Reverse Engineering

Reverse Engineering Tool to improve quality and efficiency of design, manufacture and analysis.

INTRODUCTION 

The Internet and technology in general has forever changed the world. This dawning of the technical age has morphed our lives around what we have created. Markets are no longer dictated by mere physical obstacles. Time and distance are less of an barrier than will. The shear number of Internet users enables us to develop various market networks in a virtual environment.What we used to perceive as problems, we now see as opportunities. Only companies that grow

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along side these shifts can survive in our new age. Engineering is the profession involved in designing, manufacturing, constructing, and maintaining of products, systems, and structures. At a higher level, 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 without any technical details, such as drawings, bills-of-material, or without engineering data, such as thermal and electrical properties.

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The process of duplicating an existing component, subassembly, or product, without the aid of drawings, documentation, or computer model is known as reverse engineering.

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Reverse engineering is very common in such diverse fields as software engineering, entertainment, automotive, consumer products, microchips, chemicals, electronics, and mechanical designs. For example, when a new machine comes to market, competing manufacturers may buy one machine and disassemble it to learn how it was built and how it works.

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In some situations, designers give a shape to their ideas by using clay, plaster, wood, or foam rubber, but a CAD model is needed to enable the manufacturing of the part. As products become more organic in shape, designing in CAD may be challenging or impossible. There is no guarantee that the CAD model will be acceptably close to the sculpted model. Reverse engineering provides a solution to this problem because the physical model is the source of information for the CAD model. This is also referred to as the part-to-CAD process. Another reason for reverse engineering is to compress product development times. In the intensely competitive global market, manufacturers are constantly seeking new ways to shorten lead-times to market a new product. Rapid product development (RPD) refers to recently developed technologies and techniques that assist manufacturers and designers in meeting the demands of reduced product development time. For example, injection-molding companies must drastically reduce the tool and die development times. By using reverse engineering, a threedimensional product or model can be quickly captured in digital form, re-modeled, and exported for rapid prototyping/tooling or rapid manufacturing.

Reasons for Reverse Engineering a Part or Product Following are reasons for reverse engineering a part or product: 1. The original manufacturer of a product no longer produces a product 2. There is inadequate documentation of the original design 3. The original manufacturer no longer exists, but a customer needs the product 4. The original design documentation has been lost or never existed 5. Some bad features of a product need to be designed out. For example, excessive wear might indicate where a product should be improved 6. To strengthen the good features of a product based on long-term usage of the product 7. To analyze the good and bad features of competitors' product 8. To explore new avenues to improve product performance and features 9. To gain competitive benchmarking methods to understand competitor's products and develop better products 10.The original CAD model is not sufficient to support modifications or current manufacturing methods 11.The original supplier is unable or unwilling to provide additional parts 12.The original equipment manufacturers are either unwilling or unable to supply replacement parts, or demand inflated costs for sole-source parts 13. To update obsolete materials or antiquated manufacturing processes with more current, less-expensive technologies

Application       

Copy of part - no original design. Existing part - analysis and modification. Aesthetic design - wooden or clay model is first conceptualized Custom fits for human surfaces - helmets, shoes, space suits or prostheses. Manufacturing. Inspection and quality control. Art & Sculpting

Process Flowchart

Steps 

Data Acquisition:-

Reverse Engineering is the process of producing design details in the form of CAD model from the physical part. The process consists of first scanning the object concerned to create a point cloud that represents the skin of the object.. The scanner sensor projects a laser stripe across the object to be scanned. A camera views the projected stripe so that height variations in the object can be seen as changes in the shape of the line. Each viewed stripe forms a profile, which is built up from several hundred measured points. To scanning data following hardware is available • CMM Method • FERO Arms • 3D Scanners • White Light Scanners • Laser Scanners

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Preprocessing Reverse engineering of mechanical parts involves acquiring three-dimensional position data in the point cloud using laser scanners or computed topography (CT). Representing geometry of the part in terms of surface points is the first step in creating parametric surface patches. A good polymesh is created from the point cloud using reverse engineering software.

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Segmentation and Surface Fitting

The cleaned-up polymesh, 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. Finally, the CAM produces the physical part. 

CAD Model creation The surface model thus created is exported to a Solid modeling package such as I-DEAS where the surface model is checked for water tight geometry and after modification if necessary, Finally, the CAM produces the physical part. It can be said that reverse engineering begins with the product and works through the design process in the opposite direction to arrive at a product definition statement (PDS). In doing so, it uncovers as much information as possible about the design ideas that were used to produce a particular product.

Case Study 1 Here is typical Reverse Engineering Application of Mold Development. In such case after scanning physical Die make a computerised 3D Model by using different software. This model you can compare with your original 3D model from which You have created die. This is easiest method to check quality of Die Block. In production due to long use of Mold some wear and tear happens, Which is not possible to visualise by Open eyes.To maintain quality of product you can reverse engineering.

Case Study 2 

3D inspection system for stamped sheetmetal

Manufacturing flawless, perfectly smooth surfaces of a car body is as crucial as the performance of the engine or the safety features of the vehicle for consumers when they consider buying new cars. As most car bodies are manufactured using a sheetmetal stamping process, areas where the curvature of the sheetmetal changes sharply or areas around holes often display small surface defects that can seriously damage the quality of the overall surface. In the past, manufacturers had to manually inspect car bodies and perform tedious and time consuming iterative modification of molds and manufacture test pieces until they met Class A surface tolerances. Using Reverse Engineering method the Surface Smoothness Inspection Team is now able to easily verify the surface smoothness of stamped sheetmetal based on 3D scan data from their optical scanner in minutes instead of days.

Verification To inspect their stampings, and the Surface Smoothness Inspection Team can not only evaluate surface smoothness much more accurately and faster than ever before, but also plot the smoothness deviation in true 3D. The 3D color maps that software generates directly on the sheetmetal scans makes it possible for the team to intuitively understand where the irregularities lie and to which degree, minimizing the communication error within the team or between other teams. The ease of interpreting the data made it possible to standardize the evaluation process and share the information with every involved group

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