ABRASIVE ARTICLES AND METHODS OF FORMING

Description

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application claims priority under 35 U.S.C. § 119 (e) to U.S. Provisional Patent Application No. 63/627,373, filed on Jan. 31, 2024, entitled “ABRASIVE ARTICLES AND METHODS OF FORMING,” by Subramanian RAMALINGAM et al., which is assigned to the current assignee hereof and is incorporated herein by reference in its entirety.

FIELD OF THE DISCLOSURE

The following is directed to abrasive articles and methods of forming, and particularly, to bonded abrasive articles having applications in superfinishing of workpieces.

DESCRIPTION OF THE RELATED ART

Abrasive articles can be used for cutting, grinding, or shaping various materials. Certain abrasive tools may be used in superfinishing applications and to remove small amounts of stock from a workpiece. Such applications may involve workpieces having complex surface profiles. The industry continues to demand abrasive articles that may allow improved surface finishing.

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 a flow chart illustrating a process of forming an abrasive article according to an embodiment.

FIGS. 2A-2C include illustrations of exemplary abrasive articles according to embodiments.

FIG. 2D includes a perspective-view illustration of an abrasive article according to an embodiment.

FIG. 3A includes an SEM image of a microstructure of an abrasive article.

FIG. 3B includes an SEM image of a bond microstructure of an abrasive article according to an embodiment.

FIGS. 4A-4B include images of bond pellets having different wetting ability.

FIGS. 5-9 include SEM images of bond structures of abrasive samples.

FIGS. 10A-10C include an illustration of exemplary operations involving an abrasive article according to embodiments.

Skilled artisans appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures can be exaggerated relative to other elements to help improve understanding of embodiments of the invention. The use of the same reference symbols in different drawings indicates similar or identical items.

DETAILED DESCRIPTION

The following description in combination with the figures is provided to assist in understanding the teachings provided herein. The following disclosure 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 that certain details regarding specific materials and processing acts are not described, such details may include conventional approaches, which may be found in reference books and other sources within the manufacturing arts.

Reference herein to bonded abrasive articles includes reference to a three-dimensional volume of an abrasive material having abrasive particles contained within a volume of a bond material. Bonded abrasive articles can be distinct from coated abrasive articles that may utilize a single layer of abrasive particles contained in a layer of bond or adhesive material. Moreover, the bonded abrasive articles of embodiments herein may include porosity within the three-dimensional volume of a bond material.

Embodiments are directed to abrasive articles with improved microstructure, properties, and/or performance. For example, the abrasive articles may have improved bond structures including bond post count, bond post size, ratio between bond post size to area % of bond material, ratio between bond post count to area % of bond material, ratio of bond post count to content of bond, ratio of bond post count to bond post size, ratio of bond post size to average abrasive particle size, or any combination thereof. In a further example, the abrasive articles may have improved hardness, density, hardness versus density, density variation, hardness variation, wear rates, surface finishing, or the like, or any combination thereof. Further embodiments are directed to a process of forming the abrasive articles. The process may include forming bond precursor material having particular features, such as particle sizes and/or composition, and/or careful controls over certain process parameters, such as temperatures and/or formation of improved porosity. The process may facilitate improved formation and microstructures of the abrasive articles, which may facilitate improved properties and/or performance of the abrasive articles.

FIG. 1 includes a flowchart illustrating an exemplary process 100 for forming an abrasive article. The process 100 can include a block 101, forming a mixture including abrasive particles and a bond precursor material. The bond precursor material may include a powder material that may be treated to form the bond material of the finally-formed abrasive article. In an embodiment, the bond precursor material can include a frit. In another embodiment, the bond precursor material can include an inorganic material, such as a ceramic material, a carbonate, minerals, inorganic compounds, or any combination thereof. As used herein, a reference to a ceramic can include a composition including at least one metal element and at least one non-metal element. For example, a ceramic may include material such as oxides, carbides, nitrides, borides, or a combination thereof. In still another embodiment, the bond precursor material can include an oxide-based composition, which may include some content of silica (i.e., silicon dioxide), boron oxide, alumina (i.e., aluminum oxide), alkali metal oxide, alkaline earth metal oxide, another oxide, or any combination thereof. In an embodiment, the final bond composition of the bonded abrasive body may include increased or reduced contents of one or more components compared to the composition of the bond precursor material. In another embodiment, the composition of the bond precursor material and the bond material of the finally-formed bonded abrasive body can be substantially or essentially the same. For example, a weight content difference between the content of a constituent may be at most 5% or at most 1% or less between the precursor bond material and bond material of the finally-formed bonded abrasive body.

In an embodiment, the process 100 may include pre-processing the bond precursor material before forming the mixture. An example of pre-processing may include milling, sieving, or any combination thereof. In a particular embodiment, the process 100 may include forming a precursor bond material having a particular average particle size (D50) that may facilitate improved manufacturing and formation of improved microstructures of the abrasive articles. In an exemplary process, the bond precursor material may be milled and/or sieved to have a particular average particle size. In a further embodiment, the bond precursor material may include an average particle size of at most 6 microns, such as at most 5.5 microns or at most 5 microns or at most 4.6 microns or at most 4.2 microns or at most 4 microns or at most 3.5 microns or at most 3.2 microns at most 3 microns or at most 2.6 microns or at most 2.3 microns or at most 2 microns or at most 1.7 microns or at most 1.3 microns or at most 1 micron. Additionally or alternatively, the average particle size of the bond precursor material may be at least 0.3 microns or at least 0.5 microns or at least 0.8 microns or at least 1 micron or at least 1.3 microns or at least 1.5 microns or at least 1.8 microns or at least 2 microns or at least 2.3 microns. Moreover, the bond precursor material may have an average particle size including any of the minimum and maximum values noted herein.

The abrasive particles can include a material selected from the group of oxides, nitrides, carbides, borides, silicates, superabrasives, minerals, monocrystalline, polycrystalline, amorphous, or a combination thereof. For example, the abrasive particles can include alumina, such as microcrystalline alumina (e.g., sol-gel alumina) or nanocrystalline alumina or fused alumina or the like or any combination thereof, diamond, cBN, SiC, or any combination thereof. An example of fused alumina abrasive particles may include white alumina. In another embodiment, the abrasive particles may include unagglomerated abrasive particles, or in particular, the abrasive particles may consist essentially of unagglomerated abrasive particles.

According to further embodiment, the abrasive particles can have a certain average particle size (D50), which can facilitate improved formation and/or performance of the abrasive article. For instance, the abrasive particles can have an average particle size (D50) of at least 0.1 microns, such as at least 0.3 microns or at least 0.5 microns or at least 0.8 microns or at least 1 micron or at least 1.4 microns or at least 1.8 microns or at least 2 microns or at least 3 microns or at least 5 microns or at least 6 microns or at least 7 microns or at least 8 microns or at least 9 microns or at least 10 microns or at least 11 microns or at least 12 microns or at least 13 microns or at least 14 microns or at least 15 microns or at least 16 microns or at least 17 microns or at least 18 microns or at least 19 microns or at least 20 microns or at least 21 microns or at least 23 microns or at least 25 microns or at least 28 microns or at least 30 microns or at least 32 microns. Still, in another non-limiting embodiment, the abrasive particles can have an average particle size (D50) of at most 50 microns or at most 49 microns or at most 40 microns or at most 34 microns or at most 30 microns or at most 26 microns or at most 24 microns or at most 22 microns or at most 20 microns or at most 18 microns or at most 15 microns or at most 13 or at most 12 microns or at most 11 microns or at most 10 microns or at most 9 microns or at most 89 microns or microns or at most 7 microns or at most 6 microns or at most 5 microns or at most 4 microns or at most 3 microns or at most 2 microns. It will be appreciated that the abrasive particles can have an average particle size within a range including any of the minimum and maximum values noted above. For example, the average abrasive particle size may be in a range including at least 0.1 microns and at most 40 microns or in a range including at least 0.5 microns and at most 34 microns or in a range including at least 1 micron and at most 24 microns.

In an embodiment, the process 100 may include preparing a bond precursor materials such that a ratio of an average particle size of the abrasive particles, D50a, to an average particle size of the bond precursor material, D50b, may be greater than 1 or at least 1.1 or at least 1.2 or at least 1.4 or at least 1.6. Alternatively or additionally, the ratio of D50a/D50b, may be at most 7, such as at most 6.5 or at most 6.1 or at most 5.6 or at most 5.3 or at most 4.9 or at most 4.6 or at most 4.2 or at most 3.8 or at most 3.6 or at most 3.3. Moreover, the ratio of D50a/D50b, may be in a range including any of the minimum and maximum values noted herein.

The bond precursor material can have a particular melting temperature that may facilitate improved formation and performance of the abrasive article. In at least one embodiment, the bond precursor material can have a melting temperature that is at least 800° C., such as at least 825° C. or at least 850° C. or at least 875° C. or at least 900° C. Still, in one non-limiting embodiment the melting temperature of the bond precursor material can be at most 1050° C., such as most 1000° C. or at most 950° C. or at most 935° C. or at most 925° C. It will be appreciated that the melting temperature can be within a range including any of the minimum and maximum temperatures noted above. For instance, the melting temperature of the bond precursor material can be in a range including at least 850° C. and at most 1000° C. or in a range including at least 900° C. and at most 925° C.

In some applications, secondary particles, such as a filler material, secondary abrasive particle, or both can be added to the mixture including the bond precursor material and abrasive particles. The filler material can be distinct from the abrasive particles and may have a hardness less than a hardness of the abrasive particles. The filler material may provide improved mechanical properties and facilitate formation of the abrasive article. The filler material may also be distinct from compositions contained within bond precursor material. In at least one embodiment, the filler material can include various materials, such as fibers, woven materials, non-woven materials, particles, minerals, nuts, shells, oxides, alumina, carbide, nitrides, borides, organic materials, polymeric materials, naturally occurring materials, and a combination thereof. In particular instances, the filler material can include a material such as wollastonite, mullite, steel, iron, copper, brass, bronze, tin, aluminum, kyanite, alusite, garnet, quartz, fluoride, mica, nepheline syenite, sulfates (e.g., barium sulfate), carbonates (e.g., calcium carbonate), cryolite, glass, glass fibers, titanates (e.g., potassium titanate fibers), zircon, rock wool, clay, sepiolite, an iron sulfide (e.g., Fe₂S₃, FeS₂, or a combination thereof), fluorspar (CaF₂), potassium sulfate (K₂SO₄), graphite, potassium fluoroborate (KBF₄), potassium aluminum fluoride (KAlF₄), zinc sulfide (ZnS), zinc borate, borax, boric acid, fine alundum powders, P15A, bubbled alumina, cork, glass spheres, silver, Saran™ resin, paradichlorobenzene, oxalic acid, alkali halides, organic halides, and attapulgite.

In certain instances, the secondary particles can include secondary abrasive particle including a material such as an oxide, a carbide, a nitride, a boride, a carbon-based material (e.g., diamond), an oxycarbide, an oxynitride, an oxyboride, or any combination thereof. In certain instances, the secondary abrasive particle can be particularly hard, having for example, a Mohs hardness of at least 6, such as at least 6.5, at least 7, at least 8, at least 8.5, at least 9. According to one embodiment, the secondary abrasive particles can include a superabrasive material. The secondary abrasive particles can include a material selected from the group of silicon dioxide, silicon carbide, alumina, zirconia, flint, garnet, emery, rare earth oxides, rare earth-containing materials, cerium oxide, sol-gel derived particles, gypsum, iron oxide, glass-containing particles, and a combination thereof. In another instance, secondary abrasive particle may also include silicon carbide (e.g., Green 39C and Black 37C), brown fused alumina (57A), seeded gel abrasive, sintered alumina with additives, shaped and sintered aluminum oxide, pink alumina, ruby alumina (e.g., 25A and 86A), electrofused monocrystalline alumina 32A, MA88, alumina zirconia abrasives (NZ, NV, ZF), extruded bauxite, cubic boron nitride, diamond, abral (aluminum oxy-nitride), sintered alumina, extruded alumina (e.g., SR1, TG, and TGII), or any combination thereof. The secondary abrasive particles may be diluent grains, having a hardness less than the abrasive particles, but still harder than filler materials that may be present in the abrasive article. In still other instances, the secondary abrasive particles may include shaped abrasive particles, which unlike crushed grains, each of the shaped abrasive particles can have a precise and substantially similar shape relative to each other.

Formation of the mixture can include forming a dry or wet mixture. It may be suitable to create a wet mixture to facilitate suitable dispersion of the abrasive particles within the bond precursor material. Moreover, it will be appreciated that the mixture can include other materials, including for example additives, binders, and any other materials known in the art to facilitate formation of a mixture to create a green product prior to formation of the abrasive article. In at least one embodiment, the mixture can be essentially free of a pore former.

Referring again to FIG. 1, after forming the mixture, the process 100 can continue at block 102 forming the mixture into a green body. The process of forming the mixture into a green body can include pressing, molding, casting, cutting, printing, curing, depositing, drying, heating, cooling, or any combination thereof. In a particular embodiment, the green body may be essentially free of a pore former.

Referring again to FIG. 1, after forming the green body at step 102, the process can continue at step 103 by forming the green body into bonded abrasive body. In certain instances, the process of forming the green body and the process for forming the bonded abrasive body can be combined, such that the mixture is converted directly to the bonded abrasive body. Suitable processes for forming the bonded abrasive body can include pressing, molding, casting, cutting, printing, curing, depositing, drying, heating, cooling, or any combination thereof.

In accordance with an embodiment, the process can include applying a temperature to the mixture or the green body to form the bonded abrasive body. In an embodiment, heating can be conducted at a particular temperature that may facilitate improved wetting of the abrasive particles by the bond precursor material. For example, the temperature can be sufficient to at least partially melt the bond precursor material. In another embodiment, the temperature may be sufficient to form a vitreous bond material from the bond precursor material. In another embodiment, heating can be performed at a forming temperature of the bond material, such as at most 1100° C., such as at most 1050° C., at most 950° C., at most 925° C. or even at most 915° C. In another instance, heating can be performed at a temperature of at least 850° C., such as at least 875° C., at least 900° C., or at least 920° C. It will be appreciated that the forming temperature can be within a range including any of the minimum and maximum values noted above. In a particular example, the forming temperature can be at or above the melting temperature of the bond precursor material.

