Re PDF

REVERSE ENGINEERING
Session delivered by:

Mr. Balappa .B.U
M.S. Ramaiah School of Advanced Studies, Bengaluru
Session Objectives:
On completion of this session, the student would have
understood
Importance of Reverse Engineering in CAD
applications
Techniques used for scanning, processing of the
data and generating CAD models alongwith their
applications
2
Challenges Faced by Manufacturers today...
Reduce manufacturing cycle time

Increase productivity
Reduce cost
Improve product quality
Better customer service support
Flexible in accepting changes
CAD/CAM is the one of the major solution for

many such issues
3
What is Reverse Engineering (RE)?

It is a process of generating engineering design data from existing
components
CARE Computer Aided Reverse Engineering

4
Reverse Engineering
Reverse engineering transforms real parts into engineering
models and concepts
Reverse engineering provides techniques for capturing and
representing physical models of products as tri-dimensional
data in a computer
Old form of reverse engineering includes manually measuring
of the part (using calipers, measuring gauges), copying
information from drawings, or both.
This process is more of an approximation and time consuming
and advanced techniques are employed today
5
Why the need for Reverse Engineering?

CAD models are often unavailable or unusable for parts which must
be duplicated or modified:
CAD not used in original design

Inadequate documentation on original design
Original CAD model not sufficient to support
modification or manufacturing using modern methods
Original supplier unable or unwilling to provide
additional parts
Shop floor changes to original design
To reproduce complex free form surface
Broken or obsolete part
Aesthetics in design
6
Traditional vs. RE Design Process
7
Applications of Reverse Engineering
Tool and die making

Mould making
Press tools
Aerospace and automobile Industry
Jewelry and artistic work
Or where ever there is a need to produce
free form surfaces
8
Legal Aspects of Reverse Engineering

What is the effect of copy rights act on Reverse
Engineering ?
9
Objective of Reverse Engineering

The objective of reverse engineering is to increase the ability
to maintain a manufacturing capability at its peak rate by
improving documentation for logistically unsupported
equipment and systems
Reverse engineering should not be confused with system
modernization, which involves technological upgrade of an
entire system to eliminate many portions of a current
manufacturing system
Reverse engineering is targeted at modernizing singular
components of a system to maintain or increase system
productivity
10
Typical Design Process

Idea
Concept
design
Detail design
CAD / CAM
CNC programme
Manufacturing
Finished product
11
The Reverse Manufacturing Process

Start
Idea
Concept
design
Detail design
CAD / CAM
CNC programme
Manufacturing
Start
Finished product
Reverse
Manufacturing
12
The Reverse Engineering Process

Start
Idea
Concept
design
Detail design
CAD / CAM
CNC programme
Reverse
Engineering
Manufacturing
Start
Finished product
13
Reverse Engineering Process

Reverse engineering usually consists of four stages:
Data evaluation
Data generation
Design verification
Design implementation
A reverse engineering process identifies and strengthens the

weak links in any system
New documentation support for equipment and improved
system maintenance are important byproducts of the reverse
engineering processes
14
Reverse Engineering Methods (1)

Scanning
It is the process of gathering information about an undefined 3D
surface and digitizing it
Types of Scanning:
Contact Type
Non-Contact Type
The Physical part is scanned and the cloud point data with millions of
points is acquired.
The cloud point Data is converted into a Polyganized data set, of tiny
facets.
NURBS Surfaces are created and the geometry can be exported to any
CAD, CAM and RPT Software.
15
Reverse Engineering Methods (1)
Non-contact, 3D laser scanning

Converts scanned data into
polygon and NURBs surfaces
Exports in STL, DXF and IGES
file formats for industry standard
3D CAD and solid modeling
software
Large scanning area -- up to
406.4mm (16") high x 254mm
(10") in diameter with a
resolution of 200 microns
Dual modes -- offers both rotary
and plane scanning for optimum PICZA LPX 250 Laser Scanner
performance
16
Reverse Engineering Process
17
Scanning
Scanning (digitizing) is a method of
gathering information about an

undefined two-dimensional or threedimensional shape.
The captured data can then be used
to create NC part programs or CAD
outputs.
18
Sensors
Touch-trigger digitizing
Analogue scanning
Laser scanning
Camera systems
19
Sensors
Touch-trigger probes
Advantages :-
Very accurate
Low cost
Low trigger force
Disadvantages : Slow data acquisition
20
Sensors
Analogue probes
Advantages : Accurate
Fast data stream
High density data capture
Disadvantages : Probe may deflect
around a feature
21
Sensors
Laser scanners
Advantages : Fast data capture
Non-contact
Soft material
Disadvantages : Limited Z range
Reflective surfaces
Fixed pitch
Vertical faces
22
Coordinate Measuring Machine
Granite Base
Cross Bar
Probe Mounting Assembly
Computer Interface
Quality of CMMs
Resolution
Repeatability
Accuracy
Linearity
23
Coordinate Measuring Machine

