INTRODUCTION We calculated surface roughness of the metals because we want to know whether the metals produced have some

error or not. The best metal is one which has the smoothest surface while metal with rough surface are not have good quality. This is because, metal with rough surface tend to increase the frictional force on its surface due to friction. Surftest SV-600-MITUTOYO is the machine used to calculate the surface roughness of any metal. We just need to put the metal on the tray provided and handle the machine through the computer that is equipped with the software. After we got the results, we can print out the graph including the values needed. From the graph provided, we need to manipulate the data and gets all the values to compare with the theoretical values. THEORY In any mechanical surface, the term used to describe its geometrical quality is known as surface roughness. Roughness of a surface refers to a property of a machined surface. Surface roughness is that part of surface finish (surface texture) which can be defined as the work left by the action of the production process used; such as turning operation process. Surface roughness consists of relatively closed-spaced or fine surface irregularities usually in the form of feed marks left by the cutting tool on the machined surface. Surface finish of a machine part is a significant design specification that is known to have a considerable influence like water resistance and fatigue strength. The quality of surface is a factor importance in the evaluation of machine tool productivity. In the engineering design and production, it is important to be able to specify the degree of surface roughness desired. Reference line or mean line: It is mathematically calculated mean line which is fitted into the profile so that the sum of the areas enclosed by the profile above this line equals the sum of those below. Maximum roughness depth :

It is the distance between the highest and lowest points of the profile within the evaluation length . : Distance between the mean line and the highest profile peak. : Distance between the mean line and the lowest profile valley.

Measurement length or evaluation length (

):

The horizontal limitation for the assessment of surface parameters is the measuring or evaluation length. Tracing length or traverse length ( ): It is the distance traversed by the tracing system during a measurement. It equals sum of the pre and over travel and the evaluation length. Tracing length ( ) = pre travel ( ) + evaluation length ( ) + over travel ( ). The pre travel and over travel are required by the electric filter to attenuate mechanical and electrical transients. These two lengths also correspond to a cutoff length. Mean peak to valley height ( ):

It is the average of the single peak to valley heights of n number of adjoining sampling lengths ( ).

Maximum roughness depth (

):

It is the largest single peak to valley height ( ) within n number of adjoining sample length. In the figure above, corresponds to . Arithmetical mean roughness or centre line average, average (A. A. American): (C. L. A. British) or arithmetical

is obtained by measuring the mean deviation of the peak from the centre line of a trace, the centre line being established as the line above and below which there is an equal area between the centre line and the surface trace. There is little difference between the CLA and RMS (Root Mean Square) values given for a given surface.

Centre Line Average (CLA or

):

Root Mean Square Roughness (RMS or [ ]

):

OBJECTIVES 1. To examine the surface roughness of mild steel (CNC turning), mild steel (EDM wire cut), mild steel (disk grinding) and brass. 2. To compare the theoretical value and calculated value.

CALCULATION 1) MILD STEEL (WIRE CUT)

(m) y1 y2 y3 y4 y5 y6 y7 y8 y9 y10 Total yi 2.90 3.10 2.90 2.70 1.80 3.40 2.40 4.10 2.50 2.70 28.5 yi2 8.41 9.61 8.41 7.29 3.24 11.56 5.76 16.81 6.25 7.29 84.63 yi3 24.39 29.79 24.39 19.68 5.83 39.30 13.82 68.92 15.63 19.68 261.43 yi4 70.73 92.35 70.73 53.14 10.50 133.63 33.18 282.58 39.06 53.14 839.04

Height (m) Z

Z1 4.20

Z2 6.10

Z3 3.30

Z4 4.50

Z5 5.20

Total 4.66

3Z

12.6

18.3

9.90

13.50

15.60

69.90

1. 2. 3. 4.

5.

6.

[ 7. ( ( 8. )

] ) ( ) ( )

9.

(
(

)*

) (

)*

+= -0.38
( )

10.

( (

)*

)*

+=1.17

2) MILD STEEL (CNC TURNING)

(m) y1 y2 y3 y4 y5 y6 y7 yi 1.50 2.40 1.60 2.70 1.60 2.50 1.60 yi2 2.25 5.76 2.56 7.29 2.56 6.25 2.56 yi3 3.38 13.82 4.10 19.68 4.10 15.63 4.10 yi4 5.06 33.18 6.55 53.14 6.55 53.14 6.55

y8 y9 y10 Total

2.40 2.20 2.40 20.90

5.76 4.84 5.76 45.59

13.82 10.65 13.82 103.10

33.18 23.43 33.18 253.96

Height (m) Z 3Z

Z1 3.80 11.40

Z2 3.70 11.10

Z3 3.70 11.10

Z4 3.80 11.40

Z5 4.10 12.30

Total 3.82 57.3

1. 2. 3. 4.

5.

6.

[ 7. ( ( 8. )

] ) ( ) ( )

9.

(
(

)*

) (

)*

+= -0.51
( )

10.

