Experiment 7

Title
To measure the surface roughness (Ra) of machined parts cut on machining center.

Objectives

 Measure and compare the surface roughness (Ra) at different locations on a machined
part to assess consistency of machining performance.
 Identify areas of deviation in surface finish and correlate them with potential process
issues for targeted quality improvement.

Problem statement
Inconsistent surface roughness across different portions of machined parts indicates variation in
process stability, tool condition, or machining parameters. Such variability can lead to
performance issues, non-compliance with design standards, and increased rejection rates.
Accurate and localized measurement of Ra is therefore essential to detect process flaws, ensure
uniform quality, and guide corrective actions in CNC machining operations.

Apparatus
Apparatus is required for this experiment is as follow.
 Surface roughness meter (Surtronic S128)
 Machined part

Theory

Introduction

In precision machining, the quality of a surface plays a critical role in determining the functional
performance and lifespan of a part. Surface roughness is one of the key indicators used to
evaluate surface integrity, and it directly affects how components interact in assembly, wear over
time, and behave under operational stress. Among various parameters used to characterize
surface texture, Ra, the arithmetic mean roughness, is widely adopted for its simplicity and
effectiveness. This theory discusses the definition, significance, and measurement techniques of
Ra in the context of CNC-machined parts, especially when inconsistencies arise across different
locations on a single component.

Understanding Surface Roughness and Ra

Surface roughness refers to the finely spaced irregularities that are inherent to a surface as a
result of machining or material removal processes. These irregularities are often unavoidable but
can be controlled within acceptable limits based on the desired function of the part. The
parameter Ra (arithmetic average roughness) quantifies the average vertical deviation of the
surface profile from its mean line over a sampling length. It is expressed in micrometers (µm)
and provides a numerical representation of surface smoothness.

Although Ra does not capture every detail of the surface structure (such as directionality or
spacing of peaks), it is a reliable baseline for determining whether a surface meets required
specifications. Ra is easy to interpret and remains the industry standard for routine surface
quality evaluations [1].

Importance of Ra Measurement in Machined Parts

For parts produced on CNC machining centers, maintaining consistent surface quality is crucial.
Surface roughness affects multiple performance aspects, such as:

 Mechanical Fit: Excessive roughness can interfere with precise assembly or cause
premature wear in moving parts.
 Fatigue Resistance: Smoother surfaces tend to resist crack initiation better under cyclic
loading.
 Friction and Lubrication: Proper surface texture enhances lubricant retention and
reduces friction.
 Sealing Effectiveness: Mating surfaces with lower Ra values prevent leakage in seals
and joints.
 Aesthetic Appeal: Consumer-facing products often demand smooth and visually uniform
finishes.

In the context of this experiment, where one portion of a machined part recorded an Ra of 0.30
µm and another recorded 3.6 µm, the sharp contrast highlights the importance of regular and
localized surface inspection to ensure consistency and process reliability [2].

Techniques for Measuring Surface Roughness

Surface roughness can be measured using a variety of techniques, depending on the nature of the
component and the required precision. These techniques are generally categorized into contact
and non-contact methods:

Contact Measurement (Stylus Profilometers)

The most common method involves using a stylus-type surface roughness tester. A diamond-
tipped stylus is drawn across the surface, and its vertical movements are recorded and analyzed
to compute Ra and other roughness parameters. Instruments such as the Surtronic S128, used in
this experiment, are highly reliable for typical industrial applications.

 Advantages: High precision; suitable for a wide range of surfaces.

 Limitations: May damage very soft materials; limited speed and area coverage [3].
Non-Contact Methods

These include optical systems like white-light interferometers, laser profilometers, and confocal
microscopes. These systems are ideal for delicate surfaces and offer fast, high-resolution
measurements.

 Advantages: Non-destructive; excellent resolution; faster scanning.

 Limitations: Costly and sensitive to surface reflectivity or contamination [3].

In-Process Measurement

Modern CNC systems are increasingly incorporating real-time surface measurement tools and
sensors to enable in-process monitoring. This approach helps detect roughness deviations early,
reducing the need for post-process inspection and rework [4].

