United States Patent Skeem et al. (51) METAL SINGLE LAYER ABRASIVE CUTTING TOOL HAVING A CONTOURED CUTTING SURFACE (75) Inventors: Mareus R. Skeem, Northridge, MA (US); Serge)-Tomislay Buljan, Acton, MA (US); Jean Kramp, Rumelange uy (73) Assignee: Saint-Gobain Abrasives Technology Company, Worcester, MA (US) (2) Notice: Subject to any disclaimer the teem of this patent is extended or adjusted under 35 US.C. 1540) by 0 days, (21) Appl. Now 10/963,292 (22) Filed: Oat. 12, 2004 (65) Prior Publication Data [US 2005018879 AT Max. 3, 20s Related U.S. Application Data Dusson of amltion Ns, OGS28, don a. 15 No 686,538 fed on Mat. 15,1995, now abandoned. (1) Im cL B24D 7/00 & U, 481/587; 451/541; 125/13.01 15/15 (58) Fleld of Search 4si/s4, $42, 451/544, 547, 548, 135/13.01, 13.03, 15, 20, 16001, 22; $3851, 846 66) References Cited US. PATENT DOCUMENTS. orrast A 71909 Per Laoseat A * T1918 Stat QsILSa0 A 1/1957 Fase ssid 1US00693594082 a0) Patent No. US 6,935,940 B2 5) Date of Patent Aug. 30, 2005 3016.61 A 11962. Nien Sooo A loca Pat 30050 A 1962 Christensen Snasy A * M903 Bown saxo Sima A ses Libr Naw2w A967 Lantld 3436,571 A 4/1969 Schacider etal Sinai A 21970 Linda 3aosas0 A 2107 Sanh ta (Continued) FOREIGN PATENT DOCUMENTS be ossss 802 Ep wpiars 91088 ® S7isiers 1/1982 P e127 121198 su jos “41972 Primary Examiner —Goorge Nguyen (74) Attorney, Agent, or Firm—Mary E, Porter 67 ABSTRACT. This invention relates to an abrasive cutting ool comprising 1) a substrate surface having a plurality of teeth extending therefrom, and ii) a single layer of abrasive grains chemically bonded to a east a portion of each (ooth to define plurality of cutting levels parallel to the substrate surface, the ‘uttng levels comprising st uppermost cutting fevel tnd a second uppermost cutting level, the grains having, 4 predetermined concentration, size and toughness, ‘whereby the abrasive culling tool has a culing surface ‘with a negative angle of inclination with respect to an intended direction of culling. 2 Claims, 2 Drawing SheetsUS 6,935,940 B2 Page 2 US. PATENT DOCUMENTS. $869,500 A 1/1989 Deskin 51827 8 * 1991 Asads ser 3513821 A S/1970 Bouvier SOO28GS A ALISOL Chem SSATSS1 A G/ID71 Neon Sidoo09 A 91902 Ruask et a SBaR40L A 21975. Schwarekopt 5392759 A 21995 Kwang $1632 A 9/197 Greenspan S209 A 7/1995. Sherer ota 407283 A 101983. Murat SaRRI87 A 71905 Hayasala ct 4461268 A 7/1984 Inowe S138 A 81995 Chiumiaata Si0k237 A 1/98 nove ‘6171936 BL * 11/2004 Seem et asus 4037370 A + 11087 Ishizuka nasis $800,722 81989 Veal * cited by examinerU.S. Patent Aug. 30, 2005 Sheet 1 of 2 US 6,935,940 B2 FIG. 1 PRIOR ART PENETRATION RATE FIG. 5C C22, FIG. 4D b FIG. 5DU.S. Patent Aug. 30, 2005 Sheet 2 of 2 US 6,935,940 B2US 6,935,940 B2 1 METAL SINGLE LAYER ABRASIVE CUTTING TOOL HAVING A CONTOURED. CUTTING SURFACE ‘This application i a divisional application claiming priority in U.S. Ser. No. 68/892,896, ile Jul. 15, 1997, now US. Pat. No. 6817,936, and US. Ser, No, 08/616,538, filed Mat. 15, 1996, now abandoned. BACKGROUND OF THE INVENTION Superhard abrasive cutting tools fited with saw blades, core hits and cutting, wheels for use in consrvetion appli ‘ations are typically classified as either metal matrix bonded (MB) or as ictal single layer (SL). The SL cutting tool has a single layer of abrasive grain (or “rt”) bouded to a ‘smooth metal subsiate by a minimum of bond material so that the abrasive grit is essentially exposed on the cutting ‘surface of the tool. When the cutting surace is presented to the workpiece 1 be cu, substantially only the abrasive grit ‘contacts the workpiece. Since a substantial portion of the Joad of the tool is eared by the abrasive gait, the load on ‘each culling point of the grit is very high, This condition produces high penetration rates and high cutting rates However, since the SL tool has only a single layer of abrasive, it ean no longer eflectvely cut once that layer is ‘dulled during operation The MB too! increases too life by increasing the number ‘of layers of abrasive grit om the culling surface, The typical MB tool is made by forming segments of an abrasive- ‘containing metal matrix and allaching those segments to the periphery of stecl substrate, Because abrasive grit is dispersed throughout the segments, the MB. cutting tool ‘surface remains effective after the uppermost abrasive grains dull and are removed. Accordingly, MB tools generally have 4 Tonger life than SL tools. However, since the abrasive grit ‘embedded ina metal matrix, both the metal matrix and the abrasive grit are exposed on the tool periphery. When the MB tools presented to the workpiece, both the abrasive grit and the metal matrix contact the workpiece, thereby lower- ing the load on each cutting point of the grit (as compared to an SE tool) and producing lower penetration rates and lower euting rates, Some metal single layer tools having teeth are known in the art In-one tool, rectangular tecth are provided on the ‘edge of a core dil, and a single metal layer of abrasive [grins are bonded 1o the teth. During use, the uppermost trains on the teeth cut the workpiece. However, the lage Size, high concentration and low toughness of the grains are ‘uch that these uppermost grains quickly dull when cutting, hard surfaces such as masonry, apd the pen the tool quickly falls 0 zero, In another tool, angled teeth are provided on the euting surface of a grinding wheel, and a single metal ayer of abrasive grains is electroplated tothe teeth. During use, the ‘uppermost