Surface Finish Characterization And Measurement - IIT Bombay
1 Surface Finish Characterization and Measurement Prof. S. S. Pande Mechanical Engineering Department Indian Institute of Technology, Bombay
Outline Importance of Surface Finish Basic Terminology Assessment parameters Geometrical Statistical Measuring Instruments Stylus based (2D ) Optics based (3D )
Importance of Surface Finish Aesthetic Gloss, Appearance, Touch, Feel Functional Title Friction, Lubrication and Wear Fatigue Life, Bonding Strength Assembly Performance Clearance/ Interference Motion Behaviour Slideways, Bearings
Lotus Leaf
Surface Topography of Lotus Leaf
Surface Integrity Air Metal Surface Topography Surface Roughness Profile Surface Metallurgy Sub surface material characteristics
Surface Roughness Nomenclature Flaw Roughness Height Lay Direction Waviness Height Roughness Width Waviness Width Roughness – Width Cutoff
Surface Topography Flaw Normal Section Lay Total Profile Waviness Profile Roughness Profile
Surface Roughness Profile Components and Causes Roughness – Short wave profile Tool Feed marks, Cutting phenomena Waviness – Long wave profile Axis errors, vibrations, run out Lay – machining pattern
Surface Roughness in Turning Ø Øe
Assessment of Surface Roughness Standards : ISO, BS, ANSI, DIN 2D Parameters Amplitude based Wavelength based Statistical measures 3D Parameters Area based Hybrid
Surface Roughness Measurement
Stylus Instrument Probe
TalySurf - Stylus Instrument
Cut Off Length
Surface Roughness Profile y Profile y(x)
Surface Roughness Parameters Amplitude Based Parameters Ra – Arithmetic Average (CLA) Rq – Root Mean Square (RMS) RT – Peak to Valley
Ra – Arithmetic Average y(x) profile height from mean line Digitized Profile N Number of points
Rq – Root Mean Square (RMS) Rq RMS σ
Ra and Rq parameters y Rq Ra X Mean Line
Sk - Skewness
K - Kurtosis
RT – Peak to Valley measure RT Lm Rq Ra
Amplitude Based Parameters Limitations Focus on Profile amplitude only Profile wavelength is totally ignored Profiles can be completely Different for the same Ra value
Different Profiles – Same Ra
Wavelength Based Parameters Average Peak Count Asperity Slope Auto Correlation function Power spectral Density/ Fourier Transforms
Average Peak Count
Amplitude Distribution function Amplitude Probability Distribution Function Normalized variable y mean 0 σ 1.0
Profile Height Distribution
Moments of Distribution Function Central moments are taken around the mean
Moments of Distribution Function
Skewness parameter
Kurtosis parameter
Classification of Surface Profiles
Autocorrelation Function Evaluation
AutoCorrelation Function Normalized form
A typical surface profile
Autocorrelation Function
Real surface and Autocorrelation function
Autocorrelation function and Power Spectral Density Plot
Abbot’s Bearing Area Curve Abbot – Firestone Curve X 0 Material % 100
Surface Profile and Bearing Area curve
3D Surface Roughness Measurement Optical methods Capacitance based method Air flow measurement
White Light Interferometer
Principle of Interferometer
3 D surface plots Isotropic - Random Turned surface - Periodic
Importance of Surface Finish Title. Lotus Leaf . Surface Topography of Lotus Leaf. Surface Integrity Surface Topography Surface Roughness Profile Surface Metallurgy Sub surface material characteristics . - Peak to Valley measure L m R R q R a T. Amplitude Based Parameters Limitations
for a bandwidth-limited surface-finish measurement the rms surface roughness would be given by Eq. (2), except that the integral would be computed only over the range of spatial frequencies to which the measure-ment was sensitive. Thus surface-finish measure-ments of a fractal surface that are performed with different surface-finish metrology .
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Surface finish measurements 38 mm from the top edge of the test sample were not obtainable with the Pocket Surf PS1 since it exceeded the maximum inspection range of this instrument. Figure 4. Surface finish measurements in 50 mm thick aluminum. In Figure 4, it can be seen that the average surface finish, Ra, gradually and smoothly increases
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