Abrasive article and method of forming

Abstract

An abrasive article including a bonded abrasive body including a bond material having a metal, abrasive particles contained within the bond material, and a filler blend including fine filler particles and coarse filler particles and defining a filler particle size ratio (Ff/Fc) of not greater than about 0.97, where Ff represents the average particle of the fine filler particles and Fc represents the average particle size of the coarse filler particles.

What is claimed is: 
     
         1 . An abrasive article comprising:
 a bonded abrasive body including:   a bond material comprising a metal;   abrasive particles contained within the bond material;   a filler blend including fine filler particles and coarse filler particles and defining a filler particle size ratio (Ff/Fc) of not greater than about 0.97, wherein the Ff represents the average particle of the fine filler particles and Fc represents the average particle size of the coarse filler particles.   
     
     
         2 . The abrasive article of  claim 1 , wherein the body comprises a porosity of not greater than about 14 vol % for a total volume of the bonded abrasive body. 
     
     
         3 . The abrasive article of  claim 1 , wherein the fine filler particles and the coarse filler particles comprise a same element. 
     
     
         4 . The abrasive article of  claim 1 , wherein fine filler particles comprise an average particle size of at least about 5 microns and not greater than about 120 microns. 
     
     
         5 . The abrasive article of  claim 1 , wherein coarse filler particles comprise an average particle size of at least about 15 microns and not greater than about 200 microns. 
     
     
         6 . The abrasive article of  claim 1 , wherein the filler particle size ratio (Ff/Fc) is at least about 0.03 and not greater than about 0.95. 
     
     
         7 . The abrasive article of  claim 1 , wherein the filler blend comprises a filler content ratio (Cf/Cc) of at least about 0.05 and not greater than about 10, wherein Cf represents the volume percent of fine filler particles for the total volume of the bonded abrasive body and Cc represents the volume percent of the coarse filler particles for the total volume of the bonded abrasive body. 
     
     
         8 . The abrasive article of  claim 1 , wherein the bonded abrasive body comprises at least about 1 vol % and not greater than about 50 vol % of the filler blend for the total volume of the bonded abrasive body. 
     
     
         9 . The abrasive article of  claim 1 , wherein the bonded abrasive body comprises at least about 1 vol % and not greater than about 25 vol % of the fine filler particles for the total volume of the bonded abrasive body. 
     
     
         10 . The abrasive article of  claim 1 , wherein the bonded abrasive body comprises at least about 1 vol % and not greater than about 25 vol % of the coarse filler particles for the total volume of the bonded abrasive body. 
     
     
         11 . The abrasive article of  claim 1 , wherein the bond material comprises a transition metal element selected from the group consisting of copper, tin, silver, nickel, and a combination thereof. 
     
     
         12 . The abrasive article of  claim 1 , wherein the bond material comprises bronze including copper (Cu) and tin (Sn) and wherein the bronze comprises a content of copper that is not less than a content of tin. 
     
     
         13 . The abrasive article of  claim 1 , wherein the bonded abrasive body comprises at least about 10 vol % of the bond material for the total volume of the bonded abrasive body. 
     
     
         14 . The abrasive article of  claim 1 , wherein the bonded abrasive body comprises not greater than about 85 vol % of the bond material for the total volume of the bonded abrasive body. 
     
     
         15 . An abrasive article comprising:
 a bonded abrasive body including:
 a bond material comprising a metal; 
 abrasive particles contained within the bond material; 
 a filler blend comprising:
 fine filler particles contained in the bond material having a Mohs hardness of not greater than about 4; 
 coarse filler particles contained in the bond material having a Mohs hardness of not greater than about 6; and 
 
 a porosity of not greater than about 15 vol %. 
   
     
     
         16 . The abrasive article of  claim 15 , wherein the fine filler particles and the coarse filler particles comprise a same element. 
     
     
         17 . The abrasive article of  claim 15 , wherein fine filler particles comprise an average particle size of at least about 5 microns and not greater than about 120 microns. 
     
     
         18 . The abrasive article of  claim 15 , wherein coarse filler particles comprise an average particle size of at least about 15 microns and not greater than about 200 microns. 
     
     
         19 . The abrasive article of  claim 15 , wherein the filler blend comprises a filler content ratio (Cf/Cc) of at least about 0.05 and not greater than about 10, wherein Cf represents the volume percent of fine filler particles for the total volume of the bonded abrasive body and Cc represents the volume percent of the coarse filler particles for the total volume of the bonded abrasive body. 
     
     
         20 . The abrasive article of  claim 15 , wherein the bond material comprises bronze including copper (Cu) and tin (Sn) and wherein the bronze comprises a content of copper that is not less than a content of tin.