JAYA SAKTHI ENGINEERING COLLEGE
(Approved by AICTE & Affiliated to Anna University, Chennai)
St. Mary’s Nagar Thiruninravur, Chennai- 602 024
Department of Mechanical Engineering
Question Bank
Year / Sem: III Year / V Semester
ME3592–METROLOGY AND MEASUREMENTS
Unit–I
Part – A (2 – Marks)
1. Summarize the various elements of measurement.(Nov/Dec 2023),(Nov/Dec 2020)(Nov/Dec 2019)
2. Mention the main objectives of traceability. (Nov/Dec 2023)(Nov/Dec 2019)
3. How is the standard associated with measuring a work piece decided? (Apr/May 2023)
4. Distinguish between line standards and end standards. (Apr/May 2023)
5. Distinguish between precision and accuracy. (Nov/Dec 2022)
6. Compare between Line and End standards with example.(Nov/Dec 2022)
7. How does 'person' as a factor influence the results of a measurement?(Nov/Dec 2021)
8. Discuss the basis of selecting a standard for a particular type of measurement? (Nov/Dec 2021)
9. What is legal metrology? (April/May 2014)
10. What are the basic components of a measuring system? (April/May 2012)
11. Define static response. (Nov/Dec 2013)
12. A thermometer is calibrated from 200℃ to 300℃. The accuracy is specified within ±0.25%. What is
the maximum static error? (Nov/Dec 2010)
13. What do you mean by sensitivity of a measuring instrument? (Nov/Dec 2016), (April/May 2012)
14. What is Range of measurement? (Nov/Dec2015)
15. Define Traceability. (April/May 2017)
16. What is difference between gauging and measurements?(April/May 2017)
17. Define Calibration. (Nov/Dec 2014)
18. Why are measuring instruments calibrated? (Nov/Dec 2015)
19. Define systematic errors. ((Nov/Dec 2015)
20. What are the factors affecting the inherent characteristics of measuring instruments?
(April/May 2016)
Part – B (13 – Marks)
1. Elaborate two broad categories of errors in measurement with suitable example.(Nov/Dec 2023)
(Nov/Dec 2020)
2. Explain the working principle of a pneumatic back pressure gauge. Discuss the relevance of the
characteristic curve in measurement. (Nov/Dec 2023) (Nov/Dec 2020)
3. Explain how various factors influence the measurement with supporting examples. (Nov/Dec 2023)
4. (i) Distinguish between 'precision' and 'accuracy'. (6)
(ii) Write detailed notes on the control measures you will take in order to eliminate measurement
errors in a metrology laboratory. (7) (Nov/Dec 2023)
5. Give the structure of generalized measurement system with neat sketch. (Nov/Dec 2022)
6. A person weighs around 75 kg. He checks his weight using three different instruments. Following
were the results obtained from the instruments: (Nov/Dec 2022)
Instrument 1 Instrument 2 Instrument 3
74 69 80
78 68 85
80 67 84
70 66 90
72 68 89
77 66 86
What types of errors are associated with these instruments and how it affects its accuracy and
precision?
7. Discuss the relevance of the characteristic curve in measurement.
8. Explain various types of errors that occur in engineering measurements. (Nov/Dec 2021)
9. Draw the block diagram of generalized measurement system and explain the different stages with
examples. (April/May 2016, Nov/Dec 2012 & Nov/Dec 2010)
10. Explain the purpose of calibrating the instrument and discuss the primary calibration and secondary
calibration. (April/May 2014)
11. Discuss the role in quality control in detail.
12. Describe good measurement practice.
13. Explain in detail about ISO standards.
14. Discuss the measurement system analysis in detail.
15. Describe the measurement uncertainty in detail.
16. How kurtosis is calculated?
17. Enumerate the various steps involved in calculating the measurement uncertainty.
18. Write short notes on sampling acceptance.
19. Write short notes on types of standards.
20. Enumerate the desirable characteristics of precision measuring instruments.
Part – C (15 – Marks)
1. Explain the causes of those errors with suitable examples.
2. Describe the different types of errors and its causes.
3. Distinguish between and give appropriate examples in each case (i) Repeatability and reproducibility
4. Write notes on (i) Sensitivity and reability (7) (ii) Calibration (6)
5. Elaborate on different methods of measurements.
6. In a series of successive measurements of length of the object, the readings in periodic measurements
were found to be 2.73 mm, 2.66 mm, 2.52 mm, 2.61 mm and 2.75 m. Calculate the (i) mean value of
length (ii) absolute error in each measurement, (iii) mean absolute error (iv) relative error (v)
percentage error . Express the result in proper form.
