Chapter 35:

Surface Engineering
DeGarmos Materials and Processes in
Manufacturing

35.1 Introduction

Fatigue Strength as a Function

of Finish
FIGURE 35-1
Fatigue strength
of Inconel 718
components after
surface finishing by
grinding or
EDM. (Field and
Kahles, 1971).

Surface Profiles

FIGURE 35-2
Machining
processes produce
surface flaws,
waviness, and
roughness that can
influence the
performance of the
component.

Machined
Surfaces

Machined
Surfaces

FIGURE 35-3 (a) Terminology used in specifying and

measuring surface quality; (b) symbols used on
drawing
by part designers, with definitions of symbols; (c) lay
symbols; (d) lay symbols applied on drawings.

Surface
Measurement
FIGURE 35-4 (a)
Schematic of stylus
profile device for
measuring surface
roughness and surface
profile with two readout
devices shown: a meter
for AA or rms values and
a strip chart recorder for
surface profile. (b) Profile
enlarged. (c) Examples
of surface profiles.

Surface Finish Measurement

FIGURE 35-5 Typical machined

steel surface as created by face
milling and examined in the SEM. A
micrograph (same magnification) of
a 0.00005-in. stylus tip has been
superimposed at the top.

SEM Micrograph
FIGURE 35-6 (a) SEM
micrograph of a U.S. dime,
showing the S in the word
TRUST after the region has been
traced by a stylus-type machine.
(b) Topographical map of the S
region of the word TRUST from a
U.S. dime [compare to part (a)].

Roughness

FIGURE 35-7 Comparison of

surface roughness produced by
common production processes.
(Courtesy of American Machinist.)

35.2 Mechanical Cleaning and

Finishing Blast Cleaning

Finishing Barrel

FIGURE 35-8 Schematic of

the blow of material in tumbling
or barrel finishing. The parts and
media mass typically account for
50 to 60% of capacity.

Synthetic Media Geometry

FIGURE 35-9
Synthetic
abrasive media are
available in a
wide variety of sizes
and shapes.
Through proper
selection, the
media can be tailored
to the
product being cleaned

Vibration Finishing Tub

FIGURE 35-10
Schematic diagram of a
vibratory-finishing tub
loaded with parts and
media. The single
eccentric shaft drive
provides maximum
motion at the bottom,
which decreases
as one moves upward.
The dualshaft design
produces more
uniform motion of the
tub and reduces
processing time

Media to Part Ratio

Part Examples

FIGURE 35-11 A variety of parts before and after barrel

finishing with triangular-shaped media. (Courtesy of Norton
Company.)

35.3 Chemical Cleaning

35.4 Coatings

Organic Finishes

Electroplating Processes

FIGURE 35-12 Basic steps in

the electrocoating process

Powder Coating

Powder Coating Systems

FIGURE 35-13 A schematic of a

powder coating system. The wheels
on the color modules permit it to be
exchanged with a spare module to
obtain the next color.

Electroplating Circuitry
FIGURE 35-14 Basic circuit for
an electroplating operation,
showing the anode, cathode
(workpiece), and electrolyte
(conductive solution).

Electroplating Design
Recomendations

FIGURE 35-15 Design

recommendations for
electroplating operations

Anodizing

FIGURE 35-16 The anodizing process

has many steps.

Nickel Carbide Plating

FIGURE 35-17 (Left) Photomicrograph of nickel

carbide plating produced by electroless deposition.
Notice
the uniform thickness coating on the irregularly shaped
product. (Right) High-magnification cross section
through the coating. (Courtesy of Electro-Coatings Inc.)

35.5 Vaporized Metal

Coatings

35.6 Clad Materials

35.7 Textured Surfaces

35.8 Coil-Coated Sheets

35.9 Edge Finishing and

Burrs

Burr Formation

FIGURE 35-18 Schematic

showing the formation of heavy
burrs on the exit side of a milled
slot. (From L. X. Gillespie,
American Machinist, November
1985.)

Deburring
Allowance

35.10 Surface Integrity

Burr Prevention

FIGURE 35-19 Designing

extra recesses and grooves into a
part may eliminate the need to
deburr. (From L.X. Gillespie,
American Machinist, November
1985.)

Surface Deformation

FIGURE 35-20 Plastic

deformation in the surface layer
after cutting. (B. W. Kruszynski
and C. W. Cuttervelt, Advanced
Manufacturing Engineering,
Vol. 1, 1989.)

Shot Peening

FIGURE 35-21 (a) Mechanism for formation of residual compressive stresses in

surface by cold plastic deformation (shot peening). (b) Hardness increased in surface
due to shot peening.

Surface Damage as a Function

of Rake Angle

FIGURE 35-22 The depth

of damage to the surface of a
machined part increases with
decreasing rake angle of the
cutting tool.

Surface Stress
FIGURE 35-23 (Top) A
cantilever-loaded (bent)
rotating beam, showing
the normal distribution
of surface stresses
(i.e., tension at the top
and compression at the
bottom). (Center) The
residual stresses
induced by roller
burnishing or shot
peening. (Bottom) Net
stress pattern obtained
when loading a
surface-treated beam.
The reduced
magnitude of the
tensile stresses
contributes to
increased fatigue life.

Fatigue Life with Surface

Finish
FIGURE 35-24 Fatigue life of
rotating beam 2024-T4
aluminum specimens with a
variety of surface-finishing
operations. Note the enhanced
performance that can be
achieved by shot peening and
roller burnishing.