PROJECT REPORT ON

REVERSE
ENGINEERING

GUIDE: PROF BISWANATH DOLOI

SUBMITTED BY
BIPLAB MONDAL
B.E. PRODUCTION ENGG.
ROLL: 001611701055
YEAR: 3 RD
SEM: 1 ST
 ACKNOWLEDGEMENT
The present paper on “REVERSE ENGINEERING” was undertaken as a part of completion of 3 rd year
term paper(at the end of five semester), under the guidance of Dr. BISWANATH DOLOI Department
of Production Engineering, at Jadavpur University. During this process valuable information was
gathered, which will hopefully be the basis for any future work on the reverse engineering. I wish to
express my gratitude to Dr. BISWANATH DOLOI who constantly guided me and provided me with
valuable inputs during the course of work.
 CONTENTS
1. INTRODUCTON
1.1. FUNDAMENTALS OF REVERSE ENGINEERING
1.2. NEED OF REVERSE ENGINEERING
2. FLOW CHART OF REVERSE ENGINEERING
3. DISCRETIZATION METHOD
3.1. CONTACT SCANNER
3.2. NON-CONTACT SCANNER
4. APPLICATION
5. ADAVANTAGES OF REVERSE ENGINEERING
6. SOME STUDIES ON REVERSE ENGINEERING
6.1. REVERSE ENGINEERING OF PLASTIC WASTE INTO USEFUL FUEL PRODUCTS
6.1.1. INTRODUCTION
6.1.2. MATERIALS AND METHODS
6.1.3. DATA ANALYSIS
6.1.4. RESULTS AND ANALYSIS
6.1.5. CONCLUSION
6.2. REVERSE ENGINEERING OF KAPLAN’S TURBINE BLADE FOR SMALL HYDROELECTRIC POWER
PLANT
6.2.1. INTRODUCTION
6.2.2. SCALED PHYSICAL MODEL OF TURBINE BLADE
6.2.3. RE OF TURBINE BLADES
6.2.4. CONCLUSION
6.3. IMPLEMENT OF REVERSE ENGINEERING FOR CRANKSHAFT MANUFACTURING
6.3.1. INTRODUCTION
6.3.2. OPTIMIZATION IN MATERIAL SELECTION
6.3.3. OPTIMIZATION IN WEIGHT REDUCTION
6.3.4. COST REDUCTION
6.3.5. CONCLUSION
6.4. REVERSE ENGINEERING TECHNOLOGY IN REDESIGNING PROCESS CERAMICS
6.4.1. INTRODUCTION
6.4.2. METHOLODOGY
6.4.3. RESEARCH FLOW CHART
6.4.4. ANALYSIS AND DISCUSSION
6.4.5. CONCLUSION
6.5. MANAGEMENT OF REVERSE ENGINEERING PROCESS IN THE PLASTIC INDUSTRY
6.5.1. INTRODUCTION
6.5.2. STUDY OF RE USED SOME TECHNIQUES
6.5.3. RE WITH EXAMPLE
6.5.4. RE PROCESS SELECT
6.5.5. COLCLUSION
7. CONCLUSION
8. BIBLIOGRAPHY
 1. INTRODUCTION
Nowadays reverse engineering is recognized as an important issue in the product design
process which highlights inverse methods, deduction and discovery in design. In mechanical
engineering, reverse engineering has evolved from capturing technical product data, and initiating
manual redesign procedure while enabling efficient concurrency benchmarking to a more
elaborated process based on advanced computational models and modern digitizing technologies.
Reverse engineering takes the facts we know about a device or a process and reasons backwards to
infer the principles underlying the structure–function relations. In today intensely competitive global
market, product enterprises are constantly seeking new ways to shorten lead times for new product
developments that meet all customer expectations. In general, product enterprise has invested in
CAD CAM, rapid prototyping, and a range of new technologies that provide business benefits.
Reverse engineering (RE) is now considered one of the technologies that provide business benefits
in shortening the product development cycle. Reverse engineering has been developed as an
alternative solution to define or redefine object. Nowadays, it is widely spread in the manufacturing
industry. It is used for the capitalization of information and knowledge. This is a critical issue for the
development and evolution of products.