Heating can be conducted in a suitable atmosphere. In an embodiment, the mixture can be heated in a non-oxidizing atmosphere, such as a nitrogen-rich atmosphere, and more particularly, in an atmosphere that consists essentially of nitrogen. In another embodiment, a non-oxidizing atmosphere can include one or more noble gases. Still, in another embodiment, heating can be performed in an ambient atmosphere (i.e., air).

In an embodiment, the process 100 may optionally include shaping the bonded abrasive body to form finally-formed bonded abrasive body. For example, shaping may include cutting, profiling, grinding, polishing, or any combination thereof. In a particular embodiment, the bonded abrasive body may be cut into a plurality of smaller bonded abrasive bodies and formed into finally-formed bonded abrasive bodies. In an example, the smaller bonded abrasive bodies may be finished to have desired surface features, e.g., geometries, to form finally-formed bonded abrasive bodies. FIGS. 2A-2C includes illustrations of exemplary bonded abrasive bodies having certain surface features. The formed bonded abrasive bodies may also be treated with sulfur or wax. In another embodiment, the finally-formed bonded abrasive body may be incorporated to form a finally-formed abrasive article. For example, the bonded abrasive body can be attached to a substrate, such as a hub, to facilitate formation of a bonded abrasive wheel. It will be appreciated that the finally-formed bonded abrasive body may have any suitable size and shape as known in the art and can be incorporated into various types of abrasive articles to form a finally-formed abrasive article.

FIG. 2d includes an illustration of an exemplary abrasive article including the bonded abrasive body 200 that may have an elongated shape. The bonded abrasive body 200 may include a length (L), a width (W), and a thickness (t), where the thickness (t) is the shortest dimension. The body may have a first major surface 205, a second major surface 206 opposite the first major surface and separated by thickness t, and side surfaces 207 extending between the first major surface and the second major surface. An exemplary length may include at least 1 mm and at most 250 mm. An exemplary width may include at least 0.5 mm and at most 60 mm. An exemplary thickness may include at least 0.1 mm and at most 40 mm.

FIG. 3A includes a scanning electron microscopic image of the bonded abrasive body 300 of an abrasive article according to an embodiment. The bonded abrasive body 300 includes abrasive particles 302, bond material 306 in the form of bond posts joining the abrasive particles 302, and pores 308 extending between the bond material 306 and abrasive particles 302. According to an embodiment, the bond material 306 may extend 3-dimensionally throughout the body. FIG. 3B includes an SEM image of a portion of a bonded abrasive body 310 of an exemplary abrasive article. The dark spots correspond to the bond posts. As illustrated, the bonded abrasive body 310 includes bond posts 316.

In accordance with an embodiment, the bonded abrasive body may include a particular content of the bond material that may facilitate improved performance of the abrasive article. For example, the bonded abrasive body may include at least 1 vol % of bond material for a total volume of the body. In still other embodiments, the bonded abrasive body can include at least 2 vol % bond material, such as at least 3 vol % or at least 4 vol % or at least 5 vol % or at least 6 vol % or at least 7 vol % or at least 8 vol % or at least 8.5 vol % or at least 9 vol % or at least 10 vol % or at least 11 vol % or at least 12 vol % or at least 13 vol % or at least 13.5 vol % of the bond material for a total volume of the body. In yet another example, the body of the bonded abrasive can have at most 35 vol % bond material for the total volume of the body, such as at most 30 vol % or at most 28 vol % or at most 25 vol % or at most 23 vol % or at most 22 vol % or at most 20 vol % or at most 19 vol % or at most 18 vol % or at most 17 vol % or at most 16 vol % or at most 15 vol % or at most 14 vol % or at most 13.5 vol % or at most 13 vol % or at most 12 vol % or at most 11 vol % or at most 10 vol % or at most 9 vol % or at most 8 vol % or at most 7 vol % or at most 6 vol % or at most 5 vol % or at most 4 vol % or at most 3.5 vol % or at most 3 vol % or at most 2.5 vol % or at most 2 vol % of the bond material for a total volume of the body. It will be appreciated that the bonded abrasive body can have a bond material content within a range including any of the minimum and maximum percentages noted above. For example, the content of the bond material may be in a range including at least 1 vol % and at most 30 vol % or in a range including at least 2 vol % and at most 14 vol % for the total volume of the bonded abrasive body.

It is worth noting the bonded abrasive body of embodiments herein may have improved microstructure including average bond post count, average bond post size, ratios between bond post count and/or size to area % of the bond material, ratio between bond post count and a content of the bond material, ratio between bond post size to average particle size of abrasive particles, or a combination thereof. In a particular embodiment, the bonded abrasive body may include a higher bond post count, a smaller bond post size, or both compared to a similar conventional bonded abrasive body. A similar conventional abrasive body can have similar abrasive particle size and composition, i.e., the contents of the abrasive particles and the bond material and porosity compared to the bonded abrasive body of embodiments herein. A similar conventional abrasive body may be different in the composition of the bond material, bond microstructure, or both.

In an embodiment, the bonded abrasive body can include a particular average bond post count that can facilitate improved performance of the abrasive article. In another embodiment, when the bonded abrasive body includes the bond material in a range from at least 5 vol % to at most 6 vol % for the total volume of the body and the average particle size of abrasive particles is 1 to 5 microns, the bonded abrasive body may include an average bond post count of greater than 1150 or at least 1170 or at least 1210 or at least 1260 or at least 1290 or at least 1330 or at least 1370 or at least 1430 or at least 1500 or at least 1520 or at least 1580 or at least 1620 or at least 1655 or at least 1668 or at least 1688 or at least 1700 or at least 1728 or at least 1748 or at least 1765 or at least 1778 or at least 1788 or at least 1796 or at least 1802 per a surface area of 74565 μm². Additionally or alternatively, when the content of the bond material is from 5 vol % to 6 vol % for a total volume of the bonded abrasive body and the average particle size is at least 1 micron and at most 5 microns, the average bond post count may be at most 2700 or at most 2500 or at most 2250 or at most 2150 or at most 1960 or at most 1850 per a surface area of 74565 μm². Moreover, when the bonded abrasive body includes the bond material in a range from at least 5 vol % to at most 6 vol % for the total volume of the body and the average particle size of abrasive particles is at least 1 micron and at most 5 microns, the bonded abrasive body may include an average bond post count in a range including any of the minimum and maximum values noted herein.

As used herein, the average count of bond posts in the bonded abrasive body can be determined as follows. A cross section of a bonded abrasive body can be polished using a Buehler machine with Al₂O₃ aqueous solution followed by diamond paste. High-contrasting scanning electron microscope images of the entire cross section are taken under the magnification of 1000×. Images may be similar to what is illustrated in FIG. 3A. Hitachi™ 3030 Plus or another functionally equivalent microscope may be used to obtain the images. Usually at least 4 to 6 images like FIG. 3A are needed for the entire cross section. Silicon mapping may be performed on the high-contrasting images to illuminate the bond material utilizing Quantax 75 Energy Dispersive X-ray Spectrometer from Bruker or a functional equivalent following the manufacturer's instructions. Images demonstrating only the bond material (e.g., FIG. 3B) can be obtained by subsequent analysis with ImageJ (i.e., version of 1.51q, published on Sep. 18, 2017), provided by the National Institutes of Health, to determine the number of bond posts as well as the areas of the bond posts and area % of bond. All the images of the entire cross section are analyzed to establish statistical confidence of the count of the bond posts. Newer versions of ImageJ may be used as long as the following can be performed. A suitable example may include the version of 1.52e published on Jul. 11, 2018.

Analysis is performed in the 8-bit setting, and the threshold can be set such that the percentage of the highlighted areas is as close as possible (i.e., to the extent allowed by ImageJ) to the actual content (vol %) of the bond material in the body. When the percentage of the highlighted area is within ±20% of the vol % of the bond material, images similar to FIG. 3B can then be obtained and used for determining the count and size of bond posts. Referring to FIG. 3B, bond posts 316 are shown in black and abrasive particles and pores are not visible. The total count of bond posts as well as the area of the bond posts of all the analyzed cross-sectional images is used to determine the average count of bond posts per 74565 μm². For instance, if 4 images are analyzed and have N1, N2, N3, N4 bond posts per 74565 μm², respectively, the average count of the bond posts per 74565 μm² is N, wherein N=(N1+N2+N3+N4)/4. The average bond post size can be the total bond area divided by the total count of the bond posts over the cross section.

In another embodiment, when the content of the bond material is from 1 vol % to 4 vol % for a total volume of the bonded abrasive body and the average particle size is 1 to 5 microns, the bonded abrasive body may include an average bond post count of at least 680 or at least 730 or at least 780 or at least 870 or at least 910 or at least 950 or at least 980 or at least 1030 or at least 1060 or at least 1092 per 74565 μm². Additionally or alternatively, when the content of the bond material is from 1 vol % to 4 vol % and the average particle size is 1-5 microns, the average bond post count may be at most 1700 or at most 1600 or at most 1500 or at most 1380 or at most 1260 or at most 1160 or at most 1100. Moreover, when the body includes the bond material from 1 vol % to 4 vol % for a total volume of the bonded abrasive body and the average particle size is 1-5 microns, the body can include an average bond post count in a range including any of the minimum and maximum values noted herein.

In a further embodiment, when the body includes at least 7 vol % and at most 14 vol % of the bond material and the average particle size is 1 to 5 microns, the bonded abrasive body may include a bond post count of at least 1050 or at least 1170 or at least 1210 or at least 1260 or at least 1290 or at least 1330 or at least 1370 or at least 1430 or at least 1500 or at least 1520 or at least 1580 or at least 1620 or at least 1655 or at least 1668 or at least 1688 per 74565 μm². Alternatively or additionally, when the bond material is at least 7 vol % and at most 14 vol % and the average particle size is 1 to 5 microns, the average bond post count may be at most 2700 or at most 2500 or at most 2250 or at most 2160 or at most 2080 or at most 1850 or at most 1720. Moreover, when the bond material is at least 7 vol % and at most 14 vol % of the bond material and the average particle size is 1 to 5 microns, the average bond post count may be in a range including any of the minimum and maximum values noted herein.

In an embodiment, when the average particle size is 6 to 8 microns and the content of the bond material is at least 1 vol % and at most 6 vol %, the bonded abrasive body may include a bond post count of greater than 650 or at least 680 or at least 700 or at least 720 or at least 740 or at least 790 or at least 820 or at least 850 or at least 920 or at least 1040 or at least 1080 or at least 1150 or at least 1270 or at least 1325 per 74565 μm². Alternatively or additionally, when the bond material is at least 1 vol % and at most 6 vol % and the average particle size is 6 to 8 microns, the average bond post count may be at most 1900 or at most 1850 or at most 1780 or at most 1500 or at most 1350. Moreover, when the bond material is at least 1 vol % and at most 6 vol % and the average particle size is 6 to 8 microns, the average bond post count may be in a range including any of the minimum and maximum values noted herein.

In an embodiment, when the average particle size is 6 to 8 microns and the content of the bond material is at least 7 vol % and at most 14 vol %, the bonded abrasive body may include a bond post count of greater than 1350 or at least 1380 or at least 1410 or at least 1450 or at least 1490 or at least 1520 or at least 1560. Alternatively or additionally, when the average particle size is 6 to 8 microns and the content of the bond material is at least 7 vol % and at most 14 vol %, the bonded abrasive body may include a bond post count of at most 2500 or at most 2300 or at most 2050 or at most 1960 or at most 1780 or at most 1650 or at most 1580. Moreover, when the average particle size is 6 to 8 microns and the content of the bond material is at least 7 vol % and at most 14 vol %, the bonded abrasive body may include a bond post count in a range including any of the minimum and maximum values noted herein.

In an embodiment, when the average particle size is 9 to 25 microns and the content of the bond material is at least 1 vol % and at most 6 vol %, the bonded abrasive body may include a bond post count of at least 610 or at least 650 or at least 690 or at least 720 or at least 740 or at least 790 or at least 819 per 74565 μm². Alternatively or additionally, when the bond material is at least 1 vol % and at most 6 vol % and the average particle size is 9 to 25 microns, the average bond post count may be at most 1560 or at most 1380 or at most 1250 or at most 1100 or at most 950 or at most 890. Moreover, when the bond material is at least 1 vol % and at most 6 vol % and the average particle size is 9 to 25 microns, the average bond post count may be in a range including any of the minimum and maximum values noted herein.

In an embodiment, when the average particle size is 9 to 25 microns and the content of the bond material is at least 7 vol % and at most 14 vol %, the bonded abrasive body may include a bond post count of at least 1180 or at least 1200 or at least 1225 or at least 1250 or at least 1289. Alternatively or additionally, when the bond material is at least 7 vol % and at most 14 vol % and the average particle size is 9 to 25 microns, the average bond post count may be at most 1960 or at most 1750 or at most 1540 or at most 1350. Moreover, when the bond material is at least 7 vol % and at most 14 vol % and the average particle size is 9 to 25 microns, the average bond post count may be in a range including any of the minimum and maximum values noted herein.

In a further embodiment, the bonded abrasive body may include a particular average size of bond posts that may facilitate improved properties and/or performance and formation of the abrasive articles. In an embodiment, when the average particle size of abrasive particles is 1 to 5 microns and the content of the bond material is from 7 vol % to 14 vol %, the average bond post size may be less than 4.8 μm², such as at most 4.7 μm² or at most 4.6 μm² or at most 4.5 μm² or at most 4.3 μm² or at most 4.1 μm² or at most 4.0 μm². Additionally or alternatively, the average bond post size may be at least 3.1 μm² or at least 3.3 μm² or least 3.5 μm² or at least 3.7 μm² or least 3.9 μm² when the average particle size of abrasive particles is at least 1 micron and at most 5 microns and the content of the bond material is from 7 vol % to 14 vol %. Moreover, when the average particle size of abrasive particles is 1 to 5 microns and the content of the bond material is from 7 vol % to 14 vol %, the average bond post size may be in a range including any of the minimum and maximum values noted herein.

