MOHD NUR ASHRAF BIN MOHD YUSOFF KEM100030

Title:

Surface roughness measurement

Objective:

1. To examine the surface roughness of stainless steel (disc grinding), mild steel (CNC turning),
mild steel (EDM wire cut) and brass
2. To compare the theoretical value and calculated value.

Abstract:

From the experiment, there are four metals that will be tested in the surface roughness test. The
metals used are stainless steel (disc grinding), mild steel (CNC turning), mild steel (EDM wire
cut) and brass. By done this experiment, we may found out the quality of machining and
finishing process after the process finished. The different quality of machining will be discovered
by comparing the roughness between them. This test is thoroughly by the use of Surtest SV-600-
MITUTUYO. Some calculation will be performed in order to achieve the calculated values.

Introduction:

In any mechanical surface, the term used to describe its geometrical quality is known as
surface roughness. Roughness of a surface refers to the quality machined surface. Surface
roughness is that part of surface finish (Surface Texture) which can be defined as the work left
by the action of the production process used; such as turning operation process.

The irregularity in metals usually in the form of feed marks left by cutting tool gives the
rough surface in any metals. Surface finish of a machine part is a significant design specification
that is known to have a considerable influence like wear resistance and fatigue strength. It is an
essence for any tools to be measured its quality by the machine tool productivity. In engineering
design and production, it is important to be able to specify the degree of surface roughness
desired.

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Theory:

1. Reference Line Or Mean Line

It is a mathematically calculated mean line, which is fitted into the profile so that the sum of the
areas enclosed by the profile above this line equals the sum of that below. (Refer Fig 1)

Fig 1

2. Maximum Roughness Depth(Rt / Ry)

It is the distance between the highest and the lowest points of the profile within the evaluation
length, lm.

Rp : Distance between the mean line and the highest profile peak.

Rm : Distance between the mean line and the lowest profile valley; refer Fig 1

3. Measuring Length Or Evaluation Length (lm)

The horizontal limitation for the assessment of surface parameters is the measuring or evaluation
length.

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4. Tracing Length or Tranverse Length (lt)

It is the distance traversed by the tracing system during a measurement. It equals sum of the pre
and overtravel & the evaluation length:-

Tracing length (lt) = pretravel (ll) + evaluation length (lm) + overtravel (ln).

The pretravel and overtravel are required by the electric filter to attenuate mechanical and
electrical transients. A pretravel or overtravel also corresponds to a cut-off length.

5. Mean Peak To Valley Height (Rz)

It is the average of the single peak to valley heights of n number of adjoin sampling lengths, le.

Fig 2

Mathematically, we write

Rz = (Z1+Z2+Z3+………….Zn)/n

Besides the definition given above, there is another one used by the Japanese namely, Rz (JIS)
which is also known as the ISO 10 point height parameter in ISO 4287/1-1984, is measured on
the roughness profile only and is numerically the average height difference between the five
highest peaks and the five lowest valleys within the sampling length.

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6. Maximum Roughness Depth (Rmax)

It is the largest single peak to valley height (zi) within n number of adjoining sample length.

In the Fig 2 above, z3 corresponds to Rmax.

7. Arithmetical Mean Roughness or Centre Line Average, Ra (C.L.A.British) or

Arithmetical Average.(A.A.American)

Ra is obtained by measuring the mean deviation of the peaks from the center line of a trace, the
center line being established as the line above and below which there is an equal area between
the center line and the surface trace. There is little difference between the CLA & RMS (Root
mean square) values for a given surface. Ra is universally recognized, and most used,
international parameter of roughness.