7. Explain in detail about the control charts used for different purposes.
8. Explain the methods of calibrating measuring instruments.
9. Write short notes on principle of air gauging.
10. Consider the following set of data values given in the form of a grouped frequency distribution table
below. Calculate the mean, variance, standard deviation and kurtosis for the tabulated grouped data.
Unit–II
Part – A (2 – Marks)
1. List some of the parameters measured by Angle gauges. (Nov/Dec 2023) (April/May 2023)
2. Discuss the working principle of an autocollimator. (Nov/Dec 2023) (April/May 2023)
3. Define minor diameter of a screw thread. (Nov/Dec 2023)
4. Write about the type of error that is expected in turning a particular type of steel component that is
found to possess varying hardness. (Nov/Dec 2023)
5. Which angle measuring device is best suitable for probing the V-block?(Nov/Dec 2023)
6. State "Taylor's principle of gauge design".(Nov/Dec 2022)
7. What is the purpose of angle dekkor? (April/May 2023)
8. Explain the radial runout and axial runout. (April/May 2023)
9. A Vernier scale consists of 25 divisions on 12 mm spacing and the main scale has 24 divisions on 12
mm. What is the least count? (Nov/Dec 2022)
10. Figuratively represent the different elements of external screw thread. (Nov/Dec 2022)
11. Assume that the surface roughness profile is triangular as shown in fig. If the peak to valley height is
20 mm. Calculate the Centre Line Average (CLA) surface roughness Ra (in um), if the datum line is
at the middle of the triangles
Fig. Surface Roughness Profile
12. Write short notes on 'Ring gauges'. (Nov/Dec 2021)
13. What is selective assembly? (Nov/Dec 2021)
14. List out the difficulties witnessed in the measurement of flatness of a surface. (Nov/Dec 2020)
15. Brief on the effect of stylus and skid in measurement of surface roughness. (Nov/Dec 2020)
16. Define constant chord. (Nov/Dec 2020)
17. What are the various methods used for measuring the gear tooth thickness?
18. Define gear runout. (Nov/Dec 2012)
19. The outside diameter of a gear is 110 mm and the number of teeth is 20. What is the module of gear?
20. What is lead in screw thread measurement? (Nov/Dec 2019)
Part – B (13 – Marks)
1. Discuss the procedure to measure the unknown angles with Sine Bar. Also, mention the use of Sine
Blocks. Sine Plates, and Sine Tables. (Nov/Dec 2023) (Apr/May 2023) (Nov/Dec 2020)
2. Outline the constructional details of gear tooth caliper to measure the tooth thickness. (Nov/Dec
2023) (Nov/Dec 2020)
3. (i) Explain how a sine bar is used for measuring angles of components. (6)
(ii) Compare and contrast an autocollimator with an alignment.(7) (Nov/Dec 2023)
4. Describe the method of checking the straightness of a component with diagrams wherever needed.
(Nov/Dec 2023)
5. Explain the working principle of stylus type surface roughness tester with a neat sketch.
(Apr/May 2023) (Nov/Dec 2021)
6. Explain the construction of Vernier Height Gauge with neat sketch and its applications.
(Nov/Dec 2022)
7. Explain various cases of application of sine bars with neat diagrams. (Nov/Dec 2021)
8. Explain the procedure for finding the chordal thickness of a gear using a gear tooth vernier caliper.
(Nov/Dec 2021)
9. Explain the different types of micrometer.
10. Describe the different types of comparators and its applications.
11. Explain the Johansson Microkator and Sigma comparator.
12. Derive the formula for measuring the effective diameter of a screw thread by the three-wire method
(Apr/May 2019)