In a further embodiment, when the average particle size of abrasive particles is at least 1 micron and at most 5 microns and the content of the bond material is from 5 vol % to 6 vol %, the average bond post size may be at most 3.1 μm² or at most 2.85 μm² or at most 2.68 μm² or at most 2.55 μm². Additionally or alternatively, the average bond post size may be at least 2.10 μm² or at least 2.25 μm² or least 2.50 μm² when the average particle size of abrasive particles is at least 1 micron and at most 5 microns and the content of the bond material is from 5 vol % to 6 vol %. Moreover, when the average particle size of abrasive particles is 1-5 microns and the content of the bond material is from 5 vol % to 6 vol %, the bonded abrasive body may include an average bond post size in a range including any of the minimum and maximum values noted herein.

In a further embodiment, when the average particle size of abrasive particles is at least 1 micron and at most 5 microns and the content of the bond material is at least 1 vol % and at most 4 vol %, the average bond post size may be at most 2.42 μm² or at most 2.325 μm² or at most 2.15 μm² or at most 2.00 μm². Additionally or alternatively, when the average particle size of abrasive particles is at least 1 microns and at most 5 microns and the content of the bond material is at least 1 vol % and at most 4 vol %, the average bond post size may be at least 1.50 μm² or at least 1.60 μm² or at least 1.70 μm² at least 1.80 μm² or at least 1.90 μm². Moreover, when the average particle size of abrasive particles is at least 1 to 5 microns and the content of the bond material is at least 1 vol % and at most 4 vol %, the bonded abrasive body may include an average bond post size in a range including any of the minimum and maximum values noted herein.

In a further embodiment, when the average particle size of abrasive particles is 9-25 microns and the content of the bond material is from 1 vol % to 6 vol %, the bonded abrasive body may include an average bond post size of at most 3.6 μm² or at most 3.3 μm² or at most 3.1 μm² or at most 2.9 μm² or at most 2.8 μm². Additionally or alternatively, the average bond post size may be at least 2.1 μm² or at least 2.3 μm² or at least 2.5 μm² or at least 2.7 μm². Moreover, when the average particle size of abrasive particles is 9 to 25 microns and the content of the bond material is at least 1 vol % and at most 6 vol %, the bonded abrasive body may include an average bond post size in a range including any of the minimum and maximum values noted herein.

In a further embodiment, when the average particle size of abrasive particles is 9-25 microns and the content of the bond material is from 7 vol % to 14 vol %, an average bond post size may be at most 5.9 μm² or at most 5.7 μm² or at most 5.4 μm² or at most 5.2 μm². Additionally or alternatively, the average bond post size may be at least 4.2 μm² or at least 4.5 μm² or least 4.7 μm² or at least 4.8 μm² or at least 4.9 μm² or least 5.1 μm². Moreover, when the content of the bond material is 7 to 14 vol % and the average particle size of abrasive particles is 9-25 microns, the bonded abrasive body may include an average bond post size in a range including any of the minimum and maximum values noted herein.

In a further embodiment, when the body includes at least 7 vol % and at most 14 vol % of the bond material and the average particle size is 6 to 8 microns, an average bond post size may be at most 3.5 μm² or at most 3.4 μm² or at most 3.3 μm². Additionally or alternatively, when the body includes at least 7 vol % and at most 14 vol % of the bond material and the average particle size is 6 to 8 microns, the average bond post size may be at least 2.9 μm² or at least 3.0 μm² or least 3.1 μm² or at least 3.2 μm². Moreover, when the content of the bond material is at least 7 vol % and at most 14 vol % of the bond material and the average particle size is 6 to 8 microns, the average bond post size may be in a range including any of the minimum and maximum values noted herein.

In a further embodiment, when the body includes at least 1 vol % and at most 6 vol % of the bond material and the average particle size is 6 to 8 microns, an average bond post size may be at most 2.8 μm² or at most 2.6 μm² or at most 2.4 μm² or at most 2.2 μm². Additionally or alternatively, when the body includes at least 1 vol % and at most 6 vol % of the bond material and the average particle size is 6 to 8 microns, the average bond post size may be at least 1.6 μm² or at least 1.7 μm² or least 1.9 μm² or at least 2.1 μm². Moreover, when the content of the bond material is at least 1 vol % and at most 6 vol % of the bond material and the average particle size is 6 to 8 microns, the average bond post size may be in a range including any of the minimum and maximum values noted herein.

In a further embodiment, the bonded abrasive body may include a particular ratio of the average bond post count to the content (vol %) of the bond material that may facilitate improved performance and/or manufacturing of the abrasive article. In an embodiment, when the average particle size of abrasive particles is at least 1 micron and at most 5 microns and the bond material is in a content of at least 1 vol % and at most 6 vol % for a total volume of the bonded abrasive body, the bonded abrasive body may include a particular ratio, R_c/ba, of the average bond post count (C_bp) to the vol % of the bond material (P_ba). For example, the ratio, R_c/ba, may be greater than 200 or at least 210 or at least 235 or at least 250 or at least 265 or at least 280 or at least 290 or at least 300 or at least 305 or at least 315. Alternatively or additionally, the ratio may be at most 420 or at most 405 or at most 380 or at most 370 or at most 355 or at most 335 or at most 315. Moreover, the body can include the ratio R_c/ba in a range including any of the minimum and maximum values noted herein. The ratio, R_c/ba, may be determined using the formula, R_c/ba=(C_bp/P_ba)×100, wherein C_bp is the average bond post count and P_ba is the bond content (vol %).

In a further embodiment, when the average particle size of abrasive particles is 1 to 5 microns and the bond material is in a content of at least 7 vol % and at most 14 vol % for a total volume of the bonded abrasive body, the bonded abrasive body may include a particular ratio, R_c/ba, of the average bond post count to vol % of the bond material. For example, the ratio, R_c/ba, may be greater than 158 or at least 160 or at least 165 or at least 170 or at least 174. Alternatively or additionally, when the average particle size of abrasive particles is 1 to 5 microns and the bond material is in a content of at least 7 vol % and at most 14 vol % for a total volume of the bonded abrasive body, the ratio, R_c/ba, may be at most 250 or at most 240 or at most 220 or at most 210 or at most 185 or at most 175. Moreover, the body can include the ratio R_c/ba in a range including any of the minimum and maximum values noted herein.

In a further embodiment, when the average particle size of abrasive particles is 6 to 8 microns and the content of the bond material is 1 to 6 vol % for the total volume of the body, the bonded abrasive body may include a particular ratio, R_c/ba, of the average bond post count to vol % of the bond material. For example, the ratio, R_c/ba, may be greater than 200 or at least 210 or at least 225 or at least 235 or at least 240 or at least 265 or at least 280 or at least 300 or at least 315 or at least 330 or at least 350. Alternatively or additionally, when the average particle size of abrasive particles is 6 to 8 microns and the content of the bond material is 1 to 6 vol % for the total volume of the body, the ratio, R_c/ba, may be at most 450 or at most 420 or at most 390 or at most 380 or at most 360 or at most 335 or at most 315. Moreover, the body can include the ratio R_c/ba in a range including any of the minimum and maximum values noted herein.

In a further embodiment, when the average particle size of abrasive particles is 6 to 8 microns and the content of the bond material is 7 to 14 vol % for the total volume of the body, the bonded abrasive body may include a ratio, R_c/ba, of the average bond post count to vol % of the bond material of greater than 150 or at least 155 or at least 160 or at least 165 or at least 171. Alternatively or additionally, when the average particle size of abrasive particles is 6 to 8 microns and the content of the bond material is 7 to 14 vol % for the total volume of the body, the ratio, R_c/ba, may be at most 250 or at most 220 or at most 190 or at most 180 or at most 175. Moreover, the body can include the ratio R_c/ba in a range including any of the minimum and maximum values noted herein.

In a further embodiment, when the average particle size of abrasive particles is 9 to 25 microns and the content of the bond material is 1 to 6 vol % for the total volume of the body, the bonded abrasive body may include a particular ratio, R_c/ba, of the average bond post count to vol % of the bond material. For example, the ratio, R_c/ba, may be at least 180 or at least 190 or at least 210 or at least 215 or at least 220 or at least 225 or at least 230. Alternatively or additionally, when the average particle size of abrasive particles is 9 to 25 microns and the content of the bond material is 1 to 6 vol % for the total volume of the body, the ratio, R_c/ba, may be at most 310 or at most 290 or at most 260 or at most 240. Moreover, the body can include the ratio R_c/ba in a range including any of the minimum and maximum values noted herein.

In a further embodiment, when the average particle size of abrasive particles is 9 to 25 microns and the content of the bond material is 7 to 14 vol % for the total volume of the body, the bonded abrasive body may include a particular ratio, R_c/ba, of the average bond post count to vol % of the bond material. For example, the ratio, R_c/ba, may be greater than 125 or at least 130 or at least 133. Alternatively or additionally, when the average particle size of abrasive particles is 9 to 25 microns and the content of the bond material is 7 to 14 vol % for the total volume of the body, the ratio, R_c/ba, may be at most 180 or at most 165 or at most 145 or at most 139. Moreover, the body can include the ratio R_c/ba in a range including any of the minimum and maximum values noted herein.

The bond material of the abrasive article may have a particular bond chemistry that may facilitate improved manufacturing and performance of the abrasive article. For example, the bond material can be a vitreous material including oxides, such as alumina (Al₂O₃), an alkali metal oxide, an alkaline earth metal oxide, boron oxide, silicon oxide, or any combination thereof. In one embodiment, the bond material can be essentially free of zircon (ZrSiO₄), zirconium oxide (ZrO₂), hafnium oxide (HfO₂), or any combination thereof. In another embodiment, the bond material can have an amorphous phase. In one particular embodiment, the bond material can be essentially free of a crystalline phase. In another particular embodiment, the bond material can consist essentially of a vitreous material. As used herein, the term, essentially free of, when used in reference to a component of the body or a component of the bond material, such as a compound, is intended to mean the component is present in a content of less than 1 wt %, and may be less than 0.1 wt % for the total weight of the body or the bond material.

In accordance with an embodiment, the bond material can include alumina (Al₂O₃). The alumina can be present in a certain content that can facilitate improved formation and performance of the abrasive article. For instance, the content of alumina (Al₂O₃) can be at least 21 wt % for a total weight of the bond material, such as at least 23 wt % of for the total weight of the bond material, at least 25 wt %, or at least 28 wt % or at least 30 wt % or at least 33 wt % or at least 36 wt % or at least 38 wt % or at least 40 wt % or at least 42 wt % or at least 45 wt % for a total weight of the bond material. In another instance, the bond material can include alumina (Al₂O₃) of at most 64 wt % for a total weight of the bond material, such as at most 62 wt % or at most 59 wt % or at most 57 wt % or at most 55 wt % or at most 52 wt % or at most 50 wt % or at most 48 wt % or at most 46 wt % or at most 43 wt % for a total weight of the bond material. Moreover, the content of the alumina (Al₂O₃) can be within a range including any of the minimum and maximum values disclosed herein. For instance, the bond material can include alumina (Al₂O₃) in a range from at least 21 wt % to at most 64 wt %, or in a range from at least 30 wt % to at most 52 wt %.

According to an embodiment, the bond material can include a particular total content of alkali metal oxide that can facilitate improved formation and performance of the abrasive article. In another embodiment, the body may include lithium oxide (Li₂O), potassium oxide (K₂O), sodium oxide (Na₂O), or any combination thereof.

According to an embodiment, the bond material can include the total content of an alkali metal oxide of at least 5.5 wt % for the total weight of the bond material, such as at least 6 wt % or at least 6.5 wt % or at least 7.2 wt % or at least 7.8 wt % or at least 8.0 wt % or at least 8.4 wt % or at least 8.8 wt % or at least 9.1 wt % or at least 9.5 wt % or at least 9.8 wt % or at least 10.0 wt % or at least 10.5 wt % or at least 10.8 wt % or at least 11.0 wt % or at least 11.4 wt % or at least 12.8 wt % or at least 13.6 wt % or at least 14.0 wt % for the total weight of the bond material. Alternatively or additionally, the total content of an alkali metal oxide can be at most 22.0 wt % for the total weight of the bond material, such as at most 20.0 wt % or at most 19.3 wt % or at most 18.8 wt % or at most 18.4 wt % or at most 18.1 wt % or at most 17.8 wt % or at most 17.3 wt % or at most 16.9 wt % or at most 16.3 wt % or at most 16.0 wt % or at most 15.7 wt % or at most 15.3 wt % or at most 15.1 wt % or at most 14.8 wt % or at most 14.4 wt % or at most 14.0 wt % or at most 13.5 wt % or at most 13.1 wt % or at most 12.8 wt % or at most 12.4 wt % or at most 11.8 wt % for the total weight of the bond material. Moreover, the total content of alkali metal oxide can be within a range including any of the minimum and maximum values disclosed herein. For instance, the bond material can include the total content of alkali metal oxide in a range from at least 5.0 wt % to at most 22.0 wt %.

In accordance with another embodiment, the bonded abrasive body can include a particular ratio of a content of alumina relative to a total content of alkali metal oxides, such that the bond material includes a ratio (Al₂O₃/A₂O) based on weight percent. Such a ratio may facilitate improved formation and performance of the abrasive article. In one embodiment, the ratio (Al₂O₃/A₂O) can be at most 5.7 or at most 5.5 or at most 5.4 or at most 5.2 or at most 5.0 or at most 4.9 or at most 4.8 or at most 4.7 or at most 4.6 or at most 4.5 or at most 4.4 or at most 4.3 or at most 4.2. In another embodiment, the ratio (Al₂O₃/A₂O) can be at least 1.3 or at least 1.5 or at least 1.7 or at least 1.9 or at least 2.1 or at least 2.3 or at least 2.5 or at least 2.8 or at least 2.9 or at least 3.0 or at least 3.2 or at least 3.4 or at least 3.5 or at least 3.7 or at least 3.8 or at least 3.9 or at least 4.0 or at least 4.1 or at least 4.3. Moreover, the ratio (Al₂O₃/A₂O) can be in a range including any of the minimum and maximum values noted herein.

