Surface roughness analysis: A comprehensive review of measurement techniques, methodologies, and modeling

The scale and value of surface roughness affect the wetting, fatigue, damping, emissivity, heat transfer, and aesthetic characteristics leading to applications in food, chemical, medical, and traditional mechanical industries. Starting with the definitions of roughness parameters, in this work, we presented a comprehensive review of various aspects required to characterize surface roughness. Subsequently, a well-arranged literature survey on the use of several roughness-sensing methods for various machining processes was presented. In tandem, the theoretical aspects of sensing and their limits on resolution, sensitivity, range, and accuracy have been described. Thereafter, mathematical models to reconstruct surface profiles were outlined. We also presented the ways for online measurements of roughness and integration of the former with the standards of Industry 4.0. With details on all aspects of roughness, this work is expected to assist the researchers and engineers in the selection of appropriate roughness measurement techniques that lead to application in various industries.