grains on the teeth cut the workpices. However, the weak mechanical nature of the eleetoplate hon! results Jn the lower levels of grains being peeled from the tooth. ‘Accordingly, the usefulness of the tool is limited to the usefulness ofthe uppermost layer of grains Therelore, it is an object of the present invention 10 provide «cutting (ool having the high penetration rate ‘characteristic of an SL. ool and the long life characteristic of an MB tool SUMMARY OF THE INVENTION In accordance with the present invention, there i pro= vided an abrasive cutting (ol comprising: ation rate of o 2 a) a substrate surface having a plurality of teeth extending therefrom, each tooth having a surface, and ') a layer comprising abrasive grains, the layer being chemically bonded oat least a portion othe surface ofeach tooth to define a plurality of eusting level parallel to the substrate surface, ‘wherein the grains have a rclative strength index of at least ‘one minute, as measured by the FEPA standard for measur- ing the relative strength of saw diamond. ‘Also in acoordanee with the present invention, there is provided « method of cuting, comprising the steps of: 48) providing an abrasive euting too! comprising 1a substrate surface having a plurality of teeth extending Therelrom, each tooth having a surface, and 4i) a layer comprising abrasive grains, the layer being ‘chemically bonded to at least a portion ofthe surface of ‘each tooth to define a plurality of cutting levels parallel to the substrate surface, the cutting levels comprising 3 fist uppermost cutting level and a second uppermost cutting level, the grains having a predetermined wear bb) moving the substrate surface in an intended ditection of ©) contacting the uppermost cutting level of at east one tooth to a workpiece at 8 point of contact, ‘) applying 2 constant force to the tool directed at the point of comtct ‘wherein the constant force is sulfcient to eu the workpiece, the strength of the bone! is sufficient to resist peeling, the predetermined wear resistance of the grains is sich that the {grains of the frst uppermost cutting level fracture under application ofthe constant force, and the wear resistance of the fcth are such thatthe portion of the tooth associated with the fist uppermost-cuttiag level wears at about the same rate as the grains of the first uppermost culling level Iracture, thereby causing essentially simultaneous removal ofthe grains of the frst uppermost cutting level from their bond and the portion of the tooth associated with the frst ‘uppermost cutting level, and thereby exposing the grains ofthe second uppermost cutting level tothe workpiece, ‘Also in accordance with the present invention, there is provided un abrasive eulting tool comprising: a) a substrate surface having a plurality of teeth extending therefrom, each tooth having a surface and ) a layer comprising abrasive grains, the layer being cbemically bonded to at least a portion ofthe surface of each ‘ooth to define a plurality of cutting levels parallel to the substrate surface, ‘wherein the substrate surface has an intended direction of ‘movement, wherein the plurality of tecth includes succes- sive teeth’ having successively lower uppermost cutting levels in the direction of the intended direction of movement, thereby producing a cutting surface having @ negative angle of inclination with respect to the intended Giretion of movement, ‘Also in accordance with the present invention, there is provided an abrasive euting too! comprising a) a substrate surface having a plurality of teeth extending therefrom, each tooth having a surface, and ') a layer comprising abrasive grains, the layer being chemically bonded oat least a portion of the surface ofeach ‘ooth to define a plurality of cutting levels parallel to the substrate surface, ‘wherein the substrate sueface has an intended dirvetion of| ‘movement, witercin a least a portion af each tooth has 2 face ‘whieh i inelined at @ negative angle with respect to theUS 6,935,940 B2 7 intended direction of movement, and at least a portion ofthe rains are bonded to the face having the negative angle of| inclination ‘Also in accordance with the present invention, there is provided an abrasive cutting tool comprising: ') asubstrate srface having «plurality of teeth extending therefrom, the tecth having a surface and a predetermined wear resistance, and ) 4 layer comprising abrasive grains, the layer being ‘chemically bonded to at leat s potion of the surface ofeach tooth to define a plurality of cutting levels parallel 10 the substrate surfuee, the grains having a predetermined we resistance, Wherein the wear resistance of the tweth snd the wear resistance of the grains are predetermined such tht, wheo & given cutting level contacts a workpiece under an optimum Toad, the grains of the given cutting level wear and fracture at about the same rate asthe portion ofthe tooth associated ‘with the given cutting level wears away. DESCRIPTION OF THE FIGURES. FIG. 1 shows the Hat surface of » conventional SL tol FIG. 2 compares the time dependence of penetration rate for a conventional SLcore dil With that of one embadimment cof the present invention FIG, 3 shows one embediment of the present invention wherein the teeth have a tripezoidal shape, FIGS. 4 and § show the changing shape of the FIG. 3 ‘embodiment during use, [rom a side and top view respec tively, FIG, 6 shows one embodiment of the preseat invention in whieh the teeth have a triangular shape FIG. shows one