Surface Finish and Roughness in

Machining – Ultimate Guide (with Chart)

By Sunny Meng / July 26, 2023

Surface finishes define the final appearance of parts after machining.

Aside from appearance, it also influences part strength, resistance to
wear and tear, and functionality.

So, what are surface finishes in detail? What are the factors that affect
the surface finish? How can you measure the surface roughness? Keep
reading as we provide you with answers and other important information
about surface finishes and roughness.

Table of Contents
• What is Surface Finish in Machining?
• 3 Elements Make Up Surface Finish
o Lay
o Waviness
o Roughness
• Common Types of Surface Finishes
o 1. As Machined
o 2. Bead Blasting
o 3. Powder Coating
o 4. Anodizing Surface
o 5. Polishing Surface
• Factors that Affect Surface Finish
o Machined Material
o Feed Rate And Cutting Tool
o Cutting Depth
• Surface Finishes Chart Symbols, Units, Callouts, and Standards
o Surface Units
 Rz
 Ra
 RMS
 Rmax
 Profile Roughness (PE)
 Profile Tolerances (PT)
 Profile Smoothness (PS)
o Surface Finish Symbols
o Surface Roughness Chart
 o Surface Finish Conversion Chart
o Surface Callout Symbols
• How to Measure Surface Roughness?
o Direct Measurement Methods
o Non-Contact Methods
o Comparison Methods
o Inductance Methods (In Process Technique)
• Choose the Suitable Surface Roughness for Your Project
o Project Budget
o Product Application
o Additional Surface Finish
• XinCheng Meets Your Machined Part Surface Finish Requirements
• Conclusion
• FAQ
o
 What is the difference between surface finish vs surface
finishing?
 What does a 32-surface finish mean?
 What differentiates Ra and Rz in the surface roughness chart?

What is Surface Finish in Machining?

Surface finish involves altering a workpiece surface to improve its
appearance, aesthetics, and functionality. The process entails removing
or adding materials to the surface of the machined part. Several factors
influence the type of surface finish ideal for a part, including the tool used
in machining, machining parameters, and the material being machined.

Another factor determining the type of surface finish used on a part is the
location it will be used. For instance, parts that form a seal, move against
each other, or have to fit tightly together often get special surface finish
considerations. Also, the machine is the determining factor, with 5-axis
CNC machining producing better finishes than its counterparts.

3 Elements Make Up Surface Finish

Sometimes, the term surface finish is ambiguous, as it encompasses
different elements. The elements that make up surface finish include:
Lay

Lay defines the dominating pattern and its orientation on the surface of a
part. Lay is typically created during the manufacturing process. What’s
more, Lay could be isotropic (non-directional), circular, crosshatched,
radial, or parallel.

Waviness

Waviness defines the periodic variations in surface finish present on a

part. This element often results from machining flaws caused by chatter
or deflection and warping from heat and cold. These periodic surface
flaws are sufficiently small, brief, and regular, differentiating them from
surface flaws.

A waviness profile is created based on the measurement over an

evaluation length. The waviness profile includes no surface irregularities
resulting from form variations, flatness, or roughness. The peak-to-peak
spacing of the waves is known as the waviness spacing (Wsm), whereas
the average or total waviness parameters determine the wave height.
Roughness

Also known as surface roughness, it refers to imperfections in surface

geometry. Since roughness is the feature of surface finish that is most
frequently described, measured, and computed, many people use the
term “Surface Finish” to refer to roughness.

Common Types of Surface Finishes

Surface finish is one of the most important aspects of CNC machining
as it improves appearance and influences functionality. There are several
types of surface finishes, but the common types include:
1. As Machined

As-machined parts are just off the production line and contain light tool
marks, an average amount of surface abrasion, and a particular texture
or completed appearance. According to the use case, a component’s
average surface roughness (Ra) is the difference between its real and
ideal machining surface roughness.

Leaving the surface of a CNC machined part “As machined” is quite

beneficial, especially when achieving tight dimensional tolerance and
consistency across multiple units.

However, on the downside, parts or products with this CNC machined

surface finish often have visible tool marks on their surface. They are
often exposed to environmental forces due to their distinct lack of
protective coating.

