CONTENTS

Title

Chapter
no

Certificate
declaration
Acknowledgement
Abstract
List of Figures
List of Tables
Nomenclature
Introduction
1.1

Literature

Result and Discussion

Conclusion
Future Scope
References
Appendix/ Appendices

Page no

A
SEMINAR REPORT
ON
SURFACE INTEGRITY OF ENGENEERING MATERIALS

SUBMITTED IN THE PARTIAL FULFILLMENT OF REQUIREMENT

FOR THE DEGREE OF MASTER OF MECHANICAL ENGINEERING

BY

PATIL UJJWALA S.
UNDER THE GUIDANCE OF

PROF. S.V.LOMTE

DEPARTMENT OF MECHANICAL ENGINEERING

MAHARASHTRA INSTITUTE OF TECHNOLOGY
AND EXCELLENCE CENTER, AURANGABAD- 431010
(2013-2014)

CERTIFICATE

Department Of Mechanical Engineering

Maharashtra Institute of Technology
And Excellence Center, Aurangabad- 431010
The seminar report entitled

SURFACE INTEGRITY OF ENGENEERING MATERIALS

Submitted By
PATIL UJJWALA S.
In partial fulfillment of the requirement for the award of Degree of Master of
Mechanical Engineering course of Dr. Babasaheb Ambedkar Marathwada
University, during the academic year 2014-20

Prof. S.V.Lomte
(Guide ) And (H.O.D.)

Examiner

Dr.S.P.Bhosale
(Principal)

Examiner

ACKNOWLEDGEMENT

A successful seminar marks an importance in the course of engineering study.

Any obstacle could be overcome with knowledge, proper guidance and
encouragement. With immense pleasure, I express my deep sense of gratitude
and vote of thanks to my seminar guide and Head of the Department Prof. S.
V. Lomte for his constant interest, motivation and valuable guidance during
work & completion of this seminar.
I am also thankful to Dr. S. P. Bhosale for allowing me to deliver the same. I
am also thankful to specially Dr. P. M. Ambad other staff of Mechanical Dept.
who has helped me in completing the seminar.

Patil Ujjwala S.

CHAPTER NO.1
INTRODUCTION
Surface integrity is the surface condition of a work piece after being modified by
a manufacturing process. Surface integrity can have a great impact on a parts function; for
example, Inconel 718 can have a fatigue limit as high as 540 MPa (78,000 psi) after a
gentle grinding or

as

low

as

150 MPa

(22,000 psi)

after electrical

discharge

machining (EDM)
All the varied modern technologies depend for the satisfactory functioning of their
processes on special properties of some solids. Mainly, these properties are the bulk
properties, but for an important group of phenomena these properties are the surface
properties. This is especially true in wear-resistant components, as their surface must
perform many engineering functions in a variety of complex environments. The behaviour
of material therefore greatly depends on the surface of the material, surface contact area and
environment under which the material operates. To understand the surface properties and
their influence on the performance of various components, units and machines, a branch of
science called surface science has been developed. A surface can be described in simple
terms to be the outermost layer of an en- tity. An interface can be defined to be the transition
layer between two or more entities that differ either chemically or physically or in both
aspects. Hudson [1] defines a surface or interface to exist in any system that has a sudden
change of system properties like density, crystal structure and orientation, chemical
composition, and ferroor para-magnetic ordering. Surfaces and interfaces can be exam- ined
closely using the high-resolution microscopy, physical and chemical methods available. For
their realization, a great number of simple and highly sophisticated testing machines have
been developed and used [2, 3]. These tools have been built by humans to sate their innate
curiosity of surface and interface interaction phenomena. Surface science can be defined as
a branch of science dealing with any type and any level of surface and interface interactions
between two or more entities. These interactions could be physical, chemical, electrical,
mechanical, thermal, biological, geological, astronomical and maybe even emotional