1.1. FUNDAMENTALS OF REVERSE ENGINEERING

Engineering is the process of designing, manufacturing, assembling, and maintaining
products and systems. There are two types of engineering, forward engineering and reverse
engineering. Forward engineering is the traditional process of moving from high-level abstractions
and logical designs to the physical implementation of a system. In some situations, there may be a
physical part product without any technical details, such as drawings, bills-of-material, or without
engineering data. The process of duplicating an existing part, subassembly, or product, without
drawings, documentation, or a computer model is known as reverse engineering. Reverse
engineering is also defined as the process of obtaining a geometric CAD model from 3-D points
acquired by scanning/digitizing existing parts/products. The process of digitally capturing the
physical entities of a component, referred to as reverse engineering (RE), is often defined by
researchers with respect to their specific task. Reverse engineering is now widely used in numerous
applications, such as manufacturing, industrial design, and jewellery design and reproduction For
example, when a new car is launched on the market, competing manufacturers may buy one and
disassemble it to learn how it was built and how it works. In software engineering, good source code
is often a variation of other good source-code.
Software reverse engineering is done to retrieve the source code of a program because the source
code was lost, to study how the program performs certain operations, to improve the performance
of a program, to fix a bug (correct an error in the program when the source code is not available),
to identify malicious content in a program such as a virus or to adapt a program written for use with
one microprocessor for use with another. Hardware reverse engineering involves taking apart a
device to see how it works. For example, if a processor manufacturer wants to see how a competitor's
processor works, they can purchase a competitor's processor, disassemble it, and then make a
processor similar to it. However, this process is illegal in many countries.

1.2. NEED OF REVERSE ENGINEERING

I. The original manufacturer of a product no longer produces the product, but the customer
needs the product.
II. Inspection the product and eliminate the bad features of the product and improve its
quality.
III. In a manufacturing company, company’s aim to reduce manufacturing cost of the product
and make it competitive in market.
IV. Reverse engineering also use in architectural and construction engineering
(documentation and measurement)
V. It also use in designing of clothing, footwear and other daily uses.
VI. Generating data to create dental or surgical prosthetics, tissue engineered body parts, or
for surgical planning.
VII. Documentation and reproduction of crime scenes.

Reverse engineering begins with the product and work through the design process in the opposite
direction to arrive at a product definition statement. For example, when a new machine comes to
the market, competing manufactures may buy one machine and disassemble it to learn how it was
built and how it is works(Reverse engineering of mechanical parts involves acquiring 3-D position
data in the point cloud using laser scanners or computed tomography ). Similarly a chemical
company may use reverse engineering to defeat a patent on a competitor’s manufacturing process.
Similarly in civil engineering, bridge and buildings designs are copied from past successes so there
will be less chance of catastrophic failure. In software engineering, good source-code is often a
variation of other good source code
 2. STEPS OF REVERSE ENGINEERING
STEP-1 Representing geometry of the part in terms of surface points in the first step in creating
parametric surfaces patches.

STEP-2 A good poly mesh is created from the point cloud using reverse engineering software.

STEP-3 The cleaned-up poly mesh, NURBS (non-uniform-rational B-spline) curves, or NURBS
surfaces are exported to CAD packages for further refinement, analysis, and generation of cutter tool
paths for CAM.

STEP-4 Finally, the CAM produces the physical part.

Figure-1. Steps of Reverse Engineering

 3. DISCRETIZATION METHOD
This phase is involved with the scanning strategy–selecting the correct scanning technique,
preparing the part to be scanned, and performing the actual scanning to capture information that
describes all geometric features of the part such as steps, slots, pockets, and holes. Three-
dimensional scanners are employed to scan the part geometry, producing clouds of points, which
define the surface geometry. These scanning devices are available as dedicated tools or as add-ons
to the existing computer numerically controlled (CNC) machine tools. There are two distinct types
of scanner one is contact scanner and another is noncontact scanner.

Figure-2. Scanning Process

3.1. Contact Method
I. Requires contact between the component surface and a measuring tool.
II. Uses coordinate measuring machine (CMM-with a tolerance range of+0.01 to 0.02 mm.
However, depending on the size of the part scanned, contact methods can be slow because
each point is generated sequentially at the tip of the probe), electromagnetic digitizer or sonic
digitizers to get desired coordinates.
 3.2. Non-contact method
A variety of noncontact scanning technologies available on the market capture data with no physical
part contact. Noncontact devices use lasers, optics, and charge-coupled device (CCD) sensors to
capture point data. Although these devices capture large amounts of data in a relatively short space
of time, there are a number of issues related to this scanning technology.

I. Uses light as the main tool.

II. Uses white light or laser scanners to scan 3D objects to generate CAD design.

DRAWBACKS OF NON CONTACT METHOD

The main drawbacks of the noncontact method are: there are problems with the reflection of light on the
surfaces to be scanned. This is solved by applying a powder spray on the respective surfaces, which
reduces scanning accuracy. Also, this method is with a lower accuracy class than contact scanning on
CMM machines.
 4. APPLICATION
There are various application of Reverse Engineering those are in the field of Software, automobiles,
chemical engineering, civil, mechanical, medical science, garments etc.

MANUFACTURING FIELD
To create a 3D virtual model of an existing physical part for use in 3D CAM,CAD,CAE or other
software to analysis the working of a product.

MEDICAL FIELD
Imaging, modelling and replication (as a physical model) of a patient bone structure.

SOFTWARE ENGINEERING
To detect and neutralize virus and malware.