2. Bead Blasting

Bead blasting is a finishing method that uses a pressured air gun to blast
components with tiny glass beads. This procedure primarily enhances
aesthetics by producing a matte, satin, or light-textured finish. It’s a
primary finish type that mechanically modifies the surface to change or
erase machining marks by eliminating extra material, leaving a smooth
surface in its wake.
The even and textured finish of bead blasting is a benefit. This machined
surface finish has little impact on tolerances, but it can affect critical
dimensions of the surface, which is why it is best not to cover key surface
features.

3. Powder Coating

Powder coating is the method of applying powder by static electricity to

the surface of components. The major difference between powder
coating and spray painting is using dry powder rather than liquid. The
powder used is uniformly adsorbed on the machined components’
surface before being baked into the pieces in the oven.

This produces a robust, wear- and corrosion-resistant coating that is

more long-lasting than conventional spray coating techniques. Powder
coatings are durable and highly environmentally friendly. It gives the
surface a drip-free uniform finish, improving its mechanical strength,
corrosion, and aging resistance.

4. Anodizing Surface

Anodization is a metal surface finish that involves thickening the natural

oxide layer of a CNC machined part. Aside from thickening, this process
also makes the material more durable, denser, and electrically non-
conductive.

The first step in the process involves submerging the component which
acts as an anode into an acid electrolyte bath. The next step is placing a
cathode into the tank that contains the electrolyte bath and introducing
electricity. With the introduction of electrolytes, the combination of the
atoms from the alloy and oxygen ions from the electrolyte covers the
surface of the parts. This improves the wear resistance of the parts.

5. Polishing Surface

Three main types of polishing are used on machined parts surface finish;
conventional polishing, fire polishing, and vapor polishing.

Conventional polishing involves smoothing a surface by using an

abrasive. It greatly improves the durability of parts, although there is a
risk of chipping or cracking when using this surface finish.
Fire polishing involves using an open flame at a specific temperature and
angle to melt a part’s surface layer. Fire polishing facilitates the reduction
of ridges and bumps formed during machining.

Vapor polishing is an ideal machined plastic surface finish, as it helps

clarify opaque and dull plastics. The final result after vapor polishing is
often a shiny and smooth surface. It is best to sand machined parts with
extreme imperfections before applying the vapor polish surface finish.

It is important to note that polishing generally requires skill not to

damage the product, so it is best to leave it to skilled professionals.

Factors that Affect Surface Finish

Surface finishing is usually not straightforward as there are factors that
affect the outcome of the surface finished part. These factors include;

Machined Material

The possible surface finish for a material depends chiefly on the

machined material type. Hard materials, like metals, are smooth; in
contrast, the surface finish of softer materials, like plastics, is rougher.

Feed Rate And Cutting Tool

While the CNC fixture holds the workpiece in place, the feed rate impacts
the CNC machining surface finish since it increases the number of
passes the tool makes over the material. In other words, when the feed
rate is high, it often results in a rougher surface finish, while a lower feed
rate results in a smoother finish.

In addition, CNC machining parts with blunt CNC cutting tools often
produce a poor surface finish compared to cutting with a sharper
tool.

Cutting Depth

The cut depth impacts the workpiece’s surface finish. A shallow depth of
cut results in an even or smoother surface finish, whereas a large cut
could result in a more irregular finish.
Surface Finishes Chart Symbols, Units, Callouts, and
Standards
While reading or preparing technical drawings, you could run into many
surface finish charts, symbols, and surface finish callouts. They
represent how a surface appears after being machined.

Surface Units

Without a thorough understanding of these units, it can be challenging to

measure surface roughness. These units include:

Rz

Rz calculates the average difference between the five biggest peaks and
valleys. Five different sampling durations are used for this measurement
to help weed out any potential inaccuracies.

Ra

Ra is a gauge of a surface’s general roughness. It is a number without

units that expresses the average height of peaks and valleys on a certain
length of surface imperfections.

RMS

The average roughness of a surface is measured using a surface called

the RMS- roughness average magnitude surface. The RMS roughness
magnitude of the surface is taken as an absolute number to build this
surface.

