By: T.R. Vijayaram, Ram Penumaka, Pradeep Kumar, Sai Venkata Swamy, and Hino L. Yeptho
1. Professor, Department of Mechanical Engineering, School of Mechanical Engineering, BIST, BIHER, Selaiyur, Chennai, Tamil Nadu, India
2-5.Students, Department of Mechanical Engineering, School of Mechanical Engineering, Bist, Biher, Selaiyur, Chennai, Tamil Nadu, India
This study investigates surface processing techniques aimed at achieving a surface roughness (Ra) value of < 2.5 for various materials including gray iron, steel, pure copper, aluminum, and brass. Surface roughness plays a crucial role in determining the functional and aesthetic properties of machined components. The attainment of a specific Ra value demands precise control over machining parameters and selection of appropriate finishing processes. For steel, machining operation grinding followed by finishing processes lapping is typically employed. The initial surface condition and material properties influence the material removal required to achieve the target Ra value. In the case of pure copper and aluminum, which are known for their softness and ductility, machining parameters must be carefully adjusted to prevent work hardening and excessive material removal. Similarly, brass, a copper-zinc alloy, requires tailored machining strategies to balance its machinability and surface finish requirements. Experimental  validation of machining parameters are essential steps in the surface processing of these materials to ensure repeatability and consistency in achieving the target Ra value. Advanced metrology techniques such as profilometry are utilized to accurately measure surface roughness and verify the effectiveness of the surface processing techniques.
Keywords: Surface roughness, Metallic Materials, Machining, electrical conductivity, corrosion resistance
Citation:
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