Complex Engineering Problem

To measure the Internal and External Surface Finish of a given sample

Gudgeon Pin of an Engine with the help of Surface Analyzer

Abstract
This report reviews the surface finish of the gudgeon pin which is responsible for the
connection between the piston and connecting rod. To measure the surface finish of gudgeon
pin surface analyzer is being used. The advantages of the surface finish in the designing of
gudgeon pin, as well as its various aspects, are also discussed. Why surface finish is essential
in the design of the gudgeon pin. How gudgeon pin is made. The material of the gudgeon pin
i.e. steel (why this material is being used). The design specifications of the gudgeon pin. The
surface analyzer is also discussed along with its construction and its uses all are provided.

1. Introduction
1.1. Gudgeon Pin

Gudgeon pin is used to connect the piston to the connecting rod in an Internal Combustion
(IC) engine. It is used to avoid piston motion in any other direction except rectilinear or to-
and-fro motion. It also provides bearing surface between piston and connecting rod.

Figure 1: Gudgeon Pin

1.1.1. Manufacturing & Material Gudgeon Pin

There are many materials which can be use in the manufacturing of gudgeon pin, but the
most used material is Steel. The steel is first casted into steel bars then these steel bars are
used to produce pins. These steel bars are cut down and then pins are formed by sequence of
operations turning, hardening and grinding using various machines. The final tolerance must
be less than 0.003 mm. The surface quality of pins should be very high other and covered
with ultra-hard DLC layer as they have to work in under very high temperature. The layer
also protects it from wear and tear during manufacturing process. Even a very little wear and
tear affects a lot the piston.

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1.2. Surface Finish

Surface finishing, also known as surface texture or surface topography, is the existence of a
surface as defined by the three characteristics of lay, surface roughness, and waviness. It
encompasses the small, local deviations of a surface from the perfectly flat ideal (a true
plane). One of the important factors controlling friction and transferring layer formation
during sliding is surface texture. During sliding conditions, considerable efforts were made to
study the influence of surface texture on friction and wear. Surface finishing is one of the
fundamental parameters of quality control to ensure that practical surfaces of made parts are
adjusted to the indicated gages. Parts surface finishing can affect their rubbing, wear,
exhaustion, erosion, contact joints snugness, precision location, and so on. Surface finishing
is a critical factor in assembling process observation and investigating quality control.
Surface finishing thought begins with the arrangement of the structure, with the planner
indicating, wherever vital, the surface needed to give an ideal act-this suggests that the
fashioner must have the important understanding of surface finishing and learning how it is
estimated. The generation engineer should then arrange the work with the goal that the
machine appliances used are equipped to deliver that finish and since the finish is, as a rule,
the machine administrator should know what the surface is.
1.2.1. Advantages of Surface Finish
Because of the advantages consolidated with it, the estimation of the construction surface
finish is gradually becoming vital. The advantages of estimating surface finish with deference
to quality and cost-control are as follows:
1. Through execution evaluation, the effectiveness of the manufacturing process is
enhanced.
2. Due to second rate surface finish, the quantity of parts dismissed by the client (scrap)
is reduced.
3. A section is manufactured with the greatest admissible unpleasantness, decreasing
production costs along these lines.
4. By streamlining the surface finish, the part quality is improved.
Surface profilometers and some optical procedures are available to evaluate the idea of
surface. The stylus instrument is a practically all-inclusive technique for estimating. This
procedure can be found in the laboratory, standard room and workshop throughout the world.
To assess the nature of the surface, it is recognized as a commonly used customary or regular
strategy. Despite the fact that the usual finish estimates, stylus instruments have magnificent
capacities and wide range, they are typically used to evaluate good finished machined
surfaces. The methodology is also a post-procedure approach that is not computerization-
friendly. Therefore, in shop floor applications that could be easily robotized, there is a need to
take a gander at different strategies for evaluating medium finish. In the ongoing past, higher
amounts of computerization in the shop floor have focused on using fast, solid, and savvy
methods to assess medium-finished parts surfaces. This should be possible using an advanced
method of image preparation.
1.2.2. Surface Roughness Terminology and Parameters
Ra and Rz are various roughness parameters. Ra is a surface's average roughness. Rz is the
difference between the surface's highest "peak" and the deepest "valley." You must check that

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your instrument (rugosimeter) can show you the Rz. There is no parameter to convert from
one unit to another, as the Rz depends on how you get the roughness (machining, grit
blasting, polishing, etc.).