Rmax

Anomalies like burrs and scrapes that Ra alone cannot see are more
noticeable to Rmax.

Profile Roughness (PE)

Measured in terms of the depth of the deepest valley or height or the

highest peak, profile roughness measures the size and distribution of
imperfections present on the surface of parts.

Profile Tolerances (PT)

The permitted departures from a nominal profile are known as profile
tolerances. They are crucial in ensuring that parts fit together properly
and function as intended.

Profile Smoothness (PS)

The width of the surface’s flattest region or the thickness of its thinnest
region are the conventional units of measurement for profile smoothness.

Surface Finish Symbols

These surface finish symbols represent how a surface appears after

being machined. Each of these symbols denotes a particular meaning
and can be used to express various features of a surface finish. These
include:

• Basic graphical symbol for surface texture

• The expanded graphical symbol indicating the removal of material
required
• An expanded graphical symbol indicating the removal of material
not permitted
• Surface texture graphical symbol
Surface Roughness Chart

The machining surface finish chart provides important instructions for

gauging standard surface finish characteristics. Manufacturers
consistently reference it to guarantee product quality during the
manufacturing process.
Surface Finish Conversion Chart

The surface finish conversion chart here compares the different scales
for roughness used during the manufacturing process.

Surface Callout Symbols

 • a: Single surface texture requirement
• a & b: Two or more surface texture requirements
• c: Manufacturing method
• d: Surface lay and orientation
• e: Machining allowance

How to Measure Surface Roughness?

Surface roughness (Ra) defines how smooth a surface’s profile is. There
are several measuring systems for surface roughness.
Direct Measurement Methods

This method uses a stylus to measure the surface roughness of a

surface. The process involves running the stylus at a perpendicular angle
to the material’s surface and then determining the roughness parameters
using a registered profile.

Non-Contact Methods

The machinist uses light or sound to measure the surface roughness for
this method. This method often involves using light or sound instruments
like confocal and white light to send an ultrasonic pulse onto the part’s
surface. The instrument with sensors would pick up on the reflections
caused by the uneven surface for measurement.

Comparison Methods

The comparison method uses samples with known roughness

parameters. The process here is quite simple, albeit requiring a lot of
skill. Here, the manufacturer uses visual and tactile senses to compare
the surface roughness of a newly machined part to that of a sample with
an already-known surface roughness parameter.
Inductance Methods (In Process Technique)

This method requires inductance, as it uses magnetic materials to

measure the surface roughness of a material. The inductance pickup
uses electromagnetic energy to determine the distance to the surface.
Then, using the calculated parametric value, it is possible to compute
comparative roughness parameters.

Choose the Suitable Surface Roughness for Your

Project
Here are some factors to consider when choosing the right surface
roughness for your project.

Project Budget

Your project budget is one of the main determining factors when

choosing surface roughness. For low-budget projects exposed to
polishing, painting, or other surface finishes, 3.2 μm surface finish Ra
might be your best bet, although 1.6 μm would show fewer cuts. Where
the budget is extensive, going for CNC precision machining and
smoother surface finishes like 0.4 and 0.8 μm is perfect.

Product Application

The application of the product is another factor to consider when

choosing the right machining surface finish. For products with high
precision and dimensional tolerance, it is best to go for high-grade and
smoother surface finishes. For instance, parts that would serve as
moving surfaces would require a surface finish like powder coating as it
helps reduce friction. While anodizing is better suited for products
exposed to corrosive forces for long periods.

Additional Surface Finish

Product undergoing or not-undergoing additional surface finish would

also determine the type of surface roughness suitable. Where no
additional surface finish is obtainable, it is often best to ensure the
surface is as smooth as possible, as it improves product aesthetics and
functionality.
XinCheng Meets Your Machined Part Surface Finish
Requirements
Knowing the rate at which a specific material’s surface hardens leads to
a better knowledge of surface finish. At XinCheng, we have great
knowledge and expertise in machining, including CNC machining, die
casting, vacuum casting, injection molding, sheet metal fabrication, etc.

