Production

Techniques-II
ME F313

Surface Integrity and Surface Finish

Surface Integrity is the sum of all the elements that

describes all the conditions existing on or at the

surface of a workpiece.
Two aspects of Surface Integrity:
Surface Topography: It describes the roughness, lay

or texture of the outermost layer

of the workpiece.
Surface Metallurgy:
It describes the nature of the
altered layers below the surface
with respect to the base of
matrix
material.

Surface Characterization

Principal Causes for surface alterations in

metal cutting
1. High temperature or high thermal gradient.
2. Mechanical working beyond the limit of plastic

deformation.
3. Chemical reactions and subsequent absorptions
into the nascent machined surfaces.

Surface Topography
Outermost layers of all machined surface display a great

number of both macro-geometrical and micro-geometrical

deviations from the ideal geometrical surface.
First order deviations: Form errors & macrogeometrical errors.
Second order deviations: Waviness.
Third and higher order deviations: Surface Roughness.

Surface Topography Cont

Surface finish or surface texture refers to the following

properties of the machined surface.

Roughness:

Relatively fine-spaced surface irregularities.

It is produced by cutting actions of tool edge, abrasive grains
and feed marks by cutting tool.
Waviness:
Surface irregularities, greater spacing
than
roughness. It is caused by vibration, chatter and
tool/workpiece deflections.
Flaws:
Irregularities taking place at one place or in relatively
infrequent intervals in the surface. E.g. scratch, ridge, hole or
crack etc.
Lay: The direction of predominant surface pattern.
It is specified w.r.t an edge called the reference
edge of the
workpiece.

Elements of Surface Texture

Factors affecting surface quality

Machine tool rigidity and bearing accuracies.
Finishability of work material.
Type and condition of cutting tool.
Applications of cutting fluid.
Method of chip removal.
Geometry of cutting tool.
Cutting variables.

Waviness of the surface may be due to vibrations

which in turn due to

External sources of chock and vibration.
Internal unbalancing machining elements.
Defects in the drive in machine tool.
Self-excited vibration.

Ideal roughness
Turning

For milling
2

H max

H av

4DN 2 Z 2
f2
2

9 3DN Z

For slab milling with straight cutter

For slab milling with straight cutter

Slab milling

Surface Metallurgy
It is concerned mainly on Altered Material Zone (AMZ)
Cracks
Plastic deformation
Hardness Alteration
Residual stresses
Metallurgical Transformation
Recrystallization
Intergranular Attack
Selective Etch
Heat affected zone

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