Reverse Engineering & Digitizing

Reverse Engineering is the process of taking a part and reconstructing dimensional data in a format
from which new parts, molds, or tools can be produced. Reverse Engineering can also be described
as the process of measuring a physical part or artifact, and producing new CAD geometry or
manufacturing drawings.

Or

Reverse engineering, sometimes called back engineering, is a process in which software,

machines, aircraft, architectural structures and other products are deconstructed to extract design
information from them. Often, reverse engineering involves deconstructing individual components
of larger products. The reverse engineering process enables you to determine how a part was
designed so that you can recreate it. Companies often use this approach when purchasing a
replacement part from an original equipment manufacturer (OEM) is not an option.

Scanning data is gathered to generate a CAD file for modern manufacturing methods. Components
can be accurately Reverse Engineered. Reverse Engineering is usually undertaken in order to
design / redesign a product for better manufacturability, or to take advantage of modern equipment.
e The geometry can be a physical measurement using traditional hand tools, non-contact inspection
equipment or coordinate measuring machine. It is important that the correct techniques be used to
capture geometry for any Reverse Engineering project. The data collection method is dependent
on the part shape, required accuracy, project goals, and how the final results will be used.

The expertise required for a company to supply accurate Reverse Engineering services is directly
related to the process itself. It is essential to have the ability to accurately measure a part, and to
reproduce it’s geometry from the measured results. While it is beneficial to have some experience
in the field related to the product being reverse-engineered, the skills needed to replicate complex
geometry are most valuable. Experience in providing accurate dimensional inspection services is
an important prerequisite for any Reverse Engineering function.

Example:

1. Companies often use reverse engineering on old electronic components, such as

discontinued printed circuit boards (PCBs) and connecting cards. Frequently, the products
in question will come from manufacturers that have since gone out of business. If the
manufacturer is still in business, they might no longer offer the part. The firms often reverse
engineer old electronics for the sake of continuity.

2. If an old piece of computer equipment had functions that have since been lost amid the
subsequent changes in technology, reverse engineering allows manufacturers to rediscover
these formulas and bring them up to date. Reverse engineering also enables you to develop
components that bridge the new and the old, allowing users of older equipment to connect
their devices to modern computing equipment.

3D Digitizing Technology in Product Reverse Design

3D digitization technology can be classified as contact and non-contact techniques based on the
method of 3D data acquisition as shown in Figure 1.
 The contact means that the measuring probe touches the recovery surface of objects during the
data acquisition. Contact data acquisition obtains data using a contact measuring process. The
devices include joined arms and CMMs. CMMs are widely used in industry for dimensional
inspection of manufactured parts. The most recent developments have led to the probe sensing
edges and surfaces to be measured on the part.

Non-Contact data acquisition technology uses an energy source, such as laser, white light,
microwave, radar, and ultrasonic sound, to obtain 3D data of an object without touching the surface
of objects in the measurement. There are two techniques used to receive signals of the energy
source from measured surface: reflective and transmissive methods. Reflective method uses a
receiver, such as a camera, to get the reflecting source (such as light) from the surface of objects.
According to the source used, reflective devices are divided into optical devices and non-optical
devices which use microwave, radar sensor or ultra sound. Non-optical systems are based on a
time-delay measurement to calculate the distance traveled by sound or microwaves. Transmissive
methods get a series of slices when the source is emitted through the part. These slices can be used
to produce volumetric data or feature extraction. Examples of using this technique include
ultrasound, magnetic resonance imaging (MRI), X-ray computed tomography (CT), and confocal
microscopes. This research focuses on optical scanners

Types of Modeling
Within CAD, there are three main types of 3D modeling – solid, wireframe, and surface – and each
has its own advantages and disadvantages. Of course, there are other types, but most exist either
as a subset of these three or are highly specialized for their specific purposes.

 Solid modeling works with three-dimensional shapes. The shapes may vary, but they act together
like building blocks. Some of these blocks add material while others subtract, depending on the
input. Some programs can use modifiers, working with the solids as if you were physically
milling it in a workshop. Solid modeling is fairly straightforward both for users and in terms of
computer power.
 Wireframe modeling can help in cases where the surface is complex and curved. Eventually,
you’ll find that the basic building blocks of solid modeling are too obtuse for some applications,
and wireframe modeling provides the finesse for more complex forms. However, as complexity
rises, some drawbacks emerge.
 Surface modeling is the next step up in complexity. Highly professional applications demand
smooth surfaces and seamless integration, and this can be handled by more advanced programs
that require more work and computing power. However, here you can achieve shapes that would
be nearly unattainable with the other two methods.
Coordinate Measuring Machine (CMM):
Coordinate Measuring Machine (CMM) is used for inspection purpose, this machine inspect the
object in contact method. Coordinate measuring machine can connect with the computer to get an
accurate and fast output of the object and this helps to change in design on work site.
Solid modeling involves working with primitive shapes, such as spheres, cubes, and n-sided
prisms. Yet, different programs may use different procedures. Some start with two-dimensional
sketches that are then extruded to produce a three-dimensional figure. Others add solid over solid
in order to produce more complex figures. But the end result is the same.