CHAPTER NO.2
LITERATURE REVIEW
1. SI and surface engineering are coming to the forefront of these activities as they are
two major reserves and contributors in the pursuit of designing and manufacturing
better parts and machines[ ]
2. The term was coined by Michael Field[1] and John F. Kahles in 1964.The surface
integrity of a work piece or item changes the material's properties. The consequences
of changes to surface integrity are a mechanical engineering design problem, but the
preservation of those properties are a manufacturing consideration.
3. Of this paper is the investigation of surface integrity generated in hard turning and
subsequent finish abrasive machining. The primary reason for undertaking this
problem was insufficient magnitude of compressive residual stresses after hard
turning which determines the fatigue resistance of highly loaded transmission
partCan be distinguished into two groups. First, finish belt grinding produces the
residual stresses with the maximum value of1000 MPa, which is satisfactory for
improving fatigue life. Second, the bearing properties improve due to displaying
negative values of the skew.
4. :The obtained results in the surface roughness measurement shows consistency with
other authors results, and it shows that the technique of hardened material turning
capable of producing surfaces with functionality and quality.
5. Overall, there are a few steps that can be done more details to produce a good
surface finish such as the WEDM machining parameters should be set at low pulsedcurrent and small pulse-on duration. Once the specimens have been cut, it must be
examined instantly to avoid corrosion at the surface which is leads to the bad surface
finish. Besides that, the perthometer recorder should be use gently so that the
readings can be obtained accurately due to its high sensitivity. [ ]

2.1BACKGROUND
Surface integl-ity is a relatively new term introduced by Dr. M. Field and Dr. J. Kahles of
Metcut Research Associates at the 1964 Tripartite Tech- nical Coordinating Symposium.
The effect of grinding on residual stress in metals has more than a decade of history. The
above symposium marked the beginning of an effort to understand and document all of the
surface effects and the material properties for a larger variety cf material removal processesboth traditional and non-traditional. The increasing use of EDM, ECM, LBM, and other
non-traditional processes with their unusual operating parameters has also accelerated
interest in surface integrity.

Surface integrity is defined by Dr. Kahles as, "The unimpaired or enhanced surface
condition or properties of a material resulting from a controlled manufacturing process". In
a broad sense, the concern is fo~ surface quality. Surface integrity has two ingredients-those
that relate to the surface topography and those that relate to the characteristics immediately
below the surface, i.e., surface metallurgy.

CHAPTER NO.3
3 SURFACE INTEGRITY: A NEW VISION

3.1.1 PROBLEMS WITH THE EXISTING NOTIONS OF SI

Although it is stated that the growing concern in the aerospace, automotive and
biomedical industrial segments of the manufacturing industry is to build in absolute
reliability with maximum safety and predictability of the performance of all
machined components [20], in the authors opinion, no proper definition of this
term is available to date. SI is an important consideration in manufacturing operations
because it influences the properties of the product such as fatigue strength,
resistance to corrosion, and service life. However, no one source seems to describe
how to carry out this consideration practically. In the the root cause of the problem lies in
insufficient and non-systematic information about SI from the two most common
viewpoints: the
role of SI in the product and part design and the formation of a specific set of SI
requirements in various manufacturing process.
There is a definite lack of systemic information at the level of handbooks and
standards on the quantitative correlation between SI and part performance, although a
number of research papers have been published attempting to establish
such correlations, for example, between surfaces finish and fatigue life [3847], SI
and corrosion behaviour [4850]. As a result, the vast majority of part drawings
contain information only on surface finish, rarely surface texture and bulk material
properties. Except for very few specific cases, no physical, mechanical, metallurgical and
chemical properties of the surface layer such as the level and depth of cold working, sign,
depth and distribution of superficial and in-depth manufacturing
(commonly, machining) residual stresses and so on are provided to manufacturing.
As a result, the selection of manufacturing operations and their regimes is focused
on achieving the dimensional, shape and surface finish requirements at minimum
manufacturing costs. To the best of the authors knowledge, no one literature
source, tool company catalos, machining/manufacturing handbook, shop manual,
etc., considers the selection of the components and parameters of a manufacturing
operation accounting on SI requirements.
Consider a practical example. The first issue the engineer must resolve in terms of surface
finish is what type of surface will best fulfill the intended function of the part. There may be
many factors that influence this decision, such as desired luster,
adhesion, friction, and so on. A clear understanding of performance requirements