According to an embodiment, the bond material can include sodium oxide (Na₂O). In another embodiment, sodium oxide (Na₂O) can be present in a particular content that can facilitate improved formation and performance of the abrasive article. For example, the content of sodium oxide (Na₂O) can be at least 3.3 wt % for the total weight of the bond material, such as at least 3.6 wt % or at least 4.0 wt % or at least 4.3 wt % or at least 4.7 wt % or at least 5.0 wt % or at least 5.3 wt % or at least 5.6 wt % or at least 5.9 wt % or at least 6.3 wt % or at least 6.5 wt % or at least 6.7 wt % or at least 7.0 wt % or at least 7.3 wt % or at least 7.8 wt % or at least 8.3 wt % for the total weight of the bond material. In another instance, the content of sodium oxide (Na₂O) may be at most 16.0 wt % for the total weight of the bond material, such as at most 14.6 wt % or at most 11.5 wt % or at most 10.7 wt % or at most 10.4 wt % or at most 10.1 wt % or at most 9.8 wt % or at most 9.5 wt % or at most 9.2 wt % or at most 8.8 wt % or at most 8.5 wt % or at most 8.3 wt % or at most 8.1 wt % or at most 7.8 wt % or at most 7.7 wt % or at most 7.4 wt % or at most 7.1 wt % for the total weight of the bond material. Moreover, the content of sodium oxide (Na₂O) can be within a range including any of the minimum and maximum values disclosed herein. For instance, the bond material can include sodium oxide (Na₂O) in a range from at least 3.3 wt % to at most 14.6 wt %.

In accordance with another embodiment, the bonded abrasive body can include a particular ratio of a content of alumina relative to a content of sodium oxide, such that the bond material includes a ratio (Al₂O₃/Na₂O) based on weight percent. Such a ratio may facilitate improved formation and performance of the abrasive article. In one embodiment, the ratio (Al₂O₃/Na₂O) can be at most 7.7 or at most 7.5 or at most 7.4 or at most 7.2 or at most 7.0 or at most 6.9 or at most 6.8 or at most 6.7 or at most 6.6 or at most 6.5 or at most 6.4 or at most 6.3 or at most 6.2 or at most 5.8 or at most 5.5 or at most 5.1 or at most 4.7 or at most 4.3 or at most 3.8. In another embodiment, the ratio (Al₂O₃/Na₂O) can be at least 3.3 or at least 3.6 or at least 3.8 or at least 4.1 or at least 4.4 or at least 4.7 or at least 4.9 or at least 5.0 or at least 5.2 or at least 5.3 or at least 5.5 or at least 5.7 or at least 5.9 or at least 6.1. Moreover, the ratio (Al₂O₃/Na₂O) can be in a range including any of the minimum and maximum values noted herein.

According to an embodiment, the bond material can include lithium oxide (Li₂O). The lithium oxide (Li₂O) can be present in a certain content that can facilitate improved formation and performance of the abrasive article. For instance, the content of lithium oxide (Li₂O) can be at most at most 5.4 wt % for the total weight of the bond material or at most 5.1 wt % or at most 4.6 wt % or at most 4.2 wt % or at most 3.8 wt % or at most 3.6 wt % or at most 3.3 wt % or at most 2.9 wt % or at most 2.7 wt % or at most 2.4 wt % or at most 2.1 wt % or at most 1.8 wt % or at most 1.5 wt % for a total weight of the bond material. Alternatively or additionally, the content of lithium oxide (Li₂O) of at least 0.3 wt % for the total weight of the bond material or at least 0.6 wt % for the total weight of the bond material or at least 0.8 wt % or at least 1.0 wt % or at least 1.3 wt % or at least 1.5 wt % or at least 1.7 wt % or at least 2.1 wt % or at least 2.5 wt % or at least 2.7 wt % or at least 2.9 wt % or at least 3.1 wt % for a total weight of the bond material. Moreover, the content of lithium oxide (Li₂O) can be within a range including any of the minimum and maximum values disclosed herein. For instance, the bond material can include lithium oxide (Li₂O) in a range from at least 0.3 wt % to at most 5.4 wt %.

In accordance with another embodiment, the bonded abrasive body can include a particular ratio of a content of alumina relative to the content of lithium oxide, such that the bond material includes a ratio (Al₂O₃/Li₂O) based on weight percent. Such a ratio may facilitate improved formation and performance of the abrasive article. In one embodiment, the ratio (Al₂O₃/Li₂O) can be at most 38 or at most 36 or at most 35 or at most 33 or at most 31 or at most 29 or at most 28 or at most 27 or at most 26 or at most 25. In another embodiment, the ratio (Al₂O₃/Li₂O) can be at least 6 or at least 7 or at least 9 or at least 10 or at least 11 or at least 13 or at least 16 or at least 17 or at least 19 or at least 20 or at least 21 or at least 22 or at least 23 or at least 24 or at least 25 or at least 26. Moreover, the ratio (Al₂O₃/Li₂O) can be in a range including any of the minimum and maximum values noted herein. For instance, the ratio (Al₂O₃/Li₂O) can be in a range from at least 6 to at most 38 or in a range from at least 8 to at most 33 or in a range from at least 10 to at most 26.

In accordance with an embodiment, the bond material can include a certain content of boron oxide (B₂O₃) that may facilitate formation of the abrasive article and improve performance. For example, the bond material may include at least 3 wt % of boron oxide (B₂O₃), such as at least 5 wt % or at least 6 wt % or at least 7 wt % or at least 8 wt % or at least 9 wt % or at least 10 wt % or at least 11 wt % or at least 13 wt % for a total weight of the bond material. Still, in at least one non-limiting embodiment, the bond material may include at most 23 wt % boron oxide (B₂O₃) for a total weight of the bond material, such as at most 20 wt % or at most 18 wt % or at most 17 wt % or at most 16 wt % or at most 15 wt % or at most 14 wt % or at most 13 wt % or at most 12 wt % or at most 11 wt % or at most 10 wt % for a total weight of the bond material. It will be appreciated that the bond material can include a content of boron oxide within range including any of the minimum and maximum percentages noted above.

According to another embodiment, the bond material may include a certain ratio of a content of alumina relative to the content of boron oxide, such that the bond material includes a ratio (Al₂O₃/B₂O₃) based on weight percent. Such a ratio may facilitate improved formation and/or performance of the abrasive article. In an embodiment, the ratio (Al₂O₃/B₂O₃) can be greater than 1.0 or at least 1.3 or at least 1.5 or at least 1.8 or at least 2.0 or at least 2.2 or at least 2.4 or at least 2.6 or at least 2.8 or at least 2.9 or at least 3.0 or at least 3.2 or at least 3.4 or at least 3.5 or at least 3.7 or at least 3.8 or at least 3.9 or at least 4.0 or at least 4.1. In another embodiment, the ratio (Al₂O₃/B₂O₃) can be at most 5.7 or at most 5.5 or at most 5.4 or at most 5.2 or at most 5.0 or at most 4.9 or at most 4.8 or at most 4.7 or at most 4.6 or at most 4.5 or at most 4.4 or at most 4.3 or at most 4.2. Moreover, the ratio (Al₂O₃/B₂O₃) can be in a range including any of the minimum and maximum values noted herein. For instance, the ratio (Al₂O₃/B₂O₃) can be in a range at least 1.5 to at most 5.7.

In accordance with an embodiment, the bond material can include a certain content of silicon dioxide (SiO₂) that may facilitate formation of the abrasive article and improve performance. For example, the bond material may include at least 18 wt % silicon dioxide (SiO₂) for the total weight of the bond material, such as at least 20 wt % or at least 22 wt % or at least 24 wt % or at least 25 wt % or at least 27 wt % or at least 29 wt % or at least 30 wt % or at least 31 wt % or at least 32 wt % or at least 34 wt % or at least 37 wt % for the total weight of the bond material. Still, in at least one non-limiting embodiment, the bond material may include at most 57 wt % silicon dioxide (SiO₂) for a total weight of the bond material, such as at most 55 wt % or at most 52 wt % or at most 50 wt % or at most 47 wt % or at most 44 wt % or at most 41 wt % or at most 39 wt % or at most 37 wt % or at most 36 wt % or at most 34 wt % or at most 32 wt % for a total weight of the bond material. It will be appreciated that the bond material can include a content of silicon dioxide within range including any of the minimum and maximum percentages noted above.

In still another embodiment, the bond material may include a certain ratio of a content of alumina relative to the content of silicon dioxide, such that the bond material comprises a ratio a ratio (Al₂O₃/SiO₂), based on weight percent. Such a ratio may facilitate improved formation and/or performance of the abrasive article. In an embodiment, the ratio (Al₂O₃/SiO₂) can be at least 0.6 or at least 0.8 or at least 0.9 or at least 1.0 or at least 1.1 or at least 1.2 or at least 1.3 or at least 1.4 or at least 1.5. In a particular example, the ratio (Al₂O₃/SiO₂) may be greater than 1. In another embodiment, the ratio (Al₂O₃/SiO₂) can be at most 2.5 or at most 2.4 or at most 2.3 or at most 2.2 or at most 2.1 or at most 2.0 or at most 1.9 or at most 1.8 or at most 1.7 or at most 1.5 or at most 1.4. Moreover, the ratio (Al₂O₃/SiO₂) can be in a range including any of the minimum and maximum values noted herein. For instance, the ratio (Al₂O₃/SiO₂) can be in a range at least 0.6 to at most 2.5 or in a range at least 0.8 to at most 2.1.

In another embodiment, the bond material may include a certain ratio of a content of silicon dioxide relative to the content of boron oxide, such that the bond material comprises a ratio (SiO₂/B₂O₃), based on weight percent. Such a ratio may facilitate improved formation and/or performance of the abrasive article. In an embodiment the ratio (SiO₂/B₂O₃) can be at most 4.3 or at most 4.1 or at most 3.9 or at most 3.7 or at most 3.5 or at most 3.3 or at most 3.2. Still, in one non-limiting embodiment, the ratio (SiO₂/B₂O₃) can be at least at least 1.5 or at least 1.8 or at least 2.0 or at least 2.2 or at least 2.4 or at least 2.5 or at least 2.6 or at least 2.8 or at least 2.9 or at least 3.0 or at least 3.1. It will be appreciated that the ratio (SiO₂/B₂O₃) can be within range including any of the minimum and maximum values noted above.

According to another aspect, the bond material can include a particular total content of silicon dioxide (SiO₂) and boron oxide (B₂O₃) that may facilitate improved formation and/or performance of the abrasive article. For example, the total content of silicon dioxide (SiO₂) and boron oxide (B₂O₃) may be at least 25 wt % for a total weight of the bond material, such as at least 28 wt % or at least 30 wt % or at least 32 wt % or at least 35 wt % or at least 36 wt % or at least 38 wt % or at least 40 wt % or at least 42 wt % or at least 45 wt % or at least 48 wt % or at least 50 wt %. In another example, the bond material can include the total content of silicon dioxide (SiO₂) and boron oxide (B₂O₃) of at most 66 wt % for a total weight of the bond material, such as at most 63 wt % or at most 59 wt % or at most 56 wt % or at most 53 wt % or at most 52 wt % or at most 50 wt % or at most 48 wt % or at most 46 wt % or at most 45 wt % or at most 43 wt % or at most 42 wt % for the total weight of the bond material. It will be appreciated that the bond material can include a total content of silicon dioxide (SiO₂) and boron oxide (B₂O₃) within range including any of the minimum and maximum percentages noted above.

In accordance with another embodiment, the bonded abrasive body can include a particular ratio of a content of alumina relative to the total content of silica dioxide and boron oxide (Al₂O₃/(SiO₂+B₂O₃)), such that the bond material includes a ratio Al₂O₃/(SiO₂+B₂O₃)) based on weight percent. Such a ratio may facilitate improved formation and performance of the abrasive article. In an embodiment, the ratio (Al₂O₃/(SiO₂+B₂O₃)) may be at least 0.4 or at least 0.5 or at least 0.6 or at least 0.7 or at least 0.8 or at least 0.9 or at least 1.0 or at least 1.1. In a particular example, the content of alumina may not be less than the total content of silica dioxide and boron oxide. In another embodiment, the ratio (Al₂O₃/(SiO₂+B₂O₃)) may be at most 1.7 or at most 1.5 or at most 1.4 at most 1.3 or 1.2 or at most 1.1 or at most 1.0 or at most 0.9. Moreover, the ratio (Al₂O₃/(SiO₂+B₂O₃)) can be in a range including any of the minimum and maximum values noted herein. For instance, the ratio (Al₂O₃/(SiO₂+B₂O₃)) can be in a range from at least 0.5 to at most 1.7 or in a range from at least 0.6 to at most 1.5.

According to another aspect, the bond material can include a particular content of potassium oxide (K₂O), which may facilitate suitable formation and performance of the abrasive article. For example, the bond material can include at least 0.3 wt % potassium oxide (K₂O) for a total weight of the bond material or at least 0.5 wt % or at least 0.7 wt % or at least 0.8 wt % or at least 1.0 wt % or at least 1.1 wt % or at least 1.2 wt % or at least 1.3 wt % or at least 1.4 wt % or at least 1.7 wt % or at least 1.9 wt % or at least 2.1 wt % or at least 2.3 wt % or at least 2.5 wt % for a total weight of the bond material. In another non-limiting embodiment, the bond material can include at most 5.2 wt % potassium oxide (K₂O) for a total weight of the bond material or at most 4.9 wt % or at most 4.6 wt % or at most 4.2 wt % or at most 3.8 wt % or at most 3.6 wt % or at most 3.3 wt % or at most 2.9 wt % or at most 2.7 wt % or at most 2.6 wt % for a total weight of the bond material. It will be appreciated that the bond material can include a content of potassium oxide within range including any of the minimum and maximum percentages noted above.

In accordance with another embodiment, the bonded abrasive body can include a particular ratio of a content of alumina relative to the content of potassium oxide, such that the bond material includes a ratio (Al₂O₃/K₂O) based on weight percent. Such a ratio may facilitate improved formation and performance of the abrasive article. In one embodiment, the ratio (Al₂O₃/K₂O) can be at most 49 or at most 46 or at most 45 or at most 43 or at most 40 or at most 39 or at most 38 or at most 36 or at most 35 or at most 34 or at most 33 or at most 32 or at most 29 or at most 26 or at most 22 or at most 19 or at most 16 or at most 13. In another embodiment, the ratio (Al₂O₃/K₂O) can be at least 6 or at least 8 or at least 10 or at least 12 or at least 19 or at least 20 or at least 21 or at least 22 or at least 23 or at least 24 or at least 25 or at least 26 or at least 27 or at least 29 or at least 30 or at least 31 or at least 33. Moreover, the ratio (Al₂O₃/K₂O) can be in a range including any of the minimum and maximum values noted herein. For instance, the ratio (Al₂O₃/K₂O) can be in a range from at least 8 to at most 38 or in a range from at least 10 to at most 49 or in a range from at least 12 to at most 39.