This kind of modeling is especially useful when flat surfaces or simple curves of constant radii are
involved. It also lends itself quite well to precise dimensions and angles. Think of mechanical
elements, machines, and basic representations of natural things.

Some notable pieces of software that employ solid modeling include Tinkercad and FreeCAD at
the entry-level, and for more advanced work, SketchUp, SolidWorks, and Fusion 360.

ADVANTAGES
 Tools are easy to understand and work with; the user doesn’t require extensive training.
 Computational requirements are lower since the computer isn’t working with thousands of
triangles.
 The final pieces are always mathematically correct in the sense that the model is possible
in the real world.
DISADVANTAGE
 High realism in the representation of organic shapes is almost impossible to achieve.
The most advanced of these three techniques is surface modeling. It relies on guiding lines to
define the shape and curvature of a part. The software then calculates a smooth surface that
connects the guiding lines.

This way of working imitates the way airplanes and boats are made: Think of the guiding lines as
the internal ribs of an airplane structure, the surface is the metal skin.

The aforementioned example is the exact reason why this process was devised. In aerodynamic
and thermodynamic designs, the behavior of the flow around solid shapes is of utmost importance,
and the shape of the silhouette will determine if an element is effective or not. Since the seamless
integration of all elements is necessary, surface modeling is the best way to approach these
challenges.

The use of guiding lines is not the only option. Some programs use control points or control planes,
where the desired surface follows the planes tangentially. The caveat is that, since this way of
working focuses so much on surfaces, it can produce visual representations that are not possible
 in the real world and are therefore impossible to make. Before manufacturing, it’s necessary to
ensure that the design is physically possible, or “manifold“.

No program is dedicated uniquely to this technique, this is just another tool in their box. Yet, its
underlying principles are so distinct that it’s considered as a unique modeling technique. In many
programs, the main tool that does this job is called “Loft”. Some of the programs that can handle
this type of modeling are Catia, FreeCAD, Inventor, and SolidWorks.

ADVANTAGE

 It’s possible to produce complex surfaces. This is convenient where appearance is important,
such as in the automotive industry, or where fluids are involved, such as in aircraft or
thermodynamics.

DISADVANTAGES

 This technique is more complex and requires more advanced programs.

 More advanced programs will demand far more training and experience from the designer.

Wireframe modeling represents shapes as a network of vertices. Each geometric face is composed
of at least three vertices, and each vertex can be part of one or more faces. The size and shape of
things are modified by changing the position of each vertex.
Many wireframe modeling tools use triangles as their basic elements, and the more triangles use,
the higher the realism. This is indicated by “polygon count”, the total number of triangles (or other
planar shapes) contained within the wireframe of a model.
Historically, this technique was the first to be used to model 3D figures, then having relatively low
polygon counts, making figures somewhat blocky. Nowadays, it’s not uncommon for shapes to
reach millions of polygons. This might not be a problem when software is locally run, but for web-
based software, this can cause severe lag. In some cases, there’s even a limit on the number of
polygons that can be used.
There are many programs that use this approach, but some of the main programs that allow for the
individual manipulation of wireframe vertices are Blender, Maya, and Daz 3D.
ADVANTAGE
 It’s possible to achieve more complex surfaces and curves compared to solid modeling.
DISADVANTAGES
 Users require more training.
 High resolution will require millions of polygons and computational needs will be higher.
Coordinate Measuring Machine (CMM)

Construction of coordinate measuring machine:

Computer system:
A computer is used to store the programs in it and send it to the control unit, we can change the
program directly in the computer if required.
Control unit:
This controls the machine according to the programmers designed.
Probe head:
The probe head is used to carry the probe tool.
Probe:
A probe is a measuring tool which inspects the object placed below to it.
Table:
This is to carry the object and moves according to the work.
Working of Coordinate Measuring Machine (CMM):
When an object is placed on the work table, measuring tool probe that used to make contact with
the object to inspect it, probe movement can be done through manually or by computer which is
given by programs. Control unit used to control the machine according to the signal sent by
computer programs to it, the data from the probe is collected to the computer where we can view
it. by using this type of monitoring system we can save our time in inspection method.
Different types of CMM (Coordinate measuring machine):
Column type:
This is mostly known as a universal measuring machine. due to high accuracy output, this is
mostly used.
Cantilever type:
In this type of measuring machine long length products can measure easily and it required less
space.
Bridge type:
The shape itself explains the construction. This is mostly used in bulk manufacturing industries,
it is one of the fast measuring machines with accurate