Mathematically, by definition, Ra is given by

Ra = 1/lr  z(x)  dx

Since the function, z(x) cannot be determined by means of experiment, we can do an

approximation using the formula given below:-

Fig.3

Ra = (y1+y2+y3+………..+y10)/10

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8. Root Mean Square Roughness (RMS or Rq)

Rq is the RMS parameter corresponding to Ra

Rq = [(y12+y22+y32+…+yn2)/n] 1/2

Apparatus:

 Surtest SV-600-MITUTUYO

 Stainless steel (disc grinding)

 Mild steel (CNC turning)

 Mild steel (EDM wire cut)

 Brass

Procedure:

1. The stainless steel (disc grinding) will be placed on the table of the surface measuring table.

2. The SURFTEST ver1.01 is opened by computer and the requirement of this experiment is
set. After the conditions were set, the stylus is adjusted so that it is at an appropriate height
from the sample.

3. The SURFTEST ver1.01 is started and the system is ready to measure the metal surface
roughness.

4. A graph of the surface of the sample was then displayed on the computer screen. A copy of
the graph is printed out.

5. The values of Ra, Ry, Rq, Rz, Rc, Rp, Rv, R3z, Ku and Sk are recorded.

6. The stainless steel is removed and replaced with other material Mild steel (CNC turning),
mild steel (EDM wire cut) and brass.

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Result:
From computer analysis:

STAINLESS MILD STEEL MILD STEEL BRASS

STEEL (DISC (CNC (EDM WIRE
GRINDING) TURNING) CUT)

Ra, μm 0.38 0.12 0.12 0.41

Ry, mm 2.21 0.95 1.05 2.36

Rq, mm 0.48 0.16 0.17 0.50

Rz, mm 1.42 0.64 0.67 1.36

Rc, mm 0.71 0.22 0.23 0.67

Rp, mm 1.11 0.50 0.67 0.99

Rv, mm 1.10 0.45 0.38 1.37

R3z, mm 1.34 0.61 0.59 1.16

Ku 3.2123 4.0197 6.0155 2.9513

Sk -0.1574 0.2118 1.0391 -0.5784

Calculation based on graph:

1. STAINLESS STEEL (DISC GRINDING)[1cm=0.5mm]
a. Rp = 1.8cm x 0.5mm = 0.90mm
b. Rv = 1.6cm x 0.5mm = 0.80mm
c. Ry =Rp + Rv = 1.70μm
d. Rz = (Z1+Z2+Z3+ Z4+Z5)/5
= [(3.1 x 0.5mm)+(2.3 x 0.5mm)+(2.5 x 0.5mm)+(2.7 x 0.5mm)+(3.2 x 0.5mm)]/5
= 1.38μm
e. Ra = (y1+y2+y3+………..+yn)/n
= [(1.6+0.3+1.35+1.4+1.0+0.35+1.2+1.1+0.2+0.3) x 0.5mm]/10
= 0.44μm

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f. Rq= [(y12+y22+y32+…+yn2)/n] 1/2

= [(1.62+0.32+1.352+1.42+1.02+0.352+1.22+1.12+0.22+0.32)/10]1/2
= 0.51 μm
g. Rc= (y1+y3+ y5+y7+y9)/5 + (y2+y4+y6+y8+ y10)/5
= (1.6+1.35+1.0+1.2+0.2)/5 + (0.3+1.4+0.35+1.1+0.3)/5
= (5.35 x 0.5mm )/5 + (3.45 x 0.5mm)/5
= 0.88 μm
h. R3z = (R3z1 + R3z2 + .... + R3zn)/n
= (2.35+2.1+1.4+2.65+2.2)/5
= (5.35 x 0.5mm )/5
= 1.07μm
i. Sk = (1/Rq3) [(y13+y33+y53+y73+y93) - (y23+y43+y63+y83+y103)]/10
= (1/0.513)[(1.63+1.353+1.03+1.23+0.23)-(0.33+1.43+0.353+1.13+0.33)]/10
= 0.4825
j. Ku = (1/Rq4) [(y14+y24+y34+………..+y104)/10]
= (1/0.514) [(1.64+0.34+1.354+1.44+1.04+0.354+1.24+1.14+0.24+0.34)]/10
= 1.6895

