Tetrahedral shaped abrasive particles with predetermined rake angles
Various embodiments disclosed relate to a shaped abrasive particle. The shaped abrasive particle includes at least four major faces and at least six edges joining the four major faces. One of the at least four major faces is a first rake face, a second of the at least four major faces is a second rake face. The first and second rake faces are predominantly joined along only one common edge. A dihedral angle between the first rake face and the second rake face is in a range of from about 71 degrees to about 170 degrees.
1 . An abrasive article comprising:
a backing; and
a plurality of tetrahedral-shaped ceramic abrasive particles, wherein the plurality of tetrahedral-shaped ceramic abrasive particles are monolithic, shaped abrasive particles, and wherein each of the tetrahedral-shaped ceramic abrasive particles comprises:
at least four major faces, wherein each of the at least four major faces comprises a triangular shape;
at least six edges joining the four major faces;
one of the at least four major faces being a first rake face, a second of the at least four major faces being a second rake face, and the first and second rake faces being joined along a first edge having a first length, the second rake face and a third major face being joined along a second edge, and the third major face and a fourth major face being joined by a third edge having a third length, wherein the first length of the first edge is in a range of from about 1.03 times to about 2 times the second length of the second edge and the third length of the third edge;
wherein a dihedral angle between the first rake face and the second rake face is in a range of from about 71 degrees to about 170 degrees; and
wherein each of the plurality of tetrahedral-shaped ceramic abrasive particles comprises a magnetic material or is coated with a magnetic material such that each of the plurality of tetrahedral-shaped ceramic abrasive particles is responsive to a magnetic field to provide a precise orientation of the plurality of tetrahedral-shaped ceramic abrasive particles on the backing.
2 . The abrasive article of claim 1 , wherein a dihedral angle between the backing and one of the first rake face and the second rake face of an individual tetrahedral-shaped ceramic abrasive particle is in a range of from about 80 degrees to about 135 degrees.
3 . The abrasive article of claim 1 , wherein a dihedral angle between the backing and one of the first rake face and the second rake face of an individual tetrahedral-shaped ceramic abrasive particle is about 90 degrees.
4 . The abrasive article of claim 1 , wherein the dihedral angle between the first rake face and the second rake face of about 50 wt % to about 100 wt % of the tetrahedral-shaped ceramic abrasive particles is the same.
5 . The abrasive article of claim 1 , wherein one of the first rake face and the second rake face of an individual tetrahedral-shaped ceramic abrasive particle is substantially aligned with the direction of use.
6 . The abrasive article of claim 1 , wherein the tetrahedral-shaped ceramic abrasive particles are sol-gel derived abrasive particles.
7 . The abrasive article of claim 1 , wherein the tetrahedral-shaped ceramic abrasive particles comprise alpha-alumina.
8 . The abrasive article of claim 1 , wherein the tetrahedral-shaped ceramic abrasive particles are adhered to the backing by a make coat, the make coat comprising: a phenolic resin, an epoxy resin, a urea-formaldehyde resin, an acrylate resin, an aminoplast resin, a melamine resin, an acrylated epoxy resin, or a urethane resin.
9 . A method of making the abrasive article of claim 1 , the method comprising:
adhering the plurality of tetrahedral-shaped ceramic abrasive particles to the backing.
10 . A method of using the abrasive article according to claim 1 , the method comprising:
contacting the plurality of tetrahedral-shaped ceramic abrasive particles with a workpiece;
moving at least one of the abrasive article and the workpiece relative to each other in the direction of use; and
removing a portion of the workpiece.