13. How slip gauges are manufactured?
14. What is meant by functional inspection of gears? how is it done?
15. Explain the construction and working principle of bevel protractor with a sketch.
16. Describe the various terminologies of a screw thread with suitable diagrams.
17. Discuss the various types of screw pitch errors.
18. Explain in detail the (i) Constant chord method and (ii) Base tangent method
19. Explain how slip gauges are checked for quality.
20. What is meant by functional inspection of gears? How is it done?
Part – C (15 – Marks)
1. An automobile spare parts manufacturing company has a metrology lab which is concerned with
linear and angular measurements. List 10 possible chances of errors that may arise in engineering
measurement in such a lab and the ways of fixing them. (Nov/Dec 2023)
2. How are bore gauges calibrated?
3. Briefly explain the working of a telescopic bore gauge with a neat sketch.
4. Explain the working principle of Angle dekkor and its applications.
5. Discuss the following angular measurement methods using rollers (i) Measurement of angle by using
rollers (ii) Measuring of inclined angle of an internal dovetail
6. Describe the two wire method of finding the effective diameter of screw threads
7. Illustrate explain an accurate method of measuring effective diameter of screw threads.
8. Derive the formula for measuring the effective diameter of a screw thread by the three-wire method.
9. Explain the working principle of Tool Maker’s microscope with neat sketch and its applications.
10. How a gear can be checked using Parkinson Gear tester and its limitations.
Unit – III
Part – A (2 – Marks)
1. Define tolerance and mention its classification. (Nov/Dec 2023)
2. Draw the relationship between fundamental, upper and lower deviations in limits and fits. (Nov/Dec
2023)
3. Define interchangeability
4. What is selective assembly?
5. State the advantage of interchangeable manufacturing.
6. Write the merits and demerit of selective assembly.
7. Define tolerance.
8. List the methods of representing tolerance.
9. Define tolerances stack-up.
10. Define interference free matrix
11. What is the necessary of locating center of gravity?
12. What is whole basis and software basis system?
13. What are the three terms used in limit system?
14. Why transition fit occurs?
15. When interference fit is obtained?
16. Differentiate between dimensional and form tolerances.
17. Define Shaft and Hole.
18. Calculate the fundamental deviations for a circular hole of 30 mm diameter finished to H7 tolerance.
19. Calculate the IT tolerance of diameter 45 mm of tolerance grade 5.
20. List the methods of tolerance stack-up analysis.
Part – B (13 – Marks)
1. A clearance fit has to be provided for a shaft and bearing assembly having a diameter of 40 mm.
Tolerances on hole and shaft are 0.006 and 0.004 mm, respectively. The tolerances are disposed
unilaterally. If an allowance of 0.002 mm is provided, find the limits of size for hole and shaft when
(1) hole basis system and (ii) shaft basis system are used. (Nov/Dec 2023)
2. Summarize the various methods of tolerance specification on inspection Gauges with diagrams of
disposition. (Nov/Dec 2023)
3. Briefly explain the need to specify tolerance on components.
4. Define unilateral and bilateral tolerances. Give examples for each.
5. Explain why a unilateral tolerance system is generally preferred over bilateral system.
6. Explain the terms interchangeable manufacture and interchangeable assembly.
7. With an example, briefly explain the selective assembly approach.
8. Distinguish between tolerance and allowance
9. Explain the following terms: (a) Limits (b) Fundamental deviation (c) Fundamental tolerance
10. Define fit and with the help of neat sketches,
11. Explain the different types of fits. What are the essential conditions to obtain clearance and
interference fits?
12. Differentiate between hole basis and shaft basis systems.
13. Explain the effect of work tolerance on manufacturing cost.
14. Explain the terms local interchangeability and universal interchangeability.
15. Explain why hole basis system is generally preferred.
16. What do you mean by accumulation of tolerances? Explain how it can be overcome.
17. Give a detailed classification of fits.
18. Explain the different types of geometric tolerances and symbolically represent them.
19. Briefly explain the principle of limit gauging.
Part – C (15 – Marks)
1. Design a general type of GO and NO GO gauge for components having 16 50 H7/49 fit. The
fundamental tolerance is calculated by the followingequation:
i=0.453/D+0.001D
The following data is given
(i) Upper deviation of shaft = -16D0.44
(ii) 50 mm falls in the diameter step of 30-50 mm
(iii) IT7 = 16i
(iv) IT9 = 40i
(v) Wear allowance = 10% of gauge tolerance.
