Patent ID: 7708619

Claim:
A method of producing a complex shape in a workpiece, comprising the steps of: a) grinding a workpiece at a maximum specific cutting energy within a range between about 1 Hp/in 3 min (about 2.7 J/mm 3 ) and 7 Hp/in 3 min (about 19 J/mm 3 ) at a material removal rate in a range between about 5 in 3 /min·in (about 50 mm 3 sec/mm) and about 30 in 3 /min·in (about 300 mm 3 /sec/mm) with at least one bonded abrasive wheel, thereby forming a slot in the workpiece, wherein the bonded abrasive wheel contains at least about 3 volume % of a filamentary sol-gel alpha-alumina abrasive grain having an average length-to-cross-sectional-width aspect ratio of greater than about 4:1 or an agglomerate thereof, and wherein during grinding to form the slot, a coherent jet of water-soluble oil coolant is applied to the workpiece and bonded abrasive wheel; and b) grinding the slot with at least one mounted point tool.