SURFCE FINISH AND SURFACE INTEGRITY

BY Kali dass
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INDEX
INTRODUCTION SURFACE FINISH EFFECT OF MACHINING PARAMETER ON SURFACE FINISH MEASURES OF SURFACE ROUGHNESS SURFACE INTEGRITY IMPORTANSE OF SURFACE INTEGRITY METHOD OF IMPROVING SURFACE FINISH Free Powerpoint Templates

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INTRODUCTION
Machining operation are used to produce a desired shape and size by removing excess stock from a blank in the form of chips. New surfaces are generated through a process of plastic deformation and crack propagation. A surface can be characterized by its topography and microstructure. The formers describes its micro-geometrical properties or texture in terms of roughness, waviness and lay and the latter by the depth and nature of the alternative material zone just below the surface.
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Surface integrityt of a Fig: surface characterization component can be defined as the degree of the soundness, wholeness or unimpairedness of the surface topography and microstructure as a result of the given manufacturing operation.

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SURFACE FINISH
Surface finish refers to the following properties of a machined surface. Roughness: It consists of relatively closely-spaced or fine surface irregularities, mainly in the form of feed marks left by the cutting tool on the machined surface as shown in figure. Waviness: It consist of all surface irregularities whose spacing is greater than the roughness sampling length. Vibration, chatter, and tool and work piece deflections due to cutting loads and cutting temperature may cause waviness.

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Fig: Element of surface texture.

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Lay: It denotes the predominant direction of the surface irregularities. The lay usually specified with respect to an edge called the reference edge of the work piece. Surface Flaws: These are randomly spaced irregularities, that is those which occur at some particular location on the surface or at widely varying intervals. Flaws could be due to inherent defects, such as inclusions, cracks, blow-holes, etc

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EFFECT OF MACHINING PARAMETERS ON SURFACE FINISH

Surface finish is influenced by several machining parameters including cutting tool geometry, machine tool rigidity, work piece material, cutting conditions and tool material. Tool Geometry: It is known that large the rake angles, smaller are the cutting forces. And when the cutting forces are small, deflections and waviness height are also small. Relief angles should be sufficient to prevent rubbing against the machined surfaces. Additional cutting force due to the rubbing action causes harmful deflections.
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The major and the minor (i,e. the side and the end) cutting edge should be joined by a nose of sufficiently large radius to reduce the sharpness or pointless of tool. An excessive noise radius however, is harmful because it can cause vibration and chatter. An increase in the side-cutting edge angle reduces true feed and improve chip flow and surface finish and large side cutting angles may prove harmful to surface finish by causing chatter.
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However position of a zero degree primary end-cutting edge angle over a length of 1.5 times the feed per revolution (as shown in fig.) helps in partially or totally removing the grove generated by the noise radius of the tool. The flat on the end cutting edge is figuratively called as wiper flat. Fig: Tool provided with wiper flat

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Work piece Geometry: Long slender work pieces have low stiffness against both static and dynamic forces as a result waviness effects are more pronounced. Machine Tool Rigidity and Accuracy: The machine tool affects surface finish mainly through the extent of its rigidity, freedom from alignment errors and accuracy of motions Cutting Condition: cutting condition, in general, tends to improve surface finish .
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Tool Material: Different tool material have different hot hardness, toughness and frictional behavior. High hot hardness of tool material enables the tool to be used at high cutting speeds well within the insensitive region where built-up edge practically disappears. Cutting Fluid: Cutting fluid has only an indirect effect on surface finish, by acting as coolant it reduces tool wear and keeps the cutting edge impact , by acting as a lubricant it tends to reduce friction between the sliding surface of the tool, work and chip. Templates Free Powerpoint

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MEASURES OF SURFACE ROUGHNESS

Following are the chief measures of surface roughness a) Overall height (h max): It is the height separation between two reference lines namely L p and L v (upper and lower surface line) touching the highest peak and lowest valley occurring with in sampling length L of a given surface. h max = L p L v b) Leveling Depth hp: It is the mean height of the profile above a mean line Lm where it is defined as a line so positioned in the profile that the sum of the squares of the deviations of the profile from the mean line is minimum. hp =
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c) Centre Line Average(h CLA): It is defined as the arithmetic average of the deviation of the profile above and below the mean line. h CLA = d) Root mean square value(h RMS): It is defined as the geometrical average value of the deviation of the profile above and below the mean line.
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SURFACE INTTYGRIY
Surface integrity refers to the soundness of the surface condition of manufactured parts. Besides the feed marks, it depends upon plastic deformation, micro structural changes, porosity, micro cracks, residual stress, etc. Plastic Deformation: The surface layer is plastically deformed. Extent of deformation depends upon the process parameters, namely cutting speed, dimensions of cut, tool geometry, work piece material and characteristics of the machine tool.
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Micro structural Changes: The structural changes in the micro constituents include phase transformation, intergranular attacks and recrystallization. Phase transformation occur on the account of intensive heating of the surface layer during machining. Recrystallization: Recrystallization in the surface layer may be attribute to the plastic deformation. When the service environment heats a machined part, Recrystallization and grain growth of material of the surface layers may take place.
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Residual Stress: Residual Fig : Distribution of Residual stress Stress in the surface layer of a
machined piece is a result of the removal of machining load that caused plastic deformation in it. The distribution of residual stress depends upon the cutting load, the distribution of mechanical stress and temperature during chip formation. The residual stress may be tensile or compressive high or low, deep or shallow.
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IMPORTANT OF SURFACE INTEGRITY

Surface condition affects fatigue strength of the finished part and produces distortion in the part especially if it is thin. Fatigue Strength: On the account of tensile residual stress, plastic deformation, micro-cracks, and face transformation, etc. low cycle fatigue strength of the finish parts may be substantially decrease, so under adverse condition of machining.
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Distortion: Machining removes residual stress pre-existing in the work piece. It also introduces residual stress of its own. On account of both effects, the work piece suffers distortion. Such distortion is easily noticeable or measurable on thin specimen. The amount of distortion also depends upon the work material. For example, titanium distorts much more than steel on account of its low modulus of elasticity.
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METHODS OF IMPROVING SURFACE FINISH

Surface conditions of a work piece undergoing a machining operation can be guarded against ill effects as follows: 1. By using light cuts: cutting speed, feed and depth of cut should be such that no built-up edge is formed, chip formation is continuous, cutting forces are small and cutting temperatures are low. This is possible by optimizing the cutting speed and using small feed and depth of cut.
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2. By using an effective cutting fluid: Tool
temperature, and to some extent the cutting forces, can be decreased by using a proper cutting fluid that can act as an effective coolant and lubricant. 3. By using a sharp cutting tool or one that does not have appreciable wear land. 4. By using a rigid machine-tool-work system that ration and minimizes vibration and chatter.
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5. By using a post-processing treatment that
includes compressive residual stress in the surface layer and improves fatigue life. Among such treatments are shot penning, burnishing and tumbling.

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