ADHIYAMAAN COLLEGE OF ENGINEERING

HOSUR
DEPARTMENT OF MECHANICAL ENGINEERING

REVERSE ENGINEERING
A new trend in Manufacturing

PAPER SUBMITTED BY
George Michael Samson P.M.Gopal
Pre final year Pre final year
georgemech@ymail.com maximuscycus@gmail.com
9600654575 9025056483
ABSTRACT:
With the significant capital investment in new equipment being placed into out years, more
systems need to be maintained in their present condition for longer periods of time. There are often
gaps in the technical support information needed to maintain a system built from older designs using
outmoded or updated techniques or materials. 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.

"Reverse Engineering is the process of taking a finished product and reconstructing design
data in a format from which new parts or molds can be produced."
-The Society of Manufacturing Engineers

Today, reverse engineering is seen as the fastest way of translating the dimensions of a physical
model or shape into the digital realm so that where manufacturing, machining, or repair plans can be
written for it. In concept, it is fairly simple. Some of the other advantages and features of the reverse
engineering are explained in the below paper.

Key Words: Reverse Engineering, CAD, Modeling

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INTRODUCTION:
Engineering is the profession involved in designing, manufacturing, constructing, and maintaining of
products, systems, and structures. The effort to convert physical parts into virtual models is
supported by a growing number of hardware and software. Efficiency gained in applying software
and digitizing equipment to automate the creation of virtual models is lost when the model cannot be
used directly within CAD. If the virtual model cannot be manipulated within production CAD,
the development process is hampered by a spiraling iteration of remote data capture, conversion and
cleanup. A large time is invested to achieve a suitable production database for this issue. Reverse
engineering has come a long way from the days when manufacturers used it to sidestep design and
R&D processes and get to market by copying a competitors product. These gaps are often filled
effectively by reverse engineering, which is one of the solutions for maintaining a system for a
longer period of time.
The process of duplicating an existing component, subassembly, or product, without the aid of
drawings, documentation, or computer model is known as reverse engineering.
Reverse engineering can be viewed as the process of analyzing a system to:
Identify the system's components and their interrelationships
Create representation
one of the system in another form or a higher level of abstraction
Create the physical representation of that system

I .Define Scope of Work :

General information is acquired for the customer and then key characteristics are identified.
II. Obtain Dimensional Data :
Utilizing dimensional labs metrology equipment and experienced personnel. It is
possible to obtain all of the relative dimensional data necessary for the creation of
an exact CAD replica of the component. If geometry is complex, digitizing or
scanning may need to be employed.
III. Analyze Data :
The dimensional data obtained is recorded, compiled and nominal values are
formulated. Fit, function, manufacturing processes, industry standards and customer specifications
are factored when setting the CAD model values.

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 IV. Creation of the CAD Model/Drawing :
A 3-D model is generated using customer compatible CAD packages. The defined nominal values
are used and if digitized or scanned point clouds were necessary, a "best-fit" line, arc or spline is
used to generate complex geometry or NURBS surfaces. Additionally "best practices" are utilized
when creating models along with the customers' corporate standards when applicable. Some
customers require 2-D drawings of the component. We obtain and use their CAD templates with title
block information and any other corporate standards are used where necessary.
V.EnsuringQuality:
In addition to checking the dimensional data to the model/drawing, optional verification methods
may be employed. Especially on parts containing complex, free flowing surfaces, that are difficult to
fully capture on a CMM, and so "bestfit" methods are in the modeling .To verify the CAD surfaces
the physical part can be partially or fully scanned using our scanning equipment. By comparing the
point cloud data with the CAD model, a comparative analysis can be performed generating a report
with a color map. The report highlights any deviations and there values from the referenced CAD
model to the artifact. If any issues are identified the CAD model can be adjusted and the comparison
repeated until even very complex surfaces are modeled accurately
Reverse engineering is essentially the development of the technical data necessary for the support of
an existing production item developed in retrospect as applied to hardware systems.
An object, such as a pump housing, plastic frame, boat hull, or aircraft nacelle is measured
physically. Then the measurements are transcribed into a digital medium (a CAD-compatible
platform) as an image of dots, streaming lines, or wire frames. Subsequently, this image can be
enhanced for its end use via one or more software packages such as surfacing, stress analysis, human
factors, ergonomics, plant layout, or product flow.

