Cutting tool fabrication process

Claim 1

A method of making an abrasive tool having working surfaces comprising the steps of sequentially; A. forming a negative image of the tool in a mold, B. placing a coating composition in the mold at regions that will become the working surfaces of the final tool, C. introducing into the mold a particulate abrasive and a first substrate which is flowable and setable, the abrasive and first substrate being provided, i. in proportional amounts wherein the first substrate at least partially impregnates the interstices of the particulate abrasive, and ii. in total amounts wherein the mixture of the first substrate and the particulate abrasive incompletely fills the mold, D. applying sufficient centrifugal force and/or vibratory action to the mold to cause, i. the first substrate to at least partially impregnate said interstices, and conform the first substrate-abrasive mixture to the shape of the mold, thus forming a first substrateabrasive shell, and ii. the abrasive to migrate through the first substrate into the coating composition, thus causing abrasive particles to be partially within said first substrate and partially within said coating composition, E. at least partially filling the mold with a second substrate whereby forming in situ a support for said shell in non-working regions of the final abrasive tool, whereby each abrasive grain is partially bound on a working surface of the tool by the binding composition and partially by the first substrate.

Claim 2

A method of making an abrasive tool having working surfaces comprising the steps of sequentially; A. forming a negative image of the tool in a mold, B. placing a coating composition in the mold at regions that will become the working surfaces of the final tool, C. introducing into the mold a particulate abrasive and a first substrate which is flowable and setable, the abrasive and first substrate being provided, i. in proportional amounts wherein the first substrate at least partially impregnates the interstices of the particulate abrasive, and ii. in total amounts wherein the mixture of the first substrate and the particulate abrasive incompletely fills the mold, D. applying sufficient centrifugal force and/or vibratory action to the mold to cause, i. the first substrate to at least partially impregnate said interstices, and conform the first substrate-abrasive mixture to the shape of the mold, thus forming a first substrateabrasive shell, and ii. the abrasive to migrate through the first substrate into the coating composition, thus causing abrasive particles to be partially within said first substrate and partially within said coating composition, E. at least partially filling the mold with a second substrate whereby forming in situ a support for said shell in non-working regions of the final abrasive tool, whereby each abrasive grain is partially bound on a working surface of the tool by the binding composition and partially by the first substrate.