Technion Israel Institute of Technology

Department of Mechanical Engineering 034030 Manufacturing Processes

2. Surfaces

Surfaces in Practice
Precision required in mating surfaces Tribological considerations Fatigue and notch sensitivity Electrical and thermal contact resistance Corrosion resistance Subsequent processing Appearance

Surface Structure of Metals

Surface Integrity
Metallurgical Phase transformations Hardening and softening

Mechanical Residual stresses

Geometrical Flaws or defects Surface texture

Surface Texture

Average Surface Roughness

y a + y b + y c + K + y n = y i = y dx = 0
i =1 A

Ra =

ya + yb + yc + K + yn n

1 n 1 = yi = y dx n i=1 AB A

Rq =

2 2 2 2 ya + yb + y c + K + yn 1 n 2 = yi = n n i=1

1 y 2 dx AB A

Maximum Roughness Height

Rmax = max (Hi hi )

R t = max (Hi ) max (hi )

Bearing Ratio Parameters

Various Surface Profiles

Ra = 2.4 m, Rpk = 2.6 m, Rk = 8.2 m, Rvk = 2.6 m

Ra = 2.4 m, Rpk = 0.9 m, Rk = 1.9 m, Rvk = 9.8 m

Grade

Ra, m

Some applications N1 Micrometer anvils, mirrors N2 Gage faces, comparator anvils 0.1 Precision tools, ball bearings Crankshaft journals, cam faces Piston surface, cylinder bores Motor shaft bearings Brake drums, gear teeth Gear shafts, cylinder head faces Motionless mating surfaces Clearance surfaces 0.025 0.05 N3 N4 N5 N6 N7 N8 N9 12.5 25 50 N10 N11 N12 6.3 3.2 1.6 0.8 0.4 0.2

Roughness Grade Number

10

Surface Finish
Roughness Flame cutting Snagging Sawing Planning, shaping Drilling Chemical milling Elect. discharge mach. Milling Broaching Reaming Electron beam Laser Electrochemical Boring, Turning Barrel finishing Electrolytic grinding Roller burnishing Grinding Honing Electro-polish Polishing Lapping Superfinishing Sand casting Hot rolling Forging Permanent mold casting Investment casting Extruding Cold drawing, rolling Die casting N12 N11 N10 N9 N8 N7 N6 N5 N4 N3 N2

11

N1

Symbols for Surface Texture

Symbol Interpretation Basic surface texture symbol. Surface may be produced by any method. Material removal by machining is required to produce the surface and material must be provided for this purpose.

12

Material removal is prohibited. Surface must be produced by casting, forging, powder metallurgy, injection molding, etc. To be used when any surface characteristics are specified above the horizontal line or to the right of the symbol. b c (a) Maximum roughness average (Ra , in micrometers, or Nx) (b) Maximum waviness height (in millimeters) (c) Roughness sampling length (cutoff, in millimeters) (d) Lay designation (e) Basic amount of stock provided for material removal (in millimeters)

a e d

Lay Symbols
Symbol Interpretation Lay parallel to the line representing the surface to which the symbol is applied Lay perpendicular to the line representing the surface to which the symbol is applied Lay angular in both directions to the line representing the surface to which the symbol is applied Example Symbol Interpretation

13

Example

Lay multidirectional

Lay app. circular to the center of the surface to which the symbol is applied Lay app. radial to the center of the surface to which the symbol is applied

Measuring Surface Roughness

Mechanical Profilometry Scanning Probe Microscopy

14

Interferometry

Surface Profiles
Mechanical Profilometry Scanning Probe Microscopy

15

Interferometry

1.4 mm 3.8 m 0.4 mm

400 nm

Grinded surface

Laser treated surface

BaTiO3 crystal

Asymmetrical Magnification Effect

Real profile

16

X5000

X5000

E X5000 X1000 Y A X5000 X100 B

Y C D

Shown profile

Surfaces in Contact

17

An = a b
a

Ari

A r = A ir << A n
i =1

Friction

18

m=

i
k

Friction Mechanism

19

Adhesion component

Deformation component

Measuring Friction
Frictional behavior of bodies in contact depends on many parameters, such as Load Relative sliding speed Temperature Surface condition Contact geometry Environment Rational experimental simulation of actual contact conditions should be performed to determine real frictional properties

20

Ring Compression Test

21

Lubrication Regimes: Stribeck Curve

FN h Solid 1 v Lubricant Solid 2 h0 Surface roughness, R

22

Friction Coefficient

Boundary

hR

h >> R

Mixed

Full-film

Viscosity Velocity Load

Wear
Wear is defined as the progressive loss or unwanted removal of material from a surface Different types of wear are caused by combinations of four basic wear mechanisms Adhesive Single die wear Abrasive Oxidative Surface fatigue

23

Roller Burnishing

24

Improves surface finish by removing scratches, tool marks, and pits. Compressive residual stresses left enhance wear and fatigue resistance.

Shot Peening

25

Thermal Wire Spraying

26

Metal is melted in a stream of oxyacetylene flame, electric arc, or plasma arc, and the droplets are sprayed on the preheated surface at speeds up to 100 m/s, to form a coating of up to 0.25 mm thickness

Physical Vapor Deposition

27

Sputtering

28

Chemical Vapor Deposition

29

Used to improve wear resistance.

Electroplating

30

Used to improve surface appearance, as well as to enhance wear resistance.

Electroforming

31

Design for Uniform Coating

32

Paint Application Methods

33

Used for its decorative and functional properties.