FILM ENTERTAINMENT
Animated objects are imparted motion using the reverse engineered human skeletons .
5. ADVANTAGE OF REVERSE ENGINEERING

I. CAD models are used for manufacturing or rapid prototyping applications.

II. Hence we can work on a product without having any prior knowledge of technology
involved.
III. Cost saving for developing product.
IV. Lesser maintenance cost.
V. Quality improvement.
VI. Competitive advantages.
VII. Increased productivity at lower costs.
VIII. Reproduce existing machine part or object efficiently & cost effectively.
IX. Faster time-to-market for your products.
 6. SOME STUDIES ON REVERSE ENGINEERING

6.1. Reverse engineering of plastic waste into useful fuel products

Prosper Achaw Owusua, Noble Banaddaa,b,⁎, Ahamada Zziwaa, Jeffrey Seaya,c,
Nicholas Kiggundua
6.1.1. INTRODUCTION
Plastics and their uses are part and parcel of modern daily life. The world’s annual consumption of
plastic materials was five million tonnes in the 1950’s. Currently, the global production of
polymeric materials has increased rapidly to 311 million tonnes [3]. The responsible for steady
growth of plastic materials are its low density, user-friendly and low costs.

6.1.2. MATERIALS AND METHODS

I. MASS BALANCE ANALYSIS

The mass analysis of this technology basically involves the conversion of waste plastics through
melting and cracking to produce liquid oil, gas and a solid residue. The estimation of yield of liquid
oil and solid residue fractions was based on mass. Total conversion in terms of percentage was
estimated using Eq. (1). The percentage yields of liquid product, solid residue and gaseous product
were calculated using Eqs. (2)–(4), respectively[4].

% conversion= (m-m2)/m*100………………. (1)

Liquid yield (L wt%)=m1/m*100……………..(2)

Char yield(C wt%)=m2/m*100……………….(3)

Gas yield (G wt%)=100-(L+C)………………..(4)

Where,

m=mass of sample feed (g)

m1=mass of liquid product (g)

m2=mass of solid residue/char (g)

II. Characterization of pyrolytic liquid fuel

The fundamental properties such as density, viscosity, distillation range of diesel fuels were analyzed
in this study.

 Density-Density measurement was determined according to ASTM 1298[5].The sample oil was
brought to a temperature of 15 °C. The sample was then transferred to a hydrometer cylinder
which was also brought to 15 °C. The hydrometer was then lowered into the test portion and
allowed to settle. Hydrometer reading was measured and recorded with the temperature at
equilibrium.
  Kinematic and dynamic viscosities-For viscosity determination, an approximately 10 mL of pyrolytic
sample oil was introduced into a viscometer (capillary tube). The viscometer was clean, dried and
previously calibrated. The capillary-tube was immersed in a thermostatic bath. The temperature of
the bath did not vary more than 40 ± 0.02 °C [6]. A vacuum pump was employed to draw sample
oil until it reached the upper meniscus in the viscometer tube after the stabilization of temperature
in the bath (approximately 40 min). A stop watch was used to count the flow time between the
upper and lower meniscus. After the determinability of the test of each sample, the kinematic
viscosity was obtained using Eq. (5) (ASTM D445) [7]. The average value of readings of time
was±0.20%. The dynamic viscosity was subsequently estimated using Eq.(6).

V=Ct…………………………………… (5)

Where,

v=kinematic viscosity (mm2/s)

C=viscometer calibration constant (mm2/s)/s

t=flow time (s)

η = ρv…………………………………….(6)

Where,

η=dynamic viscosity (mPa)

ρ=density (kg/L)

 Distillation-Distillation of the samples was performed in Herzog HDA-620 automatic

atmospheric distillation following ASTM D86 at ambient pressure [34]. For the procedure, 100
mL of pyrolytic liquid fuel was transferred to a distillation flat bottom flask. The distillation
flask was equipped with a thermocouple sensor. The flask was heated to keep a distillation
ratio of 4 mL/min and 5 mL/min [32,35]. The distilled sample was condensed and collected in
a measuring cylinder at room temperature. The distillation volume recovered at 250 °C, 350
°C and 365 °C together with initial and final boiling points were measured. The temperature
at which the first drop of distillate was observed was recorded as the initial boiling point (IBP,
°C) whereas the temperature at which all the oil sample in the distillation flask evaporated
was recorded as the final boiling point (FBP, °C). Also, distillation temperatures at recovered
volumes of 10%, 50%, 90% and 95% were recorded.