2. Calculate the limits for a hole shaft pair designated 25 H8/d9. Show graphically the disposition of
tolerance zones with reference to the zero-line. The lower deviation for a H type hole is zero. 25 mm
lies in the diameter range 18 mm to 30 mm. Standard tolerance for IT 8 is 25i and IT 9 is 40i, where
‘i’ is the standard tolerance unit in microns and i given as i(µm) = 0.45√ √3 D + 0.001 D. The upper
deviation for ‘d’ shaft is -16D0.44
3. Calculate the tolerances, fundamental deviations and limits of sizes for the shaft designated as 40
H8/f7 . Standard tolerance for IT 7 is 16i and IT 8 is 25i. where ‘i’ is the standard tolerance unit.
Upper deviation for ‘f’ shaft is -5.5 D0.41, 40 mm lies in the diameter range 30 – 50 mm.
4. Considering fits and tolerances give the dimensions for the hole and shaft for the following;
(a) a 12 mm electric motor sleeve bearing b) a medium force fit on a 200 mm shaft , (c) a 50 mm
sleeve bearing on the elevating mechanism of a road grader.
5. Discuss the gauge design procedures.
6. Design a workshop type progressive type GO-NOT-GO plug gauge suitable for 25 H7 with the
following information; (i) 25 mm lies in the diameter step of 18-30 mm (ii) i=0.45√3 D+0.001 D
and (iii) IT7 = 16i
7. Discuss the process capability in detail.
8. Write down the rules to be followed to perform tolerance Stack-up Analysis.
9. Explain the methods of tolerance stack-up analysis.
Unit – IV
Part – A (2 – Marks)
1. What is Datum?
2. Define FCF.
3. Mention the advantage of GD&T.
4. Compare conventional tolerance and geometric tolerance.
5. Define straightness.
6. Define straight edge.
7. Compare straightness test by using spirit level and auto collimator.
8. What is surface roughness?
9. Define the term cut-off length with respect to surface roughness measurement.
10. Define lays. Mention any four of its type.
11. Define degree of fullness and degree of emptiness in form factor.
12. State ‘material ratio’ with reference to surface finish measurement.
13. What is the secondary texture of a surface?
14. Name the various stylus probe instruments used for surface finish measurement.
15. Name the four roundness measurements methods.
16. How is roughness measure in the least squares circle method?
17. Enlist the uses of 3D real measurements.
18. Define surface metrology.
19. State the fundamental concepts used in surface finish measurements.
20. What are the methods used for measuring surface roughness?
Part – B (13 – Marks)
1. Explain the working principle of stylus type surface roughness tester with a neat sketch.
2. Discuss various acceptance tests to be conducted for milling machine with required illustration.
3. Explain the working of GD&T
4. Describe GD&T tolerancing guidelines.
5. Discuss the drawing indication of datum features
6. Discuss any two examples of datum feature notation on drawing
7. Explain GD&T symbols.
8. How does geometric tolerance perform and with an example?
9. Define straightness, describe any one method of measuring straightness of a surface.
10. How is the straightness of a straight edge measured?
11. Illustrate with a neat sketch, the measurement of straightness of machine tool guide way using
autocollimator.
12. Describe the roundness deviation measurement.
13. Enlist and explain the different methods used for measuring the roundness.
14. Describe any one method of roundness measurement.
15. Explain how V-block and three-point probe are used for measurement roughness and its limitations.
16. Explain CLS,RMS, Ten point height methods for assessment of a average roughness.
17. With a neat diagram explain the working principle of a stylus type surface finish measuring
instrument.
18. Explain with a neat sketch the working of Talysurf instrument for surface finish measurement.
19. Write short notes on the functionability of surfaces.
20. Explain the construction and working of a profilometer.
Part – C (15 – Marks)
1. Explain with neat diagrams the method for measurement of straightness of a machine tool guide way
using an Autocollimator. Show the tabulation to determine the error in straightness by choosing a
reference line passing through the first and last points of the guide way.
2. In the measurement of surface roughness heights of successive 10 peaks and troughs were measured
from a datum were 23,25,21,20,23,18,26,24,28 and 21 microns. If these measurements were obtained
on 10 mm length, determine C.L.A and RMS values of surface roughness.
3. In the measurement of surface roughness, the heights of 10 successive peaks and valleys over a mean
line for a specific sampling length were as follow: 48,28,36,32,43,21,45,20,46, and 25 microns. Find
Ten-point height of irregularities (RZ) value
4. In a measurement of surface roughness heights of successive 14 peaks and troughs were measured
from a datum were 50,48,38,26,20,19,27,22,33,20,40,26,43, and 26 microns. If these measurements
were obtained on 10 mm length, determine C.LA and RMS values of surface roughness. Also find
the relation between C.L.A and RMS results.