In addition, you can rest assured of getting the desired surface finish
outcome at XinCheng since we provide thorough dimensional inspection
reports. Besides, we do a variety of finishing procedures, including bead
blasting, electroplating, anodizing, polishing, powder coating, brushing,
and more. We guarantee surface finishes that meet your specific needs.

Conclusion
Getting the right surface finish in the machining process is almost as
important as machining the part precisely. The reason is that the right
surface finish not only influences part aesthetics and durability, it also
determines its corrosion resistance.

FAQ
What is the difference between surface finish vs surface finishing?

Surface finish describes the attributes, general surface texture, and

quality of a surface. Surface finishing, in contrast, describes the process
of altering the surface to produce a desired finish.

What does a 32-surface finish mean?

The typical surface roughness is 32 micro inches or a surface finish of

32. It is equivalent to 1/32 inch to have a 32-micron roughness. The
surface finish that is smoother and closer to a 32 finish is a 6-surface
finish.

What differentiates Ra and Rz in the surface roughness chart?

Ra represents the average distance between peaks and valleys. It also

quantifies the surface’s departure from the mean line within a sampling
length. On the other hand, Rz assists in determining the vertical
separation between the highest peak and the deepest valley. This is
accomplished within five sampling intervals, after which the observed
distances are averaged.
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Posted on 02/07/2019 by Fluid Power Journal in Features 1 Comment

By Michael Cook, Fluid Power Technical Specialist, and Kelly Volpenhein, Product Engineer,
Trelleborg Sealing Solutions
Longevity of seals is not just about the seal itself, but also about specifying the optimal mating surface
finish. There is a direct relationship between the quality of a seal’s mating surface finish and a seal’s
performance—the better the finish, the longer the seal will last. In fact, an optimal surface finish can
deliver a competitive advantage in seal longevity and performance.

In contrast, aggressive seal wear from a poor finish on the mating surface can lead to seal failure. For
instance, in a fluid power application, seal finish can influence how successfully the fluid is contained
within a system, ultimately affecting both seal and system life. This is just one example of why it is so
important to focus on both the seal and the mating surface specification. But what key parameters,
testing, preparations, and methods of finishing should be identified and why?

The good news is there’s a wealth of information available on optimizing surface finishes, including
methods for roughness testing and recommendations based on those tests.
Understanding the Ra: Rz, Rt, Rsk
Simply understanding a mating surface’s Ra, or roughness average value, is not enough to properly specify
the surface finish because it is entirely possible to have very different surface textures with similar
Ra values, and those variances can greatly affect seal performance.
For example, valleys are needed on a surface to build up sufficient fluid film to reduce friction and wear,
but a high concentration of peaks, also known as open profiles, can cause excessive wear.

Therefore, the ideal surface contains low valleys without high peaks (see Figures 1 and 2). Note
that both of these surfaces have an Ra value of 2.5.

Surface Finish

So in addition to Ra, the parameters to consider when evaluating surface topography are as follows:
1. Ra: roughness average
2. Rp: maximum profile peak height
 3. Rz: mean roughness depth
4. Tp or Rmr: profile bearing ratio
5. Rsk: degree of skew
6. Rt: total height of roughness profile
Rz refers to the average of the tallest peak to the depth of the lowest valley from each subsection of a
surface measurement. In measuring roughness, Rz offers an advantage over parameters such as Rt, which
is the height of the single tallest peak to the depth of the deepest valley in a surface trace, because it
incorporates more of the surface.
However, Rz is an average of only the most extreme instances of surface roughness. So it has the potential
to be overly affected by outliers, which take the form of sharp peaks on the surface. The presence of
outliers can unfavorably affect quality-control efforts, as well as practical analyses for the discernment
and correlation of surfaces.
In addition, surface roughness may be overly influenced by valley depth, which is considered less
detrimental to performance than peak height. Reducing outliers can help in delivering a more robust
curve and surface fitting. For example, Figure 3 shows an instance where the Rz value is the same between
two surfaces, but the profiles are very different. This demonstrates why the profile’s bearing ratio, Tp or
Rmr, is also critical for determining surface quality.