6.1.3. DATA ANALYSIS

Data collected were analyzed to determine the effects of various treatments on the yield of
product fractions using Microsoft Excel (2013 Edition). The analysis of variance (ANOVA) in
dependent variables among the treatments was carried out first to check for the significance of
treatments’ effects. All statistical tests were done at an alpha value of 0.05.
 6.1.4. RESULTS AND ANALYSIS
 Temperature Profile-

Temperature is considered to be one of the most important factors during the pyrolysis of plastic
waste since it dominates the cracking of the sample feed. The temperature variations in the reactor
with and without sample feed are, the temperature inside the reactor was comparatively lower than
the wall temperature during the first few minutes after the start of the experiment. This is because
the furnace had just heated up and the heat that reached the pyrolysis reactor was low. After 35 min,
higher rate of heat transfer occurred, where the wall and space temperatures of the pyrolysis reactor
reached 136.5 °C and 119.0 °C, respectively. The maximum temperature gradient (100 °C) was
observed after 70 min. The heating rate for the experiment was considered to be 15 °C/min. Constant
and early heating of sample feed was observed as compared to when the pyrolysis reactor was
empty which shows a delay in temperature increase at the heating zone of the pyrolysis reactor .

 Effect of silica-alumina catalyst on the yield of product fractions-

As can be inferred both polymer type and catalyst (both catalyst ratios) are significant factors
that affect the yield of liquid fractions. P-values of 0.0002 and 0.0405 were calculated for catalyst
and polymer types, respectively. Contrary, the production of gaseous fraction was greatly enhanced
when silica-alumina catalyst was added. Increasing the amount of catalyst (i.e. catalyst/feedstock
ratio of 1:10) results in an increase of gas production, but reduction of char formation is observed.
This is because when more catalysts are used the sample feed become overloaded. This means that
all the sample feed in the reactor get access to the surface of the catalyst resulting in fewer yields of
char. This result is consistent with other researchers which indicated that the presence of a catalyst
decreases the yield of char.

6.1.5. CONCLUSION
Thermal and catalytic reverse polymerization is attractive method of handling plastic waste. In the
experiment, a large temperature gradient was detected to exist between the reactor wall and inside
space of reactor. It was found that fast vaporization during cracking of HDPE in a continuous reactor
lasted for about five minutes (between 35th and 40th minutes). Based on these findings, the
presence of gas bubbles in the condenser can be used as an indicator to detect the beginning of
the cracking process.
 6.2. REVERSE ENGINEERING OF KAPLAN’S TURBINE BLADE
FOR SMALL HYDROELECTRIC POWER STATION
6.2.1. INTRODUCTION
In literature, results concerning the procedure of reverse engineering for the case of turbine blade
are available and we can divide following approaches.

i. Simulation or reconstruction of small turbine runners.

ii. Enhancing the accuracy of scanned surfaces.
iii. The static structural analysis materials at various centrifugal loads of blade.
iv. Validations of the new blade design, by similarity between original and reconstruction parts.
 Kaplan turbine
The Kaplan turbine is a propeller-type water turbine which has adjustable blades. It was developed
in 1913 by Austrian professor Viktor Kaplan, who combined automatically adjusted propeller blades
with automatically adjusted wicket gates to achieve efficiency over a wide range of flow and water
level.

Pros[8]-
a. Kaplan Turbines can achieve efficiency of up to 95%.

b. Can be implemented in low-head situations allowing for power plants at lower elevation.

c. Varying size of turbine and output allows for micro-hydropower plants instead of large dams.

d. Kaplan Turbines are relatively low cost due to the small size and low head requirements.

e. Dams build with the Kaplan Turbine design produces less environmental impact because of low
head requirements therefore the reservoir area would not be flooded as much as high head
dams.

Cons -
a. Often times, Kaplan Turbines are installed where fish migrations occur, and may potentially
affect their migration patterns and survival rates.

b. The high velocity of the turbine may cause leakage of oil based lubricant into the outlet
leading to pollution.

c. Due to the high discharge of the turbine, the water around the turbine can reach very low
pressure making the Kaplan turbine vulnerable to cavitation.

These advantages of Kaplan turbine are the primary reason for choosing this type for small
hydroelectric project .
 6.2.2. SCALED PHYSICAL MODEL OF TURBINE BLADES
The scaled turbine model was manufactured in the early 70's and, as expected, there is no computer
model of these blades. There were 6 blades and one drawing with incomplete data for control of
geometry, Fig. 4. The drawing clearly indicates that the blade geometry control was performed in 6
cylindrical sections, indicated 1-2-3-4-5-6 on the Fig. 4 which were intersected with 6 directions
indicated A-B-V-G-D-E o n t he Fig.4, originated from the centre of the sphere. The positions of the
control points X, Y are clearly defined, but the third coordinate on the pressure side ZP and the
coordinates on the suction side ZS is not defined by this control drawing.

Figure-3. Model of Turbine Blade

6.2.3. RE of Turbine Blades – Related Works-

In this paper, the goal is to create a new blade with milling. Defined necessary RE steps (point cloud,
boundary curve, solid model) do not indicate the specificity of the entire class of problem. First step
of the process is scanning the part and generating a points cloud; second step is merging and
aligning the CAD model and scanned model. The third step is deviation calculation between the two
computer models from the second step. In order to get a valid computer inspection, it is necessary
to separate the errors of the shape and the error of the position. This is the only correct way of RE
of the blade. The redesign of the blade must be carried out in such a way that the blade is designed.

