ABSTRACT Surface roughness also known as surface metrology which been used to determines the surface topography.

It is important for confirming a surfaces suitability for its function. The surface measurement conceptually includes surface shape, surface finish, surface profile roughness (Ra), surface texture and structural characterization. Therefore, this report is basically to expose the student on how to be able to comprehend the technique of the surface roughness measurement upon a specimen. The result of the surface roughness will be obtained by the Centre Line Average (CLA) or Roughness Average (R a) method using a computerize Roughness Measuring Machine. The computerized data then will be compared with the manually Roughness Average (Ra) by using the planimeter. 1.0 TITLE Surface Roughness Measurement 2.0 OBJECTIVE To obtain the value of the roughness of a specimen by the CENTER LINE AVERAGE (CLA) or ROUGHNESS AVERAGE (Ra) method by using Computerized Roughness Measuring Machine. To obtain the area from the roughness results or sinusoidal curve in . Manually calculate the CLA value and compare it with CLA of the graph. To gain percentage error below 30%. Evaluate the result.

3.0 INTRODUCTION As a glass posses good surface finishing, it is viewed to be a 100% smooth and contains no roughness. However, as the mirror undergoes the machined surface at micron level we will experienced the irregularities upon closer inspection which is known as surface roughness. Surface roughness is the measure of surface irregularities in the surface texture. Surface roughness (Ra) is an arithmetic average deviation of the surface valleys expressed in micro inches and micro meter. The ISO standards use the term CLA (Center Line Average) which is also identical (www.engineersedge.com, 2011). Hence, similar to some surface property such as hardness, the value of the surface roughness depends on the value of scale measurement. For example, engine parts may be exposed to lubricants to prevent potential wear, and these surfaces require precise engineering at a microscopic level to ensure that the surface roughness holds enough of the lubricants between the parts under compression, while it is smooth enough not to make metal to metal contact. For manufacturing and design purposes, measurement is critical to ensure that the finished material meets the design specification (www.zemetrics.com, 2011)

THEORY A surface can never be perfectly smooth and will always have two components of surface texture namely roughness and waviness as shown in Figure 2. They may vary from fine to coarse according to the machining process used.

Figure 1.0: Surface

Waviness height Flaw Roughness Width Roughness Height Waviness Width Roughness-width cutoff

the distance from a peak to a valley Defects in a surface such as scratches, burrs, casting, forging, machining and etc. The width of surface irregularities. Set of range of height of the irregularities. Refers to the measurement between successive peaks or valleys. A value greater than the maximum roughness width that is the largest separation of surface irregularities included in the measurements.

Table 1.1: Descriptions A means of measuring surface finish that is normally used by ISO is the CLA method. It measures the average values of the departures of both what are above and below the centre line of the surface through a prescribed sample length L. The mean results if several sampling lengths taken consecutively will give the actual roughness value of the surface of the component. Formula used : CLA

A L Mv

A = Sum of Area above and below centerline

L = Sample Length (graph)

Mv Vertical Magnification.
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4.1 APPARATUS

a) Figure 2.1: Specimen; piston cylinder.

b) Figure 2.2: Computerized Surface Roughness Machine.

c) Figure 2.3: Digital Planimeter.

4.2 INDUSTRIAL APPARATUS Lasercheck Instrument All Lasercheck instruments are based on patented Laser Light Scatter measurement techniques that posses precise and repeatable non-contact surface roughness measurement in the 0.01 to 10 micron range. All of the Lasercheck measurement heads use a combination of a laser illumination source and a multiple sensor detection system arranged in a proprietary configuration. Integrated electronics measure, amplify, and digitize laser light signals from the measurement surface, which is then analyzed for changes in the intensity and distribution of the pattern of laser light as it reflects from a surface. Proprietary software algorithms report changes in surface roughness based on the changes in those scattered light reflection patterns (schmittind.com/Lasercheck-surface-roughness.html, 2011) Software, design features, and accessories with Lasercheck provide capabilities to install sensors right in the manufacturing process (rather than in a lab) to perform fully-automated, real-time measurements of surface roughness. With this direct feedback, manufacturers make adjustments to their operations resulting in higher quality products, higher yields and reduced production costs (schmitt-ind.com/Lasercheck-surface-roughness.html, 2011)

Figure 2.4 : Lasercheck Instrument

Figure 2.5: Controller Lasercheck

5.0 PROCEDURE Procedure on machining process: 1. A cut off wavelength of 0.8 mm was selected on the machine. The machine was set to a Vertical Magnification of auto. And horizontal magnification of 100. 2. To make sure the diamond blade not wears or broken, technician must do a calibration test. The test use references specimen type, if the CLA result from the machine same with references specimen type, which means the diamond blade in good condition.