2. MILD STEEL (CNC TURNING)

a. Rp = 2.15cm x 0.2mm = 0.43mm
b. Rv = 2.10cm x 0.2mm = 0.42mm
c. Ry =Rp + Rv = 0.85μm
d. Rz = (Z1+Z2+Z3+ Z4+Z5)/5
= [(3.1 x 0.2mm)+(2.3 x 0.2mm)+(2.6 x 0.2mm)+(3.4 x 0.2mm)+(2.0 x 0.2mm)]/5
= 0.54μm
e. Ra = (y1+y2+y3+………..+yn)/n
= [(2.1+0.9+0.85+0.25+0.6+0.8+0.6+0.2+1.35+0.8) x 0.2mm]/10
= 0.17μm
f. Rq = [(y12+y22+y32+…+yn2)/n] 1/2
= [(2.12+0.92+0.852+0.252+0.62+0.82+0.62+0.22+1.352+0.82)/10]1/2
= 0.20 μm

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g. Rc = (y1+y3+ y5+y7+y9)/5 + (y2+y4+y6+y8+ y10)/5

= (2.1+0.85+0.6+0.6+1.35)/5 + (0.9+0.25+0.8+0.2+0.8)/5
= (5.5x 0.2mm)/5 + (2.95 x 0.2mm)/5
= 0.34 μm
h. R3z = (R3z1 + R3z2 + .... + R3zn)/n
= (2.5+1.5+2.2+2.7+1.6)/5
= 0.42μm
i. Sk = (1/Rq3) [(y13+y33+y53+y73+y93) - (y23+y43+y63+y83+y103)]/10
= (1/0.203)[(2.13+0.853+0.63+0.63+1.353)-(0.93+0.253+0.83+0.23+0.83)]/10
= 1.0991
j. Ku = (1/Rq4) [(y14+y24+y34+………..+y104)/10]
= (1/0.204) [(2.14+0.94+0.854+0.254+0.64+0.84+0.64+0.24+1.354+0.84)]/10
= 2.5032

3. MILD STEEL (EDM WIRE CUT)

a. Rp = 2.70cm x 0.2mm = 0.54mm
b. Rv = 1.15cm x 0.2mm = 0.23mm
c. Ry =Rp + Rv = 0.77 mm
d. Rz = (Z1+Z2+Z3+ Z4+Z5)/5
= [(2.8 x 0.2mm)+(2.3 x 0.2mm)+(3.8 x 0.2mm)+(3.75 x 0.2mm)+(3.0 x 0.2mm)]/5
= 0.63μm
e. Ra = (y1+y2+y3+………..+yn)/n
= [(2.1+0.35+0.75+0.6+0.2+0.1+1.8+0.2+1.2+0.6) x 0.2mm]/10
= 0.158μm
f. Rq= [(y12+y22+y32+…+yn2)/n] ½
= [(2.12+0.352+0.752+0.62+0.22+0.12+1.82+0.22+1.22+0.62)/10]1/2
= 0.21 μm
g. Rc= (y1+y3+ y5+y7+y9)/5 + (y2+y4+y6+y8+ y10)/5
= (2.1+0.75+0.2+1.8+1.2)/5 + (0.35+0.6+0.1+0.2+0.6)/5
= (6.05 x 0.2mm)/5 + (1.85 x 0.2mm)/5
= 0.32 μm

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h. R3z = (R3z1 + R3z2 + .... + R3zn)/n

= (1.4+1.8+2.6+2.1+3.0)/5
= 0.44μm
i. Sk = (1/Rq3) [(y13+y33+y53+y73+y93) - (y23+y43+y63+y83+y103)]/10
= (1/0.213) [(2.13+0.753+0.23+1.83+1.23)-(0.353+0.63+0.13+0.23+0.63)]/10
= 1.5320
j. Ku = (1/Rq4) [(y14+y24+y34+………..+y104)/10]
= (1/0.214) [(2.14+0.354+0.754+0.64+0.24+0.14+1.84+0.24+1.24+0.64)]/10
= 2.6831