Figure 2: Surface Roughness Terminology and Parameters

Average Maximum Profile Height Rz is the average of the calculated successive Rti values
over the length of the examination. This parameter is the same as Rz (DIN) if it's within the
evaluation length there are five sampling lengths
Maximum profile height Rt is the vertical distance within the evaluation length between the
highest and lowest profile points.
Roughness Average Ra is the arithmetic average over the length of the evaluation of the
absolute values of the profile heights.
Mean Line M is the reference line for the measurement of profile variations. The mean
roughness profile line is usually set by analog or digital filters with the selected cutoff
corresponding to the length of the roughness dataset.
Evaluation Length L is the length by which surface parameter estimates are evaluated. It is
prescribed that the length of the evaluation consists of five lengths of examination despite the
fact that it could include any number of lengths of examination. Otherwise called the length
of the evaluation.
Surface finish of any workpiece can be measured using Surface Analyzer.

1.3. Surface Analyzer

It is an instrument that is used to determine the surface roughness of a plane.

1.3.1. Instrument Detail
In this experiment, we are using the Surtronic S128 Surface Tester developed by Taylor
Hubson that has a handheld duo for the determination of the surface roughness of a plane or a
surface of any machine tool or workpiece, it is necessary for many areas where surface
roughness acts as an important factor.

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1.3.2. Construction
This series has a portable finish measurement system with a touchscreen. The device is made
highly durable and is built to last with an impact resistant rubberized housing, so that its
stainless-steel drive mechanisms and bearings and the heavy-duty long-life lithium polymer
battery that can give up to 2000 of the number of measurements for one-time charging. This
device machine has a 50 millimeters long stylus lift mechanism.
Some major components of the device are explained as under:
1. Measurement Button: Tactile measurement button is available beside the
touchscreen that starts the machine within 1 second for fast measurement of the
surface roughness factors.
2. Lift/Lower: This is about 50mm. of the stylus lift mechanism. It can also get 90-
degree rotation in all planes and can get into bores that are about 70mm. deep.
3. Anti-Slip Feet: these are made to stabilize the device on flat or curved surfaces. The
profile of the feet is somewhat V shaped that causes the alignment with the cylindrical
surface and keeps device stable.
4. Comfort Grip: This makes it easier to grip for the operator while noting down the
readings or changing the settings.
5. Rubberized Housing: This also supports gripping and also causes the device to be
claimed better to bear an impact.
6. Touchscreen: This makes it very easier and faster to use the device for its operation.
The to define the orientation of the screen.
7. USB 2.0 Mini: This port is to connect the charger for the charging of the lithium
polymer battery.
8. USB 2.0 Type A: This port is used to connect the printer or PC in order to get
hardcopy of the calculations or for further advanced working for surface roughness.

Figure 3: Surface Analyzer

1.3.3. Features
This device is the only one in the Surtronic S series to have the versatility of providing the
whole measurement system out of the box due to the presence of 50mm. stylus lift
mechanism. There is a facility of 90 degrees operation and can go in to the bores of up to
70mm deep. The instrument can measure the surface roughness of cylinders directly on the

