Surface Roughness Considerations in Metalworking

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Abstract
The inadequacy of average roughness values such as AA and RMS for describing surface topography in metalworking is discussed. It is suggested that an expression involving asperity height, asperity form and roughness direction is needed. Surface roughness considerations in metalworking differ from those in bearing lubrication because of metal hardness changes and plastic deformation which occur in the former. This makes the roughnesses of the opposing surfaces dependent on one another in metalworking and thus complicates the analysis considerably. While many of the contact area distributions in metalworking are Gaussian, examples are shown for metal rolling where divergence from Gaussian is pronounced. A discussion of the effects of roughness directionality upon oil film thickness in metalworking indicates a strong dependence between these two parameters.

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