( (

)*

)*

+=1.21

3) MILD STEEL (DISC GRINDING)

(m) yi yi2 yi3 yi4

y1 y2 y3 y4 y5 y6 y7 y8 y9 y10 Total

2.40 2.10 1.60 1.70 2.10 2.90 2.80 2.00 2.50 2.50 22.60

5.76 4.41 2.56 2.89 4.41 8.41 7.84 4.00 6.25 6.25 52.78

13.82 9.26 4.10 4.91 9.26 24.39 21.95 8.00 15.63 15.63 126.92

33.18 19.45 6.55 8.35 19.45 70.73 61.47 16.00 39.06 39.06 313.30

Height (m) Z 3Z

Z1 4.50 13.50

Z2 2.70 8.10

Z3 1.90 5.70

Z4 2.60 7.80

Z5 3.40 10.20

Total 3.02 45.30

1. 2. 3. 4.

5.

6.

[ 7. ( ( 8. )

] ) ( ) ( )

9.

(
(

)*

) (

)*

+= 0.02
( )

10.

( (

)*

)*

+=1.12

4) BRASS
(m) y1 y2 y3 y4 y5 y6 y7 y8 y9 y10 Total yi 0.90 2.30 2.20 3.20 1.60 2.90 2.20 1.80 1.30 2.30 20.70 yi2 0.81 5.29 4.84 10.24 2.56 8.41 4.84 3.24 1.69 5.29 47.21 yi3 0.73 12.17 10.65 32.77 4.10 24.39 10.65 5.83 2.20 12.17 115.66 yi4 0.66 27.98 23.43 104.86 6.55 70.73 23.43 10.50 2.86 27.98 298.98

Height (m) Z 3Z

Z1 3.30 9.90

Z2 2.60 7.80

Z3 3.60 10.80

Z4 2.50 7.50

Z5 5.10 15.30

Total 3.42 51.30

1. 2. 3. 4.

5.

6.

[ 7. ( ( 8. )

] ) ( ) ( )

9.

(
(

)*

) (

)*

+= -0.58
( )

10.

( (

)*

)*

+=1.35

DISCUSSION Now we can compare the calculated value and the theoretical value. For the Mild Steel (Wire Cut):
Measure Rp Rv Ry Rz Ra Rq Rc R3z Sk Ku Calculated Value, m 3.00 4.10 7.10 0.93 2.85 2.91 5.70 13.98 -0.3800 1.1700 Experimental Value, m 5.01 6.15 11.16 8.22 2.42 2.84 7.72 6.58 -0.0939 2.1439 % Error 40.12 33.33 36.38 88.69 17.77 2.46 26.17 112.46 2.69 45.43

For the Mild Steel (CNC Turning):

Measure Rp Rv Ry Rz Ra Calculated Value, m 1.70 2.70 4.40 0.76 2.09 Experimental Value, m 1.64 2.56 4.20 3.84 1.08 % Error 3.66 5.47 4.76 80.21 93.52

Rq Rc R3z Sk Ku

2.14 4.18 11.46 -0.5100 1.2100

1.24 3.56 3.82 -0.6673 2.0174

72.58 17.42 200.00 23.57 40.02

For the Mild Steel (Disc Grinding):

Measure Rp Rv Ry Rz Ra Rq Rc R3z Sk Ku Calculated Value, m 2.80 2.90 5.70 0.60 2.26 2.30 4.52 9.06 0.0200 1.1200 Experimental Value, m 4.75 4.63 9.38 4.75 1.68 2.10 3.69 4.07 0.0211 2.5230 % Error 41.05 37.37 39.23 87.37 34.52 9.52 22.49 122.60 5.21 55.61

For the Brass:

Measure Rp Rv Ry Rz Ra Rq Rc R3z Sk Ku Calculated Value, m 2.20 3.40 5.60 0.68 2.07 2.17 4.14 10.26 -0.5800 1.3500 Experimental Value, m 0.96 1.35 2.32 1.40 0.41 0.50 0.87 1.32 -0.4974 2.9492 % Error 129.17 151.85 141.38 51.43 404.88 334.00 375.86 677.27 16.61 54.22

As we can see, some of the values obtained have high percentage of error while some of them just small error. These errors occur might be because of the parallax error from the reader. To prevent the error, the reader needs to make sure both of the eyes were exactly perpendicular to the scale. Other than that, there might be some error during analysing the graph. This happen because the manipulator did not take the exact value needed. This happen because the manipulator is a student, so he did not know where he should take the point exactly. To avoid this from happen again, the student need to study hard and ask the lab assistant anything that he did not understand.

CONCLUSION The values obtained from the experiment:

Measure Rp Rv Ry Rz Ra Rq Rc R3z Sk Ku Mild Steel (Wire Cut), m 3.00 4.10 7.10 0.93 2.85 2.91 5.70 13.98 -0.3800 1.1700 Mild Steel (CNC Turning), m 1.70 2.70 4.40 0.76 2.09 2.14 4.18 11.46 -0.5100 1.2100 Mild Steel (Disc Grinding), m 2.80 2.90 5.70 0.60 2.26 2.30 4.52 9.06 0.0200 1.1200 Brass, m 2.20 3.40 5.60 0.68 2.07 2.17 4.14 10.26 -0.5800 1.3500

This shows the roughness of the metal.