Top Hat Burnishing – Gearbox Drive Shaft

Challenge Details


Propose a consistent and robust process that would replace the grinding process that has to be done on a separate machine to achieve the required finish on multiple contoured profiles.


Monaghan Tooling proposed a Single Roll OD Top Hat Burnishing solution with a 0.125” (3.175mm) radius carbide roll.  The Top Hat Roll tool was able to follow along the profiles of the part generating an excellent surface finish. 

***Elliott Tool# 590010080558M

Overall Results

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Benefits Realized

CycleTime Savings

The Top Hat Roll burnishing solution resulted in 30 minutes per part in time savings.

Cost Savings

The solution allowed for the part to be finished on the same machine. This freed up the grinding machine to be used for other operations resulting in cost savings