Basics of Surface Technologies
Introduction
Surface of a piece of metal, generally, consists of several layers: Dirt, dust, grease, lubricant
residues, cleaning-compound
residues, and pollutants
Generally much harder
than the base metal
• Deformed plastically and work hardened to a greater extent
Structure depends on during the manufacturing process
the composition and • The depth and properties depends on:
processing history ✔ The processing method
✔ Amount the frictional sliding the surface encountered
Introduction
Surface integrity describes:
• Topological (geometric) features of surfaces
• Mechanical and metallurgical properties
Surface integrity influences:
• Fatigue strength
• Resistance to corrosion
• Service life
Surface defects caused due to inadequate surface integrity:
• Defects in the original material
• The method by which the surface is produced
• Improper control of the process parameters
Surface Texture and Roughness
• Surface Texture: regardless of the method of
production, surface characteristics
• Surface texture identification and
measurable quantities:
• Flaws or defects: random irregularities,
such as scratches, cracks, holes,
depressions, seams, tears, or inclusions.
• Lay (directionality): direction of the
predominant surface pattern, usually
visible to the naked eye.
Surface Texture and Roughness
• Roughness:
✔ closely spaced, irregular deviations on a
small scale
✔ Expressed in terms of its height, width,
and distance along the surface
• Waviness:
✔ A recurrent deviation from a flat surface
✔ Measured in terms of the space
between adjacent crests of the waves
(waviness width) and height between
the crests and valleys of the waves
(waviness height).
Surface Texture and Roughness
Surface Texture and Roughness
Surface roughness is characterized by two methods.
• Arithmetic mean value (Ra) :
where all ordinates are absolute values and n is the number of readings
• Root-mean-square roughness ( formerly identified as RMS):
Surface Texture and Roughness
Friction
Plays an important role in manufacturing processes –
• relative motion and
• forces that are always present on tools, dies, and workpiece
Friction –
• dissipates energy, thus generating heat, which can have detrimental effects on an
operation.
• Impedes free movement at interfaces, thus significantly affecting the flow and
deformation of materials in metalworking processes
• Friction is not always undesirable: for example, without friction, it would be impossible
to roll metals, clamp workpieces on machines, or hold drill bits in chucks.
Phenomenon of friction
Adhesion theory: Two clean and dry surfaces, contact each other at only a fraction of
their apparent contact area.
• The normal (contact) load, N, is supported by minute asperities.
• the normal stresses at these asperities are high; this causes plastic deformation at
the junctions.
• Their contact creates an adhesive bond—the asperities form micro welds.
Phenomenon of friction
Abrasion theory: an asperity from a
hard surface penetrates and plows
through a softer surface. Plowing
may:
✔ Cause displacement of the
material
✔ Produce small chips or
slivers.
Wear
• Wear has important technological and economic significance because:
• It changes the shapes of tools and dies.
• Affects the tool life, tool and die dimensions.
Uses of wear in manufacturing:
• Dull drill bits that have to be reground
• Worn cutting tools that have to be indexed
Types of Wear
ADHESIVE WEAR:
• If a tangential force is applied,
shearing can take place either: (a) two contacting asperities
✔ At the original interface
✔ Along a path below or above the
interface causing adhesive (b) adhesion between two asperities
wear/sliding wear
✔ During sliding, fracture occurs
along a path in the weaker or
softer component
(c) the formation of a wear particle
Types of Wear
Adhesive wear can be reduced by:
• Selecting materials with weaker adhesive bonds
• Using a harder material as one member of the pair
• Using materials that oxidize more easily
• Applying hard coatings
• Using an appropriate lubricant
Types of Wear
ABRASIVE WEAR:
Caused by –
• a hard, rough surface or
• a surface containing hard, protruding particles
• sliding across another surface
• microchips or slivers are produced as wear particles.
Types of Wear
There are two basic types of abrasive wear:
• Two-body wear:
Abrasive action between two sliding
surfaces or between a hard, abrasive
particle in contact with a solid body.
• Three-body wear:
Abrasive particle is present between
two sliding solid bodies, such as a
wear particle carried by a lubricant.
Types of Wear
CORROSIVE WEAR:
Caused by chemical and electrochemical
reactions between the surface and the
environment.
• Corrosive wear can be reduced by:
✔ Selecting materials that will resist
environmental attack
✔ Applying a coating
✔ Controlling the environment
✔ Reducing operating temperatures
in order to lower the rate of
chemical reaction.
Types of Wear
FATIGUE WEAR:
• Caused when the surface of a material is
subjected to cyclic loading, such as rolling contact
in bearings.
• Thermal fatigue is another type of fatigue wear,
whereby surface cracks are generated by thermal
stresses from thermal cycling, as when a cool die
repeatedly contacts hot workpieces.
Types of Wear
FATIGUE WEAR Mechanism
• This type of wear can be reduced by –
• Lowering contact stresses
• Reducing thermal cycling
• Improving the quality of materials by
removing impurities, inclusions etc.
Types of Wear
• Erosion is caused by loose particles
abrading a surface
• Fretting corrosion occurs at interfaces that
are subjected to very small reciprocal
movements
• Impact wear is the removal (by impacting
particles) of small amounts of material
from a surface.
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