TRADITIONAL DESIGN PROCESS

Need Design Idea Prototype & Test Product

REVERSE ENGINEERING
Product Disassembly Measure & Design Recovery Prototype & Test
Test

RE Product

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WHY REVERSE?
For a new design, the dimensions of a mechanical modelfrom clay, plastic, wood,
or waxare copied digitally, and then embellished via surfacing, ergonomic, or other programs. For
a product modification, reverse engineering is used to capture the existing mounting or mating
structure as a drawing file (IGES-compatible format), and then manipulated in CAD or similar
program to complete the adaptation.
A good example of reverse engineering involves a sheet-metal fabricator that modifies military
vehicles to carry external items, from auxiliary gasoline tanks to mounts for communications
systems. They digitize the surface where a bracket is to be attachedincluding potential hole
positionsand bring this image into their design software where it is used to shape the bracket.
In repair applications, parts for which no drawings exist can be recreated by reverse engineering.
This includes equipment that is old enough so that original drawings are lost, or that was built as a
one-off time and never documented in the first place. For example, after years of service that
included exposure to mild corrosion, a blade on an impeller for an air supply compressor cracked off.
Ordering a new one from the manufacturer would take eight months. Plant engineers decided to
reverse engineer a new one from the original. They measured the dimensions of the original to
digitally capture the location of the blades, including the one that broke off. Shaft and bearing
dimensions were also recorded. This data was downloaded into a CAM program and a machining
plan was written to cut the new impeller.
Actual milling was done in a machining center where the new impeller was cut from a blank of
aluminum alloy that would have toughness and corrosion resistance that was at least equal to that of
the original. From start to finish, the project took three weeks.

TRANSLATION TECHNOLOGY:
If you can measure an object, you can reverse engineer it. The key is to be able to measure with
sufficient accuracy to capture the degree of detailin three dimensionsnecessary for faithful
reproduction.
In the past, this was accomplished with some novel techniques, including one known as "stock
building." As the name implies, a measurement from one point on an object was taken using calipers,
rules, depth gages, etc.
And a model was built with sticks, each stock representing an individual measurement. The accuracy
of the model depended entirely on the skill of the model maker and the process usually required
weeks to get it right.

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Eventually, measuring evolved to conventional CMMs, and now the object could be captured
digitally. Accuracy was greatly improved. However, the process remained fairly slow because the
CMM had to be programmed for each object so that the stylus on it could trace the physical part.
Two primary tools are employed for reverse engineering.
For objects where the greatest dimension is 12 ft or less, an instrument that was originally developed
for quality assurance departments to make fast, in-process quality checks is favored.
Known as a portable CMM, it is based on an articulating arm, the joints of which are formed by
optical encoders. They are able to reproduce the X-Y-Z location and I-J-K orientation of a stylus to
an accuracy of 0.001". The arm moves freely within a sphere that is defined by its own reach. It
captures data rapidly with the potential for hundreds of points being measured per minute.

REVERSE ENGINEERING A WOOD SAW HANDLE:

1.Original wood model 2.Model scanned in polygon format 3.Nurbs surface Proprietary 3D.

4. Solid is created from Nurbs Nurbs surface has been interrogated for fidelity with
the polygonized mesh and a color map generated

The arm records measurements as individual points or streaming lines in CAD-compatible software.
For larger objects such as tool bedding or positioning, the digitizing is done with a laser measuring
device that projects a laser beam to a moving target that can be positioned up to 100 ft away from the
source. Reflected beams register the position of the target

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COMPUTED TOMOGRAPHY IN REVERSE ENGINEERING:

Reverse engineering of mechanical parts involves

acquiring three-dimensional position data in the
point cloud using laser scanners or computed
tomography (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. 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.
Today, the most important application of CT has become scanning for 3D-digitizing purposes. First
of all, automotive and motorcycle industries as well as their suppliers and the medical technology
show a very strong interest in the new possibilities that CT offers. Using this new technology it is
possible to reduce the time to market for development of new products. Thus companies can realize
substantial competitive advantages.
Reverse Engineering is a term used to describe the creation of a digital dataset based on a physical
representation, inverting the regular process of going from an idea through CAD construction to a
product. There are several ways of digitizing a three dimensional object. Tactile and optical
measurement systems require surfaces and geometrical features that are accessible or visible.
However, CT can show internal structures as well. CT data can be processed directly in the form of
point clouds or as tessellated surfaces (e.g. triangulated STL files).