embodiment of the present invention ia ‘which each tooth comprises a plurality of projections ‘extending from the base to different heights, FIGS. 8 and 9 show two prefered embodiments of the teeth of the present invention, FIGS. 10, TL and 12 show embextiments of the present Jnvention wherein the subsirate i a wheel, core bit and biade, respectively DETAILED DESCRIPTION OF THE INVENTION For the purposes of the present invention, the eviting ‘surface 11 of a Tooth is considered 10 be the grains which ate bonded tothe tooth. A specific “cutting level” ofa tooth are all of the grains which are bonded fo the tooth atthe same distance from the subsirate surface. Similarly, a specific “cutting level” of a tool are all of the grains which ate bonded tothe too atthe sime distance from the substrate ‘surface, The “uppermost” cutting level & that which is farthest away from the substrate surface. The portion of @ tooth which is “associated” with & specific cuting level is that slice of the tooth which is positioned at the same ‘distance [vom the substrate surface asthe specified euting level. A plurality of cuting levels having "about the same number of grains” are those whose number of grains are between about 80% and 120% of the mean number of grains for those levels. The “concentration” of grit on a tooth is determined relative tothe theoretical hexagonal close pack ing of spheres. thas been found that when a the surface ofa cutting too! 's contoured with teeth which allow a plurality of eutting levels tobe formed b) the grains bonded to the toth surface have predetermined wear resistance which leas to failure % o 4 by fracture rather than dung ) the bond between the pri and teeth i strong enough to resist peeling, and dl) the toath ‘wear resistance is predciermined 10 match the grain Wear resistance so tha the tooth wears avvay a abot the same rate the grains wear and fracture, the resultant tool possesses advantages not found in the peor at tols. In particular, the {ool of the present invention has a longer life anda higher penetration rate than the both the conventional flat rimmed SL tool and the SL tools having teeth Te longer life of the present invention is attributed to is ability to eontinally provide fresh, sharp abrasive at the leading edge of each tooth as the eulting proceeds. See, for ‘example, FIG. 3. When the tool is presented to the work- Piece 27 s0 that the substrate surface & is parallel to the ‘workpiece surface, the angled ((e., non-parallel) face 4 of the cling surface produces » similarly angled orientation with respect to the workpiece surface. Sinoe this portion of the ctling surface is now angled towards the workpicee surface, only the fist uppermost cutting level contacts the ‘workpiece, thereby becoming the lading edge. Aste grains ‘of the first uppermost cutting level eut the workpieee, the Tacture and fall away before they signficanly dull. At the same time, the portion of the tooth associated with the frst "uppermost cutting level is mace of material which abrades Way at about the same rate asthe first uppermost cutting level, thereby exposing the fresh, sharp abrasive grains 3 of the second uppermost cutting level. This process repeats itself as each successively lower cutting level of grains ringing the tooth becomes the leading edge, cuts, dulls abit, {alls aay and, upon simultaneous abrasion of the postion of the tooth associated with that cuting love, exposes the fresh cutting level beneath i. Accordingly, itis believed that the present invention is the frst SL tool To provide fresh cutting levels of abrasive grain during use ‘Moreover, sinee oy a portion ofthe grains on te cuting surface contacts the workpiece at any onetime, the load per grain is mich highor than that found ia a conventional Rat ‘immed SI tool having the same amount of grain, leading to even higher penetration rates, Funber advantages of the present invention are best understood by contrasting iis peneeation rate pratle (over time) with that of a conventional (or “continuous rim") SL core bil. Ia continuous rim SI. tool, as shawn in FIG. 1, the Substrate surface SS is essentially smooth and the grains G bonded thereto contact the workpiece W during each cutting period. The initial penetration cate of this took; denoted by {he Region 1A in FIG. 2, is somewhat high because the irregularity of the grain shapes produce few initial contact points, Soom afterwards, those intial contact points dll and fssentally all of the grains on the tool ean contact the workpiece. However, because there are so many grains ‘comtacting the workpicce at any one time, the lower load per rain limi the cutting eat. As the grains dull, thee cutting tlicieney falls and the penetration rate falls (Region 1B). Eventually, the grains dll tothe point of polishing (Region 10), and the tool's usefulness has been spent Tnone embodiment ofthe SI.tool ofthe present vention, 4s, exeimplified by the trapezoid tonth design shown in FIG. 3,only the grains Hat the first uppermos.cuting level ofthe ‘woth? intially contact the workpiece 27. Since these grains ate sharp, thet contact produces very bigh initial penets- tion rate, as denoted by Region 3A in FIG. 2. As cutting proceeds, these grains dull and the penetation rate falls ily: However, before they dul significantly, these gr fracture and fall away, thus exposing the portion af the toath associated with the uppermost cutting level. When that portion of the tooth is removed by the abrasive action theUS 6,935,940 B2 5 