will influence the selection of the manufacturing process and the specific measurement
parameters that should be used, and could have a dramatic effect on cost
reduction. Once the decision on the required surface finish is made, the next challenge is to
select the proper machining operation to achieve the desired surface
finish. A great variety of available cutting tool designs, tool materials, tool geometries,
essential features and properties of machining systems, coolants, fixtures,
etc., makes it difficult to assign SI requirements even in the simplest machining
operations such as turning, milling and drilling. Figure 1.20 shows that the achievable
surface finish (as one of the simplest yet practical parameters of SI) varies
hundreds of per cent for the listed operations. As is known [23, 24, 26], SI describes not
only the topological (geometric) aspects of a surface and its physical and chemical
properties, but also mechanical and

Figure 1.20 surface finish

2.1 DEFINITION
Surface integrity in the engineering sense can be defined as a set of various properties
(both, superficial and in-depth) of an engineering surface that affect the performance
of this surface in service.
Surface integrity is the sum of all of the elements that describe all the conditions existing on
or at the surface of a piece of finished hardware. Surface integrity has two aspects. The first
is surface topography which describes the roughness, lay or texture of the outermost layer of
the work piece; i.e., its interface with the environment. The second is surface metallurgy
which describes the nature of the altered layers below the surface with respect to the base or
matrix material. It is the assessment of the impact of manufacturing processes on the
properties of the work piece material.
The topography is made up of surface roughness, waviness, errors of form, and flaws. The
surface layer characteristics that can change through processing are: plastic
deformation, residual stresses, cracks, hardness, overaging, phase changes,recrystallization,

in tergranular attack, and hydrogen embrittlement. When a traditional manufacturing

process is used, such as machining, the surface layer sustains local plastic deformation
These properties primarily include surface
finish, texture and profile; fatigue corrosion and wear resistance; adhesion and
diffusion properties. When applicable, other service properties such as for example,
optical properties, absorptive, adsorption, bonding capability, emissivity,
flatness, frictional resistance, score strength, stain resistance, surface temperature,
surface tension, thermal emissivity, wash ability, wet ability, biological and chemical
properties, should also be considered.

Figure no 1

2.2 THE DEFINED SI PARAMETERS ARE CLASSIFIED AS:

I.
II.
III.
IV.
V.
VI.
VII.

geometrical parameters (e.g., surface finish, texture, bearing curve parameters);

physical parameters (e.g., micro hardness, residual stresses, microstructure);
chemical parameters (e.g., affinity oxidation, adsorption, chemisorptions, surface
electrical polarization, surface chemical reactions,);
biological parameters (e.g., cell attachment, cell proliferation).
A simplified checklist for SI considerations is shown in Figure 1.21. For each and
every responsible part, a set of unique SI requirements is defined depending upon:
service (working) conditions of the surface: forces, temperatures, contact stresses

2.3VARIABLES
Manufacturing processes have five main variables: the work piece, the tool, the machine
tool, the environment, and process variables. All of these variables can affect the surface
integrity of the work piece by producing:[3]

High temperatures involved in various machining processes

Plastic deformation in the workpiece (residual stresses)

Surface geometry (roughness, cracks, distortion)

Chemical reactions, especially between the tool and the workpiece

Figure no 2 A simplified checklist for SI considerations

The processes that affect surface integrity can be conveniently broken up into three
classes: traditional processes, non-traditional processes, and finishing treatments.
Traditional processes are defined as processes where the tool contacts the workpiece
surface; for example: grinding, turning, and machining. These processes will only damage
the surface integrity if the improper parameters are used, such as dull tools, too high feed
speeds, improper coolant or lubrication, or incorrect grinding wheel hardness.
Nontraditional processes are defined as processes where the tool does not contact the
workpiece; examples of this type of process include EDM, electrochemical machining,
and chemical milling. These processes will produce different surface integrity depending on
how the processes are controlled; for instance, they can leave a stress-free surface, a
remelted surface, or excessive surface roughness. Finishing treatments are defined as
processes that negate surface finishes imparted by traditional and non-traditional processes
or improve the surface integrity. For example, compressive residual stress can be enhanced

via peening or roller burnishing or the recast layer left by EDMing can be removed via
chemical milling.
Finishing treatments can affect the work piece surface in a wide variety of manners. Some
clean and/or remove defects, such as scratches, pores, burrs, flash, or blemishes. Other
processes improve or modify the surface appearance by improving smoothness, texture, or
color. They can also improve corrosion resistance, wear resistance, and/or
reduce friction. Coatings are another type of finishing treatment that may be used to plate an
expensive or scarce material onto a less expensive base material

