Reverse engineering and CAD-CAM approach for manufacturing of spare parts. Case study (original) (raw)

Reverse engineering applications for recovery of broken or worn parts and re-manufacturing: Three case studies

Advances in Engineering Software, 2009

Damaged or broken parts are generally too expensive to replace, or are no longer available. RE can be defined as: 'Systematic evaluation of a product with the purpose of replication. This involves design of a new part, copy of an existing part, recovery of a damaged or broken part, improvement of model precision and inspection of a numerical model. Advantages of the technique include immediate feedback, data reduction, direct generation of geometry and higher precision of the final product. This paper shows some possibilities of use and benefit from utilising the RE-methodologies and techniques in production process, especially in the case when exists parts without 3D-CAD support. This paper, which defines obtaining CAD data step by step from damaged three different parts to reproduce or make a new design for some recoveries, has not get any technical drawings. When these parts had been recovered, some problems occurred. These problems have been solved by referring to some practical approaches. Establishing continuity across curve and surface patches is an important concept in the free form surface modeling. The CAD models were recovered and reconstructed to consider parametric and geometric continuity. The iso-phote method was used for surface continuity analysis. Hence, in this work, not only occurring problems but also solving methods were explained. Firstly, CAD models are created from damaged and broken parts by data digitization method by using CMM and the process was explored in detailed. Later, CAD models that had been obtained earlier are transferred into CAM module of the software and G codes are taken by the NC post-processor, and finally, the parts are manufactured by means of CNC milling machine. Additionally, this paper presents a review of the part digitization techniques available for reverse engineering.

Reverse Engineering in Product Manufacturing

Journal of emerging technologies and innovative research, 2019

In the field of manufacturing and design industry, reverse engineering has proved to be beneficial for the growth and development of the mechanical industries. This technique has been generally accepted as an effective product design and development process technique. In standard computerized manufacturing system, the operating order normally begins with the concept of the product and finishes with various types of machine or CNC operations to turn raw material into finished product which is ready to enter in the market. Using some digitization methods, it is always necessary to replicate a CAD model of the actual component where the documents and drawings prepared by the designers are not accessible and are needed for review and modifications to create an enhanced product design. The essential steps involved in reverse engineering method include classification of geometric structures and associated surface depictions, segmentation & the surface fittings of the basic & free-forms model shape & the development of realistic CAD models. This paper discusses about the technique of reverse engineering and its implementation fields related to the advancement of product design. Redesign of the product and reverse engineering work would substantially minimize the costs and time required for manufacturing the physical components in the manufacturing industries.

Reverse Engineering – an Effective Tool for Design and Development of Mechanical Parts

2018

The Reverse Engineering has already found an extensive application in industry and other different fields. Reverse engineering (RE) is a process of taking the existing physical model and reproducing its surface geometry in three-dimensional (3D) data file on a computer-aided design (CAD) system. This paper will analyze the real situation in one industrial plant and provide comparative analysis of the application of current measuring methods and possibility of incorporating digital measurement. The Reverse Engineering (RE) is based on a method of reducing the time of dimensioning and modeling of mechanical parts which can be complex by geometry or dimensionally very accurate. In this paper we can give some practical examples of parts that are really produced in one manufacturing factory. Recommendation for digitalization will be of crucial importance for every company in its measurement and quality control activities.

Manufacture of Automotive Component Using Reverse Engineering and Manufacturing Additive Techniques

ESTEEM Academic Journal, 2023

Reverse engineering is an extraction process of design data from an existing product in order to get its 3D model by data acquisition method. This type of engineering is often applied in software engineering, biomedical field, and parts restoration. The main reasons for implementing reverse engineering are due to obsolete parts, unavailable spare parts and the absence of documentation design.. The objective of the work is to reproduce an automotive part utilizing a 3D printer from data acquisition and CAD model. The reverse engineering technique in this work involves data acquisition, surface and model construction, post-processing and fabrication of the final product. One of the equipment in the non-contact method, the 3D scanner is used to extract design data from the master part. Then, the scanned model is transferred to Solidworks in order to reconstruct the missing features in the model. The findings show that the reverse engineering technique used in this work can reproduce the automative part which is near net-shape of the master part. However, the CAD model require some surface and model reconstruction due to data loss during the conversion of information from scanning data to CAD data. After the final product is fabricated using a 3D printer, it is compared with the master part in terms of the difference of dimensions found between them. Besides, the data loss occurred throughout data acquisition is also discussed in this work. As a conclusion, reverse engineering should be the best alternative to reproduce an object without any design details provided.

