Method for forming a workpiece

1. A method of forming a workpiece comprising:

removing material while rotating a workpiece having a machinability rating of not greater than a machinability rating of Inconel 718 at a specific grinding energy of not greater than about 7 Hp/in 3 min (about 19 J/mm 3 ) for a material removal rate of at least about 2.5 in 3 /min·in, by moving multiple grinding wheels relative to the rotating workpiece in sequence at different locations on the rotating workpiece and oriented at different angles relative to a lateral reference plane of the rotating workpiece,

wherein each of the multiple grinding wheels forms a distinct complex surface feature of a complex shape of the workpiece.

2. The method of forming a workpiece of claim 1 , wherein each of the multiple grinding wheels comprises:

a first surface perpendicular to an axis of rotation of the grinding wheel;

a second surface opposite the first surface;

an outer perimeter extending between the first and second surfaces and defining a thickness of the grinding wheel; and

a diameter that is greater than the thickness of the grinding wheel.

3. The method of forming a workpiece of claim 2 , wherein the outer perimeter defines a grinding surface.

4. The method of forming a workpiece of claim 3 , wherein the grinding surface comprises a peripheral contour configured to form one of the at least two complex features of the contiguous complex shape on a surface of the workpiece.

5. The method of forming a workpiece of claim 1 , wherein removing material from the rotating workpiece comprises moving at least three grinding wheels.

6. The method of forming a workpiece of claim 1 , wherein removing material is conducted at a specific grinding energy of not greater than about 6.0 Hp/in 3 min for a material removal rate of at least about 2.5 in 3 /min·in.

7. The method of forming a workpiece of claim 1 , wherein at least one of the multiple grinding wheels is oriented at an angle (α) relative to a reference plane of the rotating workpiece and wherein the angle (α) is an acute angle.

8. The method of forming a workpiece of claim 1 , wherein the multiple grinding wheels comprises a bonded abrasive body having abrasive grains contained within a bond material.

9. The method of forming a workpiece of claim 8 , wherein the bond material comprises a ceramic material comprising a vitreous material.

10. The method of forming a workpiece of claim 9 , wherein the vitreous material comprises an oxide.

11. The method of forming a workpiece of claim 9 , wherein the abrasive grains comprise at least about 2 vol % for a total volume of the bonded abrasive body.

12. The method of forming a workpiece of claim 9 , wherein the bonding material comprises at least about 2 vol % for a total volume of the bonded abrasive body.

13. The method of forming a workpiece of claim 9 , wherein the body comprises a porosity of at least about 0.5 vol % for a total volume of the bonded abrasive body.

14. The method of forming a workpiece of claim 13 , wherein the porosity of the body comprises at least about 10 vol % interconnected porosity for a total volume of the porosity of the bonded abrasive body.

15. A method of forming a workpiece comprising:

removing material while rotating a workpiece having a machinability rating of not greater than a machinability rating of Inconel 718 at a specific grinding energy of not greater than about 7 Hp/in 3 min (about 19 J/mm 3 ) for a material removal rate of at least about 2.5 in 3 /min·in, by moving at least two grinding wheels relative to the rotating workpiece in sequence at different locations on the rotating workpiece and oriented at different angles relative to a lateral reference plane of the rotating workpiece,

wherein each of the at least two grinding wheels forms a distinct complex surface feature of a complex shape of the workpiece, and

wherein the at least two grinding wheels comprises:

a first grinding wheel having a grinding surface for grinding a first complex feature on the workpiece;

a second grinding wheel having a grinding surface for grinding a second complex feature on the workpiece; and

a third grinding wheel having a grinding surface for grinding a third complex feature on the workpiece.