Zone-Wise Uncertainty Propagation and Dimensional Stability Assessment in CNC-Turned Components Using Manual and Automated Metrology Systems
Accurate measurement uncertainty quantification and its propagation are critical for dimensional compliance in precision manufacturing. This study presents a novel framework that examines the evolution of measurement error along the axial length of CNC-turned components, focusing on spatial and mate...
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MDPI AG
2025-07-01
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| Online Access: | https://www.mdpi.com/2075-1702/13/7/585 |
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| author | Mohammad S. Alsoufi Saleh A. Bawazeer Mohammed W. Alhazmi Hani Alhazmi Hasan H. Hijji |
| author_facet | Mohammad S. Alsoufi Saleh A. Bawazeer Mohammed W. Alhazmi Hani Alhazmi Hasan H. Hijji |
| author_sort | Mohammad S. Alsoufi |
| collection | DOAJ |
| description | Accurate measurement uncertainty quantification and its propagation are critical for dimensional compliance in precision manufacturing. This study presents a novel framework that examines the evolution of measurement error along the axial length of CNC-turned components, focusing on spatial and material-specific factors. A systematic experimental comparison was conducted between a manual Digital Vernier Caliper (DVC) and an automated Coordinate Measuring Machine (CMM) using five engineering materials: Aluminum Alloy 6061, Brass C26000, Bronze C51000, Carbon Steel 1020 Annealed, and Stainless Steel 304 Annealed. Dimensional measurements were taken from five consecutive machining zones to capture localized metrological behaviors. The results indicated that the CMM consistently achieved lower expanded uncertainty (as low as 0.00166 mm) and minimal propagated uncertainties (≤0.0038 mm), regardless of material hardness or cutting position. In contrast, the DVC demonstrated significantly higher uncertainty (up to 0.03333 mm) and propagated errors exceeding 0.035 mm, particularly in harder materials and unsupported zones affected by surface degradation and fixture variability. Root-sum-square (RSS) modeling confirmed that manual measurements are more prone to operator-induced error amplification. While the DVC sometimes recorded lower absolute errors, its substantial uncertainty margins hampered measurement reliability. To statistically validate these findings, a two-way ANOVA was performed, confirming that both the measurement system and machining zone significantly impacted uncertainty, as well as their interaction. These results emphasize the importance of material-informed and zone-sensitive metrology, highlighting the advantages of automated systems in sustaining measurement repeatability and dimensional stability in high-precision applications. |
| format | Article |
| id | doaj-art-c0fd4d10f4b7465895dbba5b11408472 |
| institution | DOAJ |
| issn | 2075-1702 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Machines |
| spelling | doaj-art-c0fd4d10f4b7465895dbba5b114084722025-08-20T03:08:01ZengMDPI AGMachines2075-17022025-07-0113758510.3390/machines13070585Zone-Wise Uncertainty Propagation and Dimensional Stability Assessment in CNC-Turned Components Using Manual and Automated Metrology SystemsMohammad S. Alsoufi0Saleh A. Bawazeer1Mohammed W. Alhazmi2Hani Alhazmi3Hasan H. Hijji4Department of Mechanical Engineering, College of Engineering and Architecture, Umm Al-Qura University, Makkah 21955, Saudi ArabiaDepartment of Mechanical Engineering, College of Engineering and Architecture, Umm Al-Qura University, Makkah 21955, Saudi ArabiaDepartment of Mechanical Engineering, College of Engineering and Architecture, Umm Al-Qura University, Makkah 21955, Saudi ArabiaDepartment of Mechanical Engineering, College of Engineering and Architecture, Umm Al-Qura University, Makkah 21955, Saudi ArabiaDepartment of Mechanical Engineering, College of Engineering and Architecture, Umm Al-Qura University, Makkah 21955, Saudi ArabiaAccurate measurement uncertainty quantification and its propagation are critical for dimensional compliance in precision manufacturing. This study presents a novel framework that examines the evolution of measurement error along the axial length of CNC-turned components, focusing on spatial and material-specific factors. A systematic experimental comparison was conducted between a manual Digital Vernier Caliper (DVC) and an automated Coordinate Measuring Machine (CMM) using five engineering materials: Aluminum Alloy 6061, Brass C26000, Bronze C51000, Carbon Steel 1020 Annealed, and Stainless Steel 304 Annealed. Dimensional measurements were taken from five consecutive machining zones to capture localized metrological behaviors. The results indicated that the CMM consistently achieved lower expanded uncertainty (as low as 0.00166 mm) and minimal propagated uncertainties (≤0.0038 mm), regardless of material hardness or cutting position. In contrast, the DVC demonstrated significantly higher uncertainty (up to 0.03333 mm) and propagated errors exceeding 0.035 mm, particularly in harder materials and unsupported zones affected by surface degradation and fixture variability. Root-sum-square (RSS) modeling confirmed that manual measurements are more prone to operator-induced error amplification. While the DVC sometimes recorded lower absolute errors, its substantial uncertainty margins hampered measurement reliability. To statistically validate these findings, a two-way ANOVA was performed, confirming that both the measurement system and machining zone significantly impacted uncertainty, as well as their interaction. These results emphasize the importance of material-informed and zone-sensitive metrology, highlighting the advantages of automated systems in sustaining measurement repeatability and dimensional stability in high-precision applications.https://www.mdpi.com/2075-1702/13/7/585measurement uncertaintyerror propagationCNC machiningcoordinate measuring machinedigital vernier caliperdimensional stability |
| spellingShingle | Mohammad S. Alsoufi Saleh A. Bawazeer Mohammed W. Alhazmi Hani Alhazmi Hasan H. Hijji Zone-Wise Uncertainty Propagation and Dimensional Stability Assessment in CNC-Turned Components Using Manual and Automated Metrology Systems Machines measurement uncertainty error propagation CNC machining coordinate measuring machine digital vernier caliper dimensional stability |
| title | Zone-Wise Uncertainty Propagation and Dimensional Stability Assessment in CNC-Turned Components Using Manual and Automated Metrology Systems |
| title_full | Zone-Wise Uncertainty Propagation and Dimensional Stability Assessment in CNC-Turned Components Using Manual and Automated Metrology Systems |
| title_fullStr | Zone-Wise Uncertainty Propagation and Dimensional Stability Assessment in CNC-Turned Components Using Manual and Automated Metrology Systems |
| title_full_unstemmed | Zone-Wise Uncertainty Propagation and Dimensional Stability Assessment in CNC-Turned Components Using Manual and Automated Metrology Systems |
| title_short | Zone-Wise Uncertainty Propagation and Dimensional Stability Assessment in CNC-Turned Components Using Manual and Automated Metrology Systems |
| title_sort | zone wise uncertainty propagation and dimensional stability assessment in cnc turned components using manual and automated metrology systems |
| topic | measurement uncertainty error propagation CNC machining coordinate measuring machine digital vernier caliper dimensional stability |
| url | https://www.mdpi.com/2075-1702/13/7/585 |
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