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Roughness: Micro-Inches or Micro-Meters (Microns)

The document discusses the importance of proper surface roughness on metal, chrome-plated, and ceramic-coated rolls used in plastic film and sheet production. Surface roughness provides traction to pull the film and prevent sticking, and can impart texture. Surface roughness is most commonly measured using the Ra (roughness average) method, and ranges from less than 0.5 micro-inches for a mirror finish to over 300 micro-inches for coarse textures. Processors are expected to achieve consistent finishes but many do not own the inexpensive profilometers needed to accurately measure roll roughness.

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89 views3 pages

Roughness: Micro-Inches or Micro-Meters (Microns)

The document discusses the importance of proper surface roughness on metal, chrome-plated, and ceramic-coated rolls used in plastic film and sheet production. Surface roughness provides traction to pull the film and prevent sticking, and can impart texture. Surface roughness is most commonly measured using the Ra (roughness average) method, and ranges from less than 0.5 micro-inches for a mirror finish to over 300 micro-inches for coarse textures. Processors are expected to achieve consistent finishes but many do not own the inexpensive profilometers needed to accurately measure roll roughness.

Uploaded by

rabikm
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Roughness

The correct surface finish on metal, chrome-plated, and ceramic-coated rolls does a lot to
improve film and sheet quality. Conversely, an inappropriate roll finish can damage the
product and slow output. If a roll is too rough, it can scuff the film or cause it to stick to
the roll. If a customer wants a satin finish or texture and the roll is too smooth, the
customer won’t get the product quality it wants. With thin films, too smooth a roll can
also create a vacuum through lack of air release, causing the film to stick.

Surface roughness provides traction to pull the film, air release to keep film from
sticking, and imparts surface texture, depending on the resin, gauge, heat, and
pressure used. All rolls in a plastic film or sheet line have specific surface-finish
requirements that depend on their function. Rolls with different finish requirements
include chill rolls; stretch, nip, and polishing rolls; machine-direction orienters; and
rolls for corona treating. They may be coated with one of several materials including
chrome, nickel, ceramic, or sprayed metal.

Roughness is commonly calculated using one of four


methods: Ra (roughness average), RMS (root mean square),
Rz (a 10 point average), and Rt or Rmax (maximum between
peak and valley). Different methods can be combined to give
more detail on roughness.

All four methods measure some combination of peak and


valley distances in the surface texture and give results in
either micro-inches or micro-meters (microns). A micro-inch
The only roll-finish
is much smaller than a micron, so don’t confuse them. A
spec that is free of
micro-inch is one-millionth of an inch; a micron is one-
ambiguity is a mirror
millionth of a meter. So one micron is equal to 39.37 micro-
finish. All other roll
inches. A finish that totals one micro-inch is finely polished
finishes must be
while one that totals one micron is coarsely textured.
precisely measured
and specified.
The most common measuring method is Ra or roughness
average. Metal finishing rolls range from an Ra of 0 to 0.5 micro-inches for a highly
polished mirror finish for optical-grade products, up to Ra 50 or 60 micro-inches for
satin-finished products, or possibly as much as Ra 300 micro-inches for embossed or
coarsely textured products. Ceramic coatings, which are porous, start at around Ra 2
micro-inches.

How rough is rough?

Roughness is measured by a profilometer/parthometer, an easy-to-use, hand-held


device available in a variety of sizes, shapes, stylus configurations, accuracy levels,
and prices. Cost starts at around $2000 for a simple model and goes up for high-tech
versions.

All profilometers measure the physical depth of surface irregularities using some
form of diamond or brush-type stylus attached to an arm that travels in a straight
line for a specified “cutoff” or sampling length, typically 0.03 in. Most profilometers
allow for various cutoff lengths. The profilometer transforms the information from the
stylus into an electrical signal and converts that signal into usable data.

An inexpensive profilometer is essential


to measure roll surface finishes—yet
most processors don’t own one.

Surface finishes are very costly, at times more expensive than the roll itself. Roll
makers achieve different finishes by polishing for gloss, superfinishing for a mirror
finish, or grit blasting. Varying the blast media, media size, nozzle size, pressure,
and duration creates a wide range of textures from satin to extremely coarse.

The wrong finish costs as much to apply as the right one. Since film end users and
converters are becoming more demanding, processors are expected to achieve more
consistent clarity and surface finish and more sharply embossed textures.

Surface roughness is calculated by a profilometer using any of four common


methods: Ra, RMS, Rz, and Rt (Rmax).
A. Ra or roughness average is the average of peak and valley distances measured
along the centerline of one cutoff length (usually 0.03 in.).

B. RMS or root mean square is an older method, not common today, averaging only
the heights of all points measured in one cutoff length. Readings are similar to Ra
but about 10% higher.

C. Rz, a 10-point average, is an average of the five highest peaks and the five lowest
valleys measured in one cutoff length.

D. Rt (Rmax), maximum height between peak and valley, is the value of the vertical
distance between the highest peak and lowest valley measured along one cutoff
length.

There are many more methods of measuring roughness, such as Rp, Rq, Rx, and Ry,
used by other industries and in other parts of the world, but not common in
measuring roll finishes for plastics.

Michael Hebert is general manager of the Perma-Flex Engineering Div. of Perma-Flex


Roller Technology LLC in Orange, Mass., which builds and repairs rolls for cast and
biaxially oriented film, blown film, and sheet.

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