In accordance with another embodiment, the bonded abrasive body can include a total content of alkaline earth oxide. For example, the bonded abrasive body may include CaO, MgO, SrO, BaO, or any combination thereof. In another embodiment, the bonded abrasive body may be essentially free of one or more of alkaline earth metal oxides including CaO, MgO, SrO, and BaO. In a further embodiment, the bonded abrasive body can include a total content of alkaline earth metal oxide of at most 5 wt % for a total weight of the bond material, such as at most 4 wt % or at most 3 wt % or at most 2 wt %. In another embodiment, the total content of alkaline earth oxide may be at least 0.5 wt % or at least 0.8 wt % or at least 1 wt % or at least 1.3 wt % or at least 1.6 wt % or at least 1.9 wt % for the total weight of the bond material. Moreover, the total content of the alkaline earth metal oxide may be in a range including any of the minimum and maximum percentages noted herein. In another embodiment, the bond material may include at most 2 wt % or at most 1 wt % of CaO, MgO, SrO, or BaO.

In another embodiment, the bond material may include a particular ratio of a total content of an alkali metal oxide to a total content of an alkaline earth metal oxide that may facilitate improved formation of the abrasive article. In an example, the ratio may be greater than 1, at least 2, at least 3, at least 5, at least 6, at least 7, at least 8, at least 9, or at least 10. In another example the ratio of the total content of the alkali metal oxide to the total content of the alkaline earth metal oxide is at most 25, at most 23, at most 20, at most 18, at most 17, at most 15, at most 13, or at most 11. Moreover, the ratio of the total content of an alkali metal oxide to the total content of an alkaline earth metal oxide may be in a range including any of the minimum and maximum values noted herein.

In another embodiment, the bond material can include a content of certain components that facilitates suitable formation and/or performance of the abrasive article. Such components can include manganese dioxide (MnO₂), magnesium oxide (MgO), calcium oxide (CaO), iron oxide (Fe₂O₃), titanium dioxide (TiO₂), barium oxide (BaO), zinc oxide (ZnO), phosphorous oxide (P₂O₅), zirconium oxide (ZrO₂), or any combination thereof. For example, in one instance, the bond material can include at most 2.0 wt % for the total weight of the bond of any one of manganese dioxide (MnO₂), magnesium oxide (MgO), calcium oxide (CaO), iron oxide (Fe₂O₃), titanium dioxide (TiO₂), barium oxide (BaO), phosphorous oxide (P₂O₅), zirconium oxide (ZrO₂), or zinc oxide (ZnO). In another embodiment, the bond material can include at most 1 wt % or even not greater than 0.5 wt % of manganese dioxide (MnO₂), magnesium oxide (MgO), calcium oxide (CaO), iron oxide (Fe₂O₃), phosphorous oxide (P₂O₅), barium oxide (BaO), zinc oxide (ZnO), zirconium oxide (ZrO₂), or titanium dioxide (TiO₂). In one embodiment, the bond material can be essentially free of any one of or combination of manganese dioxide (MnO₂), magnesium oxide (MgO), calcium oxide (CaO), barium oxide (BaO), zinc oxide (ZnO), iron oxide (Fe₂O₃), phosphorous oxide (P₂O₅), zirconium oxide (ZrO₂), or titanium dioxide (TiO₂).

In accordance with another embodiment, the bonded abrasive body may have a certain content of porosity and type of porosity that may facilitate improved performance of the abrasive article. In accordance with an embodiment the body can include at least 15 vol % porosity for a total volume of the body. In a more particular embodiment, the body can include at least 24 vol % porosity for the total volume of the body, such as at least 26 vol % or at least 27 vol % or at least 28 vol % or at least 29 vol % or at least 30 vol % or at least 31 vol % or at least 32 vol % or at least 33 vol % or at least 34 vol % or at least 35 vol % or at least 36 vol % or at least 37 vol % or at least 38 vol % or at least 39 vol % or at least 41 vol % or at least 44 vol % or at least 46 vol % or at least 48 vol % or at least 50 vol % or at least 52 vol % or at least 53 vol % or at least 54 for a total volume of the body. Still, in other non-limiting embodiment, the body may include a porosity of at most 68 vol % for the total volume of the body or at most 67 vol % or at most 66 vol % or at most 64 vol % or at most 63 vol % or at most 60 vol % or at most 59 vol % or at most 58 vol % or at most 57 vol % or at most 56 vol % or at most 55 vol % or at most 54 vol % or at most 53 vol % or at most 52 vol % or at most 51 vol % or at most 50 vol % or at most 49 vol % or at most 48 vol % or at most 47 vol % or at most 46 vol % or at most 45 vol % or at most 44 vol % or at most 43 vol % or at most 42 vol % or at most 40 vol % or at most 39 vol % or at most 38 vol % for a total volume of the body. It will be appreciated that the body can include a content of porosity within a range including any of the minimum and maximum percentages noted above.

In an embodiment, the bonded abrasive body may have interconnected porosity, closed porosity, or a combination thereof. Interconnected porosity defines a series of interconnected channels extending through the body. Interconnected porosity may also be referred to herein as open porosity. Open porosity or interconnected porosity can be distinct from closed porosity, which is defined as discrete pores within the body that are not connected to adjacent pores and do not form an interconnected network of channels through the body. Closed porosity does not allow a fluid to flow freely through the volume of the body.

In an embodiment, the bonded abrasive body may include a particular content of open porosity that may facilitate improved performance of the abrasive article. In an embodiment, the body can include at least 5%, such as at least 10% or at least 20% or at least 30% or at least 40% or at least 50% or at least 60% or at least 70% or at least 80% or at least 90% or even at least 95% interconnected porosity for the total volume of porosity in the body. In at least one embodiment, essentially all the porosity of the body can be interconnected porosity. Still, in at least one non-limiting embodiment, the body can have at most 95%, such as at most 92% or at most 90% or at most 85% or at most 80% or at most 75% or at most 70% or at most 65% or at most 60% or at most 55% or at most 50% or at most 45% or at most 40% of the total porosity (vol %) may be interconnected porosity. It will be appreciated that the body can include a content of interconnected porosity within a range including any of the minimum and maximum values noted above.

In another embodiment, the bonded abrasive body may include a particular content of closed porosity that may facilitate improved performance of the abrasive article. In an embodiment, the body can include at least 1%, such as at least 5% or at least 10% or at least 20% or at least 30% or at least 40% or at least 50% or at least 60% or even at least 75% of closed porosity for the total volume of porosity in the body. In at least one embodiment, essentially all the porosity of the body can be closed porosity. Still, in at least one non-limiting embodiment, the body can have at most 95% of closed porosity of the total porosity (vol %), such as at most 90% or at most 85% or at most 80% or at most 75% or at most 70% or at most 65% or at most 60% or at most 55% or at most 50% or at most 45% or at most 36% or at most 20% of closed porosity of the total porosity (vol %). It will be appreciated that the body can include a content of closed porosity within a range including any of the minimum and maximum values noted above.

In a further embodiment, the bonded abrasive body may include a particular permeability that may facilitate improved performance of the abrasive article.

In still another instance, the body may include a certain content of abrasive particles, which may facilitate improved performance of the abrasive article. For example, the body may include at least 26 vol % abrasive particles for a total volume of the body, such as at least 29 vol % or at least 31 vol % or at least 32 vol % or at least or at least 33 vol % or at least 34 vol % or at least 35 vol % or at least 36 vol % or at least 37 vol % or at least 38 vol % or at least 39 vol % or at least 40 vol % or at least 41 vol % or at least 42 vol % or at least 43 vol % or at least 44 vol % or at least 45 vol % or at least 46 vol % or at least 47 vol % or at least 48 vol % or at least 49 vol % for a total volume of the body for a total volume of the body. Still, in one non-limiting embodiment, the content of abrasive particles in the body can be at most 60 vol % for a total volume of the body, such as at most 58 vol % or at most 55 vol % or at most 54 vol % or at most 53 vol % or at most 52 vol % or at most 51 vol % or at most 50 vol % or at most 49 vol % or at most 48 vol % or at most 47 vol % or at most 46 vol % or at most 45 vol % or at most 44 vol % or at most 43 vol % or at most 42 vol % or at most 41 vol % or at most 40 vol % or at most 39 vol % or at most 38 vol % or at most 37 vol % or at most 36 vol % or at most 35 vol % for a total volume of the body. It will be appreciated that the content of the abrasive particles within the body can be within range including any of the minimum and maximum percentages noted above.

In an embodiment, the bonded abrasive body can have a certain modulus of rupture (MOR), such as at least 0.5 MPa or at least 0.8 MPa or at least 1 MPa or at least 3 MPa or at least 5 MPa or at least 8 MPa or at least 12 MPa at least 20 MPa or at least 30 MPa or at least 32 MPa or at least 35 MPa or at least 38 MPa or at least 40 MPa or at least 42 MPa or at least 43 MPa or at least 44 MPa. In another embodiment, the MOR can be at most 55 MPa, such as at most 52 MPa or at most 49 MPa or at most 48 MPa or at most 47 MPa at most 45 MPa or at most 43 MPa or at most 40 MPa. The MOR of the body may be affected by the content of the bond material. For instance, the body can have a relatively higher MOR when the body includes a relatively higher content of the bond material. It will be appreciated that the MOR can be in a range including any of the minimum and maximum values disclosed herein. MOR can be measured using a standard 4-point bending test on a sample of size 4″×1″×0.5″, where the load is applied across the 1″×0.5″ plane, generally in accordance with ASTM D790, with the exception of the sample size. The failure load can be recorded and calculated back to MOR using standard equations.

In an embodiment, the bonded abrasive body can have a certain modulus of elasticity (MOE), such as at least 0.5 GPa or at least 1.0 GPa or at least 1.5 GPa or at least 2.0 GPa or at least 3.0 GPa or at least 5.0 GPa or at least 8.0 GPa or at least 10 GPa or at least 15 GPa or at least 20 GPa or at least 24 GPa or at least 27 GPa or at least 30 GPa or at least 32 GPa or at least 35 GPa. In another embodiment, the MOE can be at most 41 GPa or at most 39 GPa or at most 37 GPa or at most 35 GPa or at most 31 GPa or at most 26 GPa or at most 22 GPa or at most 17 GPa or at most 13 GPa or at most 10 GPa or at most 7 GPa or at most 5 GPa or at most 1 GPa. The MOE of the body may be affected by the content of the bond material. For instance, the body can have a relatively higher MOE when the body includes a relatively higher content of the bond material. It will be appreciated that the MOE can be in a range including any of the minimum and maximum values given above. MOE can be calculated through measurement of natural frequency of the composites using a GrindoSonic instrument or similar equipment, as per standard practices in the abrasive grinding wheel industry.

In one embodiment, the bonded abrasive body can have a ratio of the MOR to MOE that may facilitate improved performance of the abrasive article.

In an embodiment, the bonded abrasive body can include a particular density that may facilitate improved performance and/or manufacturing of the abrasive article. In an embodiment, the bonded abrasive body can include a density of at least 1.51 g/cm³ or at least 1.53 g/cm³ or at least 1.58 g/cm³ or at least 1.63 g/cm³ or at least 1.66 g/cm³ or at least 1.72 g/cm³ or at least 1.75 g/cm³ or at least 1.79 g/cm³ or at least 1.83 g/cm³ or at least 1.85 g/cm³ or at least 1.83 g/cm³ or at least 1.87 g/cm³ or at least 1.92 g/cm³. In an embodiment, the abrasive article can include a density of at most 2.10 g/cm³ or at most 2.05 g/cm³ or at most 2.00 g/cm³ or at most 1.95 g/cm³ or at most 1.93 g/cm³. It will be appreciated that the density may be in a range including any of the minimum and maximum values noted above.

In an embodiment, the bonded abrasive body can include a particular hardness that may facilitate improved performance and/or manufacturing of the abrasive article. In an embodiment, the bonded abrasive body can include a particular Atlantic Rockwell hardness value of at least 34, at least 40, at least 45, at least 50, at least 60, at least 70, at least 80, at last 100, at least 130, at least 160, or at least 180. In another embodiment, the bonded abrasive body can include Atlantic Rockwell hardness value of at most 200 or less than 200, such as at most 190, at most 170, at most 150, at most 130, at most 110, at most 90, at most 80, at most 70, at most 60, at most 50, at most 43, or at most 36. Moreover, the bonded abrasive body can include Atlantic Rockwell hardness may be in a range including any of the minimum and maximum values noted above. Atlantic Rockwell hardness is tested using modified Rockwell system and scale is Atlantic Rockwell. The system utilizes a ball applied under pressure onto the sample. The hardness value is the depth of the ball indentation. The ball diameter is 5 mm. Pre-load is 10 kg and main load is 50 kg.

In a further embodiment, a batch of abrasive articles may include a plurality of abrasive articles of embodiments herein. In an example, a batch of abrasive articles may include at least 5 abrasive articles, at least 6, at least 7, at least 8, or at least 10 abrasive articles. In a further embodiment, the batch of abrasive articles may have relatively lower variations in particular properties, such as density, hardness, microstructures, or the like or any combination thereof. In another embodiment, the batch of abrasive articles may include a hardness variation within ±10% of an average Atlantic Rockwell hardness of the batch.

The abrasive article of embodiments herein can be suitable for various applications. In accordance with an embodiment, the abrasive article may be particularly suited for superfinishing applications. In another embodiment, the abrasive article may include fixed abrasives, such as grinding stones, grinding wheels, or any combination thereof. A particular example may include superfinishing sticks, honing sticks, or the like, or any combination thereof. In still another embodiment, the abrasive articles may be utilized for precision grinding, honing, or the like, or any combination thereof. For example, the abrasive article can be utilized to grind workpieces including bearings, automotive parts, such as the engine and camshaft, ball valves, prosthetic implants, or another object with complex profiles, or any combination thereof. Exemplary work pieces may include a material include steel, such as tool steel, chrome steel, and carbon steel. A particular example of workpieces may include high-carbon chromium alloy steel, such as 52100 steel, 100Cr6 steel with or without carbonitriding, and 1080 bearing steel, or the like, or any combination thereof.

