DEPARTMENT OF MECHANICAL ENGINEERING

METROLOGY AND MEASUREMENT (18ME505)

QUESTION BANK
 UNIT-I

BASICS OF METROLOGY
PART-A (2 MARKS)

1. What are the uses of measurement?

2. What is generalized measurement system?
3. What are the basic components of a measuring system?
4. Distinguish between Line standard and End standard.
5. Define the term Sensitivity of an instrument.
6. What is the relationship between sensitivity and range?
7. Differentiate accuracy and Uncertainty with example.
8. Differentiate between precision and accuracy.
9. Define the term reliability.
10. Give any four methods of measurement.
11. Give classification of measuring instruments.
12. Define Span.
13. Distinguish between repeatability and reproducibility.
14. Define interchangeability.
15. Define error.
16. Distinguish between static and random error?
17. What are the sources of error?
18. Write short note on “Systematic errors”.
19. What are the factors affecting the accuracy of the measuring system?
20. Write short notes on the classification of error
21.Define measurand and comparator.
22. What are material standards? List their disadvantages.
23. What is the current definition of metre? What is its reproducibility?
24. Write a note on wavelength standards.
25. List the advantages of wavelength standards.
PART-B (16 MARKS)

1. Explain the need for measurement

2. Differentiate between precision and accuracy with suitable example.
3. Write short notes on i)repeatability ii)Accuracy iii)Sensitivity iv)Uncertainty
4. Explain in detail the basic element of the accuracy of measuring systems.
5. State the requirements for an instrument to measure accurately.
6. What are the requirements of an inspection tool?
7. Draw the block diagram of a generalized measurement system and explain the various stages
with an example
8. What are the various possible sources of errors in measurements? What do you understand by
systematic error and random errors?
9. Explain in detail various types of errors that may arise in engineering measurements.
10.Describe the various factors affecting the measurements.
11.Explain the various types of errors in measurements.
12.Explain the different types, control and estimation of uncertainty.
13.Describe the process of measurement in the role of quality control.
14.Explain statistical analyses of measurement data with suitable examples.
15.Describe the importance of calibrations in measuring instruments.
16. Define metrology. Explain the significance of metrology.
17. Differentiate between sensitivity and consistency.
18. Briefly explain legal and deterministic metrology.
19. Distinguish between direct and indirect measurements. Give two examples of each.
20. Describe any five methods of measurement.
21. Define the following: (a) Range of measurement (b) Sensitivity (c) Consistency (d)
Repeatability (e) Calibration (f) Traceability
22. Differentiate between accuracy and precision.
23. What are the possible sources of errors in measurements? Briefly explain them.
24. Explain the important elements of measurements.
25. Differentiate between systematic and random errors.
26. Discuss the relationship between accuracy and cost.
27. List the objectives of metrology.
28. Discuss the different reasons for the occurrence of systematic errors.
29. Explain the role of standards of measurements in modern industry.
30. Write a brief note on the evolution of standards.
31. Describe the following with neat sketches: (a) Imperial standard yard (b) International
prototype of metre
32. With the help of a block diagram, explain the hierarchical classification of standards.
33. How are standards subdivided?
34. Distinguish between primary, secondary, tertiary, and working standards.
35. What do you understand by line and end standards? Give examples.
36. Discuss the characteristics of line and end standards.
37. With a neat sketch, explain how Brookes level comparator is used to subdivide end
standards.
38. Describe the procedure to transfer from line standard to end standard.
39. With an example, explain how end standards are derived from line standards.
 UNIT-II
LINEAR AND ANGULAR MEASUREMENT

PART-A (2 MARKS)

1. List any four linear measuring instruments.

2. Give the advantages of digital vernier caliper.
3. What are the various types of linear measuring instruments?
4. List the various linear measurements?
5. List out any four angular measuring instrument used in metrology.
6. Mention any four precautions to be taken while using slip gauges.
7. What are the chances of error in using sine bars?
8. Why is sine bar not suitable for measuring angle above 45˚?
9. What are the limitations of sine bar?
10. What are constructional requirements of a good sine bar?
11. State the requirement of accuracy in the construction of a sine bar.
12. What is meant by wringing of slip gauges?
13. Name any two materials commonly used for gauges.
14. What are the merits of mechanical comparators?
15. What is comparator? How they are classified?
16. What are limit gauges?
17. State the advantages and disadvantages of sigma comparators.
18. List the various parts of an optical comparator.
19. What are the disadvantages of electrical and electronic comparator?
20. Classify the comparator according to the principles used for obtaining magnification.