workpiece, the grins ofthe Seoondl uppermost cutting level ‘Jom both he sloped portion ofthe tot and the four sides ‘of the tooth (such as side 8) become exposed to the works Piece. Since these grains of the second uppermost cutting level are stil sharp, they cut very elciently. However, there fare many more grains a! this cutting level und a portion of| the subsite now contacts the workpiece, thus distributing the tool's load over a wider area. Accordingly, the load per rain is somewhat lessened and the penetration rate, as ‘denoted by Region 3B of FIG. 2 falls slightly. Aste leading ‘edge travels sil farther dowa the tooth, the load por ‘contacting grain steudily decreases as the area of the tooth ‘contacting the workpiece and the number of grains in the ‘eutting level contacting. the workpiece both increase. Consequently, the penetration rate falls sill farther (egion '3C), When the leading edge reaches the grains 6 bonded (0 the right side of the tooth 7, both the horizontal cross- sectional area of the tooth and the aumber of grains con tacting the workpiece stop increasing. Accordingly, the load per grain stabilizes and the peneration rate reaches a steady ‘Stale condition (region 3D). The stetdy state condition ‘continues until the lading edge reaches the bottom of the tooth Because the steady state cutting conltion is desirable, in preferred embodiments a least about S0% (andl more pret= ably at least about 75%) ofthe cating levels have about the same number of grains. In some embodiments, this steady state region exists in each tooth. In some ‘embodiments, a steady stat region (ie. successive euting Jevels having about the sume number of grins) is present in at Feast the lowermost 0% of the tooth, FIGS. 4 and § display the change ia the condition ofthe tooth and cutting levels during us, as viewed from the side ‘of the tooth and from the perspective of the workpiece, respectively, wherein the hatched regions of FIGS, $6-Sd represent the portion ofthe tooth in contact with the work- piece. FIGS, 4a and Sa correspond to region 3a; FIGS. 4 and Sb correspond to region 36, ee “The trapezoidal tooth embodiment is preferred for 1wo reasons, Firat the sloped face 4 of the tooth restricts initial ‘workpiece contact to the few grains atthe first uppermost culling Level, and restricts subsequent contact 10 only a ‘minimum of grains and tooth area at lower cutting levels the face. This condition provides a very high intial cutting rate (‘egions 3a-3e of FIG. 2) whieh is important for ‘reatng an inal cut in a workpiece. Second, a the Lowest ‘eutting levels, the normal dispesition ofthe tooth sides $ and 7 guarantee that the number of grains and the area of the substrate in contact with the workpiece remains constant for the duration of the operation, Ths condition produces along steady sate condition (Region 3D of FIG. 2) of a significant penetration rate, wherein Working grains are simply eplaced by fresh grains before they significantly dull. This is impor taat in operations where extended reliability is needed, In preferred embodiments having trapezoidal teeth, at Jeast the uppermost 10% of the cuting surface of cach tat ‘comprises Fae disposed at an angle of between about 5 and. 60 degrees relative to the surface substrate. More preferably, the lowest 50% of each tooth has a constant cross ‘Sectional area parallel 1 the substrate surface, ‘Although the trapezoidal shape of the tooth of FIG. 3 provides particular advantages, the shape of the footh can be Any shape which provides for gradual presentation of fresh abrasive grain tothe workpiece as the abrasive grains whieh have been in contact with the workpiece fracture and fall away before they dull. For example, the triangular Shaped s o 6 tooth of FIG, 6 is also considered an embodiment of the present invention. In this embodiment, the cutting tool comprises substeate surface 16 and a series of triangular fecth 12 extending from the siefuce. In this ease only the grains at the uppermost cutting level 13 (hose bonded to the {op of each 100th 12) contact the workpivee W, thereby efining the leading edge. As those grains are worn away, fresh grains 14 (those atthe second uppermost cutting level) become the leading edge. In ts initial stages, the penetration behavior of this tooth would be relatively similar to that of the trapezoidal tooth of FIG. 3 (Regions 3a-3e of FIG. 2), but with the triangular tooth contact area expanding less rapidly than that ofthe trapezoid (given equal base lengths Land grain oad), leading to higher intial penetration rats, Inthe later stages of the triangular loots life, however, the substrate area contacting the workpiece continues to grow, as does the number of grains contacting the workpiece ‘Accondingly, steady state condition isnot reached and the penetration rate falls off much quicker. Although all of the grains in FIG. 6 are bonded to teeth, the subscate surface 16 may also bave grains brazed thereon. nother embodiments, asin FIG. 7, each tooth comprises 4 series of projections extending step-like to cilerent Tengths from the base of the substrate surface. In this ‘embodiment, the grains 22 bonded tothe fop ofthe tallest projection 23 consitute the uppermost cutting level and ‘uniformly coataet the workpiece 27 atthe beginning of the ‘operation, and as these grains 22 are worn away, fresh gr 24 bonded to a slightly shorter projection 28 become the leading edge ofthe cutting surface. This proces is repeated as grains 26 on projection 27 becoming the