Subject Code & Name: ME25C15 – Metrology and Measurements
Regulation: R-2025
Semester: IV (Fourth Semester)
Branch: B.E. Mechanical Engineering (Smart Manufacturing) (Mech(Smart))
Credits / L-T-P: 3 Credits | L-T-P: 2-0-2
Course Objectives
- This course introduces principles of measurement, metrology, and tolerance analysis in manufacturing.
- It enables application of measurement techniques and modern metrology tools for precision and quality control.
Full Unit-wise Syllabus
Unit I – Basics of Metrology
Measurement, Need, Process, Role in quality control; Factors affecting measurement, SWIPE; Errors in Measurements, Types, Control, Measurement uncertainty – Types, Estimation, Problems on Estimation of Uncertainty, Statistical analysis of measurement data, Measurement system analysis, Calibration of measuring instruments, Principle of air gauging- ISO standards.
Practical: 1. Calibration of linear measuring instruments – Vernier caliper, micrometer, Vernier height gauge using gauge blocks and reporting the calibration uncertainty 2. Perform gauge repeatability and reproducibility analysis
Unit II – Measurement of Linear, Angular Dimensions, Assembly and Transmission Elements
Linear Measuring Instruments: Vernier caliper, Micrometer, Vernier height gauge, Depth Micrometer, Bore gauge, Telescoping gauge; Gauge blocks – Use and precautions, Comparators, Working and advantages, Angular measuring instruments, Bevel protractor, Clinometer, Angle gauges, Precision level, Sine bar, Autocollimator, Angle dekkor, Alignment telescope. Measurement of Screw threads, Single element measurements, Pitch Diameter, Lead, Pitch. Measurement of Gears, purpose, Analytical measurement, Runout, Pitch variation, Tooth profile, Tooth thickness, Lead, Functional checking – Rolling gear test.
Practical: 1. Measurement of external and internal linear dimensions in the given component using vernier caliper, micrometer, vernier height gauge, depth micrometer, bore gauge and telescopic gauge. 2. Measurement of angles using bevel protractor and sine bar. 3. Non-contact (Optical) measurement using measuring microscope, profile projector and video measurement system
Unit III – Tolerance Analysis
Tolerancing– Interchangeability, Selective assembly, Tolerance representation, Terminology, Limits and Fits, Problems (using tables IS919); Design of Limit gauges, Problems. Tolerance analysis in manufacturing, Process capability, tolerance stackup, tolerance charting.
Practical: 1. Use of mechanical and pneumatic comparators to check the dimensions in a component and variation from the given standard. 2. Process capability analysis of a given machining process 3. Tolerance stackup analysis in a given assembly
Unit IV – Metrology of Surfaces
Fundamentals of GD & T, Conventional vs Geometric tolerance, Datums, Inspection of geometric deviations like straightness, flatness, roundness deviations; Simple problems, Measurement of Surface finish, Functionality of surfaces, Parameters, Comparative, Stylus based and Optical Measurement techniques, Filters, Introduction to 3D surface metrology- Parameters.
Practical: 1. Measurement of geometric parameters – Roundness, runout, parallelism, perpendicularity, symmetry – in the given components using V-block / Bench center / Height gauge / roundness tester. 2. Measurement of surface roughness in components manufactured using various processes (turning, milling, grinding, etc.,) using stylus-based instruments.
Unit V – Advances in Metrology
Lasers in metrology, Advantages of lasers, Laser scan micrometers; Laser interferometers, Applications, Straightness, Alignment; Ball bar tests, Computer Aided Metrology, Basic concept of CMM, Types of CMM, Constructional features, Probes, Accessories, Software, Applications, Multi-sensor CMMs. Machine Vision, Basic concepts of Machine Vision System, Elements, Applications, On- line and in-process monitoring in production, Computed tomography, White light Scanners.
Practical: 1. Measurement of features in a prismatic component using Coordinate Measuring Machine (CMM) and offline Programming of CNC Coordinate Measuring Machines for repeated measurements of identical components 2. Machine tool Metrology – Geometrical / Alignment tests on lathes / milling machines and measurement of straightness using autocollimator / electronic level.
Tasks: T1. Dimensional variation in parts; plan measurement and calibration. T2. Inconsistent inspection results; perform Gauge R&R analysis. T3. Assembly fit issues; analyze and assign proper tolerances. T4. Surface and geometric errors; select suitable measurement methods.
Course Outcomes (COs)
- CO1: Explain principles of metrology, measurement systems, tolerances, surface metrology, and advanced measurement techniques.
- CO2: Apply measurement instruments and techniques for dimensional analysis and tolerance evaluation.
- CO3: Analyze measurement data, uncertainty, and process capability for interpreting system performance.
- CO4: Evaluate GD&T, surface metrology, and advanced measurement systems for quality validation.
Assessment Pattern (Quick Note)
- Weightage: Continuous Assessment 50% | End Semester Examinations 50%
- Internal methodology: Written Test (40%), Practical (30%), Activity (30%). Practical: Lab Experiments (50%), Tasks (50%) (Each student must complete a minimum of two tasks). Activity: Review of GATE/ESE Questions (10%), Mini Project/ Quiz/ Assignment Programs/ Flipped Class /Seminar Presentation (20%)
Source: Official Anna University – B.E. Mechanical Engineering (Smart Manufacturing) R-2025 Syllabus
Last Updated: October 2026
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