Figure-4. Cylindrical Section: Suction Side (s); Pressure Side (p)

  WORK COORDINATE SYSTEM SETTING
The first step in the blade redesign is an alignment of working coordinate system according datum
features. The blade is scanned in an arbitrary coordinate system, its position and orientation is not relevant
for further work. This step is critical because it will determine the exact position of the boundary entities.
The old drawing defines the position of the coordinate system but does not clearly indicate which surfaces
are the reference (datum plane, datum axis). Errors made at the very beginning, run through the entire
process, leading to the final product. Errors made initially cannot be corrected later, they become
systematic errors.

 PRESSURE AND SUCTION SIDE RAPID SURFACING

Redesign process has been carried out in two basic steps:

(1) Rapid surfacing: base for cylindrical section.

(2) Detailed surface meshing; leading edge smoothing, trailing edge modification to make tangency with
boundary plane, trimming to boundary sphere and hub, filleting, reflection analysis and back if necessary.

 TRIMMING LOWER SIDE OF THE BLADE

Before determining the trimming limit, the blade is scaled to the boundary sphere diameter of 310mm as
defined by the design requirement. The maximum angle of rotation of the blade is 10 degrees, and for
this reason the boundary angle defining the trimming limit set to 12 degrees.

Figure-5. (a) New Boundary Sphere Dia. 310mm; (b) Limit of Angular Position

The lower side of the blade is trimmed exactly to the hub for this position of 12 degrees. This provides a
gap between the blade and the hub for all angles of rotation less than 12 degrees. Practically, the blade
should not rotate more than 10 degrees because of risk of encroachment.
  Smoothness Verification
The final check of the reverse design of the blade involves checking the smoothness of the surface of the
pressure and the suction side. Reflection give quick visual feedback as to the quality of the surfaces, surface
irregularities and discontinuities will be readily apparent .

6.2.4. Conclusion
In this paper, we showed RE application in small turbine blade modelling as a novel concept by scale.
Geometric reverse engineering has been extended to capture the shape essence of the physical product,
manufacturing processes as well as digital product within a lifecycle perspective. Shape segmentation and
shape/feature recognition are fundamental problems in shape processing for geometric reverse
engineering in this case. Through the discrete curvatures, a novel framework has been proposed and
successfully tested on turbine blade.

The limitations of these methods were considered and compared with other approaches. Foremost
among these limitations are:

a. non-smoothness of the boundaries of the shapes,

b. sampling from rough surfaces,

c. lack of external source of information and knowledge.

Future work in this subject will be:

a. data mining for shape generation, and

b. RE topology optimization by additive manufacturing.

 6.3. IMPLEMENT OF REVERSE ENGINEERING FOR CRANKSHAFT
MANUFACTURING
6.3.1. INTRODUCTION
 Reverse Engineering- Reverse engineering is a new concept that donates the process of generating
engineering design data from the existing components. Reverse Engineering describe the
interrelationships between the components and create representations of the system in a new
modified for (reduce the error). Reverse Engineering is having applications in the following fields
like software engineering, automotive, consumer products, microchips, chemicals, electronics, and
mechanical designs.
 Measurement using CMM- The crankshaft material which selected doesn’t have accurate data.
Hence, in this work RE method has been used to obtain the preferable data. A complete data of
the product must be built in order to represent the CAD model. The crankshaft consists of different
geometric proportions since they are very intricate in dimensions the CMM requires to handle the
parts with greater accuracy. The cloud points are carried in CMM were to be noted. These points
should be noted as minimum as possible. Normally the crankshaft of different formation. They
have circular, cone and more complex shapes in order.

6.3.2. OPTIMIZATION IN MATERIAL SELECTION

Crankshaft is a large component with a complex geometry in the engine, which converts the reciprocating
displacement of the piston to a rotary motion with a four link mechanism. Since the crankshaft experiences
a large no of load cycles during its service life fatigue performance and durability of this component has
to be consider in this design process. Design developments have always been an important issue in the
crankshaft production industry, in order to manufacture a less expansive component with the minimum
weight possible and proper fatigue strength and order to functional requirements.

According to crankshaft in engine possess some uniform pressure on the bearing during compression
stroke it possesses a 3.5 MPa of uniform pressure due to connecting rod on the top of bearing. This is
analysed with help of ANSYS and the total deformation is obtained for three different materials. These are
obtained by fixing the lower portion of the crankshaft while pressure is exerted on top of bearing. There
is no change in the dimensions acquired using CMM. The dimensions are same for a three different
materials hence the component is modeled using CATIA. The static structural analyses are carried for three
different materials.