DEA
Gantry
CMM
powered by Virtual DMIS
software
It provides for the needs of
the
aerospace
and
automotive industries with
its ability to generate
inspection points from
CAD
imported
part
surfaces
24
Capture Devices
CMM
Advantages : Machine may have spare capacity
Large scanning area
Machine tool released for cutting
Very accurate
Disadvantages : Slow data capture
Few CMMs have scanning
capability
25
Capture Devices
Scanning machine
Advantages : Fast data capture
Small styli - fine detail
Contact / Non contact
adaptability
Leaves machine tool for
cutting
Purpose built for scanning
Disadvantages : Limited working range
Limited to data digitizing 26
Touch-trigger Probe Digitizing
Available on a range of controllers
Performance 100 - 300 mm/min

3-5 points per second
27
Integrated Scanning Systems
Selca
Fagor
NUM
Heidenhain
Performance 1000 - 3000 mm/min
Up to 750 points per second

28
29
Limitations of Scanning Systems

Limitations of Contact Type Scanning
Probe itself
Vibration, Humidity, Heat and other
environmental conditions
Accuracy
Non Contact Methods
Machine Vision
Laser Probing
MRI ( For Non Metallic Objets )
ERI ( For For Metallic Objects )
30
3-D Scanning
Model of surface
Dot cloud
3-D Scanner
31
3-D Scanning
Standard Tripod
Scanner Head
32
3-D Scanning
33
Software Used for Reverse Engineering
CopyCAD
HighRES, Inc.
PolyWorks
RevEng
RevWorks
Alias|Wavefront
3D RESHAPER
Imageware
RapidForm
34
Example...
35
Example...
36
Example...
37
Data Capture
Scanning methods
Data presentation
38
Scanning Methods
Parallel scanning X or Y
Angular scanning
Radial scanning
Scanning within a polygon
39
Scanning Methods
Single 2D profile
Multiple 2D profiles
40
Scanning Methods
Captured 2D profile
for use in developing
scanning strategies
41
Scanning Methods
42
Scanning Methods
X axis
Y axis
Grids defined to suit part geometry

User defined stepover
Data density automatically controlled
Scanning speed automatically controlled
Unmanned operation
Any angle
Radial
Polygonal boundary
43
Automated Part Inspection
44
Automated Verification
45
Reverse Engineering - Woodworking
46
Data Processing
Data manipulation
CAD outputs
Machining path output
47
Data Manipulation
Male / female
inversion with a mirror
about the Y axis
48
Data Manipulation
Scale / Rotate / Mirror

49
Data Manipulation
Scale / Translate / Merge

50
Machining
51
Applications
Automotive
Bottles and closures
Chocolates and confectionery
Coins and securities
Footwear
Jewellery / Giftware
Medical
Packaging
Pattern making
Rapid prototyping
Toys
52
Steps Involved in Reverse Engineering

Step 1: The physical part is scanned using any scanning methods to
acquire the surface topography. This output is typically a
point cloud data set containing millions of points
Object is scanned
Point Cloud is product
53

Step 2: The point cloud set is converted to a polyganized data set,
consisting of millions of tiny facets. At this stage the polygons
can be manipulated to improve the surface finish or to
add/remove existing features
Polygon and Nurbed

model is produced
54

Step 3: Finally NURBS (Non Uniform Rational B-Splines) surfaces
are added to the polyganized model. This results in a watertight
surface file. The geometry can be exported to any CAD, CAM and
rapid prototyping Software. This file can also be converted directly to
a parametric Solid works or Pro-E file
Polygon model ports to

produced digital manufacture
Nurbs surface ports to CAD and CAM55
Example...
Step 1: A cloud of points taken from scanned data using a digitizer

such as a laser scanner, computed tomography, or Faro arms.
56
Example...
Step 2: Convert the point cloud to a polygonal model. The resultant

mesh is cleaned up, smoothed, and sculpted to the required shape and
accuracy.
57
Example...
Step 3: Draw or create curves on the mesh using automated tools

such as feature detection tools or dynamic templates
58
Example...
Step 4: Create a restructured mesh using semiautomatic tools