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workpiece. There is no need of fixtures or some accessories. There is also facility of directly
measuring the inverted surfaces or the inside cylinders.
The instrument has an instant start technology so that eunuch powerup can be ready for the
measurement within a second as soon as we push the power or measure button.
The touchscreen software is easy to operate with four buttons on the screen that provide the
worker with basic functions like filters and scan lengths whereas the menu structure gives a
very comprehensive set features including more than 50 surface parameters or also comprise
of the list of standards’ bodies installed in that software. Some examples of these standard
bodies are ISO 4287 or ASME B45.1. The touchscreen can be fixed to any orientation like
portrait or landscape to get readings easily as per required by the operator.
USB connectivity, printing, PC charging and PC data analysis all are obtained via the
industry standard USB port connections so there is no need to buy custom chargers or data
cards as its requirements are not that complicated to get. They are commonly available.
Some basic features of Surtronic S series are given as under:
1. Standard and Traceability: the device has some reference standards which can be
used either to check for the calibration of the device or check the wear of stylus.
2. Fast and Reliable: pressing the measurement button starts the device within 1 second
and a traceable measurement process is performed along with the display of the graph
for the surface roughness factor. It can be printed (optional) at the very same time if
printer is connected via USB 2.0 Type A.
3. User Friendly: The device is quite easy to use just like a smartphone. With a 4.3’
display that is providing results as 7 parameters per page along with some
measurement settings and system information.
4. Built to last: The body of the device is covered by rubberized moldings that help the
reduction of damage at impact. The whole mechanism is of stainless steel so that there
are no chances of rusting. The gears and bearings of the instrument are unwearable.
Plus, there is a high battery timing. The battery is of Lithium polymer of up to
3000mAh and can perform 2000 measurements for one-time charging.
5. Instant Measurement: By this device, a measurement can be done within very few
seconds if the machine is in standby mode. Fully charged, it can remain in standby
mode for more than 5000 hours.
6. In situ Measurements: The device monitors the roughness variation in situ
measurements. For instance, it can check the variation in the roughness of the turbine
blade at an early stage as a sign of warning.
7. Tally Profile Software: The device has integrated a software feature as tally profile.
This featured software is basically based on PC analysis. It comes in three versions as
“Lite, Silver, Gold”. Lite has less features and is good for shop floor inspection
level. Silver has a bit more features for R&W parameters and a statistics module with
full report printing. Gold has best features and is applied at the laboratory level
analysis.
8. Outstanding Graphics: The device has amazing graphics. The operator can easily
print the graphs without the worry of bad quality of the hardcopy of these
measurement analysis.
9. Advanced Time saving analysis templates: The operator can store templates for a
particular sort of analysis which are to be used in the future. These are stored in the

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 internal memory and can be used at the time of need saving our time to produce a
template at that time.
10. Full Compatibility: The device has full compatibility with other Taylor Hubson
machines and softwares.it means that any analysis made in any other Taylor Hubson
device can be imported to this SURTRONIC S128 Tally profiler software.
11. PC Specifications: This device works properly if supported by the PC of these
specifications:

Figure 4: PC specifications for Surface Analyzer

12. In depth Analysis: We can zoom or level the graphs to remove the extra features or
defects from our analysis. Distance measurement between features can also be
calculated and the step height and peak of the graph can be determined as well.
1.3.4. Specifications
Now we will give tabular presentation of the specifications of Surtronic S series portable
surface roughness tester:
1. Technical

Figure 5: Technical Specifications for Surface Analyzer

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 2. Component Capacity

Figure 6: Component Capacity

3. Measurement capability

Figure 7: Measurement Capability

4. Analysis Capability

Figure 8: Analysis Capability

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1.3.5. Areas of Applications of Surtronic S128
Process Control
Grinding, turning, honing, milling, polishing and extrusion processes highly demand the
usage of this tester because these operations related to machining are highly dependent on the
surface roughness factor to keep their smoothness of the surface.
Automotive
Gears, con rods, crankshafts and blocks also need such testing device that keeps the worker
updated about the surface smoothness.
Heavy Industry
Ship building, pipe lines and sheet steel.
Aerospace
Turbine blades, turbine shafts and wing composites.
Others
Print rollers, flooring and bonding are also some areas where Surtronic S128 is highly in
demand for its usage.

2. Apparatus
1. Gudgeon Pin
2. Surface Analyzer

3. Working Procedure
First of all, a workpiece is determined for which we have to find the surface roughness
profile. We select the assessment length that is provided in three sets by this device. The
precision is set by the operator on this device. Now the stylus is placed on that surface and
measurement start button is pressed available beside the touch screen. The device starts to
move the stylus automatically on the surface. Within few seconds time, a profile is generated
on the touchscreen representing the different parameters of the surface roughness. The
parameters are built in functions in the device so we get the numerical values of these
parameters directly. These values are obtained and compared with the standard graph given
by the company to check the tolerances and check whether we are in the safe limit of the
surface roughness or not.

4. Observations

5. Comments

6. References

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