Referring to FIGS. 10A-10C, exemplary superfinishing operations are illustrated. In FIGS. 10A-10B, the abrasive article 1001 is operated on outer ring raceway of the outer ring of ball bearing 1010. The abrasive article 1001 is pushed against the raceway in the direction 1011 and at the same time oscillates while the ring rotates at a high speed in the direction 1012. The directions of movements of the abrasive article 1001 is illustrated and referred to as 1011.

In FIG. 10C, the abrasive article 1051 is operated on inner ring raceway of the inner ring of ball bearing 1050. The abrasive article 1051 is pushed against the raceway in the direction 1061 and at the same time oscillates while the ring rotates at a high speed. The directions of movements of the abrasive article 1051 is illustrated and referred to as 1061.

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 embodiments as listed below.

EMBODIMENTS

Embodiment 1. An abrasive article, comprising a bonded abrasive body including abrasive particles contained in a bond material comprising an inorganic material, wherein:

• • the abrasive particles have an average particle size (D50) of 1 to 5 microns;
  • the bond material is in a content of at least 1 vol % and at most 6 vol % for a total volume of the bonded abrasive body; and
  • the bonded abrasive body comprises a ratio of an average bond post count to the content of the bond material of greater than 200.

Embodiment 2. An abrasive article, comprising a bonded abrasive body including abrasive particles contained in a bond material comprising an inorganic material, wherein:

• • the abrasive particles have an average particle size (D50) of 1 to 5 microns;
  • the bond material is in a content of at least 7 vol % and at most 14 vol % for a total volume of the bonded abrasive body; and
  • the bonded abrasive body comprises a ratio of an average bond post count to the content of the bond material of greater than 158.

Embodiment 3. An abrasive article, comprising a bonded abrasive body including abrasive particles contained in a bond material comprising an inorganic material, wherein:

• • the abrasive particles have an average particle size (D50) of 6 to 8 microns;
  • the bond material is in a content of at least 1 vol % and at most 6 vol % for a total volume of the bonded abrasive body; and
  • the bonded abrasive body comprises a ratio of an average bond post count to the content of the bond material of greater than 200.

Embodiment 4. An abrasive article, comprising a bonded abrasive body including abrasive particles contained in a bond material comprising an inorganic material, wherein:

• • the abrasive particles have an average particle size (D50) of 6 to 8 microns;
  • the bond material is in a content of at least 7 vol % and at most 14 vol % for a total volume of the bonded abrasive body; and
  • the bonded abrasive body comprises a ratio of an average bond post count to the content of the bond material of greater than 150.

Embodiment 5. An abrasive article, comprising a bonded abrasive body including abrasive particles contained in a bond material comprising an inorganic material, wherein:

• • the abrasive particles have an average particle size (D50) of 9 to 25 microns;
  • the bond material is in a content of at least 1 vol % and at most 6 vol % for a total volume of the bonded abrasive body; and
  • the bonded abrasive body comprises a ratio of an average bond post count to the content of the bond material of greater than 180.

Embodiment 6. An abrasive article, comprising a bonded abrasive body including abrasive particles contained in a bond material comprising an inorganic material, wherein:

• • the abrasive particles have an average particle size (D50) of 9 to 25 microns;
  • the bond material is in a content of at least 7 vol % and at most 14 vol % for a total volume of the body; and
  • the bonded abrasive body comprises a ratio of bond post count to the content of the bond material of greater than 125.

Embodiment 7. The abrasive articles of any one of embodiments 1 to 6, wherein the bond material comprises a total content of an alkali metal oxide greater than 6 wt % for a total weight of the bond material.

Embodiment 8. The abrasive articles of any one of embodiments 1 to 6, wherein the bond material comprises a total content of an alkaline earth metal oxide less than 5 wt % for a total weight of the bond material.

Embodiment 9. The abrasive articles of any one of embodiments 1 to 6, wherein the bond material comprises a ratio of a total content of an alkali metal oxide to a total content of an alkaline earth metal oxide of greater than 1, at least 2, at least 3, at least 5, at least 6, at least 7, at least 8, at least 9, or at least 10; and/or wherein the ratio of the total content of the alkali metal oxide to the total content of the alkaline earth metal oxide is at most 25, at most 23, at most 20, at most 18, at most 17, at most 15, at most 13, or at most 11.

Embodiment 10. The abrasive article of embodiment 1, wherein when the content of the bond material is from 4 vol % to 6 vol %, the bonded abrasive body comprises an average bond post count of greater than 1100 or at least 1120 or at least 1170 or at least 1210 or at least 1260 or at least 1290 or at least 1330 or at least 1370 or at least 1430 or at least 1500 or at least 1520 or at least 1580 or at least 1620 or at least 1655 or at least 1668 or at least 1688 or at least 1700 or at least 1728 or at least 1748 or at least 1765 or at least 1778 or at least 1788 or at least 1796 or at least 1802; and/or wherein when the content of the bond material is from 4 vol % to 6 vol %, the average bond post count is at most 2700 or at most 2500 or at most 2250.

Embodiment 11. The abrasive article of embodiment 1 or 10, wherein the ratio of the average bond post count to the content of the bond material is at least 210 or at least 235 or at least 250 or at least 265 or at least 280 or at least 290 or at least 300 or at least 305 or at least 315; and/or wherein the ratio of the average bond post count to the content of the bond material is at most 420 or at most 405 or at most 380 or at most 370 or at most 355 or at most 335 or at most 315.

Embodiment 12. The abrasive article of embodiment 1, wherein when the content of the bond material is from 1 vol % to 4 vol %, the bonded abrasive body comprises an average bond post count of at least 680 or at least 730 or at least 780 or at least 870 or at least 910 or at least 950 or at least 980 or at least 1030 or at least 1060 or at least 1092; and/or wherein when the content of the bond material is less than 4 vol %, the average bond post count is at most 1700 or at most 1600 or at most 1500 or at most 1380 or at most 1260.

Embodiment 13. The abrasive article of embodiment 1 or 12, wherein the ratio of the average bond post count to the content of the bond material is at least 210 or at least 235 or at least 250 or at least 265 or at least 280 or at least 290 or at least 300 or at least 305 or at least 315; and/or wherein the ratio of the average bond post count to the content of the bond material is at most 420 or at most 405 or at most 380 or at most 370 or at most 355 or at most 335 or at most 315.

Embodiment 14. The abrasive article of embodiment 2, wherein the bonded abrasive body comprises an average bond post count of at least 1050 or at least 1170 or at least 1210 or at least 1260 or at least 1290 or at least 1330 or at least 1370 or at least 1430 or at least 1500 or at least 1520 or at least 1580 or at least 1620 or at least 1655 or at least 1668 or at least 1688; and/or wherein the average bond post count is at most 2700 or at most 2500 or at most 2250 or at most 2160 or at most 2080 or at most 1850 or at most 1720.

Embodiment 15. The abrasive article of embodiment 2 or 14, wherein the ratio of the average bond post count to the content of the bond material is at least 160 or at least 165 or at least 170 or at least 174; and/or wherein the ratio of the average bond post count to the content of the bond material is at most 250 or at most 240 or at most 220 or at most 210 or at most 185 or at most 175.

Embodiment 16. The abrasive article of embodiment 3, wherein the average bond post count is greater than 650 or at least 680 or at least 700 or at least 720 or at least 740 or at least 790 or at least 820 or at least 850 or at least 920 or at least 1040 or at least 1080 or at least 1150 or at least 1270 or at least 1325; and/or wherein the average bond post count is at most 1900 or at most 1850 or at most 1780 or at most 1500.

Embodiment 17. The abrasive article of embodiment 3 or 16, wherein the ratio of the average bond post count to the content of the bond material is at least 210 or at least 225 or at least 235 or at least 240 or at least 265 or at least 280 or at least 300 or at least 315 or at least 330 or at least 350; and/or wherein the ratio of the average bond post count to the content of the bond material is at most 450 or at most 420 or at most 390 or at most 380 or at most 360 or at most 335 or at most 315.

Embodiment 18. The abrasive article of embodiment 4, wherein the average bond post count is greater than 1350 or at least 1380 or at least 1410 or at least 1450 or at least 1490 or at least 1520 or at least 1560.

Embodiment 19. The abrasive article of embodiment 4 or 18, wherein the ratio of the average bond post count to the content of the bond material is at least 155 or at least 160 or at least 165 or at least 171; and/or wherein the ratio of the average bond post count to the content of the bond material is at most 250 or at most 220 or at most 190 or at most 180 or at most 175.

Embodiment 20. The abrasive article of embodiment 5, wherein the average bond post count is at least 610 or at least 650 or at least 690 or at least 720 or at least 740 or at least 790 or at least 819; and/or wherein the average bond post count is at most 1860 or at most 1780 or at most 1500 or at most 1350.

Embodiment 21. The abrasive article of embodiment 5 or 20, wherein the ratio of the average bond post count to the content of the bond material is at least 190 or at least 210 or at least 215 or at least 220 or at least 225 or at least 230; and/or wherein the ratio of the average bond post count to the content of the bond material is at most 310 or at most 290 or at most 260 or at most 240.

Embodiment 22. The abrasive article of embodiment 6, wherein the average bond post count is at least 1200 or at least 1250 or at least 1289; and/or wherein the average bond post count is at most 1960 or at most 1750 or at most 1540 or at most 1350.

Embodiment 23. The abrasive article of embodiment 6 or 22, wherein the ratio of the average bond post count to the content of the bond material is at least 130 or at least 133; and/or wherein the ratio of the average bond post count to the content of the bond material is at most 180 or at most 165 or at most 145 or at most 139.

Embodiment 24. The abrasive article of any one of embodiments 1 to 23, wherein the content of aluminum oxide (Al₂O₃) is at least 23 wt % of for the total weight of the bond material, at least 25 wt %, or at least 28 wt % or at least 30 wt % or at least 33 wt % or at least 36 wt % or at least 38 wt % or at least 40 wt % or at least 42 wt % or at least 45 wt % for the total weight of the bond material; and/or wherein the content of aluminum oxide (Al₂O₃) is at most 64 wt % for the total weight of the bond material, at most 62 wt % or at most 59 wt % or at most 57 wt % or at most 55 wt % or at most 52 wt % or at most 50 wt % or at most 48 wt % or at most 46 wt % or at most 43 wt % for the total weight of the bond material.

Embodiment 25. The abrasive article of any one of embodiments 1 to 24, wherein the total content of an alkali metal oxide is at least 5.5 wt % for the total weight of the bond material or at least 6 wt % or at least 6.5 wt % or at least 7.2 wt % or at least 7.8 wt % or at least 8.0 wt % or at least 8.4 wt % or at least 8.8 wt % or at least 9.1 wt % or at least 9.5 wt % or at least 9.8 wt % or at least 10.0 wt % or at least 10.5 wt % or at least 10.8 wt % or at least 11.0 wt % or at least 11.4 wt % or at least 12.5 wt % or at least 13.2 wt % or at least 14.1 wt % for the total weight of the bond material; and/or wherein the total content of an alkali metal oxide is at most 22.0 wt % for the total weight of the bond material or at most 20.0 wt % or at most 19.3 wt % or at most 18.8 wt % or at most 18.4 wt % or at most 18.1 wt % or at most 17.8 wt % or at most 17.3 wt % or at most 16.9 wt % or at most 16.3 wt % or at most 16.0 wt % or at most 15.7 wt % or at most 15.3 wt % or at most 15.1 wt % or at most 14.8 wt % or at most 14.4 wt % or at most 14.0 wt % or at most 13.5 wt % or at most 13.1 wt % or at most 12.8 wt % or at most 12.4 wt % or at most 11.8 wt % for the total weight of the bond material.

Embodiment 26. The abrasive article of any one of embodiments 1 to 15, wherein the alkali metal oxide comprises lithium oxide (Li₂O), potassium oxide (K₂O), sodium oxide (Na₂O), or any combination thereof.

Embodiment 27. The abrasive article of any one of embodiments 1 to 16, wherein the bond material comprises sodium oxide (Na₂O) in a content of at least 3.3 wt % for the total weight of the bond material or at least 3.6 wt % or at least 4.0 wt % or at least 4.3 wt % or at least 4.7 wt % or at least 5.0 wt % or at least 5.3 wt % or at least 5.6 wt % or at least 5.9 wt % or at least 6.3 wt % or at least 6.5 wt % or at least 6.7 wt % or at least 7.0 wt % or at least 7.3 wt % or at least 7.5 wt % or at least 7.8 wt % or at least 8.3 wt % for the total weight of the bond material; and/or wherein the content of sodium oxide (Na₂O) is at most 16.0 wt % for the total weight of the bond material or at most 14.6 wt % or at most 11.5 wt % or at most 10.7 wt % or at most 10.4 wt % or at most 10.1 wt % or at most 9.8 wt % or at most 9.5 wt % or at most 9.2 wt % or at most 8.8 wt % or at most 8.5 wt % or at most 8.3 wt % or at most 8.1 wt % or at most 7.8 wt % or at most 7.7 wt % or at most 7.4 wt % or at most 7.1 wt % for the total weight of the bond material.

Embodiment 28. The abrasive article of any one of embodiments 1 to 27, wherein the bond material comprises lithium oxide (Li₂O) in a content of at most 5.4 wt % for the total weight of the bond material or at most 5.1 wt % or at most 4.6 wt % or at most 4.2 wt % or at most 3.8 wt % or at most 3.6 wt % or at most 3.3 wt % or at most 2.9 wt % or at most 2.7 wt % or at most 2.4 wt % for a total weight of the bond material; and/or where the content of lithium oxide (Li₂O) of at least 0.6 wt % for the total weight of the bond material or at least 0.8 wt % or at least 1.0 wt % or at least 1.3 wt % or at least 1.5 wt % or at least 1.7 wt % or at least 2.1 wt % or at least 2.5 wt % or at least 2.8 wt % for a total weight of the bond material.

