Dimensional Accuracy and Measurement Variability in CNC-Turned Parts Using Digital Vernier Calipers and Coordinate Measuring Machines Across Five Materials

Abstract

Attaining dimensional accuracy in CNC-machined parts is essential for high-precision manufacturing, especially when working with materials that exhibit varying mechanical and thermal characteristics. This research provides a thorough experimental comparison of manual and automated metrological systems, specifically the Digital Vernier Caliper (DVC) and Coordinate Measuring Machine (CMM), as applied to five different engineering alloys through five progressively machined axial zones. The study assesses absolute error, relative error, standard deviation, and measurement repeatability, factoring in material hardness, thermal conductivity, and surface changes due to machining. The results indicate that DVC performance is significantly affected by operator input and surface irregularities, with standard deviations reaching 0.03333 mm for Bronze C51000 and relative errors surpassing 1.02% in the initial zones. Although DVC occasionally showed lower absolute errors (e.g., 0.206 mm for Aluminum 6061), these advantages were countered by greater uncertainty and poor repeatability. In comparison, CMM demonstrated enhanced precision and consistency across all materials, with standard deviations below 0.0035 mm and relative errors being neatly within the 0.005–0.015% range, even with challenging alloys like Stainless Steel 304. Furthermore, a Principal Component Analysis (PCA) was conducted to identify underlying measurement–property relationships. The PCA highlighted clear groupings based on sensitivity to error in manual versus automated methods, facilitating predictive classification of materials according to their metrological reliability. The introduction of multivariate modeling also establishes a new framework for intelligent metrology selection based on material characteristics and machining responses. These results advocate for using CMM in applications requiring precise tolerances in the aerospace, biomedical, and high-end tooling sectors, while suggesting that DVC can serve as an auxiliary tool for less critical evaluations. This study provides practical recommendations for aligning measurement techniques with Industry 4.0’s needs for accuracy, reliability, and data-driven quality assurance.