PART-B (16 MARKS)

1. Explain with a neat sketch how a Vernier caliper is used for linear measurement.
2. Sketch and explain the function of optical protractor with vernier.
3. Explain with a neat sketch the construction and of working Sigma compactors
4. Describe the precautionary measures to be taken at various stages of using slip gauges.
5. With a neat sketch explain the construction and working principle of Solex pneumatic
comparator.
6. Explain mathematically why error in sine bar increases when the angle being measured
exceeds 45˚.
7. Explain the working method of mechanical optical comparators with sketch.
8. Explain with a neat sketch, the construction and working of a Tool Maker’s Microscope.
9. What is the principle of Angle dekkor? How is it used for the measurement of angles?
10.With neat sketch explain the construction and working principle of differential pneumatic
comparator.
11.Explain the working principle of autocollimator and briefly explain its application
12.Describe the working principle, advantages and disadvantages of optical comparators
13.Describe the working principle, advantages and disadvantages of optical projectors.
14.Explain the working principle of autocollimator and briefly explain its application
15.With neat sketch explain the working principle of sine bar for measuring angles.
16.With the aid of sketch describe the principle of operation of a comparators.
17.With neat sketch explain the working principle of any two linear measuring instruments.
 UNIT-III
TOLERANCE ANALYSIS
PART-A (2 MARKS)

1. Define unilateral and bilateral tolerances. Give examples for each.

2.Explain why a unilateral tolerance system is generally preferred over bilateral system.
3. Explain the following terms: (a) Limits (b) Fundamental deviation (c) Fundamental tolerance
4. Define fit and with the help of neat sketches, explain the different types of fits.
5. Give a detailed classification of fits.
6. Distinguish between tolerance and allowance.
7. Explain the effect of work tolerance on manufacturing cost.
8. Explain why hole basis system is generally preferred.
9. With a neat sketch, discuss compound tolerance.
10.What is Process capability
11.Define Tolerance stack up and tolerance charting
12. Define the following terms: (a) Basic size (b) Zero line (c) Tolerance zone (d) International
tolerance grade (e) Tolerance class (f) Upper and lower deviations
13. Write a note on gauge materials.
14. Distinguish between a measuring instrument and a gauge.
15. Describe why a GO gauge should be of full form.
16. Classify gauges.

PART-B (16MARKS)

1. Briefly explain the need to specify tolerance on components.

2. Explain the terms interchangeable manufacture and interchangeable assembly.
3. With an example, briefly explain the selective assembly approach.
4. What are the essential conditions to obtain clearance and interference fits?
5. Differentiate between hole basis and shaft basis systems.
6. Explain the terms local interchangeability and universal interchangeability.
7. Briefly explain the principle of limit gauging.
8. List the essential considerations made in the selection of materials for gauges.
9. State and explain Taylor’s principle of gauge design.
10. List the different points that have to be considered in the design of gauges.
11. Explain the different systems used to specify tolerances on gauges.
12. How are plain plug gauges designated?
13. Explain the term ‘gauge maker’s tolerance’.
14. Discuss why wear allowance should be provided to gauges.
15. With a neat sketch, explain double-ended plug gauge.
16. Give a sketch of and explain a snap gauge.
17. Describe a progressive plug gauge with a neat diagram.
18. With the help of neat sketches, discuss metal limits for hole and shaft gauging.
19. Explain why special attention should be given to GO gauges compared to NOT GO gauges
during the design of gauges.
20. The tolerances for a hole and shaft assembly having a nominal size of 40 mm are as follows:
+0.021 −0.0 40
Hole =40 +0.000 mm and shaft = 40−0.0 75 mm

Determine (a) maximum and minimum clearances (b) tolerances on shaft and hole (c) allowance
(d) MML of hole and shaft (e) type of fit
21. A shaft is manufactured within the specified limits of 30.02 and 29.98mm. Find the high and
low limits of the bush to give a maximum clearance of 0.10mm and minimum clearance of
0.02mm.
22. Calculate the limits, tolerances, and allowances on a 25mm shaft and hole pair designated
H7/g6 to get a precision fit. The fundamental tolerance is calculated by the following equation:
i = 0.453√3 D + 0.001D The following data is given:
(a) Upper deviation of shaft = −2.5D0.34
(b) 25 mm falls in the diameter step of 18–30 mm
(c) IT7 = 16i
(d) IT6 = 10i
(e) Wear allowance = 10% of gauge tolerance
In addition, determine the maximum and minimum clearance.
23. Design the general type of GO and NO GO gauge for components having 30 H7/f8 fit.
Given that
(a) i = 0.453√3 D + 0.001D
(b) upper deviation of ‘f’ shaft = −5.5D0.41
(c) 30mm falls in the diameter step of 18–30mm
(d) IT7 = 16i (e) IT8 = 25i
(f) wear allowance = 10% of gauge tolerance