Embodiment 29. The abrasive article of any one of embodiments 1 to 28, wherein the bond material comprises potassium oxide (K₂O) in a content of at most 5.2 wt % for the total weight of the bond material or at most 4.9 wt % or at most 4.6 wt % or at most 4.2 wt % or at most 3.8 wt % or at most 3.6 wt % or at most 3.3 wt % or at most 2.9 wt % or at most 2.7 wt % or at most 2.4 wt % for a total weight of the bond material; and/or where the content of potassium oxide (K₂O) of at least 0.5 wt % for the total weight of the bond material or at least 0.7 wt % or at least 0.8 wt % or at least 1.0 wt % or at least 1.1 wt % or at least 1.2 wt % or at least 1.3 wt % or at least 1.4 wt % or at least 1.9 wt % or at least 2.3 wt % or at least 2.5 wt % for a total weight of the bond material.

Embodiment 30. The abrasive article of any one of embodiments 1 to 29, wherein the bond material comprises a content of boron oxide (B₂O₃), wherein the content of boron oxide (B₂O₃) is at least 3 wt % or at least 5 wt % or at least 6 wt % or at least 7 wt % or at least 8 wt % or at least 9 wt % or at least 10 wt % or at least 11 wt % or at least 13 wt % for a total weight of the bond material; and/or wherein the bond material includes at most 21 wt % boron oxide (B₂O₃) for a total weight of the bond material, such as at most 20 wt % or at most 18 wt % or at most 17 wt % or at most 16 wt % or at most 15 wt % or at most 14 wt % or at most 13 wt % or at most 12 wt % or at most 11 wt % or at most 10 wt % for a total weight of the bond material.

Embodiment 31. The abrasive article of any one of embodiments 1 to 20, wherein the bond material comprises a weight content ratio of alumina to boron oxide (Al₂O₃/B₂O₃), wherein the ratio is at least 1.8 or at least 1.9 or at least 2.0 or at least 2.1 or at least 2.3 or at least 2.5 or at least 2.8 or at least 3.2 or at least 3.4 or at least 3.5 or at least 3.7 or at least 3.8 or at least 3.9 or at least 4.0 or at least 4.1; and/or wherein the ratio (Al₂O₃/B₂O₃) is at most 5.7 or at most 5.5 or at most 5.4 or at most 5.2 or at most 5.0 or at most 4.9 or at most 4.8 or at most 4.7 or at most 4.6 or at most 4.5 or at most 4.4 or at most 4.3 or at most 4.2 or at most 3.8 or at most 3.4 or at most 3.1 or at most 2.7 or at most 2.5.

Embodiment 32. The abrasive article of any one of embodiments 1 to 31, wherein the bond material comprises a content of silicon dioxide (SiO₂), wherein the content of silicon dioxide (SiO₂) is at least 18 wt % for the total weight of the bond material or at least 20 wt % or at least 22 wt % or at least 24 wt % or at least 25 wt % or at least 27 wt % or at least 29 wt % or at least 30 wt % or at least 31 wt % or at least 32 wt % or at least 34 wt % or at least 36 wt % for the total weight of the bond material; and/or wherein the bond material comprises at most 55 wt % silicon dioxide (SiO₂) for the total weight of the bond material or at most 52 wt % or at most 50 wt % or at most 47 wt % or at most 44 wt % or at most 41 wt % or at most 39 wt % or at most 37 wt % or at most 36 wt % or at most 34 wt % or at most 32 wt % for a total weight of the bond material.

Embodiment 33. The abrasive article of any one of embodiments 1 to 32, wherein the bond material comprises a weight content ratio of alumina to silica dioxide (Al₂O₃/SiO₂), wherein the ratio (Al₂O₃/SiO₂) is at least 0.6 or at least 0.8 or at least 0.9 or at least 1.0 or at least 1.1 or at least 1.2 or at least 1.3 or at least 1.4 or at least 1.5; and/or wherein the ratio (Al₂O₃/SiO₂) is at most 2.5 or at most 2.4 or at most 2.3 or at most 2.2 or at most 2.1 or at most 2.0 or at most 1.9 or at most 1.8 or at most 1.7 or at most 1.5 or at most 1.4 or at most 1.2 or at most 0.9.

Embodiment 34. The abrasive article of any one of embodiments 1 to 33, wherein the bond material comprises a total content of silicon dioxide (SiO₂) and boron oxide (B₂O₃) of at least 25 wt % for a total weight of the bond material, such as at least 28 wt % or at least 30 wt % or at least 32 wt % or at least 35 wt % or at least 36 wt % or at least 38 wt % or at least 40 wt % or at least 42 wt % or at least 45 wt % or at least 47 wt % or at least 50 wt %; and/or wherein the total content of silicon dioxide (SiO₂) and boron oxide (B₂O₃) is at most 62 wt % for a total weight of the bond material, such as at most 59 wt % or at most 57 wt % or at most 55 wt % or at most 53 wt % or at most 52 wt % or at most 50 wt % or at most 48 wt % or at most 46 wt % or at most 45 wt % for the total weight of the bond material.

Embodiment 35. The abrasive article of any one of embodiments 1 to 34, wherein the bond material comprises a weight content ratio of silicon dioxide to boron oxide (SiO₂/B₂O₃), wherein the ratio (SiO₂/B₂O₃) is at least 1.5 or at least 1.8 or at least 2.0 or at least 2.2 or at least 2.4 or at least 2.5 or at least 2.8 or at least 2.9 or at least 3.0 or at least 3.1; and/or wherein the ratio (SiO₂/B₂O₃) is at most 4.3 or at most 4.1 or at most 3.9 or at most 3.7 or at most 3.5 or at most 3.3 or at most 3.2.

Embodiment 36. The abrasive article of any one of embodiments 1 to 35, wherein the bond material comprises a weight content ratio of alumina to a total content of silica dioxide and boron oxide (Al₂O₃/(SiO₂+B₂O₃)), wherein the ratio (Al₂O₃/(SiO₂+B₂O₃)) is at least 0.5 or at least 0.6 or at least 0.7 or at least 0.8 or at least 0.9 or at least 1.0 or at least 1.1; and/or wherein the ratio (Al₂O₃/(SiO₂+B₂O₃)) is at most 1.7 or at most 1.5 or at most 1.4 at most 1.3 or 1.2 or at most 1.1 or at most 1.0 or at most 0.8.

Embodiment 37. The abrasive article of any one of embodiments 1 to 36, wherein the bond material comprises a weight content ratio of the content of alumina to a total content of alkali metal oxides (Al₂O₃/A₂O), wherein the ratio (Al₂O₃/A₂O) is at most 5.7 or at most 5.5 or at most 5.4 or at most 5.2 or at most 5.0 or at most 4.9 or at most 4.8 or at most 4.7 or at most 4.6 or at most 4.5 or at most 4.4 or at most 4.3 or at most 4.2 or at most 3.7 or at most 3.3 or at most 3.0 or at most 2.7 or at most 2.5 or at most 2.3; and/or wherein the ratio (Al₂O₃/A₂O) is at least 1.6 or at least 1.8 or at least 2.1 or at least 2.5 or at least 2.8 or at least 2.9 or at least 3.0 or at least 3.2 or at least 3.4 or at least 3.5 or at least 3.7 or at least 3.8 or at least 3.9 or at least 4.0 or at least 4.1 or at least 4.3. Moreover, the ratio (Al₂O₃/A₂O) can be in a range including any of the minimum and maximum values noted herein.

Embodiment 38. The abrasive article of any one of embodiments 1 to 37, wherein the bond material comprises a weight content ratio of alumina to sodium oxides (Al₂O₃/Na₂O), wherein the ratio (Al₂O₃/Na₂O) is at most 7.7 or at most 7.5 or at most 7.4 or at most 7.2 or at most 7.0 or at most 6.9 or at most 6.8 or at most 6.7 or at most 6.6 or at most 6.5 or at most 6.4 or at most 6.3 or at most 5.9 or at most 5.7 or at most 5.2 or at most 4.7 or at most 3.5 or at most 3.3; and/or wherein the ratio (Al₂O₃/Na₂O) is at least 2.8 or at least 3.1 or at least 3.3 or at least 3.8 or at least 4.1 or at least 4.4 or at least 4.7 or at least 4.9 or at least 5.0 or at least 5.2 or at least 5.3 or at least 5.5 or at least 5.7 or at least 5.9 or at least 6.1.

Embodiment 39. The abrasive article of any one of embodiments 1 to 38, wherein the bond material comprises a weight content ratio of alumina to lithium oxide (Al₂O₃/Li₂O), wherein the ratio (Al₂O₃/Li₂O) can be at most 38 or at most 36 or at most 35 or at most 33 or at most 31 or at most 29 or at most 28 or at most 27 or at most 26 or at most 25 or at most 22 or at most 18 or at most 15 or at most 12; and/or wherein the ratio (Al₂O₃/Li₂O) can be at least 7 or at least 8 or at least 10 or at least 12 at least 14 or at least 17 or at least 19 or at least 20 or at least 21 or at least 22 or at least 23 or at least 24 or at least 25 or at least 26.

Embodiment 40. The abrasive article of any one of embodiments 1 to 39, wherein the bond material comprises a weight content ratio of alumina to potassium oxide (Al₂O₃/K₂O), wherein the ratio (Al₂O₃/K₂O) can be at most 49 or at most 46 or at most 45 or at most 43 or at most 40 or at most 39 or at most 38 or at most 36 or at most 35 or at most 34 or at most 33 or at most 32 or at most 27 or at most 23 or at most 18 or at most 15; and/or wherein the ratio (Al₂O₃/K₂O) can be at least 10 or at least 12 at least 14 or at least 17 or at least 19 or at least 20 or at least 21 or at least 22 or at least 23 or at least 24 or at least 25 or at least 26 or at least 27 or at least 29 or at least 30 or at least 31 or at least 33.

Embodiment 41. The abrasive article of any one of embodiments 1 to 40, wherein the bonded abrasive body comprises porosity including open porosity, closed porosity, or a combination thereof, wherein the porosity is at least 26 vol % for a total volume of the bonded abrasive body or at least 26 vol % or at least 27 vol % or at least 28 vol % or at least 29 vol % or at least 30 vol % or at least 31 vol % or at least 32 vol % or at least 33 vol % or at least 34 vol % or at least 35 vol % or at least 36 vol % or at least 37 vol % or at least 38 vol % or at least 39 vol % or at least 41 vol % or at least 44 vol % or at least 46 vol % or at least 48 vol % or at least 50 vol % or at least 52 vol % or at least 53 vol % or at least 54 for a total volume of the body; and/or wherein the body comprises the porosity of at most 68 vol % for the total volume of the body or at most 67 vol % or at most 66 vol % or at most 64 vol % or at most 63 vol % or at most 60 vol % or at most 59 vol % or at most 58 vol % or at most 57 vol % or at most 56 vol % or at most 55 vol % or at most 54 vol % or at most 53 vol % or at most 52 vol % or at most 51 vol % or at most 50 vol % or at most 49 vol % or at most 48 vol % or at most 47 vol % or at most 46 vol % or at most 45 vol % or at most 44 vol % or at most 43 vol % or at most 42 vol % or at most 40 vol % or at most 39 vol % or at most 38 vol % for a total volume of the body.

Embodiment 42. The abrasive article of any one of embodiments 1 to 41, wherein the bonded abrasive body comprises a content of abrasive particles, wherein the content of abrasive particles is at least 26 vol % or at least 29 vol % or at least 31 vol % or at least 32 vol % or at least or at least 33 vol % or at least 34 vol % or at least 35 vol % or at least 36 vol % or at least 37 vol % or at least 38 vol % or at least 39 vol % or at least 40 vol % or at least 41 vol % or at least 42 vol % or at least 43 vol % or at least 44 vol % or at least 45 vol % or at least 46 vol % or at least 47 vol % or at least 48 vol % or at least 49 vol % for a total volume of the body for a total volume of the body; and/or wherein the content of abrasive particles is at most 60 vol % for a total volume of the body or at most 58 vol % or at most 55 vol % or at most 54 vol % or at most 53 vol % or at most 52 vol % or at most 51 vol % or at most 50 vol % or at most 49 vol % or at most 48 vol % or at most 47 vol % or at most 46 vol % or at most 45 vol % or at most 44 vol % or at most 43 vol % or at most 42 vol % or at most 41 vol % or at most 40 vol % or at most 39 vol % or at most 38 vol % or at most 37 vol % or at most 36 vol % or at most 35 vol % for a total volume of the body.

Embodiment 43. The abrasive article of any one of embodiments 1 to 42, wherein the average particle size of the abrasive particles is at most 50 microns or at most 49 microns or at most 47 microns or at most 46 microns or at most 44 microns or at most 42 microns or at most 40 microns or at most 38 microns or at most 36 microns or at most 34 microns or at most 32 microns or at most 30 microns or at most 29 microns or at most 28 microns or at most 26 microns or at most 24 microns or at most 22 microns or at most 21 microns or at most 20 microns or at most 19 microns or at most 18 microns or at most 17 microns or at most 16 microns or at most 15 microns or at most 13 microns or at most 12 microns or at most 11 microns or at most 10 microns or at most 9 microns; and/or wherein the average particle size at least 0.1 microns or at least 1 micron or at least 5 microns or at least 8 microns or at least 10 microns or at least 12 microns or at least 14 microns or at least 15 microns or at least 16 microns or at least 17 microns or at least 18 microns or at least 19 microns or at least 21 microns or at least 23 microns or at least 26 microns or at least 28 microns or at least 30 microns or at least 32 microns or at least 35 microns or at least 36 microns or at least 38 microns or at least 40 microns or at least 42 microns at least 44 microns or at least 46 microns or at least 48 microns.

Embodiment 44. The abrasive article of any one of embodiments 1 to 43, wherein the bonded abrasive body comprises the content of the bond material of at most 14 vol % for the total volume of the body or at most 13.5 vol % or at most 13 vol % or at most 12 vol % or at most 11 vol % or at most 10 vol % or at most 9 vol % or at most 8 vol % or at most 7 vol % or at most 6 vol % or at most 5 vol % or at most 4 vol % or at most 3.5 vol % or at most 3 vol % or at most 2.5 vol % or at most 2 vol % for the total volume of the body; and/or wherein the bonded abrasive body comprises 1 vol % at least of the bond material or at least 2 vol % or at least 3 vol % or at least 4 vol % or at least 5 vol % or at least 6 vol % or at least 7 vol % or at least 8 vol % or at least 8.5 vol % or at least 9 vol % or at least 10 vol % or at least 11 vol % or at least 12 vol % or at least 13 vol % or at least 13.5 vol % of the bond material for the total volume of the body.

