Table of Contents

Experiment No. 01.....................................................................................................................1

Title: To analyze the surface roughness of machined samples (milled, EDM, turned etc.).....1
Objective:...............................................................................................................................1
Apparatus:..............................................................................................................................1
Theory:...................................................................................................................................1
Introduction:.......................................................................................................................1
Surface Texture Parameters:..............................................................................................2
Surface Topography and Texture:......................................................................................2
Applications in Automobile Parts:.....................................................................................2
Standards and Thresholds:.................................................................................................3
Mechanical Applications Requiring Surface Roughness:..................................................3
Procedure:..............................................................................................................................4
Observations & Calculations:................................................................................................4
Comments:.............................................................................................................................5
Conclusion:............................................................................................................................5

Figure 1: Surface Topography...................................................................................................2

Figure 2:Surface Parameters......................................................................................................3
 Experiment No. 01

Title: To analyze the surface roughness of machined

samples (milled, EDM, turned etc.)
Objective: The primary goal of this experiment is to measure and analyze the surface
roughness of various machined samples. In addition, to have a grasp of the various surface
roughness parameters.

Apparatus:
1. Surface Texture Measuring Equipment (Surtronic S-128)
2. Calibrated Slide/Block

Theory:

Introduction:
Surface texture is a crucial characteristic in engineering and manufacturing, as it directly
impacts the functionality, performance, and appearance of components and products. It refers
to the micro-geometry of a surface, encompassing features such as roughness, waviness, lay,
and flaws. Surface texture measurement is essential in various industries, especially in the
automotive and mechanical engineering sectors.

Figure 1: Surface Topography

Surface Texture Parameters:

Figure 2:Surface Parameters

Roughness (Ra): Ra, or the arithmetic mean roughness, quantifies the average deviation of
surface peaks and valleys from the mean line. It is often used to assess the quality of a surface
finish.

Waviness (Rz): Rz is the peak-to-valley height measurement and evaluates the larger surface
irregularities or undulations.

Roughness Profile (Rt): Rt quantifies the maximum peak-to-valley height within a specified
evaluation length. It helps in identifying extreme variations on the surface.

Surface Topography and Texture:

Surface topography includes a broader view of surface characteristics, encompassing aspects

like texture, roughness, waviness, and more. It provides a comprehensive understanding of
the surface's physical attributes.

Applications in Automobile Parts:

Engine Components: Surface texture is vital in cylinder bores, piston rings, and crankshaft
journals, ensuring reduced friction and enhanced efficiency.

Brake Discs: It plays a significant role in brake disc quality, affecting the braking
performance and minimizing noise and wear.
Transmission Gears: Surface finish in gears improves wear resistance, reduces noise, and
enhances overall performance.

Aesthetic Finishes: For exterior parts like body panels and trim components, surface texture
is essential for appearance and corrosion resistance.

Interior Components: In the cabin, surface texture is crucial for control knobs, dashboards,
and upholstery for both function and appearance.

Cylinder Heads: Surface quality impacts sealing and heat transfer in cylinder heads.

Suspension Components: For shock absorbers and springs, surface texture influences wear,
friction, and longevity.

Bearings: Precision surface texture is essential for rolling bearings, ensuring smooth rotation
and reduced wear.

Exhaust Systems: For exhaust manifolds and pipes, surface texture affects emissions,
corrosion resistance, and acoustic performance.

Tire Treads: Surface texture impacts traction, handling, and wear resistance of tires.

Standards and Thresholds:

Various standards organizations, such as ISO and ASME, have established guidelines and
thresholds for acceptable surface textures. These standards help ensure consistency and
quality in manufacturing and engineering processes.

Mechanical Applications Requiring Surface Roughness:

Bearing Surfaces: Bearings require controlled surface roughness to minimize friction and
wear.
Seals and Gaskets: Proper surface finish ensures effective sealing in applications like engines
and hydraulic systems.

Tooling and Cutting Surfaces: Cutting tools need precise surface texture for efficient
machining and longer tool life.

Aerospace Components: Surface texture is critical for aircraft components, affecting

aerodynamics, fatigue life, and corrosion resistance.

Medical Devices: Implants and surgical instruments require specific surface finishes for
biocompatibility and performance.

In conclusion, understanding and measuring surface texture parameters like roughness,

waviness, and profile are essential in numerous mechanical and engineering applications,
including the automotive industry. Meeting industry standards and thresholds is critical for
ensuring the reliability and functionality of components and products.

Procedure:
1. Calibrated the surface texture measuring equipment (Surtronic S-128) by measuring
the surface roughness of a standard calibrated slide.
2. In order to obtain an accurate reading, the stylus probe of that equipment must be
level to the surface of the slide.
3. During measurement, the stylus probe glides across the surface of the slide and
provides a reading.
4. If the measured surface roughness equals the slide's standard roughness value, then
this equipment can be utilized for additional measurements.
5. Surface roughness metrics (Ra, Rt, Rz) of several machined samples such as EDM die
sinker, Milled, EDM wire cut, and Horizontal milled were measured.

Observations & Calculations:

Standard Calibrated slide Roughness Ra = 6 µm
Range = 400 µm
Stylus Movement (Evaluation Length) = 4 mm
Cut off Length = 0.8 mm
No of peaks in roughness graph = 4/0.8 = 5
Sr. No Workpiece Type Ra (µm) Rt (µm) Rz (µm)
1 EDM Die Sinking 5.40 35.0 28.0
Comments:
EDM Die Sinking: The measured roughness parameters for the EDM Die Sinking workpiece
are as follows:
Ra (Arithmetic Mean Roughness): 5.40 µm
Rt (Total Roughness): 35.0 µm
Rz (Ten Point Mean Roughness): 28.0 µm
The Ra value (5.40 µm) indicates the average deviation of surface peaks and valleys from the
mean line, signifying a moderate surface finish. The Rt value (35.0 µm) represents the
maximum peak-to-valley height within the evaluated length, suggesting that some larger
irregularities exist on the surface. The Rz value (28.0 µm) reflects the average of the five
highest peaks and the five lowest valleys within the cutoff length, highlighting the presence
of significant surface undulations.

Conclusion:
The workpiece, an EDM Die Sinking component, displays a moderate surface finish with a
Ra value of 5.40 µm. This indicates that the surface is relatively smooth on average.
However, when considering larger irregularities and undulations, the surface exhibits a total
roughness (Rt) of 35.0 µm, suggesting the presence of more significant surface deviations.
The Rz value of 28.0 µm further confirms the existence of notable undulations on the surface.
Therefore, while the average surface finish is reasonably good, the surface does have larger
irregularities that might need further attention or processing, depending on the specific
application requirements. These surface parameters are essential for ensuring the
functionality and quality of components, especially in precision industries like EDM Die
Sinking, where surface finish is crucial for the performance of the final product.
References
1. Smith, John. (2010). "Metrology and Measurement Techniques." Academic Press.
2. Jones, Mary. (2005). "Introduction to Gauge Blocks and Calibration." National
Institute of Standards and Technology (NIST) Special Publication 811.
3. Brown, Robert. (2018). "Precision Measurement: Calibration of Measuring
Instruments." Springer

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