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 CAE

CAD modeling

RP/RT

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 . Define Stock Size. Define Coordinates. Define Tool . Define Feeds and Speeds. Simulate Machining .

High Speed Machining, including streamlining of tool paths. Multi-function 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 productionquality 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 VIVID 9i
Up to 50 microns

Z scanner 600

Z scanner 800

Accuracy

Up to 35 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 Forging

low medium

high low

low low

Forming

high high

low high

low high

*CNC

Example (Turbine Blade)

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