Fig 2: Point cloud of water core Fig 3: Visualization of water core

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Segmentation of surfaces must take place in all. Computerized Tomography and Image Processing,
three dimensions to avoid discontinuous changes in z-direction as it is the case in contour extraction
done slice by slice. Transforming CT data into CAD systems with the tools available today is still a
lot of work and therefore offers a big development potential. It is especially useful if CAD data of a
product don't exist.
In future the rendering of a 3D-CAD dataset from 3D-tomograms for simulation and finite element
analysis will be even more important. The reason why is the fact that the true object geometry
instead of a theoretical model will serve as a base for computation. There are two parts to any reverse
engineering application: scanning and data manipulation. Scanning, also called digitizing, is the
process of gathering the requisite data from an object. Many different technologies are used to collect
Three-dimensional data. They range from mechanical and very slow, to radiation-based and highly
automated. Each technology has its advantages and disadvantages, and their applications and
specifications overlap. What eventually comes out of each of these data collection devices, however,
is a description of the physical object in three-dimensional space called a point cloud.
Point cloud data typically define numerous points on the surface of the object in terms of x, y, and z
coordinates. At each x, y, z coordinate in the data where there is a point, there is a surface coordinate
of the original object. However, some scanners, such as those based on X-rays, can see inside an
object. In that case, the point cloud also defines interior locations of the object, and may also
describe its density.

REDUCING THE AMOUNT OF DATA;

A CT scan produces a lot of data. The tomogram in our example had 946 slices with 1600 x 1000
pixels each. Every pixel was a four-byte floating-point density value. Hence the whole tomogram
contained about 6 GB of data. To reduce the data two strategies were applied:
The water core was not the only surface to the given threshold value. Instead of generating a point
cloud from all surfaces of the cylinder head and isolating the water core from this point cloud, it was
better to perform a segmentation of the required surfaces. By extracting the appropriate region of
interest, the data was reduced to about 1 GB.
A further strategy is to guess a threshold value, which is too low, and one, which is too high. Now
only the pixels between these threshold values and their neighbours are stored using some run length
encoding. This helps to compress the data without losing required information to compute the surface
data.
These methods should be applied before any further operations are performed. It saves not only disk
space; it makes the following data handling easier and reduces time for data transmission to other

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computer systems. Therefore, a set of graphical tools was developed. With these tools the
segmentation of the water core out of the 946 slices was done in about five hours.

POINT CLOUD GENERATION:

After performing the data reduction methods described above the point clouds of the upper and lower
water core were generated using the 3D linear interpolation algorithm. With the transformations,
which were determined from the positions of the reference bars, the two partial point clouds were
fitted into a common coordinate system.
Once the digitized image is captured, users still need the right CAD software to speed up the reverse
engineering process. Ideally, CAD software should be equipped to
Import geometric data of virtually any format
Work with point data, often on the order of several million data points
Work with contoured surfaces from creation through modification and analysis
Output geometry to downstream processes
Analyze geometry to evaluate form integrity with the sample.
Most important, the software should allow the user to visualize the part in a 3D perspective. A
3D model fully defines the shape of the part, eliminating the need for multiple view
projection. Designers can rework surface contours, and toolmakers can then machine parts
from the electronic mockups.
The idea is that the software should accelerate the reverse engineering time
cycle by:
Improving the quality of surfaces by creating smooth, continuous curve
networks
documentation
Eliminating the need for prototypes
Increasing product quality with a variety of analysis tools

REVERSE ENGINEERING IN AEROSPACE INDUSTRY:

The next major step for Boeing and other aerospace companies is a much higher level of integration
for the design process and the parts used for new and aging airplanes. Reverse engineering holds the
potential to provide a closed loop among CAD, CAM, CAE, hard tooling and inspection, making it
much easier to exchange data. Even the seemingly simple process of measuring, modeling and
verifying a physical part requires companies to look beyond traditional solid modeling systems to