Embodiment 45. The abrasive article of any one of embodiments 1 to 44, wherein the bond material comprises a vitrified material comprising a crystalline phase, an amorphous phase, or any combination thereof.

Embodiment 46. The abrasive article of any one of embodiments 1 to 45, wherein the bond material comprises a crystalline material, an amorphous material, or any combination thereof.

Embodiment 47. The abrasive article of any one of embodiments 1 to 46, wherein the bonded abrasive body comprises a modulus of elasticity (MOE) of as at least 0.5 GPa or at least 1.0 GPa or at least 1.5 GPa or at least 2.0 GPa or at least 3.0 GPa or at least 5.0 GPa or at least 8.0 GPa or at least 10 GPa or at least 15 GPa or at least 20 GPa or at least 24 GPa or at least 27 GPa or at least 30 GPa or at least 32 GPa or at least 35 GPa; and/or wherein the bonded abrasive body comprises the MOE can be at most 41 GPa or at most 39 GPa or at most 37 GPa or at most 35 GPa or at most 31 GPa or at most 26 GPa or at most 22 GPa or at most 17 GPa or at most 13 GPa or at most 10 GPa or at most 7 GPa or at most 5 GPa or at most 1 GPa.

Embodiment 48. The abrasive article of any one of embodiments 1 to 47, wherein the bonded abrasive body comprises a density of at least 1.51 g/cm³ or at least 1.53 g/cm³ or at least 1.58 g/cm³ or at least 1.63 g/cm³ or at least 1.66 g/cm³ or at least 1.72 g/cm³ or at least 1.75 g/cm³ or at least 1.79 g/cm³ or at least 1.83 g/cm³ or at least 1.85 g/cm³ or at least 1.83 g/cm³ or at least 1.87 g/cm³ or at least 1.92 g/cm³; and/or wherein the density is at most 2.10 g/cm³ or at most 2.05 g/cm³ or at most 2.00 g/cm³ or at most 1.95 g/cm³ or at most 1.93 g/cm³.

Embodiment 49. The abrasive article of any one of embodiments 1 to 48, wherein the bonded abrasive body comprises Atlantic Rockwell hardness of at least 34, at least 40, at least 45, at least 50, at least 60, at least 70, at least 80, at last 100, at least 130, at least 160, or at least 180; and/or wherein the bonded abrasive body comprises Atlantic Rockwell hardness of at most 200 or less than 200, such as at most 190, at most 170, at most 150, at most 130, at most 110, at most 90, at most 80, at most 70, at most 60, at most 50, at most 43, or at most 36.

Embodiment 50. A batch of abrasive articles, comprising a plurality of abrasive articles of any one of embodiments 1 to 49.

Embodiment 51. The batch of abrasive articles of embodiment 49, wherein the plurality of abrasive articles comprise at least 5 abrasive articles, at least 6, at least 7, at least 8, or at least 10 abrasive articles.

Embodiment 52. The batch of abrasive articles of embodiment 50 or 51, comprising a hardness variation within ±10% of an average Atlantic Rockwell hardness of the plurality of abrasive articles.

Embodiment 53. A process of forming an abrasive article including a bonded abrasive body, comprising:

• • preparing a bond precursor material such that the bond precursor material has a first average particle size;
  • forming a mixture including abrasive particles and the bond precursor material, wherein the abrasive particles have a second average particle size (D50), and wherein a ratio of the second average particle size to the first average particle size is greater than 1;
  • forming a green body from the mixture;
  • forming the bonded abrasive body from the green body.

Example 1

Representative abrasive Samples S1 to S8 and S10-S11 were formed according to embodiments herein. The average particle size of the precursor bond material was 2 to 3 μm. Abrasive samples C11-C12 and C14-C18 were formed in the same manner as S1-S5 and S10-S11 except that the bond precursor particles have the average particle size of 12-15 μm. C10 was also formed in the same manner except a different bond precursor composition was used and the average particle size of the bond precursor was 325 mesh. In brief, the mixtures including the bond precursor materials and white alumina abrasive particles were molded by pressing at room temperature to form the green bodies which were then kept in the molds and heat treated at approximately 900° C. for 8 hours in air to form finally-formed bonded abrasive bodies. Sample C13 represents the industry standard. The bond compositions of bonded bodies of Samples S1 to S8, S10-S11, C11 to C12 and C14 to C18 are included in Table 1. The bond composition of C10 and C13 are included in Table 2 and 3, respectively. It should be understood that the sum of the contents of all the bond components totals 100% even though ranges are provided. The contents of the components are relative to the total weight of the bond material.

	TABLE 1
	Component	Content (wt %)
	Al2O3	30-47
	B2O3	8-15
	BaO	0.01
	CaO	0.8-1.3
	K2O	0.8-3
	Li2O	1.2-3.3
	MgO	0.32
	Na2O	5.1-8.9
	SiO2	28-39
	SrO	<0.01
	Total	100

TABLE 2
Bond Composition of Sample C10

Components	Li2O	Na2O	K2O	CaO	B2O3	Al2O3	SiO2
Contents	2	10	6	1	17	21	43
[wt %]

TABLE 3
Bond Composition of Sample C13

Com-
ponents	Li2O	Na2O	K2O	CaO	B2O3	Al2O3	SiO2	MgO	SrO
Contents	0.23	3.68	1.01	4.81	20	26.9	41.8	0.58	0.76
[wt %]

Further information of the abrasive samples is included in Tables 4-9. The contents of the bond materials, porosity, and abrasive particles are with respect to the total volume of the respective body. At least 3 samples were made per each composition. It is to be appreciated that even though ranges are provided for contents of components, the sum of the contents of all the components totals 100%.

TABLE 4
Compositions of the abrasive samples

	Abrasive	Average size
	particles contents	(D50) abrasive	Porosity
Samples	(vol %)	particles (μm)	(vol %)
S1	36-38	9-10	52-54
S2	36-38	3-5	52-54
S3	36-38	9-10	56-60
S4	36-38	6-7	52-54
S5	40-42	6-7	54-59
S10	40-42	6-7	54-56
S11	40-42	6-7	56-59
C10	33-35	9-10	55-57
C11	36-38	9-10	52-54
C12	36-38	3-5	52-54
C13	36-38	3-5	52-54
C14	36-38	9-10	56-60
C15	36-38	6-7	52-54
S6	36-38	3-5	56-60
C16	36-38	3-5	56-60
S7	36-38	3-5	55-57
C17	36-38	3-5	55-57
S8	36-38	3-5	52-54
C18	336-8	3-5	52-54

FIGS. 5-9 include images of cross sections of the bodies of C11-C13 and S1-S2. Bond posts are shown in black. Abrasive particles and pores are not visible. ImageJ was used to determine the count and size of bond posts and area % of the bond material as described in embodiments of this disclosure. Average bond post counts and sizes are noted in Tables 5-6 below. Samples S1, C10 and C11 have similar bond contents and average abrasive particle sizes and Samples S1 and C11 have the same bond chemistry. S1 had significantly more bond post count in average and higher ratio of the bond post count to the content of bond than C10 and C11, and thus, an improved microstructure over C10 and C11. Samples S2, C12, and C13 have similar bond contents and average abrasive particle sizes and Samples S2 and C12 have the same bond chemistry. S2 had significantly more bond post count in average and smaller bond post size than C12 and C13, and thus, an improved microstructure over C12 and C13. Sample S3 and Sample C14 have similar bond contents, average abrasive particle sizes and bond chemistry. Sample S3 has more bond post count in average and higher ratio of the bond post count to the content of bond than Sample C14.

TABLE 5
	Average Ratio of
	average bond post	Bond	Average
	count to content of	content	bond post	Average bond
Samples	bond	(Vol %)	count	post size (μm2)

C10	56	9-10	540	13.64
S1	133.2	9-10	1289	5.16
C11	119.8	9-10	1160	6.04

TABLE 6
	Average Ratio of
	average bond post	Bond	Average
	count to content of	content	bond post	Average bond
Samples	bond	(Vol %)	count	post size (μm2)
S2	174.4	9-10	1688	3.97
C12	106.1	9-10	1027	6.82
C13	154.8	9-10	1464	4.85

TABLE 7
	Average Ratio of
	average bond post	Bond	Average
	count to content of	content	bond post	Average bond
Samples	bond	(Vol %)	count	post size (μm2)
S3	230.1	3-4	819	2.73
C14	167.1	3-4	595	3.82

As shown in Table 8, Samples S4 and C15 have similar bond contents, average abrasive particle sizes and bond chemistry. Sample S4 has more bond post count in average and higher average bond count to bond content ratio than Sample C15. Samples S4 is expected to have improved performance over Samples C15 including stock removal, surface finish (e.g., roughness Ra), or both. Average bond post count and size are evaluated for Samples S5, S10 and S11 and included in Table 8. S10 and S11 are made having the same bond chemistry as S5. It is expected Samples S5 and S10-S11 has an improved microstructure, e.g., average bond post count, ratio of average bond post count to bond content, bond post size, or any combination thereof, compared to a similar sample made with bond precursor having an average size greater than D50 of the abrasive particle, e.g., 12-15 μm.

TABLE 8
	Average Ratio of
	average bond post	Bond	Average
	count to content of	content	bond post	Average bond
Samples	bond	(Vol %)	count	post size (μm2)

S4	230.1	9-10	1560	3.25
C15	167.1	9-10	1343	3.58
S5	331.2	4-0	1325	2.16
S10	304.2	2-3	855	2.00
S11	352.1	2.0	695	2.02

TABLE 9
	Average Ratio of
	average bond post	Bond	Average
	count to content of	content	bond post	Average bond
Samples	bond	(Vol %)	count	post size (μm2)

S6	306.7	3-4	1092	1.93
C16	188.5	3-4	671	2.52
S7	316.1	5-6	1802	2.53
C17	193	5-6	1100	3.3
S8	174.4	9-10	1688	3.97
C18	106.1	9-10	1027	6.82

As shown in Table 9, Samples S6 and C16 have similar bond contents, average abrasive particle sizes and bond chemistry, but Sample S6 has more bond post count in average and higher average bond count to bond content ratio than Sample C16. Samples S7 and C17 have similar bond contents, average abrasive particle sizes and bond chemistry, but Sample S7 has more bond post count in average and higher average bond count to bond content ratio than Sample C17. Samples S8 and C18 have similar bond contents, average abrasive particle sizes and bond chemistry, but Sample S8 has more bond post count in average and higher average bond count to bond content ratio than Sample C18. It is expected Samples S6-S8 have improved performance over their respective control Samples C16-C18 including stock removal, surface finish (e.g., roughness Ra), or both.

The samples have the same dimension of 8×30×28 mm and are tested in superfinishing of a workpiece using a plunge test, similar to the illustrations of FIG. 10A-10B or FIG. 10C. It is expected Samples S1-S3 has improved performance over Samples C10-C14 including stock removal, surface finish (e.g., roughness Ra), or both.

Hardness and density variation of Samples S1-S3 are decreased compared to Samples C10-C12. Hardness was tested on modified Rockwell system with Atlantic scale as described in embodiments herein. Minimum of 6 indents per side (top/bottom) were made for each sample. Hardness variation (%) was calculated as standard deviation/mean.

	TABLE 10
	Sample	Hardness variation (%)
	C10	12%
	C11	15%
	C12	17%
	S1	8%
	S2	4%
	S3	2.5%

Example 2

The wetting ability of the bond materials of C10 and S1 were evaluated. Small pellets of similar sizes are pressed using the bond precursor of C10 and S1 and heated in a furnace at the ramp rate of 10° C./hour from 18° C. to up to approximate 930° C. The height of pellets is measured versus heating temperatures. Pellet height of the bond precursor material of S1 starts to decrease at a temperature lower than the temperature of the bond precursor material of for C10, which may suggest a lower melting temperature of bond precursor material of S1 compared to C10. Lower height of the bond precursor of S1 compared to C10 at a same temperature may suggest improved wettability of the bond precursor of S1 over the bond precursor C10. FIG. 4A includes an image of a pellet of the bond precursor C10 heated at above 900° C. for an hour and FIG. 4B includes an image of a pellet of the bond precursor S1 heated at the same temperature for the same period of time. The pellet formed by the bond precursor of S1 demonstrates significantly smaller height compared to C10 and thus improved wetting ability over C10. It is to be appreciated that bond materials with high wetting ability may form bond posts with smaller sizes while bond materials with low wetting ability may form bond posts with larger sizes. Smaller bond post sizes and higher average bond post count suggests improved microstructure of the bonded abrasive body.

The foregoing embodiments are directed to bonded abrasive products, and particularly superfinishing sticks, which represent a departure from the state-of-the-art. The abrasive articles of the embodiments herein utilize a combination of features that facilitate improved performance over similar conventional abrasive articles. As described in the present application, the abrasive articles may be made with a bond precursor material having a particular average particle size, particular bond chemistry, or both. During formation of the abrasive article, the bond material demonstrates improved wetting ability, compared to conventional bond materials, which facilitates formation of improved microstructure, such as improved average count of bond posts, bond post sizes, or both, which in combination with other features, such as average abrasive particle sizes, porosity, or both, facilitates improved formation and microstructure of the bonded abrasive body, which in turn facilitates improved properties and/or performance of the abrasive articles. Not wishing to be bound to any theory, carefully controlled milling of bond precursor materials, achieving particular particle sizes of bond precursor materials, obtaining higher ratios of abrasive particle size to bond precursor particle size, and/or selection of bond chemistry may facilitate formation of improved microstructures of the bonded abrasive body. For example, the bonded abrasive body may include improved number of bond posts compared to corresponding conventional abrasive products.

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. Reference herein to a material including one or more components may be interpreted to include at least one embodiment wherein the material consists essentially of the one or more components identified. The term “consisting essentially” will be interpreted to include a composition including those materials identified and excluding all other materials except in minority contents (e.g., impurity contents), which do not significantly alter the properties of the material. Additionally, or in the alternative, in certain non-limiting embodiments, any of the compositions identified herein may be essentially free of materials that are not expressly disclosed. The embodiments herein include range of contents for certain components within a material, and it will be appreciated that the contents of the components within a given material total 100%.

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.