leading edge. ‘Accoedingly, the collective grains 22, 24 and 26 are con- sidered to constitute a single cutting surface disposed at langle tothe substrate surface. Similarly, a large number of| thin, closely spaced, successively shorter teeth (as shown ia FIG. 7a) function essentially equivalently to those in FIG. 7. ‘Anoilier Feature ofthe teeth of FIG, 7is that he abrasive grains are applied only to selected faces ofeach tooth. In this embodiment the graias 22 atthe top ofthe face 23 constitute the leading edge which contacts the workpiece 20. The vertical faces 28-31 of the tooth do not bive any grain bonded to them. In operation, this tool moves inthe left 10 right direction against a workpiece 20 (as signified by artow ‘A) to produce a negative rake ‘is anticipated tha, in some application, the yeains athe Ieading edge ofa sharply sloping face willbe susceptible t0 undercutting. Undereutting occurs when a sharp grain in ‘contet withthe workpiees Is prematurely removed because ‘svar has removed the underlying bond. Therefor, in some embodiments, the tool is designed to have at Teast one culting surface 4 which slopes downward toward the sub- Strate surface 8 at an angle of between about 5 and degrees, and the tool is moved across a workpieee W in a rection of negative rake (as signified by arrow B). Under these conditions, the grains ofthe second uppermost cutting level 3 are suficently close to the grains of the first "uppermost cutting level 1 to physically protect the integrity ‘of the bond tothe grins ofthe first uppermost cuting level 1 from the swat, thereby preventing the undercuting of those grains 1. The prefered angle for preventing undereut- ‘ing appears 1 be indepeadent of grain size, but varies with the concentration. When the concentration of the abrasive grain is about 100%, the angle required for protection is between about 26 and about 32 degrees. When the concen- tration ofthe abrasive grain is about SO, the angle required for protection is between about 14 and about 17 degrees, ‘When the concentration ofthe abrasive gran i about 25%,US 6,935,940 B2 7 the angle required for proteetion is between about 9 and about 11 degrees, When the concentration of the abrasive gain is about 12%, the angle required for protection is hretween about 5 and about 7 degrees. In other words, the angle of protection should be no more than about I degree for every three percentage points of grain concentration, In other embodiments the tooth has a shape as showa in FIG. 8, This tooth 68 comprises an angled portion 62 whieh rises at an angle of about 45 degrees on one side, a Hat top 63, and a descending portion 64 on the back side. Moving the tooth across a workpiece in the direction of arrow C provides the desired negative rake condition In other embodiments, the tooth has a contour as shown in FIG. 9, The tooth i rounded at ils junction with the Substrate surface (U) and atthe upper most ends (E). The teeth also have radial grooves (G). The rounded edges provide the uppermost grains with protection from Undercuttng, while the radial grooves provide space for an additional level of abrasive grain which will become the leading edge when the uppermost grains tracture and fall away. Since a conventional SL whee! heats up to between about S0C and 100 C during use and undergoes significant thermal ‘expansion, expansion gaps, of “gullet”, aze often designed Into the perimeter ofthe wheel. For example,oma typical 12 inch diameter wheel, these gaps are about Yi inches wide, thout % inches in height, ae spaced about 2 inches apart, ‘ypieally comprise no mace than 5% of the citeular perim~ ‘ler and sometimes have abrusive grain adhering t0 thi hottoms and sides. However, these gaps are completely different thaa the spaces between the telh of the present Jvention, as there are so many grains onthe long fat of & ‘conventional SL wheel there is effectively only one euting level, and the Tower load per grain at that cuting level merely dulls and does not fracture the grains of that cutting level In preferred embodiments, the cutting surface of the present invention typically comprises an angled face com- prising atleast 20% ofthe cutting levels, preferably between 18% and 1OQE. Although not required itis also preferable that the angled face include the uppermost 10% of the culling levels. It i still more preferable that the angled face ‘comprise at least 50% and most preferably at least 75% of the uppermost cutting levels on the tooth Te teth ofthe present invention are typically spaced so that thei base lengths L (as in FIG. 3) constitute at east about 10% of the substrate surtaee, prelerably between thout 309% and 604%, When the bases comprise less than 10% te teeth are mechanically weak and prone 10 beading and breakage. Typical teeth materials include fiber reinforced plastics, steel, and other appropriale materials having a structural strength of between 20 Re and 70 Rez However in preferred ‘embealiments, the grains and teeth ate particularly designed to wear at about the same rate. The wear resistance of any material is determined by its hardness and fracture toughness, and increasing either [ator inereases the wear resistance of the material, In the case of the layer of the present inveation, the wear resistance is generally deter ‘mined by the wear resistane ofthe grains. In grains such as «diamond or eubie boron nitride, the hardess ofthe material ‘ean not be significantly varied so the grain’s fracture tough= ness is typically the