Robust binder bonded grinding wheel

Abstract

An abrasive tool includes a matrix material and an abrasive grain contained within the matrix material. The matrix material includes a binder and an block copolymer. The block copolymer including a binder miscible block and a binder immiscible block. The binder immiscible block of the block copolymer can form toughening domains within the matrix material. A method of forming an abrasive tool includes blending a binder powder, an block copolymer powder, and an abrasive grain to form a blended powder, shaping the blended powder, and curing the blended powder.

1 .- 82 . (canceled) 
     
     
         83 . An abrasive tool comprising:
 a matrix material comprising a binder and a block copolymer, the block copolymer including a binder miscible block and a binder immiscible block, wherein the binder immiscible block forms a plurality of toughening domains dispersed within the matrix material; and   an abrasive grain contained within the matrix material.   
     
     
         84 . The abrasive tool of  claim 83 , wherein the binder is a phenolic resin, an epoxy resin, or any combination thereof 
     
     
         85 . The abrasive tool of  claim 83 , wherein the block copolymer includes poly(methyl methacrylate), polystyrene, polybutadiene, or any combination thereof 
     
     
         86 . The abrasive tool of  claim 83 , wherein the abrasive tool has a percent increase G1C of at least about 20% over a similar abrasive tool without the block copolymer, wherein the percent increase is based on the equation ((GN−GC)/GC×100%) wherein GN represents the G1C of an abrasive tool having the block copolymer and GC represents the G1C of the abrasive tool without the block copolymer. 
     
     
         87 . The abrasive tool of  claim 83 , wherein the abrasive tool has a percent increase SpWOF of at least about 10% over a similar abrasive tool without the block copolymer, wherein the percent increase is based on the equation ((SN−SC)/SC×100%) wherein SN represents the SpWOF of an abrasive tool having the block copolymer and SC represents the SpWOF of the abrasive tool without the block copolymer. 
     
     
         88 . The abrasive tool of  claim 83 , wherein the matrix material includes from about 70 wt % to about 95 wt % binder. 
     
     
         89 . The abrasive tool of  claim 83 , wherein the matrix material includes from about 5 wt % to about 30 wt % block copolymer. 
     
     
         90 . The abrasive tool of  claim 83 , wherein the abrasive grain is present in an amount from about 50 wt % to about 80 wt % of the abrasive tool. 
     
     
         91 . The abrasive tool of  claim 83 , wherein the body comprises an outer diameter within a range of about 15 cm to about 100 cm. 
     
     
         92 . The abrasive tool of  claim 83 , wherein the body comprises an average thickness of not greater than about 3 cm. 
     
     
         93 . The abrasive tool of  claim 83 , wherein the matrix material comprises a plurality of toughening domains having a first phase formed from the binder immiscible block and wherein each of the toughening domains is at least partially surrounded by a second phase formed from the binder miscible block and the binder 
     
     
         94 . A method comprising:
 blending a binder powder, a block copolymer powder, and an abrasive grain to form a blended powder, the block copolymer including a binder miscible block and a binder immiscible block;   shaping the blended powder; and   curing the blended powder to form an abrasive tool.   
     
     
         95 . The method of  claim 94 , wherein the blended powder includes from about 15 wt % to about 50 wt % binder, about 1 wt % to about 15 wt % block copolymer; and about 50 wt % to about 80 wt % abrasive grain. 
     
     
         96 . An abrasive tool comprising:
 a matrix material comprising:
 a binder; 
 a block copolymer within the binder, the block copolymer having at least a first portion and a second portion; 
 a plurality of toughening domains dispersed within a binder, wherein each of the plurality of toughening domains comprise the first portion of the block copolymer; and 
 an abrasive grain within the matrix material. 
   
     
     
         97 . The abrasive tool of  claim 96 , wherein the toughening domains include an average diameter between and including 0.1 μm and 25.0 μm. 
     
     
         98 . The abrasive tool of  claim 96 , wherein the toughening domain hardness is between and includes about 60% of the binder hardness and about 90% of the binder hardness. 
     
     
         99 . The abrasive tool of  claim 96 , wherein the matrix material includes a toughening domain concentration between and including 1 toughening domain per 1μm 2  and 10 toughening domains per 1μm 2 . 
     
     
         100 . The abrasive tool of  claim 96 , wherein the block copolymer comprises a polydispersity index between and including about 1.1 and about 1.4. 
     
     
         101 . The abrasive tool of  claim 96 , further comprising a burst speed of at least about 6800 RPM. 
     
     
         102 . The abrasive tool of  claim 96 , wherein the block copolymer comprises a molar mass of at least about 3000 g/mol.