After comparison of three different materials the forged steel has been selected as a feasible material.
Thus forged steel is selected as a feasible material. Further optimization is carried in the material by
reducing its weight to 18%. The weight reduced component is also checked for durability, performance
and efficiency.
 6.3.3. OPTIMAZATION IN WEIGHT REDUCTION
The main objectives were reducing the weight and manufacturing cost while improving or maintaining
the fatigue performance of the original component. In addition, the bending stiffness has to be kept within
permissible limits. The optimization carried out in this work was not based on only the typical geometrical
optimization techniques. . Several cases of geometric modifications were considered. Weight reduction is
carried in bearing by reducing the diameter so that the material is reduced at some extent. . For further
optimisation material from crank web thickness is removed. A significant percentage of the weight in the
crankshaft is in the crank counterweight or web mass. Therefore, reducing the weight of this section could
result in an improvement in weight reduction of the component. Hence there is some changes in
geometrical dimensions and the component is remoulded once again using CATIA see table 1(Data
collected from paper).

S. no Title Existing dimensions Optimized dimensions

1 Shaft diameter 40mm 35mm
2 Two rectangular slots - 10,20mm
3 Drill hole 15mm Extended to 7mm

Table 1. Geometric optimisation of crankshaft

The drill hole is extended in order to withstand the balancing counter weights due to weight reduction.
These modifications reduce the weight of the original crankshaft by 18%. The final optimized geometry is
modeled. It should be noted that the fatigue strength of the optimized crankshaft is significantly higher
than the original crankshaft due to a slight increase in the stress range of 7% at the fillet and a significant
increase on the order. After weight reduction the feasible material which we found that forged steel is
suitable for better performance and durability after comparison with different material is considered here.
Thus same ANSYS operations were carried out after weight reduction is done on forged steel material.
Thus the results are calculated and tabulated. Thus the values obtained after weight reduction is compared
to the previous material comparison in order to check whether the deformation is within permissible limits.
These values were tabulated in table 2(Data collected from paper)

S no Title Cast iron Aluminum alloy Forged steel

1 Total deformation 1.6304e-3mm 3.888e-3mm 1.2543e-3mm
2 Shear stress 5.4711Mpa 6.024 Mpa 5.1048Mpa
3 Shear strain 8.3675e-5 6.9967e-5 6.0056e-5
Table 2. Comparison after weight reduction

Thus comparing above results the feasible material after weight reduction is doesn’t very much in their
performance, efficiency, and durability. Thus forged steel is suitable material for crankshaft.
 6.3.4. COST REDUCTION
The material’s alternatives for the automotive crankshaft is based on manufacturing economics. Steel
forging, nodular cast iron, micro-alloy forging, and austempered ductile iron casting are considered as
manufacturing options to evaluate the cost effectiveness.. They concluded that the production volume of
the crankshaft and the requirements of the engine are predominant 34 factors in cost effective production
route for this application. If the design requires better mechanical properties, then other alternatives must
be considered.

At production volume above 200,000 parts/year, micro-alloyed steel forgings offered the most cost
effective high performance crankshaft. They attributed this to the die and machining tool lives, which are
improved for the micro-alloyed steel forging, but at lower than 200,000 parts/year production volume the
cost savings obtained do not compensate for higher raw material cost of the micro-alloyed forged steel.
ADI crankshafts were cost effective at low production runs (below 180,000 parts/year). Sensitivity with
respect to volume production was evaluated. Based on their assumptions, raw material was about 30% of
the final cost, whereas, machining cost was 47% for the forged steel crankshaft. The raw material cost of
the micro-alloyed steel forging crankshaft was 38%, which is higher than that of forged steel, but the
machining percentage cost was 43% which reduced the cost of the final component. In addition, the heat
treatment process was eliminated for the micro-alloyed steel crankshaft, which was 3.5% of the final cost
of the forged steel, resulting in further final cost reduction.

6.3.5. CONCLUSION
1. The crankshaft is normally manufactured from cast iron, where as in our study three different materials
which possess different properties are selected and they are simulated in ANSYS for structural analysis.

2. Thus the structural analysis gives detailed study about those materials and their deformation and stress
and strain factors. The durability and performances of each material is found out.

3. Thus forged steel is selected as a feasible material, further optimization is carried in the material by
reducing its weight to 18%. The weight reduced component is also checked for durability, performance
and efficiency.
 6.4. Reverse engineering technology in redesign
process ceramics: application for CNN plate
Paulus Wisnu Anggoro*, Baju Bawono, Ivan Sujatmiko
6.4.1. INTRODUCTION
Ceramics are generally made by taking mixtures of clay, earthen elements, powders, and water and
shaping them into desired forms. Once the ceramic has been shaped, it is fired in a high temperature
oven known as kiln. PT. Doulton Indonesia is a manufacturing ceramics tableware industry for international
brand PT. Doulton Indonesia produced tableware with 3 kinds of body, there are Bone China body, Ivory
body, and Earthenware body. Bone China body is ceramics material that include bone ash in the mixtures,
the colour is white and semi transparently. Then Ivory body is ceramics material has light yellowish colour
and Earthenware body is a traditional ceramics material has brownish colour. In the mid of 2013 Research
and Development (R&D) from PT Doulton Indonesia tried to developing a new ceramics body that looks
like Bone China body but not using Bone Ash Materials, the name is Low Sag body. This new body have
two objectives, first for efficiency material because this material not using Bone Ash (Bone Ash material is
quite expensive). The second, is for efficiency setter because this material is more-stronger than bone
china, so when firing this material not using setter and not deformed too much.