4. BRASS
a. Rp = 1.3cm x 1.0mm = 1.3mm
b. Rv = 1.7cm x 1.0mm = 1.7mm
c. Ry =Rp + Rv = 1.3+1.7=3.0mm
d. Rz = (Z1+Z2+Z3+ Z4+Z5)/5
= [(1.6 x 1.0mm)+(1.6 x 1.0mm)+(1.4 x 1.0mm)+(1.5 x 1.0mm)+(2.1 x 1.0mm)]/5
= 1.64μm
e. Ra = (y1+y2+y3+………..+yn)/n
= [(0.1+0.2+0.5+0.7+0.15+0.5+0.8+0.2+0.2+1.0) x 1.0mm]/10
= 0.44μm
f. Rq= [(y12+y22+y32+…+yn2)/n] ½
= [(0.12+0.22+0.52+0.72+0.152+0.52+0.82+0.22+0.22+1.02)/10]1/2
= 0.53 μm
g. Rc= (y1+y3+ y5+y7+y9)/5 + (y2+y4+y6+y8+ y10)/5

= (0.1+0.5+0.15+0.8+0.2)/5 + (0.2+0.7+0.5+0.2+1.0)/5

= 0.87 μm
h. R3z = (R3z1 + R3z2 + .... + R3zn)/n
= (0.9+1.55+1.3+1.4+1.7)/5
= 1.37μm

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i. Sk = (1/Rq3) [(y13+y33+y53+y73+y93) - (y23+y43+y63+y83+y103)]/10

= (1/0.533) [(0.13+0.53+0.153+0.83+0.23)-(0.23+0.73+0.53+0.23+1.03)/10
= 1.4338
j. Ku = (1/Rq4) [(y14+y24+y34+………..+y104)/10]
= (1/0.534) [(0.14+0.24+0.54+0.74+0.154+0.54+0.84+0.24+0.24+1.04]/10
= 2.2560

Comparison between theoretical values and calculated values

1. STAINLESS STEEL (DISC GRINDING)

Theoretical Calculated Percentage difference
value value (%)
Ra, μm 0.38 0.44 15.8
Ry, mm 2.21 1.70 23.1
Rq, mm 0.48 0.51 6.3
Rz, mm 1.42 1.38 2.8
Rc, mm 0.71 0.88 23.9
Rp, mm 1.11 0.9 18.9
Rv, mm 1.10 0.80 27.3
R3z, mm 1.34 1.07 20.1
Ku 3.2123 1.6895 47.4
Sk -0.1574 0.4825

2. MILD STEEL (CNC TURNING)

Theoritical Calculated Percentage difference
value value (%)
Ra, μm 0.12 0.17 41.67
Ry, mm 0.95 0.85 10.5
Rq, mm 0.16 0.20 25.0
Rz, mm 0.64 0.54 15.6
Rc, mm 0.22 0.34 54.5
Rp, mm 0.50 0.43 14.0
Rv, mm 0.45 0.42 6.7
R3z, mm 0.61 0.42 30.6
Ku 4.0197 2.5032 37.7
Sk 0.2118 1.0991

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3. MILD STEEL (EDM WIRE CUT)

Theoretical Calculated Percentage difference
value value (%)
Ra, μm 0.12 0.158 31.7
Ry, mm 1.05 0.77 26.7
Rq, mm 0.17 0.21 19.0
Rz, mm 0.67 0.63 6.0
Rc, mm 0.23 0.32 39.1
Rp, mm 0.67 0.54 19.4
Rv, mm 0.38 0.23 39.5
R3z, mm 0.59 0.44 25.4
Ku 6.0155 2.6831 55.4
Sk 1.0391 1.5320 47.4

4. BRASS
Theoretical Calculated Percentage difference
value value (%)
Ra, μm 0.41 0.44 7.3
Ry, mm 2.36 3.0 27.1
Rq, mm 0.50 0.53 6.0
Rz, mm 1.36 1.64 20.6
Rc, mm 0.67 0.87 29.9
Rp, mm 0.99 1.3 31.3
Rv, mm 1.37 1.7 24.1
R3z, mm 1.16 1.37 18.1
Ku 2.9513 2.2560 23.6
Sk -0.5784 1.4338

Discussion:

In the experiment, the factor that is evaluated is the R a value, which is the mean deviation of the
peaks from the centre line of the trace. In this case surface is considered good if the R a value is
equal or less than 0.1m.