Rsk classifies the magnitude and direction of surface roughness. Positive numbers represent surfaces
consisting predominately of peak asperities or harsh qualities. Negative numbers represent surfaces that
consist primarily of valleys.
Rsk is an excellent parameter for measuring surfaces expected to have peaks or valleys. However, if a
surface has been largely planarized and few peaks or valleys remain, Rsk returns to nearly zero. In this
situation, Rsk could inaccurately suggest that a surface with higher roughness is superior to a surface with
lower roughness. Thus, Rsk on its own is not descriptive enough to differentiate between rough and
smooth surfaces.
Testing Methods
Surface roughness can be measured using a profilometer. This can either be a contact type, where a stylus
measures surface roughness with the results depending on the stylus and scan length, or a non-contact
type that uses white-light interferometry to characterize the surface topography in 2D or 3D.

Defining the surface topography with a

noncontact profilometer is the preferred method of testing; however, contact profilometry is more
commonly used in the industry due to its lower cost.

The tables on this page contain recommendations for choosing mating surfaces for a variety of seal types
within linear, rotary, and static applications. Notice that dynamic linear and rotary applications require a
better surface finish than static applications. Also, elastomer and polyurethane seals can operate against a
rougher finish than polytetrafluoroethylene-based (PTFE) seals. It is critical to take both the dynamic
operation of the seal and its material into account when specifying contact surface finish values.
Mating Surface Preparation

Slipper seals run well against un-plated surfaces at moderate speeds and pressures. In high-speed and
high-pressure reciprocating applications, harder surfaces are recommended. This is because a seal will
polish its mating surface, especially when made of softer metals, during the run-in period.

The run-in period is the initial time frame of high wear and friction, where the seal begins to polish the
mating surface by breaking off the peaks. Once the peaks are broken off and the hardware and seal reach
an equilibrium state, the run-in period ends.

For example, after the run-in period, a

reciprocating rod of stainless steel with a hardness of 28 to 30 Rockwell C and a 25µin / 0.635µm
Ra surface will typically be polished by the seal to 12µin / 0.30µm Ra or better.
Seal friction and wear will decrease accordingly after the run-in period. Therefore, it is important to
reduce the run-in period by precisely controlling the surface profile, especially on harder mating surfaces.
In applications where the mating surface is plated or coated, the hardware material is still considered
critical. If the plating is supported by a soft substrate, it may crack or carve-in under a high pressure load
due to insufficient support. The plating could also crack if it does not meet the suggested thickness.
Proper hardening of the substrate material, along with proper coating thicknesses, will ensure the
dynamic running surface is not damaged.

Methods of Finishing

There are a variety of surface finishing methods for use on fluid-power components, including plunge and
centerless grinding, turning, lapping, honing, roller burnishing, and polishing. However, most sealing
surfaces are ground and polished. Hand polishing usually results in inconsistent finishes across the work
piece and should only be used when absolutely necessary.
Generally speaking, super finishing imparts a more consistent polished surface. This process involves
applying an abrasive paper or other abrasive media via machine to polish a surface. The operator can
tune the process by adjusting the scale or grit of the abrasive or by changing the feed speed.

Summary

Consideration of the surface finish that mates against a seal is essential to ensuring a leak-free sealing
system with a long life in fluid power applications. Step one in selecting the optimal surface finish for a
particular sealing system is understanding a surface’s Ra value, but this does not tell the whole story.
Rather, a number of finish parameters, including maximum profile peak height, mean roughness depth,
profile bearing ratio, the degree of skew, and the total height of the roughness profile should be taken into
account.
Finally, it’s important that both mating surface preparation and finishing methods be considered during
the selection process. Working with a seal supplier that has expertise in supporting the specification of
mating surfaces can ensure that fluid power application and system lives are maximized.
• performance
• seals
• surface finish

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One thought on “Beyond Ra: Why Surface Finish Matters in Seal
Performance”

1. Thelma
02/09/2021 at 17:20
Team, where did you find “Static Application – Mating Surface” for an elastomer seal? I need to
know the reference.
I will work with LSR and I need to define the mating surface finish, one part has a finishing of .6
um and the other side has a finishing of 22um (it is crazy, I know). How can i ask to my supplier
of these metal parts meet the mating surface finishing without a reference?
Thanks for your feedback.

REPLY