , wherein the slurry further comprises a plasticizer. 
     
     
         45 . The method of  claim 43 , wherein spray drying is carried out at a temperature less than 400° C. 
     
     
         46 . The method of  claim 43 , wherein spray drying is carried out at a temperature less than 350° C. 
     
     
         47 . The method of  claim 43 , further comprising adhering the aggregates to a substrate to form a coated abrasive product. 
     
     
         48 . The method of  claim 43 , further comprising adhering the aggregates to each other to form a bonded abrasive product. 
     
     
         49 . The method of  claim 43 , further comprising deploying the aggregates in an aqueous base to form a slurry. 
     
     
         50 . A method for machining a workpiece, comprising:
 providing a workpiece having an initial surface roughness Ra i ;   abrading the workpiece with a single abrasive product to remove material from the workpiece, whereby the workpiece has a final surface roughness Ra f  and Ra f  is not greater than 0.2Ra i , the final surface roughness being achieved with said single product without use of another abrasive product, wherein the abrasive product comprises green, unfired abrasive aggregates, the aggregates having a generally spheroidal or toroidal shape, the aggregates comprising an abrasive grit particles and a nanoparticle binder.   
     
     
         51 . The method of  claim 50 , wherein Ra f  is not greater than 0.1Ra i . 
     
     
         52 . The method of  claim 51 , wherein Ra f  is not greater than 0.05Ra i . 
     
     
         53 . The method of  claim 52 , wherein Ra f  is no greater than 0.01Ra i . 
     
     
         54 . (canceled)