festure which is varied. One common measure ofthe fracture toughness of a grain is ils relative Streogth index, as measured by the FEPA standard for measuring the relative srength of saw diamonds, In general % o 8 rains having a celative stength index of atleast one minute fre deste I the tooth of the present invention is made of 4 material other than a meta, then the harass or fracture foughness af the material ean be varied inorder to match the swear resistance eats. Inthe case of the teeth of the present invention being made of a metal such as steel, the fracture oughness is already very high and so the hardness of the metal is varied in order to provide the matching wear rate In one particuacly prefered embodiment, the tooth is made of a metal (preferably a steel) having a hardness of between 238 Rand 42 Ra while the grain (preferably a diamond) has ‘relative strength index of atleast ne minute. Core drilling tools of the present invention having a tooth hardness of 38-42 Ra (such as mild steel) were observed to effectively fut 4 broad range of building materials including cured feoncrete, concrete block, andl dense limestone block. Effective replenishment of grains via the exposure of lower cutting levels may also depend upon the aggressive- ess ofthe workpiece. IF the teeth are 100 sof or too hard, the effectiveness of the lool ean easily be sigoilicanly reduced by 50% of more, Teeth having a hardness of sbout ‘50 Ra were infective in culling limestone, as tbe limestone ‘ould not abrade the harder stel quickly enough to expose sharp new grit at lower cutting levels. Therefore, when the workpiece is hard and non-abrasive, the teth preferably have t hardness of about 28 Ra, Conversely, teeth having 2 hardness of about 28 Ra were ineffective in drilling conceete block, as the conerete block abraded the solier teeth 100 rapidly, thereby removing grit which were still sharp. Therefore, when the workpiece is solt and abrasive, the teeth preferably have a hardness of about 64 Re. Inthe eases af both the too-hard teth and the too-softtetb, the tool life ‘was less than 50% o the life of the tooth having the haedness fof botween 38 Ra and 42 Ra, Because the total area of the grain contact points deter- ‘mines the normal siress at the point of contact with the ‘workpiece and hence the cutting rae, factors such as tot thickness, and grain size, concentration and toughness also are important factors ‘The present invention can use any abrasive grains which abrasive his a grain size of less than 1000 um, preferably between 100 um and 600 um, and is typically present in 2 concentration of less than 75%. In prefeered embodiments, superabrasives such as diamond grit and eubie boroa nitride and boron suboxide are used, typically in gain sizes found fon conventional SL wheels. When diamond is used, it ‘typically has a gran size of between about 100 and 1000 umn and is present in a concentration of about 50%. When cubic boron nitride i used, it typically has grain sie of between bout 100 and S00 wim, and is present in a concentration of about 50%, In general, when the material to be cutis very hoard (Le. has a Knoop hardoess of over 700 Re), 2 tough, song abrasive having a relative suength index of less than 1 minute (as measured by the FEPA standard for measuring te relative strength of saw diamonds) is selected. Other ‘conventional abrasives such as seeded sol gel alumina and silicon earbide may also be desirable in selected applica- Inne preferred embodinent, each tooth has a trapezoidal ‘configuration with a top length of about [5 mm, a bottom length of shout 6:5 mm, a width of about 2 mm, a height of bout 2.8 mm, and fas an angled face having an angle of| about ~45 degrees. The diamond's FEPA size designation is 501 and the relative strength index is about 1.38 minutes (3300 eycles), as measured by the FEPA standard for mea-US 6,935,940 B2 7 ‘suring the relative strength of saw diamonds, The diamond it concentration is about 50%, or about 0.03 giem?, and is bonded by a bronze titanium bond to teeth made of a see] having « hardness of about 38-42 Ra, is believed some beuzes used in conventional SL. tools ‘ean be used in accordance with the present invention, ‘Typical brazes include nickel alloys such as Ni—Ce alloys, and reactive brazes such 8 bronze-titanium brazes. The braze must provide a chemical bond wich is strong enough to resist the simultaneous peeling of lower cutting levels ‘when an upper cutting level is removed during grinding. In some instances, the abrasive grains can be coated with a ‘lal such as llanium or tungsten for eller adherence wo the braze ‘The SL tool of the present invention ean be advant geously used to cut say’ workpieces having a Knoop hard- ness of at least S00 and which have been conventionally cut by diamond-laden tools, in particular, inorganic materials ‘sch as glass, tile, concrete and composites having hard dispersoids. It is especially desirable in masonry appliea- tions where the workpiece is selected from the group con- sisting of brick, such as Hime-silies, cement block, and cconerete, sich as cured conerete. It’ may be used 10 cil, ‘ceramic refractories such as alumina, silicon carbide and silicon nitride. It may also be wsed in cutting softer materials Tike plasties and composites. In many hand-triling applications involving tols ofthe present invention, the contact hetween the surface of the workpiece andthe cuting surfaces of the too caries a load ‘of a9 more thin about 30 to 40 pounds The present