From the experiment, there are differences between the theoretical and calculated values from
because the sample, n taken in the calculation is not big enough and this will affect final result.
Besides that, the value of Ra, Rq, Rz, Rp and Ry calculated deviates from the standard readings
(printed at the bottom of graph sheet). This is caused by three main factors:-

1. Surface of materials

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Before the experiment is done, the surface of materials should be cleaned complete removal of
the oxide film from surface to have an accurate reading. If not, it will affect the roughness of the
surface.

2. Size of materials

The size of the sample must be big and readings must be taken randomly all over the observed
area. But, the experiment is done on only a very small portion of the surface. So, in our
calculations, the sample size is inadequate to give a good approximation for the surface
roughness values.

3. Experimental error

The machine used to analyze the surface roughness has a very sensitive sensor. When the
surrounding factors (e.g. wind, temperature etc) vary, it will affect the roughness of the surface,
and the readings will differ from the actual one.

ENGINEERING VIEW IN ASPECT OF SURFACE TEXTURE:

For any engineering component, surface texture is a pattern, which is made onto the component
surface by tool cutting edge. The repeated pattern on the whole surface is sort of pattern designed
on the component surface.

The designer using certain symbol normally draws the quality and surface texture pattern of a
component, which is to be machined. Components like heat transferring tube and brake must
have controlled surface texture. For the heat transferring tube, if the surface of the tube is a bit
rough, the tube will transfer the heat even faster. The same thing also applies to the brake. Brake
needs rough surface to ensure its efficiency.

Thus, attention is significant while dealing with surface machinery process. In producing a high
quality surface, but not deal with the real function of the component, great expenditure is needed.
In addition, it will also increase the cost of producing.

Surface roughness at different part of a component would have the difference of 2 units in
magnitude. Reasons and considerations, which should be done, are as below:

A. Corrosion resistance

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Rough surface encourages corrosion media to be trapped between the small holes on the surface.
This causes the rough material easier to corrode compare to the smooth one.
B. Fatigue and notch sensitivity
The rougher the material’s surface, the shorter the fatigue life.
C. Electrical and thermal contact resistance
The rougher the material’s surface, the higher the resistance against the electric and thermal.
D. Accuracy required on mating surfaces
Certain material needs difference surfaces. Bearing ball needs a smooth surface while drum
brake needs a rough surface.
E. Continuous process like painting and polishing at certain roughness may produce a
stronger bond.
F. Cost considerations
The tidier the surface of material, the higher the cost.
G. Appearance
Smooth surface has a greater appearance.

Conclusion:

Sample Stainless Steel Mild Steel Mild Steel Brass

Manufacturing CNC EDM Wire CNC
Disc Grinding
process Turning Cut Turning
Ra (µm) 0.44 0.17 0.158 0.44
Surface Slightly
Rough Smooth Rough
condition smooth

After carrying out this experiment, we can conclude that there are a few factors that affect the
roughness of the surface. The manufacturing process and the material are the main factors that
cause the roughness of the surface. From the result, we found that EDM wire cut is an ideal
manufacturing process which can produce a smooth cut. However, CNC turning and disc

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grinding are consider as not a suitable process to produce smooth cut that will be used in
manufacturing according to the result above.

Types of material are also important to produce a smooth surface due to the function and
the cost in manufacturing. Brass and stainless steel are rough materials but they have lower cost.

As the conclusion, we can say that the different type of surface of one material will have
different properties. The experiment is valid.

References:

1. Fundamentals of Manufacturing (Material, Processes, and System) Mikell P.Groover.

2. http://en.wikipedia.org/wiki/Surface_roughness

3. Laboratory manual

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