4 MATERIAL PROPERTIES
These pamphlets are primarily associated with the impact of the man- ufacturing plocess on
the material properties. It is equally important to know the effect of the state of the material
being presented for processing: Pamphlet 2' illustrates one such case in the ECMing of
lnconel 718. The high cycle fatigue data also shows some of the variations in endurance
fatigue strength when aging follows machining vs machining in the solution treated and
aged state. The material state is as important to surface integrity as the specific process
operating parameter
5 SURFACE TOPOGRAPHY
Surface topography is concerned with the geometry oi the outermost layer of the work
piece, its texture and its interface with the environment. These features have been well
expressed for some time in ANSI Standard 846.1-1962, (GE Co.-Standard FPD-STD18H1). In surface topography. roughness height from an average center line is frequently
described by the AA (arithmetic average) micro inch readings

Figure No 3 comparison of surface to

CHAPTER NO.4
SURFACE METALLURGY

Surface metallurgy, the second ingredient in surface integrity, is concerned primarily with
the host of effects a process has below the visible surface. The subsurface characteristics
occur- in various layers 01 zones. The sub- surface altered material zones (AMZ) can be as
simple as a stressed condition different from that in the body of the material or as complex
as a grain structure change interlaced with intergranular attack (IGA). While undisturbed
subsurface conditions are known, they are the excep- tion. Changes can be caused by
chemical, thermal, electrical, or mechanical energy and affect both the physical and the
metallurgical properties of the material. The subsul-face altered material zones can be
grouped by their principal energy modes as follows
Mechanical: Plastic deformarmation, Tears and laps, Hardness alterations, Cracks
(macroscopic & microscopic) , Residual stress, Processing inclusions introduced,Fatigue
strength changes
Metallurgical: Transformation of phases, Grain size and shape, Precipitate size and
distribution, Foreign inclusions in material ,Twinning
Chemical: lntergranular attack (IGA) ,lntergranular corrosion (IGC) ,lntergranular oxidation
(IGO),Contamination ,Embrittlement ,Pits or selective etch ,Corrosion ,Stress corrosion
Thermal: Heat affected zone (HAZ) ,Recast or redeposit material ,Resolidified material
Electrical : Conductivity change ,Magnetic change
4.1 AMZ's DEFINED
4.1.1CRACKS

Cracks are fissures in materials discernible with the un- aided eye or with 10X or less
magnifcation. The micro- cracks are only discernible at the greater magnification.
4.1.2 PLASTIC DEFORMATION
Micro structural changes, generally including elongation of grain structure and increased
hardness, caused by exceeding the yield point of the material
4.1.3 HARDNESS ALTERNATION
Changes in hardness of surface layers as a result of heat, mechanical working or
chemical change during processing
4.1.4 RESIDUAL STRESSES
Those stresses which are present in a material after all external forces (or thermal gradients,
or external energy) have been removed.
4.1.5 METALLURGICAL TRANSFORMATIONS
These include resolidified layers, redeposited material, chemical reaction, depletion,
grain structure change, or recrystallization as a result of external influences.
4.1.6 RECRYSTALLIZATION
The formation of a new, strain-free grain or crystal structure from that existing in the
material prior
to processing usually as a result of plastic deformation and subsequent heating.
4.1.7 INTERGRANULAR ATTACK
A form of in-process corrosion or attack in which preferential reactions are concentrated at
the network ofgrain boundaries usually in the form of sharp notches or discontinuities.
4.1.8 SELECTIVE ETCH
A form of in-process corrosion or attack in which preferential reactions are concentrated
within and through the grains or concentrated on certain constituents in the base material.
4.1.9 HEAT AFFECTED ZONE (HAZ)
That portion of a material not melted yet subjected to sufficient thermal energy to contain
microstructure alterations.
6 INCREASING CONCERN FOR SURFACE INTEGRITY
The evel-incl-easing strength capabilities of the new aerospace materials has
been accompanied by an increase in sensitivity to processing valriables. The
concern for surface integrity is the reflection of concern for component
integrity and can be summarized in this listing:
a Thinner sections are more PIrevalent
a More sensitive and difficult alloys are being employed
a Higher stress levels are usual
Designs are closer to material limits and capabilities