6.4.2.METHOLODOGY
Reverse engineering is to extract the data generation pattern, remanufactured product from the parts or
raw mode. Reverse engineering is methods in a design products, this method is usually used to design
and to modify a product based on existing products. Reverse Engineering Method needs equipment such
as 3D scanner and CMM (Coordinate Measuring Machine) to catch data, and change physical data to
electronic data that can be processed in software CAD.

I. CMM (Coordinate Measuring Machine): CMM is actually a machine to measure an item with
precision, CMM consists of 3 axis motors auto detection and a probe as sensors that receive data
from the outside. The touch results from probe will be shown in the form of point cloud that would
form a line. With the CMM Machine, make it easier to drawing in 3D Software because we have a
pattern of shape as a reference.
II. 3D Scanner: 3D scanner is a tool that used to capture shape into forms STL file/ mesh. With 3D
scanner makes it easier for us in the process to drawing in 3D software and ensure what we draw
same like the product that we want to copycat.
6.4.3. RESEARCH FLOWCHART






 





 















 6.4.4.ANALYSIS AND DISCUSSION
Item CNN Plate diameter 220 mm as pilot item for Low Sag Body Project, we must make the clone with
the different material and treatment. Different of treatment between bone china body and low sag body
is on firing method, if bone china body is using set up process when firing, but low sag body item in
condition don’t use set up process when firing.

Figure-6. Original shape CNN plate 22cm with bone china body

First trial we tried to using existing (original) model CNN plate 22cm but with low sag body, after firing
clay get deformed in the rim section. The rim are dropped because clay structure not more strong when
get pressure in the high temperature. So we must design the movement of clay structure when firingto
get the new model for low sag body same like original model. With Reverse Engineering Technology we
can take CAD data from trial result easily and compare it with standard piece model. The output scanning
from CMM Machine is point cloud, then many point cloud must be processed using CAD software. Many
point cloud become base construction of shape the model, so we just follow the point cloud to get 2D
sketch model. After we get 2D sketch model of trial result then we compare it with 2D sketch the original
model. When we compare it, there are different model between original model and trial result model.
And then we analyse how far the dropped movement from the rim, and we get value about 8.92 degrees.

Based one analyse result, we decide to redesign clay model. The improvement for new design at the rim
section, rim of plate are spring about 9 degrees. The purpose is to make rim droped at the right place
when firing, make the Low Sag model same like Bone China model.

Figure-7.Comparing shape between trial result vs standard piece (original shape)

Next step we trial with clay model spring 9 degrees, the biscuit result for this trial is good. Some sample
same like with standard piece. But the effect firing with out setter still giving negative effect, many sample
are crooked at the rim after checked by Quality Control team. Crooked is kind of ceramics defect, the
edge of rim become weavy and make plate not tidy when stacking. This defect is effect from firing
condition, clay structure is not strong when firing in the high temperature and make some section at the
clay are deformed. To decrease potentially for crooked, we redesign clay model.

Then the new trial result we scan using CMM machine to get overall shape and dimension. Based on CMM
result, the writer redesign again the clay model, in the edge of the rim and made roll shape to give clay
structure more strength and keep clay structure not deformed when firing.

6.4.5.CONCLUSION
The output from this research is a new design model, mould as master mould, and biscuit prototype of
item CNN plate diameter 220 mm that have roll edge shape. The roll edge shape giving more strength
to structure of clay, to keep clay not deformed too much when firing in high temperature. With Reverse
Engineering, experimental time to build this research can reduced if compared with forward engineering
(conventional) method. So, the experimental cost for this research more-cheaper.
 6.5. Management of the reverse engineering process in
the plastics industry
6.5.1. INTRODUCTION
For the plastics industry, the RE process relies heavily on contact-type and noncontact Reflective / Optical
/ Active equipment.