24. Design a general type of GO and NO GO gauge for components having 50 H7/d9 fit.
The fundamental tolerance is calculated by the following equation:
i = 0.453√3 D + 0.001D The following data is given:
(a) Upper deviation of shaft = −16D0.44
(b) 50mm falls in the diameter step of 30–50mm
(c) IT7 = 16i (d) IT9 = 40i
(e) Wear allowance = 10% of gauge tolerance
 UNIT-IV
METROLOGY OF SURFACES
PART-A(2MARKS)

1.What is geometric dimensioning and tolerancing?

2.What are the acceptable dimensions and tolerances for GD&T?
3. Identify the prominent types of ‘lay’ by means of symbols only
4. Explain the following methods of quantifying surface roughness: (a) Rz value, (b) RMS value,
and (c) Ra value.
5. Distinguish between comparison and direct measurement of surface roughness.
6. List the major features of the stylus system of measurement.
7. What is a profilometer?

PART-B (16MARKS)

1. What is the justification for studying surface metrology as a specialized subject?

2. With the help of an illustration, explain the following terms: roughness, waviness, lay, and
flaws.
3. What are the primary reasons for surface irregularities?
4. Distinguish between skidless and skid-type instruments.
5. With the help of a neat sketch, explain the working principle of the Tomlinson surface meter.
6. With the help of a neat sketch, explain the Taylor–Hobson talysurf.
7. Discuss the effect of phase relationship between the stylus and the skid on measurement
accuracy.
8. What is a cut-off wavelength? List the recommended cut-off wavelengths for some of the
typical manufacturing operations.
9. How is the interferometry technique useful for measurement of surface irregularities?
10. What is the measurement concept in the ‘Mecrin’ instrument?
11. Describe the flatness testing method by using Interferometery applied.
12. Discuss on geometric and dimensional toleranceing with suitable examples.
 UNIT-V

LASER AND ADVANCES IN METROLOGY

PART-A (2 MARKS)

1. Name the different types of interferometer?

2. Write the application of Laser Interferometry.
3. Name the common source of light used for interferometer
4. What is crest and trough? 5. What is wavelength?
6. What is meant by alignment test on machine tools?
7. List the various geometrical checks made on machine tools.
8. Distinguish between geometrical test and practical test on a machine tool.
9. What are the main spindle errors?
10. Write the various tests conducted on any machine tools
11. Why the laser is used in alignment testing?
12. Classify the machine tool test
13. What are the different types of geometrical tests conducted on machine tools?
14. What is CMM?
15. List any four possible causes of error in CMM.
16. Name the types of accuracy specification used for CMM.
17. Discuss the application of computer aided inspection
18. State the application in machine tool metrology
19. Name the type of accuracy specifications used for CMM
20. State the applications of CMM

PART-B (16 MARKS)

1. Explain the construction and working principle of laser interferometer with neat diagram?
2. Explain the use of laser interferometer in angular measurement.
3. Explain with a neat sketch the working of Taylsurf instrument for surface finish measurement.
What is the symbol for fully defining surface roughness and explain each term?
4. Describe in detail the method of checking roundness by using Roundness Measuring Machine.
State its advantages.
5. Sketch and describe the optical system of a laser interferometer.
6. Define explain the working principle of Tomlinson surface meter with a neat sketch. Define
straightness. Describe any one method of measuring straightness of a surface.
7. Explain how the straightness error of a Lathe bed is checked using a Auto-collimator
8. With neat sketches, explain the significance of some important parameters used for measuring
surface roughness. Why so many parameters are needed?
9. How surface finish is measured using LASER. How the angle is measured using a laser
interferometer?
10. Discuss the steps involved in computing flatness of surface plate.
11. How are CMMs classified with respect to constructional features? Sketch and state their
main applications, merits and demerits.