0 Reliability requirements are more stringent

a Longevity requirements at-e increasing
a Awareness that there is a significant depth of impact of processes on
materials i s increasing.
7 MANUFACTURING TRENDS
With the increased strength of materials has come an increased difficulty in machining
them. Some of the new nickel based alloys have only 5-10 per- cent of the machinability
rating of more conventional alloys. Fortunately, new cutting tool materials, more machine
power and the advent of the electrical and other non-traditional material removal processes
has enabled manufacturers to process these tougher materials. The principal causes for the
surface alterations that have been found in material removal operations are: a High
temperatures or high thermal gradients a Mechanical working beyond the limit of plastic
deformation a Chemical reactions and subsequent absorption into the nacent machine
surface

7 SURFACE INTEGRITY EVALUATION TECHNIQUES

At this point in time, definitive and complete sets of collated data onspecific process and
mater-ial combinations are quite fare. A concerte deffort is being made by the USAF on
their-~~P721-8~program to colleca few sets of comprehensive data. The Genera l
Electr~c Company icollecting surface integrity data in a separate encyclopedia. Three types
of surface integrity evaluation programs have been developed to provide three increasingly
deep levels of study. TheMDS data includes the basic surface topography that is normal
in assessing a machined surface and some of the metallurgical measurements. The SDS
gives measure of the impact on material properties and is considered the basidata set forcorrelation and comparisons. The EDS carries the investigations even deeper and
includes specialized and environmentally
related effects. The three levels are outlined as follows
:
7.1 MINIMUM DATA SET, OR SURFACE METALLOGRAPHY (MDS)
7.1.1 Surface roughness and texture or lay (photos and profile traces)
- Macro cracks
7.1.2 Micro hardness profile or map
7.1.3Microsection metallurgical assessment (1000X preferred)
- Microstructure transformation
- Micro cracks
- Foreign or processing inclusions
- IGA, HAZ, Selective etch, etc
- Scanning electron microscope (SEMI photos (20, 200, 1000,
2000X preferred)
7.1.4 STANDARD DATA SET (SDS)

Minimum data set

0 Residual stress profile
0 Fatigue strength (screening tests at room temp )
7.1.5 EXTENDED DATA SET fED.5)
0 Standard data set
0 Stress corrosion tests
0 Fatigue strength (design data)
0 Other specially selected tests.
8 SURFACE FINISH EVALUATION
The usual method for measuring surface roughness is with a small radius probe that ttaces a line on the surface and measures the amplitude of the roughness from a centre
line. The arithmetic average (AA) reading is expressed in micro inches. Only one line (with
relatively lge probe) is measured and the significant spot can be smaller and in other
areas. Attempts are being made to expand these measutement capabilities as illustrated in
this micro topographic map of a milled surface.

figure no .4

9SOME TYPICAL DEFECTS OF THE MACHINED SURFACE AFFECTING ITS

SI
Various defects are caused by and produced during part manufacturing compromising
SI. These defects can be classified as those of the original material and those
imposed during manufacturing. Amongst many defects found in practice, the following
are most common:
called micro
cracks.
micro structural changes caused by temperature
and high contact pressures. Included are phase transformations, re-crystallization, alloy
depletion, decarburization, and molten and re-cast, re-solidified, or re-deposited material, as
in electrical-discharge machining.

