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Surface Roughness speaks to fine detail imperfections, but there may also be much coarser irregularities. For example, a surface may be warped or deflected from the ideal.

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Engineering prints call out a great many things in their attempt to make sure the part that gets made matches the designer’s intent. Aside from dimensions and tolerances, another important callout is Surface Finish.

– Profiling Techniques: Here, a high-resolution probe is used to measure the surface. Think of a sensitivity more in line with a phonograph needle than a typical CNC Probe.

Surface roughness is a measure of finely spaced surface irregularities. Surface roughness is usually what machinists refer to when talking about “surface finish.” When talking about all three characteristics, they may use the term “Surface Texture” more properly.

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Ra is by far the most commonly used Surface Finish parameter. One reason it is so common is that it is fairly easy to take the absolute value of a signal and integrate the signal using analogue electronics, so Ra could be measured by instruments that contain no digital circuits.

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One approach to Surface Finish is to use abrasives or sand the surface. This chart converts from abrasive grit to Surface Finish Ra values:

This is a very ROUGH estimate and not an exact conversion!Avg Max height of the profileRz ISO Roughness HeightRPM Average max profile peak heightRMSRMS = SQRT( (M1^2 + M2^2 + M3^2 + M4^2) / 4 )Root Mean Square

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In the United States, surface finish is usually specified using the ASME Y14.36M standard. The rest of the world commonly uses International Organization for Standardization (ISO) 1302.

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If you’re 3D Profiling, each pass of the ballnosed cutter leaves a “scallop” in the surface of the material. Our G-Wizard Calculator software has a special Mini-Calc that will help you adjust for a scallop height that delivers the required surface finish:

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– Area Techniques: With an area technique, a finite area is measured and this provides a statistical average of the peaks and valleys. Examples of area techniques include optical scattering, ultrasonic scattering, and capacitance probes. Area techniques are easier to automate and faster to execute, but profiling techniques are often more accurate.

Ra, while common, is not sufficient to completely characterize the roughness of a surface. Depending on the application, surfaces with the same Ra can perform quite differently. Here are 4 surfaces with the same Ra and quite different shapes:

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The Lay is the direction of the predominant surface pattern and is usually determined by the production method used to process the surface. Here are some typical Lay patterns:

The goal of the designer is to specify surface finishes that are as coarse as possible but will still function within the part’s desired operating parameters. The goal of the machinist is to achieve surface finishes on parts that are as good as those required by the designer but not better as that results in the cheapest-to-manufacture parts. It’s important for the designer and manufacturer to agree on exactly which parameters (Ra, Rz, etc.) are to be used for inspecting and accepting parts. While there are commonly accepted conversions between these, actually using the same parameters for the inspection that the designer used with the design always yields the best results.

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How do product designers decide what surface finishes to require, and how should CNC machinists think about surface finishes?

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Another important consideration is friction. Reducing surface roughness typically reduces friction, which can be critical to reducing wear and increasing the efficiency of sliding parts.

Rmax is particularly sensitive to anomalies such as scratches and burrs that may not be obvious from measures such as Ra that rely on averages.

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Surface Finishes vary tremendously by the manufacturing process used to achieve them. A flame-cut plate edge has a radically different surface finish than a ground surface, for example. Choosing a process that’s capable of achieving the desired surface finish is the first step in figuring out how to manufacture a part that requires a particular finish. Sometimes, more than one process must be overlaid to achieve the desired result cost-effectively.

In general, adjust feeds and speeds for a lower chipload at the same rpms for a better finish. Take a finish pass that’s relatively light as well. Make sure as you’re doing this to avoid rubbing, which is very hard on tool life.

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The Surface Finish Units we would use for parameters like Ra would be either micro-inches (English or Imperial) or micrometres (Metric). Our chart of surface finishes by manufacturing process (see above) gives both.

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Turning is very similar to 3D profiling in that the stepover, in this case determined by the feedrate while turning, results in scallops that match the shape of the turning insert. We use this to good effect when turning threads, but if we want a smooth shaft, we’ll have a surface finish requirement that must be met. That will determine feedrate and insert nose radius we can use for the job. G-Wizard has a nice calculator for that too:

Our G-Wizard Calculator software has a handy “Tortoise-Hare” slider that makes it easy to dial in proper feeds and speeds for a finishing pass:

Rz is often preferred to Ra in Europe, particularly Germany. Instead of measuring from the centerline like Ra, Rz measures the average of the 5 largest peak-to-valley differences within five sampling lengths. While Ra is relatively insensitive to a few extremes, Rz is quite sensitive since it is the extremes it is designed to measure.

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M1, M2, … Mn are measure valuesAverage Roughness in micro-meters or micro-inches. Ra is the arithmetic mean deviation of the profileRc Mean height of profile irregularitiesRku Kurtosis of the profileRmax Maximum roughness depthRmr Material Ration of the profileRpRp = MAX( M1, M2, M3, … )Max profile peak heightRqRq = RMSRoot mean square deviation of the profileRsk Skewness of the profileRt Max height of the profileRvRv = MIN( M1, M2, M3, … )Max Profile Valley DepthRy Max height of the profileRzRz = Ra x 7.2

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Surface Finish is a measure of the overall texture of a surface that is characterized by the lay, surface roughness, and waviness of the surface. Surface Finish, when it is intended to include all three characteristics, is often called Surface Texture to avoid confusion, since machinists often refer to Surface Roughness as Surface Finish. Another term, analogous to Surface Texture, is Surface Topology.

Ra is also known as Arithmetic Average (AA) or Center Line Average (CLA). It is the average roughness in the area between the roughness profile and its mean line. Graphically, Ra is the area between the roughness profile and its centerline divided by the evaluation length. The evaluation length is normally five sample lengths where each sample length is equal to one cutoff length.

There are a variety of considerations, and they may even vary for different stages in the manufacture of a particular part. For example, we may have a surface finish requirement on a casting that ensures the finish (think of it as the deviations of the surface of the casting from an ideal) is good enough that the allowance made for extra material that will be machined off in a future step is sufficient. If the casting is too imperfect, the trough of imperfection may be below the expected machined surface of that future step.

There are a number of different characteristics we might measure with respect to Surface Finish. Two of the most important are the height of the roughness peaks and their separation, often referred to as “Ra” and “D”:

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Enter the maximum scallop height and G-Wizard will tell you the resulting RA and RMS surface finish as well as calculate the stepover. BTW, if you want to know how to pick optimal stepovers and tool diameters for 3D Profiling, we’ve got an article on that too!

The required surface finishes are very much determined by the function and use of the component. Ship’s propellors start out with fairly high surface finish standards, but in actual use, they erode pretty quickly. Optical and especially components used with X-rays have some of the finest surface finish requirements achievable.

There are many factors that affect surface finish, with the biggest being the manufacturing process (see table above). For machining processes, such as milling, turning, and grinding, factors such as cutting tool selection, machine tool condition, toolpath parameters, feeds, speeds, tool deflection, cut width (stepover), cut depth, coolant, and vibration are just a few of the many.

– Microscopy Techniques: These techniques are usually more qualitative because they rely on measurement of contrast to provide information about peaks and valleys.