In different manufacturing processes, different values of surface roughness values are obtained from the produced products. These surface roughness values are determined by the surface roughness measurement methods. In this article, we will explain the general relation between the manufacturing process types and surface roughness values that obtained from them.
Generally the worst surface roughness values are obtained from casting operations. Generally again, machining operations for better surface are applied to the cast parts. In sand casting of iron, the typical surface tolerance value is 1.3mm (0.050in), which is not acceptable in most applications. After the cating operation of iron, various machining processes are applied to them as a finishing operation. For example in general turning operations, the surface tolerance values is typically around 0.05mm(0.002in) which is a much more advanced and accceptable surface tolerance in most applications.
But the plastic molding tolerance values are much more acceptable compared to sand casting. For instance molding of Polystyrene has surface tolerance values of around 0.015mm(0.006in) which is more acceptable value.
If the surface tolerance values are expected as more better from a manufacturing process, some finishing abrasive processes can be applied at the end of the process. With these abrasive processes such as grinding, honing etc. much more better surface can be obtained for typical applications that surface characteristics are very important. For example in grinding operations, surface tolerance values around 0.008mm(0.0003in) can be obtained. These kinds of surface roughness values are very superior and can be obtained for specific tasks.
In manufacturing, there are also non-traditional methods of production that the desired hig quality surface roughness tolerances can be obtained. Around these non-traditional manufacturing methods, there are kinds of electric discharge, chemical machining etc. For example around 0.08mm(0.003in) surface roughness tolerance values can be obtained with laser beam cutting method. These kinds of tolerance values can be appropriate for different applications.
So there is a strict relation between the manufacturing process and the surface roughness tolerances. A good manufacturing engineer must understand this relation in a very professional manner.
The relation between surface roughness and manufacturing processes can be explained like above basically. Leave your comments and questions below about ‘Manufacturing processes and surface characteristics’!