Figure 3.1: References specimen type

Figure 3.2: The picture shown different diamond blade. The top blade is good condition and the below is the wear or broken blade. 3. The component was placed on the Auto levelling table at a suitable position such that when the pick-up head is lowered, its stylus contacts the surface of the specimen. 4. The machine was set ready to record the measurement. 5. The roughness profile graph was obtained for the specimen.

Procedure on manual process: 1. 2. 3. 4. 5. 6. The graph was make sure not out from the border line. Three measurements were selected side by side. Drew two vertical lines across the border between three measurements. The side out between in two lines was ignored. Somewhere in the middle graph, a straight line was sketched and labeled as CLA line. Anything at the top CLA line considered as an area above and at the below CLA line considered as an area below. 7. Point at the cross section area between two lines was made. Point first considered as SP = starting and other point considered as TP = turning point. 8. Digital planimeter was used to measure the above and below area.

Figure 3.3: Shown a student use digital planimeter to find area.

6.0 RESULTS The value of the surface roughness (Ra) that was obtained by using a computerize Roughness Measuring Machine:Ra = 3.38 m by using planimeter:Area above, A ( ) 1.8 2.2 2.3 Area below, B ( ) 4.5 4.6 4.3

A1 A2 A3

B1 B2 B3

SAMPLE CALCULATIONS The Centre Line Average (CLA) or Roughness Average (Ra)

CLA =

A__ (L x Mv)

;L

= 8.6 cm

Mv = 1900

For Area A A (avg) = A1+ A2+ A3 3 = 1.8+2.2+2.3 3 = 2.1 cm For Area B B (avg) = B1+ B2+ B3 3 = 4.5+4.6+4.3 3 =4.47 cm

Total area, A

A = A (avg) + B (avg) = 2.1+ 4.47 = 6.57 cm

CLA =

6.57 cm 8.6cm x 1900

= 4.02 m

Percentage of error, | |

| = 18.93%

7.0 DISSCUSSION 1. We notice that there is a difference of value between the CLA and Ra. This is due to many errors occurring while conducting this experiment especially when handling the digital planimeter. The device is so sensitive that can detect any small movement. If we make a backward movement, it will affect the machines reading. The possible error involved are: 1) Parallax error- while measure the upper and lower area of the roughness profile graph with digital planimeter. 2)Human error - Not expert enough to handle the digital planimeter. - Talk while using planimeter causes some vibration on the hand. - Movement on the paper graph was not smooth 3) Machine error-equipment was not well functioning. It does not gives the exact values. 3.

2.

The necessary precaution are: 1) Make sure that eyes position is at the right position while using the digital planimeter. It must be focus at the point that located in the lenses. 2) Take a reading twice or more to get the average value. For precision, let other student taking the 2nd and 3rd reading so we can compare it if our reading is correct. 3) Try to use the planimeter first until us confident to use it. Careful when take the reading and stay focus. 4) Make sure that we use the standard digital planimeter that had get certificate.

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8.0 CONCLUSION All the objectives for this experiment can be considered successfully achieved. It is because errors that obtained from the experiment are small, reasonable and make sense. All errors are not large to say that this experiment is a failure. From the experiment, the value of Centre Line Average (CLA / Ra) is 3.38m (theoretical value) compare to the actual value from the roughness measuring machine is 4.02m. The percentage error is 18.93% Here have some recommendations that maybe would help to reduce or terminate all those errors. From our point of view, student should be more careful and alert while conducting the experiment and must deeply understand about how to use the digital planimeter.

9.0 RECOMMENDATIONS There are several recommendations that can be applied:1. 2. 3. 4. 5. The experiment should have more stable table. The person in charge should poses good data collecting techniques. Person should full of concentration while handling the planimeter. Applied with good lighting while handling the planimeter. Person should fully understand upon using the planimeter before starting the experiment.

10.0 REFERENCES 1. R.Winrow, Experiments in Production Technology for Engineering Students, Edward Arnold, 1966 2. 2.10.2 Geofeerey G. Thomas, Engineering Metrology, London Butterworths, 1974. 3. http://www.zemetrics.com/surface-roughness-measurement.shtml 4. http://www.engineersedge.com/surface_finish.htm 5. http://www.mfg.mtu.edu/cyberman/quality/metrology/surface.html 6. http://www.schmitt-ind.com/Lasercheck-surface-roughness.html

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