Product Development from 3D Scanner to CNC Machine in Reverse Engineering

2018

The purpose of this article is to introduce reverse engineering procedure (REP). It can achieved by developing an industrial mechanical product that had no design schemes throughout the 3D–Scanners. The aim of getting a geometric CAD model from 3D scanner is to present physical model. Generally, this used in specific applications, like commercial plan and manufacturing tasks. Having a digital data as stereolithography (STL) format. Converting the point cloud be can developed as a work in programming by producing triangles between focuses, a procedure known as triangulation. Then it could be easy to manufacture parts unknown documentation and transferred the information to CNC-machines. In this work, modification was proposed and used in RE program, which is from CAD-CAM software’s that used to redesign and modify on point of cloud in 3D modeling. This paper presents reverse engineering (RE) of the flange of water pump. Used mechanical and damaged parts have been selected which had a...

Reverse Engineering Applications in Manufacturing Industries: An Overview

With the evolving needs of today's manufacturing industries in the area of product development, 3D CAD model has become very important. Often in many situations there is a need to remanufacture a physical part where the CAD data is not available with the manufacturer or is lost because of several reasons. In such cases reverse engineering is found to be an effective and efficient tool. Reverse engineering is an approach where the physical parts are digitized in order to obtain a virtual model. Digitization can be done either manually or it can be fully automatized for better and fast scans. The virtual models so obtained are helpful in many applications but often used for redesign operations. This paper reviews the reverse engineering process and its application in various manufacturing industries. After a brief introduction, methodology used in reverse engineering and its applications in different fields have been discussed. Future scope of RE is also discussed in this paper.

A way of supporting the servicing of production machines using reverse engineering and 3d printing techniques

Technologia i Automatyzacja Montażu, 2022

The use of machines and devices causes their components to wear out, which leads to damage. The easiest and fastest method of repair is to replace this element with a new one. The problem arises when the desired element is not available on the market, technical documentation is unavailable or the costs of acquiring a new element are too high. In such a situation, engineering reconstruction, also known as reverse engineering, is used, which allows for the reconstruction of technical documentation and the production of a new product thanks to additive technology. The article presents the process of reverse engineering and the types of additive manufacturing technology. The aim of the article is to present the possibilities of using the reverse engineering method and 3D printing in the reconstruction of sample machine parts. The work uses the FDM (Fused Deposition Modeling) spatial production technology. The relevance of the article is confirmed by the possibility of its practical use in the field of machine servicing support.

A CASE STUDY ON DESIGN OF THE COMPONENT FOR COMPLEX SHAPES USING REVERSE ENGINEERING

The paper describes about the state of art technology in preparing the existing component using digitized data by using optical scanners. Whereas the copy milling and CMM process was a traditional process by which the data could not be generated for creating a CAD model with precise accuracy. The study also in visages how to generate the Cloud point data and how it can be converted into CAD model for the given product using Polyworks software. The CAD file formats (i.e. ply & STL) i.e. cloud point data conversion which is generated by using white light scanner was further investigated with the other reverse engineering software's such as Image ware and Polyworks. The digitization process for the given component was developed using the Breuckmann OPTOCAT White light scanner. The modeling irregularities in the component were observed and studied using the reverse engineering software. The methodology adopted in this research is such as scanning, data preparation and Quality Checks of the material were studied [1].

Use of 3D-scanning and reverse engineering by manufacturing of complex shapes

Applications of Reverse Engineering to speeding up a product realization process have gained momentum in recent years. The aim of this paper is to firstly provide a brief overview of Reverse Engineering technology and the reasons for its development. Furthermore is presented Renishaw Cyclone 2 scanning device with a probe head, which was used for digitizing a real model of a face. Digitized model with assistance of CAD/CAMtechnique had been applied for making a real copy of the face in another material. On the basis of the special computer software the whole procedure from a digitized model to the real copy of the face was verified in the last section.

Part Design and Evaluation through Reverse Engineering Approach

2000

Most manufacturing enterprises focus on the delivery of increased productivity with high quality products through integration of computer aided design (CAD)/computer aided manufacturing (CAM) with computer aided engineering (CAE) tools. When this concept is applied to reverse engineering (RE), the challenge lies in quickly editing and modifying point cloud data collected from scanning the object to design of a three