Super-finishing of forms, required to generate geometry like that of the involute of a gear, is a multistep process
where gear blanks are roughed, heat treated, ground to precise tolerances allowing for additional stock removal to
occur in another value added process to generate super-finishes to less than 1 Ra µin. A solution that enables the
rough and finish grinding to occur that produces super-finished surfaces to less than 1 Ra µin while maintaining
precise geometries is Molecular Decomposition Process (MDP).
Surfaces generated by the applied MDP technology, as reviewed at scanning electron microscopes (SEM), clearly
illustrate no evidence of plowing tearing or smearing of the base material. This reduced mechanical force at the
surface of materials being exposed to the MDP technology yields improved surfaces. Appropriately defined
processes have reproducible results of surface finishes to 1 Ra µin or better. In addition, while these reduced
mechanical and thermal forces allow for the product to be produced with super finishes, another benefit of the MDP
system is a burr free component. This assists in reducing the number of steps required to produce a completed gear
or component.