59
Example...
Step 5: Fit NURBS surfaces using surface fitting and editing tools
60
Example...
Step 6: Export the resulting final NURBS surface that satisfies

accuracy and smoothness requirements to a CAD package for
generating tool paths for machining
61
Example...
Step 7: Manufacture and analyze the part for physical, thermal,

and electrical properties
62
Case Study: Duplication of Existing Tool

with CARE
Part
Surface Model
Tool
Scanned Data
63
Free Form Surface Modeling using RE
64
65
66
Mockup of a Fuel Tank for a

sport
Vehicle made in wood and clay
67
Point Cloud Data

68
Final Output as a 69Surface File given to Customer

Applications of Reverse Engineering

Medical
Hip ball
93,414 points
Time 44mins
Hip socket
374,061 points
Time 3hr. 45mins
70
Applications
Medical
Scan time 4hr. 7min.

206,495 data points
Scanning strategies
Stylus 0.5mm ball
Stepover 0.05mm
Scanning speed 1000 mm/min.
Scanning deflection 0.2mm
71
Applications
Jewellery
+
Icon and frame

scanned, scaled and
joined
Rendered image of
joined model
2,631,058 data points

Machined sample
inverted and mirrored
72
Applications
Shoes
240,313 data points

327,131 data points
Automatic split line

generation from
captured data
Cyclone indexer
used to capture
data from both
sides of the master
73
Applications
Shoes
Scanning strategies
Stylus 1.0mm ball
Pitch 3mm
Stepover 0.1mm
Scanning speed 1000 mm/min
Scanning deflection 0.2mm
Scanning time 8hr. 46min
790,276 data points
74
Session Summary
The importance of reverse engineering in CAD
environment was discussed
The various techniques used for scanning were
briefed
The importance and methods of processing data
obtained through reverse engineering were
explained
The methods for generating CAD models from
reverse engineering were discussed along with
their applications
75

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REVERSE ENGINEERING

Session delivered by:

M.S. Ramaiah School of Advanced Studies, Bengaluru

Challenges Faced by Manufacturers today...

Reduce manufacturing cycle time

CAD/CAM is the one of the major solution for

What is Reverse Engineering (RE)?

CARE Computer Aided Reverse Engineering

Why the need for Reverse Engineering?

CAD not used in original design

Traditional vs. RE Design Process

Applications of Reverse Engineering

Tool and die making

Legal Aspects of Reverse Engineering

Objective of Reverse Engineering

Typical Design Process

The Reverse Manufacturing Process

The Reverse Engineering Process

Reverse Engineering Process

A reverse engineering process identifies and strengthens the

Reverse Engineering Methods (1)

Reverse Engineering Methods (1)

Non-contact, 3D laser scanning

Reverse Engineering Process

gathering information about an

Disadvantages : Slow data acquisition

Coordinate Measuring Machine

Coordinate Measuring Machine

M.S. Ramaiah School of Advanced Studies, Bengaluru

Touch-trigger Probe Digitizing

Available on a range of controllers

Performance 100 - 300 mm/min

M.S. Ramaiah School of Advanced Studies, Bengaluru

Integrated Scanning Systems

Performance 1000 - 3000 mm/min

Up to 750 points per second

M.S. Ramaiah School of Advanced Studies, Bengaluru

Limitations of Scanning Systems

Non Contact Methods

Software Used for Reverse Engineering

Grids defined to suit part geometry

Automated Part Inspection

Reverse Engineering - Woodworking

Scale / Rotate / Mirror

Scale / Translate / Merge

Steps Involved in Reverse Engineering

Point Cloud is product

Steps Involved in Reverse Engineering

Polygon and Nurbed

Steps Involved in Reverse Engineering

Polygon model ports to

Nurbs surface ports to CAD and CAM55

Step 1: A cloud of points taken from scanned data using a digitizer

Step 2: Convert the point cloud to a polygonal model. The resultant

Step 3: Draw or create curves on the mesh using automated tools

Step 4: Create a restructured mesh using semiautomatic tools

Step 6: Export the resulting final NURBS surface that satisfies

Step 7: Manufacture and analyze the part for physical, thermal,

Case Study: Duplication of Existing Tool

Free Form Surface Modeling using RE

Free Form Surface Modeling using RE

Free Form Surface Modeling using RE

Free Form Surface Modeling using RE