REVERSE ENGINEERING

Murad
 ?What is Reverse Engineering

 It’s a process of duplicating an existing component,

subassembly, or product.

 An activity you do to determine how a product

works.

 It’s also using various measuring devices.

 Learn the ideas and technology that were originally

used to develop the product.

 For simple part, it is easy to create a CAD file. But

for complex surfaces, it is nearly impossible.
 ?What can be used for

 Replicating parts that have no CAD data.

 Documenting existing architectural work.

 Documenting museum pieces.

 Crime Scene Investigation.

 Creating 3D data files of the human face.

 Medical Device.
Benefits

 Higher accuracy on complex surfaces

vs. hand measuring.

 Faster process compared to traditional

methods.

 Replicate existing geometry quickly

and inexpensively.
The Flow Chart of Reverse Engineering

Object

3D Scanning

Feature Detect Surface Reconstruct

CAE CAD modeling RP/RT

CAE
CAM

Manufacturing Process CNC

Products / Mould
3D scanner

Reverse Engineering of a mechanical component

requires a precise digital model of the objects to be
reproduced and that what can 3D scanner offer.

These data points are then processed to create a usable

digital model, usually using specialized reverse
engineering software (CAE).
 3D scanner

a device that analyzes a

real-world object or
environment to collect
data on its shape and
possibly its appearance
(i.e. color).
The collected data can
then be used to construct
digital three dimensional
models.
Technology
 Laser triangulation (Faro Arm)

 Time of flight laser scanners

 Phase shift laser scanners

3D scanner areas
 Human body scanner.

 Industrial tracking.

 Building measurement.

 Medical applications.
Computer Aided Engineering (CAE)

CAE is the software that analyzes designs which have

been created in the computer or that have been
created elsewhere (3D scanning) and entered into
the computer.
CAE areas
 Stress analysis on components and
assemblies using FEA (Finite Element
Analysis).

 Thermal and fluid flow analysis

Computational fluid dynamics (CFD).

 Mechanical event simulation (MES).

Benefits of CAE
 Easy of testing, analyzing and
optimizing the design consistently.

 Design confidence knowing that the

product will meet performance
requirements before it is built.

 Design optimization versatility cost,

quality, or reliability.
Computer-aided manufacturing (CAM)

CAM is a programming tool that makes it possible to

manufacture physical models using computer-aided
design (CAD) programs.

 Faster production .
 Precise dimensions .
 Uses only the required amount of
raw material (minimizing waste).
Computer-aided manufacturing (CAM)

CAM Steps Typical areas of concern

 Define Material .  High Speed Machining,

 Define Stock Size. including streamlining of
tool paths.
 Define Coordinates.
 Define Tool .  Multi-function
 Define Feeds and Machining.
Speeds.
 Simulate Machining .  5 Axis Machining.
Rapid Prototyping

Today, The Rapid Prototyping are

used for a much wide range of
applications and are even used
to manufacture production-
quality parts in relatively small
numbers (prototype).
 Rapid Prototyping

 Stereo lithography (SLA)

 Fused Deposition Modeling

(FDM)

 Selective Laser Sintering

(SLS)
MANUFACTURING PROCESS
 Casting

 Turning

 Grinding

 Milling

 Shaper

 Forging
Computer Numerical Controlled (CNC)

In Industry it is not efficient or

profitable to make everyday
products by hand.
On a CNC machine it is possible
to make hundreds or even
thousands of the same item in a
day.
Computer Numerical Controlled (CNC)

How CNC machine work:

CNC run on G-Code, This code is made up of
commands that tell the mill how to cut your part.
Example (Turbine Blade)
Example (Turbine Blade)
3D Scanning

Feature

Name Faro arm Konica Minolta Z scanner 600 Z scanner 800

VIVID 9i

Accuracy Up to 35 microns Up to 50 microns Up to 80 microns Up to 40 microns

Resolution - - 0.1 mm in Z 0.05 mm in XYZ

Example (Turbine Blade)
CAE:
 We use finite element method by Ansys or

other program to find the stress in the part

and modified it.
 Also we use thermal and fluid flow analysis

Computational fluid dynamics (CFD) .

Rapid prototyping:
 Selective Laser Sintering (SLS)

 Fused Deposition Modeling (FDM)

 Stereo lithography (SLA)

Example (Turbine Blade)
There is many type of manufacturing process can be
used :

Manufacturing process Cost Quantity Quality

Casting low high low

Forging medium low low

Forming high low low

CNC* high high high

Example (Turbine Blade)