Factors Influencing Surface Roughness

Several machining parameters and tool conditions directly influence surface roughness. These
include:

 Feed Rate: Higher feed rates usually result in more pronounced tool marks, increasing
Ra.
 Cutting Speed: Within optimal ranges, higher cutting speeds can improve finish;
however, excessively high speeds may induce chatter or thermal damage.
 Tool Wear and Geometry: A sharp, well-maintained tool produces a smoother finish,
while worn tools can create grooves and irregularities.
 Workpiece Material: Harder materials typically produce better finishes under the same
conditions compared to softer, gummy metals.
 Coolant and Lubrication: Adequate use of coolant helps dissipate heat and flush chips,
reducing surface damage [2], [4].

In this experiment, the significant variation in Ra suggests that one or more of these parameters
were inconsistent during the machining process. Such discrepancies must be identified and
corrected to maintain quality.

Industrial Relevance and Standards

Surface roughness is governed by international standards such as ISO 4287, ASME B46.1, and
DIN EN ISO 1302, which define how surface texture should be measured, reported, and
interpreted. Typical industrial requirements include:

 Precision bearing surfaces: Ra < 0.8 µm

 General machined surfaces: Ra = 1.6–3.2 µm
 Rough machining or pre-processing: Ra > 6.3 µm
The Ra value of 0.30 µm observed in one portion of the experiment reflects a high-quality
surface suitable for precision applications, while the 3.6 µm reading exceeds the limits for most
fine-finish requirements. This reinforces the need for multiple-point surface inspection and
continuous monitoring during machining operations to ensure uniformity [1], [5].

Conclusion

Surface roughness, and specifically the Ra parameter, is a crucial indicator of machining

performance and part quality. Inconsistencies in Ra values, as seen in the conducted experiment,
reveal potential issues in process stability or tooling. Regular and accurate surface measurement,
along with well-controlled machining parameters, are essential to meet design requirements and
prevent downstream failures. Implementing both traditional stylus-based tools and modern in-
process monitoring techniques allows manufacturers to maintain high-quality standards across all
machined parts.

Procedure:
 Turn on the surface roughness meter
 After calibration of meter place the machined part on a flat surface
 Now adjust the measuring pin so that it is flat and touching the surface of machined part
 The height of measuring pin can be adjusted as needed.
 After this press the Button so that the meter starts to take a reading
 After this note down the reading of Arithmetic roughness (Ra)
 Do this 2 to 3 time on different places
 Thus, in this way Arithmetic roughness (Ra) of machined part is measured.

Observations:
On First portion of machine part roughness Ra value came out to be 0.30 micro meter with Rt
and Rz

Figure 01: Ra value on first portion

On Second portion of machine part roughness Ra value came out to be 3.6 micro meter with Rt
and Rz 31 and 21.5, respectively
 Figure 02: Ra value on second portion

Results:

Surface roughness (Ra) measurements were taken at two locations on the machined part. The
first location recorded an Ra value of 0.30 µm, indicating a fine surface finish. In contrast, the
second location showed a much rougher surface with an Ra value of 3.6 µm, along with Rt and
Rz values of 31 µm and 21.5 µm, respectively.

Comments:

The significant difference in Ra values between the two regions suggests non-uniform
machining, likely caused by uneven tool wear, inconsistent feed rates, or improper machine
calibration. While the first location meets high-precision standards, the second exceeds
acceptable roughness limits. This highlights the need for consistent process control and regular
tool inspection to ensure uniform surface quality.

References

1. ISO 4287:1997 – Geometrical Product Specifications (GPS) – Surface texture: Profile

method – Terms, definitions, and surface texture parameters.
2. Groover, M.P. (2013). Fundamentals of Modern Manufacturing: Materials, Processes,
and Systems. Wiley.
3. Whitehouse, D.J. (2002). Handbook of Surface Metrology. Institute of Physics
Publishing.
4. ASME B46.1-2009 – Surface Texture (Surface Roughness, Waviness, and Lay).
5. M. Rahman, A. Senthil Kumar, H.S. Lim (2001). “Optimization of the machining
conditions for milling operations,” Journal of Materials Processing Technology, 116(1),
39–43.