5. Describe filters on surface finish measurements.
6. Enumerate an example of filtering in surface finish measurement.
7. Write short notes on 3D surface metrology.
8. Discuss the parameters involved in 3D surface measurement.
Unit – V
Part – A (2 – Marks)
1. Discuss the major applications of CMM. (Nov/Dec 2023)
2. Outline the elements of flexible inspection system. (Nov/Dec 2023)
3. What are the metrological uses of lasers? (Nov/Dec 2023)
4. Suggest a case where machine vision system can be used for identifying the outsiders.
(Nov/Dec 2023)
5. Why is laser preferred in engineering metrology? (Nov/Dec 2022)
6. List any four possible causes of errors in CMM. (Nov/Dec 2022)
7. What is the advantage of using polarized beam splitter over ordinary glass based beam splitter?
(Nov/Dec 2021)
8. Mention about the uses of various types of probes used in CMMs. (Nov/Dec 2021)
9. Name the types of laser. (Nov/Dec 2018)
10. Why is monochromatic light used in interferometry instead of white light? (Apr/May 2018)
11. State the principle of interferometry. (Nov/Dec 2012)
12. What are diffraction gratings?
13. What factor the accuracy of laser interferometer mainly depends? (Apr/May 2019)
14. Write down the uses of a laser interferometer. (Nov/Dec 2010)
15. What is the advantage of using polarized beam splitter over ordinary glass-based beam splitter?
16. Define tough trigger probes.
17. What is meant by “Qualifying the tip” in CMMs?
18. Define machine vision.
19. Write any four applications of artificial vision systems in manufacturing industries.
20. What is white light scanner?
Part – B (13 – Marks)
1. Elaborate the construction and working principle of Laser Interferometer used in metrology.
(Nov/Dec 2023)
2. Analyze the five popular physical configurations used in machine vision system. (Nov/Dec 2023)
(Nov/Dec 2019)
3. (i) Compare and contrast an AC and DC laser interferometer, (6)
(ii) Suggest a CMM that is best suitable for offline inspection of assemblies and justify your answer.
(7) (Nov/Dec 2023)
4. Explain with case studies the use of laser interferometers for linear and angular measurements.
(Nov/Dec 2021)
5. Describe various Industrial applications of CMMs with sketches. wherever needed. (Nov/Dec 2021)
6. With a neat sketch, explain the procedure of dimensional measurement using a laser gauge.
(Nov/Dec 2018)
7. Explain the working principle of a DC laser interferometer with a neat diagram.
8. Explain the working principle of a AC laser interferometer with a neat diagram.
9. What is meant by alignment test on machine tools? Give its importance.
10. Discuss the need, types and constructional features of the coordinate measuring machine.
11. With neat sketch explain the various types of CMM based on its construction.
12. Explain the construction and working of various bridge types of coordinate measuring machines.
13. Write short notes on working principle of touch trigger probe.
14. Explain the construction and working details of horizontal arm CMM.
15. Describe the various types of probes used in CMM.
16. Enumerate the role of computers in metrology.
17. Write a brief note on the laser as a means of alignment checking.
18. What are the important features in CMM software?
19. Illustrate the basic concept involved in the machine vision system.
20. Explain the calibration of three coordinate measuring machine with their sketches.
Part – C (15 – Marks)
1. Enunciate the various stages involved in machine vision system with an example. (Nov/Dec 2023)
(Apr/May 2023) (Nov/Dec 2020)
2. What are the possible chances of employing machine vision in a food processing company that
manufactures a wide variety of food items and beverages? Also discuss the ways machine vision
system could be used at different stages of food processing. (Nov/Dec 2023)
3. List the various configurations of coordinate measuring machine. Explain the constructional features
of any three configurations of CMM. Point out the applications of CMM in machine tool metrology.
(Nov/Dec 2022)
4. Sketch and describe the principle of laser triangulation sensor.
5. Explain the scope of machine vision in a bottling plant with suitable sketches.
6. Describe how to use laser interferometer to predict machine tool accuracies.
7. Develop a machine vision system for part sorting and bin packing operations and draw the block
diagram of machine vision system.
8. Describe on-load testing and off-load testing in condition monitoring.
9. Explain the principle of computed tomography.
10. Discuss the working of a white light scanners with a neat sketch.