-metallic elements or compounds in the metal

-metal embitterment or
corrosion.
by high stresses due
to friction or tool in manufacturing.
Visually distinguished microcracks are normally formed in the machining of brittle
materials (Figure 1.6) or low-speed machining operations (Figure 1.7). This is
because high temperature and pressure in machining of ductile materials causes
healing of visible cracks. In service, however, such cracks may came to light as the
strength of the healed bonds is smaller that that of the original material. Figure 1.8
shows a fatigue crack developed in the trunnion pin of an airplane. It originated in
the root of the machining groove due to hidden pre-existed surface damage and
was associated with shallow intergranular penetrations. Figure 1.9 shows a fretting
crack developed from a grinding defect on a crankshaft shoulder.

8.1 INCREASED REQUIREMENTS ON SI COME TOGETHER WITH:

1New machine tools and assembly units capable of producing surfaces of high
quality equipped with advanced controllers capable of producing parts and machine
with repeatable quality.
used on the shop floor. It is common nowadays that a powertrain plant in the
automotive industry is equipped with an advanced materials lab having sophisticated
equipment for inspecting part and surface metallurgy, physical and chemical
surface properties.
Therefore, it seems that the scene is set for the implementation of the ideas of SI
in continuous efforts to improve the quality of the product while reducing their
manufacturing costs.
8.2 BENEFITS FROM SURFACE INTEGRITY CONTROL
The benefits that can accrue from surface integrity are:
I.
A better understanding of the process and process control limits
II.
Cost avoidance by use of surface integrity practices only where required
III.
A reduction in scrap or rework incidents (do it right the first time)
IV.
Better quality control
V.
Producibility/machinability data enhanced by surface integrity limits
VI.
More valid value analysis
VII.
Better definition of manufacturing leeways

VIII.

Guidance to advanced process design or application.

CONCLUDING REMARK
1The time needed for a new manufacturing concept to establish itself is mainly
a function of the effort required of users to switch their mindset to the new concept
and be productive. Some technologically simple ideas, e.g., tool coatings, can be
instant successes, but more sophisticated multidisciplinary concepts as SI need
many years to gain a foothold
2Machining process parameters that affect/improve SI should be assigned selectively for
critical parts or even to critical machined surfaces to minimize an increase in cost of
machining due to improved SI. Although SI guidelines should be
primarily intended for finishing machining operation where the final components
surfaces are produced for the use in service or for further surface-engineering applications
(e.g., coatings), it is important, however, to know the type and depth of
surface alternation on rough operations. Thisis because the subsequent finishing
operation may be greatly affected by this alternation. Furthermore, imperfections
concealed by rough machining are exceptionally deceptive and may easily lead to
failures during subsequent finishing operations or in the service life of the product
3This paper is a result of international collaborative work on SI and its effects on products
functional performance and lifetime of a machined component. The extensive review of
previous work on residual stresses and SI in machining shows their profound impact on

the lifetime of a machined component. This review focuses mainly on machining of

critical components for industry applications from materials such as stainless steels,
Ni and Ti alloys, and hardened steels used for dies and moulds, bearings and automotive
components. The SI issues encountered through this review are material-specific and
application-dependent. For example, controlling the residual stresses in machining of
aerospace components is one of the major critical issues while this is somewhat less of an
issue for other applications such as machining of dies and moulds, where the quality of
the machined surface (e.g., polish ability) becomes more important.
4Compressive residual stresses occurring at the machined surface were determined after belt
grinding. In comparison, CBN hard turning induced tensile stresses localized at the
distance of a few microns beneath the machined surface. In general, the 9 m belt grinding
leads to the localization of residual stresses in a very thin sub layer of 5 m5 It is
important to observe that some parameters presented wider standard deviation values
(Skewness Ssk, Reduced peak height Spk and Reduced valley height Svk), therefore
their functional values application must be carefully considered. Many parameters are
more sensitive to surface conditions change, and as a result, a large dispersion in results is
verified often causing ambiguity [8] functional
correlation results..
4Machining with slant tools can improve surface finish and bearing
properties of surfaces on both steel parts. Oblique turning produces surfaces with
blunt irregularities which are characterized by theRMS slope (Rq) of about 5.
5In general, oblique turning processes produce Rsk/Rkuenvelopes, which
allow selecting the desired process conditions in order to produce surfaces with
desired bearing properties. Moreover, the values ofthe reduced peak height Rpk
of 0.3-0.4 m were obtained for steel parts

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