6.5.2. STUDY OF REVERSE ENGINEERING AND SOME

TECHNIQUE-
 Polygonal modelling-
The first stage in the RE process consists in transforming point clouds into a polygon mesh. The
mesh object is obtained by sophisticated techniques, which involve point smoothing and cloud
sampling based on curvature. The object thus obtained becomes as close as possible to the real
object. In some cases, the RE process stops here because from the polygon mesh the part can be
obtained using CNC technologies or 3D printers. However, for plastic parts where the mould is
intended to produce the piece, the precision of the polygon mesh is not sufficient.
 Surface modelling-
Unlike a CAD application, in RE software there is 3D modelling tools for polygonal models. The
simplest, fastest and intuitive method that converts the polygon model into 3D surfaces is the ability
to fit a network of NURBS surfaces over a polygonal model built from digitized point clouds. These
NURBS patches are used to control the fitting to continuously join and obtain a complete surface
– G2, G1, or G0 continuity control over NURBS patch boundaries.
 Solid modelling-
The RE process using a dedicated solid model application consists in extracting features from
the polygon or point cloud model. Sometimes, it not even need point cloud, only a few points are
drawn on the surface of the piece and the feature is built like in any CAD application: a work plane
is selected, then lines, arcs, and other geometric elements are created. The parametric sketches
are then transferred to the solid CAD modeler by using add-ins (for SolidWorks, CATIA, NX, Creo
etc). The solid thus obtained is error free, all exterior surfaces are closed, and can be very well
machined on CNC machines.

6.5.3. REVERSE ENGINEERING WITH EXAMPLE

In the example below, the task was to perform the RE process for the door lock hole of an electric
cabinet. The geometry of the piece can be seen very well in Figures 3 and 4. The mold making this
product is over 30 years old. The company that makes the plastic parts still has a market for this
product, but due to the wear of the mold, the manufactured parts have a large number of scrap.
 Figure-8.The door lock hole of an electric cabinet-- the lower part geometry

For CAD, the SolidWorks application was chosen. As mentioned, the RE process was accomplished in two
ways: (i) complete scanning of parts and obtaining a cloud of points with Creaform scanner, and (ii) 3D
measurement / modelling with FaroArm.

6.5.4. REVERSE ENGINEERING PROCESS SELECTION

To compare the results of the RE process for the previously presented parts, we have prepared the matrix
of desired system attributes and their overall importance. In the literature, it is customary that the
importance of a particular attribute takes values between 1 and 5, where 1 means no importance and 5
means extremely important.

Table 1 presents the weighting grid for RE processes. In the RE 1 process, the 3D scanner was used, and
in the RE 2 process the polyarticulate arm was used. The RE 1 process used RE one software from the
above, the RE 2 process used the other software.
 Table-1
Importance of Score 1 Weighted Score 2 Weighted

feature Score 1 Score 2

Accuracy 5 3 15 4 20

Resolution 5 3 15 5 25

Measured 3 5 15 3 9
volume

Operator 3 5 15 2 6
ability

Time of data 3 5 15 1 3
collection

Cost and 2 1 2 5 10

maintenance

Inspection 4 3 12 5 20

module

5 2 10 4 20

RE module 5 4 20 4 20

Learning curve 3 2 6 5 15

Engineer skills 3 3 9 3 9

Time of RE 3 4 12 2 6

Cost and 2 2 4 4 8

maintenance

TOTAL 150 171

Also, Table 1 is relevant only for the specific case presented in paragraph 3. For other types of parts, it is
very likely that the configuration of the table will be quite different. It is noted that there are not too large
differences between the RE 1 process and the RE 2 process. That is, there are no big differences between
3D scanning and polyarticulate arm measurement. However, in this case, polyarticulated arm
measurement and direct solid construction in SolidWorks is more beneficial than obtaining NURBS
surfaces. Due to the fact that the scores are so tight, it may be that a company prefers an RE process
instead of another, precisely because it has more skills in that area.

6.5.5.CONCLUSION
The paper presented the RE process for polymeric material parts. A classification has been made of the
possibilities to achieve this process, from hardware, software and current RE technologies. Also, the paper
tries to help managers in the polymer materials industry make a decision when they are using a RE process.
The correct (optimal) selection of the RE process is very difficult.

The difficulty lies in the fact that there are a multitude of parameters to be correlated, and they are in a
continuous movement. In the paper, two hardware and two RE software applications were selected to
conduct experiments.

It has been assumed that there is the same level of competence in using the RE system in one case and
the other. Note that the results obtained are suitable for a particular type of parts, and that the level of
generalization is somewhat reduced.

In the future, our desire is to deepen research and increase the level of confidence of results through a
more in-depth comparative analysis for both hardware and software applications.
 CONCLUSIONS
Here, I showed that many insights of reverse engineering in the product development process may be
gained from novel concepts, methods and tools of shape engineering. Geometric reverse engineering
has been extended to capture the shape essence of the physical product, manufacturing processes as
well as digital product within a lifecycle perspective. Shape segmentation and shape/feature recognition
are fundamental problems in shape processing for geometric reverse engineering.

This project was as gratifying as it was challenging. It sparked me to understand how professionally
designed systems are brought to fruition. In the allotted time for disassembly we were able to disassemble
and itemize each individual component. This task involved knowledge which helps me a lot, delegation of
side objectives, theories and general conclusions. In turn, by the termination of the Written report, I finish
this report within deadlines.
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