LIST OF CHAPTERS

CHAPTER NO TITLE PAGE NO

1 INTRODUCTION 1

1.1 HISTORY 2

1.2 METHODOLOGY 3

2 LITERATURE SURVEY 4

2.1 REVERSE ENGINEERING 4

2.2 ADDITIVE MANUFACTURING 5

3 REVERSE ENGINEERING 6

3.1 COMPUTER AIDED REVERSE ENGINEERING 7

3.2 FEATURE BASED REVERSE ENGINEERING 7

3.3 BASIC STEPS OF REVERSE ENGINEERING 8

3.4 SOLID MODELING 10

3.5 APPLICATION OF REVERSE ENGINEERING 10

3.6 REVERSE ENGINEERING IN MODERN INDUSTRIES 12

3.7 MODERN DIGITIZATION SYSTEM 12

4 ADDITIVE MANUFACTURING OR 3D PRINTING 14

4.1 ADDITIVE MANUFACTURING PRROCESS 15

5 AIRCRAFT BRAKES 17

5.1 TYPES AND CONSTRUCTION OF AIRCRAFT BRAKES 17

5.2 SERVICING AND MAINTENANCE 25

5.3 BRAKE MALFUNCTIONS AND DJLVAMAGE 28

6 MATERIAL SELETION AND SKILLS REQUIRED 30

6.1 LEVELS OF REVERS ENGINEERING 30

6.2 LEVELS OF ANALYSIS IN REVERSE ENGINEERING 30

6.3 SKILLS AND KNOWLEDGE REQUIRED 31

6.4 MEASURING INSTRUMENTS HANDLING SKILL 31

6.5 MATERIAL SELECTION 31

6.6 TOLERANCES 31

6.7 HEAT TREATMENT 32

6.8 INSTRUMENT AND GAUGES 33

7 METAL ADDITIVE MANUFACTURING CYCLE IN 34

AEROSPACE INDUSTRY
7.1 PROCESSES REVIEW 35

7.2 ADDITIVE MANUFACTURING 37

7.3 DEFECTS AND ITS INSPECTION METHODS 41

7.4 AM MATERIAL BEHAVIOR 45

7.5 AM DESIGN OPTIMIZATION 46

7.6 THREATS 47

7.7 DESIGN LIMITATIONS 49

7.8 CASE STUDIES FROM AEROSPACE INDUSTRY 50

8 NON-DESTRUCTIVE INSPECTION OF COMPOSITES 53

8.1 VISUAL INSPECTION 53

8.2 AUDIBLE SONIC TESTING 53

8.3 AUTOMATED TAP TEST 54

8.4 ULTRASONIC INSPECTION 54

 8.5 TRANSMISSION ULTRASONC INSPECTION 55

8.6 PULSE ECHO ULTRASONIC INSPECTION 55

8.7 RADIOGRAPHY 57

8.8 THERMOGRAPHY 57

8.9 NEUTRON RADIOGRAPHY 57

8.10 MOISTURE DETECTOR 58

9 MANUFACTURING PROCESS OF BRAKE CALIPER 59

THROUGH METAL 3D PRINTING

9.1 DESIGN & ANALYSIS OF SINGLE PISTON FLOATING 59

BRAKE CALIPER
9.2 HYDRAULIC BRAKE SYSTEM 60

9.3 RESEARCH METHODOLOGY 60

9.4 3D MODELING OF THE BRAKE CALIPER 63

9.5 STRUCTURAL ANALYSIS OF THE BRAKE CALIPER 64

9.6 DIRECT METAL LASER SINTERING(DMLS) 68

9.7 STEP BY STEP PROCESS OF DMLS 3D PRINTING 70

9.8 SUPPORT STRUCTURES 72

9.9 BRAKE CALIPER ASSEMBLY 73

10 PROJECT OVERVIEW 76

10.1 METHODOLOGY 76

10.2 APPLICATIONS 77

10.3 ADVANTAGES & DISADVANTAGES 80

10.4 COST ESTIMATION 82

11 CONCLUSION 83

REFERENCES 84