invention can be used ia typical SL ‘configurations, including wheels, core bits and flat blades, ‘Therefore, in accordance with FIG. 10, there is provided an abrasive cuting wheel comprising: 1) a circular dise 71 having a substrate surface 72 and a plurality of teeth 73 extending from the subsiate surface, snd i) a single layer of abrasive grains 76 chemically bonded to the perimeter of each tooth to define a cuting surface on ‘each woth ‘When used in a cuting wheel operation, the dise is typically made ofstel and has a diameter of between about 4 and about 40 inches; fora ten inch blade, the teeth are preferably of a trapezoidal shape, total bout 20 to 90 in hhumber, have a height of about 0.402 o 0.20 inches, a width ‘of about 0.02 o 1.2 inches, and a thickness of about 0.02 10 (012 inches; the abrasive is typically diamond in the size range of 500 um, preferably between about 450 and 650 um having «relative stengt index of atleast one minute and jn a concentration of about (01 to 0.08 giem2; the Work- piece is typically concrete of masoarys and the teth move along the workpiece in negative rake In accordance with FIG. Ll, there is provided an abrasive ‘core drill comprising 1) a barrel 81 comprising a frst end 82 having a plrality ‘of teeth 83 extending therefrom, and ii) a single layer of abrasive grains 8S chemically bonded to the tcth to define @ cutting surface 86 on each toth, ‘When used in a core dill operation, the bartels typically made of steel and has a diameter of between about 1 and about 6 inches; the projections are preferably of trapezoid ‘shape ot about 10 to 60 in number, have a height of about (0.05 t0 0.3 inches, a wid of about 0.1 10 0.5 inches and a thickness of about «04 to 0.12 inches: the abrasive is typically diamond in the size range of 500 um, preferably % o 10 between about 430 and $40 um, having a relative strength index of at lest-one minut, and in a conceatration of about 0.01 to 0.08 giem2; the workpiece is typically masonry or cconcrete; and the teeth move along the workpiece in ne: tive rake "The SL core drill of the present invention is completely diferent than the prior ant steel ole saw blade discussed above having teeth covered with abrasive, as these hole saw blades typically use much larger, much weaker abrasives in ‘uch greater concentrations (ic, typically on the order of 100F%) and are used at very high applied loads to cut very soft materials such as wood or plastics. In conventional use ‘ofthis type of hole sa the gras on the eading ede ofthis tool donot fracture and fall aay during grinding, but only ull Since the grain size, toughness and grain concentration prevent grain replenishment atthe leading edge, this eon- Yentional hole saw in no way suggests the advantages found in the present invention In accordance with FIG. 12, here is provided an abrasive blade comprising 1) a blade 91 having a linear substrate surface 92 and a plurality of teeth 93 extending trom the linear substate Surface, and ii) a single layer of abrasive grains 95 bonded to each tooth to define @ cutting surface 96 of each toot, ‘When used in a blade operation, the blade is typically ‘made of steel and has a length of between about 3 and about 9 inches; the projections are preferably of trapezoid shape, total about 10 10 100 in number, have height of about 0.08 100125 inches, » width of about (05 to 0.12 inches, and & thickness of about O05 to. 0.15 inches; the abrasive is typically diamond in the size range of 300 to 600 um, preferably between about 300 and S00 um, having a relative strength index ofa least one minute, and ina conceatration ff about 0.01 and 0.08 gvem2; the workpiece is typically light concrete or cinder block; and the teeth move along the workpiece in a condition of negative rake ‘COMPARATIVE EXAMPLE I "This test examined the behavior of holes saws baving Mat rims. Two 25 inch diameter hole saws having Mat rims were selected as the starting substrates. Bronze-itanium braze paste was applied to the rim, covered with about 1000 mg of ‘iamond abrasive to produce an abrasive concentation of| bout 100%, and the brize was melted by conventional ‘vacuum furnscing One of the tools so made contained 35/40 SDA 100+ iamond abrasive. Cutting was undertaken by band drilling 1508 rpm with a load of 30-40 pounds. This tool drilled ‘nly about 20 80-inch holes though heavy weight conccete block (*HCB") before the diamond was dulled and the cating rate fell below about 2 em/min ‘COMPARATIVE EXAMPLE Il ‘This test examined the behavior of hole saws having conventional MB seemenis. Thee MB segments containing ‘iamond were affixed to a core dell substantially similar to ‘hat of Comparative Example ‘These tools were tested under conditions substantially similar to those of Comparative Example I, and drilled an average of 400 em through HCB at an average of 5.3 ‘COMPARATIVE EXAMPLE IIL ‘This test examined the hehavior of a conventional hole saw having essentially rectangulae weth to which lowUS 6,935,940 B2 i toughness, large sized grain were alixed in a concentrator ‘of about 100%. These tools were tested under conditions ‘ubstaatally similar to those of Comparative Example I, nd drilled an average of only 3.em befor the cutting fell below 2eminia, EXAMPLE In this embodiment, core drills ofthe present invention swore made sing 66 mm diameter outlet bis having 22 mm wall thickness and made of 1020 steel having a 38-42 Ra hardness. The contour of the cutting surface was substan- ally similar to that shown in FIG. 9 “The crown of the bit was contoured by turing & 1 mm radius onto the leading edge of the steel Substrate and then riling nine 0,050 inch wide slots spaced equally round the petiphery. This procedure produced nine 0.403 inch wide, 10.200 high teth, Two equally spaced radial grooves (0.062: Jnches wide, 10825 inches deep) were then ground into the face of ech tooth. A0.035 inch layer of bronze titanium was then applied to the teth apd a layer of 35/40 SDA 100s ‘diamond (about 450 mg) was applied to the braze sucface tnd the resulting assembly was placed ia a vacuum furnace for conventional braze curing. Bits made in accordance with this example were used 10 hand dell heavy weight concrete HCB blocks. After about 120-140 inches of drilling, the diamond on the face ofthe teeth was worn away, Howover, the bits continued to cut sa acceptable rate (about 5 emyimin) because of the diamond positioned in the grooves of the teeth and on the periperal faces ofthe tect. These bits drilled another 0-80 inches of ‘concrete ater the uppermost diamond wore away. The total ‘depth of eut was about 180-220 inches, o¢ 490-560 em. EXAMPLE IL In this embodiment, tools ofthe present invention were sacle using 66 mm diameter outlet bits having. 42 axm Wall thickness and made of 1020 steel having a 3812 Re hardness. The contour of the cutting surface was substan- ‘ally similar to that shown in FIG. . Assinge layer of abrasive grain consisting essentially of 05 g of 35140 mesh SDA 100+ diamond and bronze titanium braze was applied to the contour of each bit. These bits were use to drill holes in HCB blocks. Initia penetration rates were about 3-4 iaches a minute. Although the diamond on the lending edge of the contour was worn away after only afew holes, the bits continued to dil over four meters of concrete block. When the lests were sis- pended after exch bit drilled 80 boles, the bits were still ‘riling a an acceptable rate of about 1.5-2 inches (38-5 n) pee minute. Dilling power varied between abeiit 350) tnd 550 watts over the course of the test, while spesilic ‘eneray varied between about 0.30 and 0.73 Jimm3. When testing resumed, the average life was found tobe 194 holes, ‘or about 988 em, The average speed was 6,7 em/see and the average power was about 41-4 W. Drilling was ended when then peneteation fell blow 2.5 emimin of the bit wore cut. ‘Therefore, the tool having pointed teeth produces superioe results, EXAMPLE IIL ‘Tis test examined the behavior of a hole saw having a reversed tooth orientation. The tooth configuration inthis ‘ease Was similar to that of Example TI, except that the angle ‘of orientation was reverse so thatthe descending portion of the tooth was the leading edge, thereby producing positive % o 12 rake, These tools were tested under conditions substantially Similar to those of Example I After drilling only 5 em, the teeth were so worn that only 20 of the height of the tat remained. (In contrast, this level of wear was found in the teeth of Example I ony ater a fll 400 em of drilling.) This tool dried for 396 em before the penetration rate fell below 25 emimin and had an average penetration rate of 54 femimin. Accordingly, the tool having teth oriented for 2 ‘negative rake produces superior results ‘The reslts of the above tess are summarized in Table ‘TABLE L Diese Dll (om) Send (minis) Wo chai 1An abrasive cutting tool comprising: ) 4 monolithic substrate having a substrate surface with «plurality of teeth extending therefrom, exch tooth having a contoured surface, layer comprising superabasive grains the layer being ‘chemically bonded to t lest a portion of the surface of ‘each tooth to define a plurality of cutting levels parallel to the substrate surface, and each cutting level on each tooth being oriented sich that a porion of exch euting level overlaps at least a portion of each other euting level ofthe tooth; and ©) 8 firs uppermost cutting level consisting of bonded ‘Superabrisve grain, and suecessive uppermost cutting levels, comprising bonded superubrasive grains and 3 portion of the tooth, among the plurality of eutting levels of each tooth; whereby after the first uppermost cutting level has been ‘worn vay by cutting @ workpiece, each successive upper- ‘most cutting fevel of the tooth presen tothe workpiece & fing of superabrasive grain around the contoured surface of| the toot, snd substantially all superabrasve grain within the ring simullancously engages in cutting and wherein the substrate surface has an intended direction ‘of movement and wherein the plurality of teeth includes: sueeessive teth having successively lower uppermost cut ting levels in the direction of the intended direction of ‘movement, thereby producing a cutting surface having & negative angle of inclination with respect to the intended irection of movement. 2. An abrasive cutting tool compris 8) substrate surface having a plurality of teeth extending therefrom, each tooth having a surface and b) a layer comprising abrasive grains, the layer being ‘chemically bonded to atleast a portion ofthe surface of ‘each tooth to define plurality of cutting levels parallel to the substrate surface, ‘wherein the substrate suslace has an intended direction of| ‘movement, whereia the plurality of teeth includes sucees- sive teeth’ having successively lower uppermost culling levels in the direction of the intended direction of movement, thereby producing a cutting surface having @ ‘negative angle of inclination with respect to the intended irction of movement,