SURFACE TEXTURE

 Introduction

 terminology

 Reasons for controlling surface texture

 Parameters Rz, Ra,Rq, and Rm

 Symbols used for lay and roughness

 instruments used for surface texture

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Surface texture : tool leaves certain lines/
patterns on the work piece.

Roughness and waviness are

irregularities caused by
production processes.

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Roughness: short wavelength irregularities

Cause: individual scratch or tool marks produced by a single

traverse of a planning tool across surface
Waviness:
Causes: vibrations, hard spots, imperfect truing of grinding wheel,
chatter, heat treatment etc.

Lay: collective characteristic of a particular process 7

Smooth and flat

Smooth but not flat

Intermediate stages

Flat but not smooth

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Reasons for controlling surface texture

 To reduce the initial wear of the parts that are in contact.

 To improve the fatigue resistance

 To allow the fine geometric and dimensional tolerances to

be held.

 to reduce the frictional wear.

 To reduce the corrosion by min the number of crevices

where the corrosion proceeds at high rate

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Calculation of Rz

Rz – Average peak to valley height

  ( 1 1000
𝑅𝑧 𝑖𝑛 𝜇 𝑚 )= [ ( P 1+ P 2+ P 3+ P 4+ P 5 ) − ( V 1+V 2+V 3+V 4 +V 5 ) ] x
5 𝑉
V- Vertical magnification
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Calculation of Ra 1.Draw a st. line XX,touch
the deepest valley

2. Select sampling length,

S T whole wavelength are
enclosed.

 3. Find the area under

the curve using
planimeter/ordinate
method.
Height of centre line CC

4. The trace is now divided into two halves

V-vertical
  ∑ 𝑎𝑟𝑒𝑎𝑠 𝑃+ ∑ 𝑎𝑟𝑒𝑎𝑠 𝑄 1000 1 magnification,
𝑅𝑎 ( 𝑖𝑛 𝜇 𝑚 ) = 𝑥 𝑥 H-horizontal
𝐿 𝑉 𝐻
magnification.
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Note:

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Roughness Measurement

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 Movement of stylus due to surface irregularities is used to compute roughness
 Stylus tip – 5-10 µm radius, diamond
 Pointer probe drawn slowly over surface
 magnification switch and cutoff selector, display and recorder.

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Taylor Hobson Talysurf Electrical integrating
stylus instruments
Carrier modulating
principle

Moving coil type

Abott profilometers

Piezo electric
Sigma
microtest

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Further reading….
Ishigaki, H. and Kawaguchi, I., 1981. Effect of a skid on the accuracy of
measuring surface roughness. Wear, 68(2), pp.203-211.

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Stylus type profilometer

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 NOTE:

In conventional contact mode profiling, a mechanical stylus comes in contact with the
surface to trace the surface features, which is time consuming method and tends to
alter/damage the surface features. Scratch width<2.5 µm depth<0.05 µm

non-contact optical profilometer is able to trace the surface topography and quantify the
roughness without damaging the actual surface features. It utilizes optical light interference
principles to scan and quantify topographic features of various materials ranging from hard
ceramics/metals to soft polymers or biological cells.

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How non contact type profilometers work?

https://www.zygo.com/?/met/profilers/optical
profilersabout.htm
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Most commonly used instruments under this
category are:

1. Tomlinson surface meter

2. Taylor Hobson talysurf

3. ‘Abott’Profilometer

4. Sigma micro test.

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 Oscillatory motion of
stylus converted into
electrical signals.

Magnification
normal to the
surface-1000 to
50000,
And along the
surface 50 to 100X

D-pointed stylus,
Tip dimension=0.0001”,
Force=0.1gm,
Bottom reach=0.0002”
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Abott profilometer and Sigma Micro test- refer text book.
PROFILOGRAPH

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Tactile Surface
assessment

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Applications:
1. For relatively smooth
irregular surfaces
2. As a comparator for two
surfaces.
3. As a limit gauge for
roughness
4. To establish the direction of
lay.
5. To measure short lengths
down to 1 mm which is
inaccessible to stylus
instruments.
6. To correlate with frictional
qualities of rough surface.
7. As a comparator for non
metallic surfaces.

0. 1 to 0.4 µm. ±12%

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 More than 5µm Ra

For rough
turned,
Grit blasted
Shaped, cast
surfaces

Quick
measurement
possible

Rz=4Ra

How surface finish and sphericity 48

of ball brg is checked?
#1. A rectilinear pen recording of a diamond turned surface is shown in figure. The sampling
length L used was 0.8mm V/H magnification ratio was 5000/100. Calculate Ra if areas above
and below mean line are as follows:
A B C D E F
60 115 96 92 109 70

Ans:1.355µm 49
 Sum of areas=542mm2

 
Ra=

Ra=1.355µm

#2. Give the following information, determine Ra value for the given surface

∑ 𝑎𝑟𝑒𝑎𝑠𝑎𝑏𝑜𝑣𝑒𝑐𝑒𝑛𝑡𝑟𝑒𝑙𝑖𝑛𝑒=480𝑚𝑚2
 

∑ 𝑎𝑟𝑒𝑎𝑠𝑏𝑒𝑙𝑜𝑤𝑐𝑒𝑛𝑡𝑟𝑒𝑙𝑖𝑛𝑒=480𝑚𝑚2
 

Vertical magnification 15000, horizoantal

magnification=100
a) Find out the grade of Ra value
b) What is the IS:3073-1967 symbol for representing in microns
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# The surface finish on the flat surface of a turned workpiece is not to exceed 5µm Ra, the
measurement to be made at a meter cut off 0.8mm and to be made at right angles to the
machining marks(radially). Explain the meaning of this specification and how it would be
shown on a drawing?

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Effect of nose radius on surface finish

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Effect of corner radius

 Increasing the corner radius improves the surface finish.

 Increasing the corner radius improves cutting edge strength.

 Increasing the corner radius too much increases the cutting resistance and causes

chattering.

 Increasing the corner radius decreases flank and rake wear.

 Increasing the corner radius too much results in poor chip control.

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