A bonded abrasive tool includes a bonded abrasive body having a bond matrix material including an organic bond material, abrasive grains contained within the bond matrix material, and chopped fiber bundles within the bond matrix material. The tool further has a porosity within the bonded abrasive bo
A bonded abrasive tool includes a bonded abrasive body having a bond matrix material including an organic bond material, abrasive grains contained within the bond matrix material, and chopped fiber bundles within the bond matrix material. The tool further has a porosity within the bonded abrasive body, wherein a majority of the porosity includes pores surrounding the chopped fiber bundles.
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1. A bonded abrasive tool comprising: a bonded abrasive body comprising: a bond matrix material comprising an organic bond material;abrasive grains contained within the bond matrix material;chopped fiber bundles within the bond matrix; andporosity within the bonded abrasive body, wherein the porosit
1. A bonded abrasive tool comprising: a bonded abrasive body comprising: a bond matrix material comprising an organic bond material;abrasive grains contained within the bond matrix material;chopped fiber bundles within the bond matrix; andporosity within the bonded abrasive body, wherein the porosity comprises two phases, a first phase comprising small pores uniformly dispersed within the bond matrix material, and a second phase comprising large pores selectively disposed around the chopped fiber bundles. 2. The bonded abrasive tool of claim 1, wherein the large pores are voids extending laterally around portions of the peripheral surfaces of the chopped fiber bundles. 3. The bonded abrasive tool of claim 1, wherein the large pores are voids extending longitudinally along a portion of the length of the chopped fiber bundles. 4. The bonded abrasive tool of claim 1, wherein the large pores comprise irregular cross-sectional shapes. 5. The bonded abrasive tool of claim 1, wherein the small pores comprise a circular cross-sectional shape. 6. The bonded abrasive tool of claim 1, wherein the large pores have an average pore size (P1) and the small pores have an average pore size (Ps), and the bonded abrasive body comprises a pore size ratio between the average size of the large pores and the small pores (P1:Ps) of at least about 2:1. 7. The bonded abrasive tool of claim 6, wherein the pore size ratio (P1:Ps) is within a range between about 2:1 and about 10:1. 8. The bonded abrasive tool of claim 1, wherein the large pores have an average pore size (P1) within a range between about 1 mm and about 10 mm. 9. The bonded abrasive tool of claim 1, wherein the small pores have an average pore size (Ps) of not greater than about 1 mm. 10. The bonded abrasive tool of claim 1, wherein the bonded abrasive body comprises not greater than about 12 vol % porosity. 11. The bonded abrasive tool of claim 1, wherein at least about 75 vol % and not greater than about 98 vol % of the total volume of porosity is large pores. 12. The bonded abrasive tool of claim 1, wherein a majority of the porosity comprises pores surrounding the chopped fiber bundles. 13. A bonded abrasive tool comprising: a bonded abrasive body comprising: a bond matrix material comprising an organic bond material;abrasive grains contained within the bond matrix material;chopped fiber bundles within the bond matrix having a length within a range between about 1 mm and about 5 mm; andporosity within the bonded abrasive body, wherein the porosity comprises two phases, a first phase comprising small pores having circular cross-sectional shapes uniformly dispersed within the bond matrix material, and a second phase comprising large pores extending laterally around portions of the peripheral surfaces of the chopped fiber bundles. 14. The bonded abrasive tool of claim 13, wherein the bonded abrasive body comprises a fracture toughness within a range between about 750 J/mm2 and about 1100 J/mm2. 15. The bonded abrasive tool of claim 13, wherein the chopped fiber bundles comprise a length (l), a width (w), and an aspect ratio (l:w) defined by the length and the width of at least about 2:1. 16. The bonded abrasive tool of claim 13, wherein chopped fiber bundles comprise at least about 200 fibers bonded together with an organic binder. 17. The bonded abrasive tool of claim 13, wherein the chopped fiber bundles comprise a glass material. 18. A bonded abrasive tool comprising: a bonded abrasive body comprising: a bond matrix material comprising an organic bond material;abrasive grains contained within the bond matrix material;chopped fiber bundles within the bond matrix; andporosity within the bonded abrasive body, wherein the porosity comprises two phases, a first phase comprising small pores uniformly dispersed within the bond matrix material, and a second phase comprising large pores surrounding the chopped fiber bundles, the bonded abrasive body demonstrating a material removal rate (MMR) of at least about 13 in3/min and having a G-ratio (MMR/WWR) of not greater than about 40 while grinding a metal workpiece having a thickness of 0.5 inches with a downforce applied to the bonded abrasive body of at least about 45 HP. 19. The bonded abrasive tool of claim 18, wherein the MRR is within a range between about 13 in3/min and about 17 in3/min. 20. The bonded abrasive tool of claim 18, wherein G-ratio is within a range between about 25 and about 40.
Kalinowski Paul W. (Boylston MA) Ramakrishnan Muni S. (Northboro MA) Rue Charles V. (Petersham MA) Sheldon David A. (Worcester MA) Swanson Brian E. (Northboro MA), Bonded abrasive products containing sintered sol gel alumina abrasive filaments.
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