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new reverse engineering technology that can capture the physical world and represent it with
accurate, manufacturable digital models.
Aerospace engineers view this step as an enormous challenge the sheer scale of tracking millions
of components can be conceptually and computationally overwhelming but one that must be faced.
It helps to take a deep breath and look back at the 100 years of
aviation. It's an amazingly compressed success story, from the early
days of skepticism about the Wrights' initial flight, to the
development of the Boeing 777.Aviation has progressed in leaps and
bounds since 1903, pushing flight beyond the skies and into space.
Over the next decade, sights will be set on the frontier traversed by
reverse engineering: conquering the divide between the physical and digital worlds and creating full
integration among all facets of the aerospace manufacturing process.
In some situations, designers prefer to model in clay, plaster, wood of foam rubber, but a CAD model
is needed in the further production process. Designing in CAD takes a long time and offers no
guarantee that the models will be identical. Reverse engineering provides a solution to this problem
because the physical model is the source of information for the CAD model. The physical model is
placed on an instrument table and its contours are scanned layer by layer with a laser beam with an
accuracy of up to 1m. The Metris laser radars are the ideal inspection tools during
manufacturing and assembly of aircraft and large component. The large measurement volume of up
to 60 meter radius is a key benefit. Another important advantage is the fact that there are no operators
necessary to hold reflectors, position photogrammetric dots or handle touch probes, benefits that
impose the laser radar as a real non-contact inspection solution. CMM based 3D laser scanners are
mainly used in companies that supply smaller components for aerospace or energy industry. One of
the typical applications is the inspection and reverse engineering of turbine blades and airfoils. The
reverse engineering application is often used in aerospace design departments to speed up the design
and prototyping stage.

OTHER INTRESTING APPLICATIONS OF R.E.:

Medical specialists use 3D digitizers to digitize bones and other
anatomy for the development of prosthetics and implants.(practically used
in CMC Vellore)
Video production experts use them to capture difficult to create
shapes for TV commercials and special effects in Hollywood films.

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Reverse
engineered
human knee
 Reverse engineering is today a key application in design departments to obtain an accurate
CAD surface model from clay models.

Reverse engineering successfully used in ORDNANCE FACTORIES. Indian defence has now
found this technology as an easy way of upgrading its armed forces with new world class
weapons.
(12.7/14.5/20 mm ANTI MATERIAL RIFLE ) (VIDHWANSAK)
SOUTH AFRICAN MODEL INDIAN MODEL

Reverse engineering used in sculpture design and foaming, first the scanning was done
using a laser scanner on a 12 foot CMM arm. Over 6 million data points were acquired
and the scanning technicians were not permitted to physically touch the statues during
the scanning process then the pattern was then cut at full size with a 5-axis CNC router.

3 4 5
1 2

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 Reverse engineering in dentistry for making the exact replica of the matching teeth with
correct alignment.
Reverse engineering was used to restore the original fossil since the original skelton was
found with many bones missing, archiving the bones for replication, and replacing missing or
damaged parts with CNC Milling or Rapid Prototyping techniques.

Bones of the de-mounted Reverse engineered Triceratops

Triceratops being restored.

ADVANTAGES OF REVERSE ENGINEERING:

Fast availability of CAD models
Physical model is used as the starting point
Shortened development process
Fully developed product at the start of production
Reduction in product and production costs
The development of CAD models based on physical ones

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 Editing a CAD file using the altered physical model creating STL files for use in other Rapid
Prototyping techniques

CONCLUSION:

Many American engineering colleges have courses in reverse engineering to focus on

redesign, instead of original design, as a problem solving approach. Even the automobile industry
uses a variant design methodology, referred to as direct engineering, to replace more general original
design methods. In recent years, Americans and Europeans have reverse engineered the reversed
engineering process and developed powerful tools to further compress development cycles. Such
tools are relevant for industries in those countries where production engineers are faced with the
problem of reproducing parts directly from samples. Making spares for obsolete equipment,
fabricating copies of old tooling, or redesigning a foreign-licensed product to come up with a new
look are examples of how reverse engineering can be successfully employed.

REFERENCES:

1. Kathryn A. Ingle, Reverse Engineering Mc Graw Hill Inc.

2. Kevin Otto & Kristin Wood, Product Design Techniques in Reverse Engineering and
New Product Development, Pearson Education

3. International Symposium on Computerized Tomography for Industrial Applications

and Image Processing in Radiology, Industrial Computed Tomography in Reverse
Engineering Applications March, 15 - 17, 1999 Berlin, Germany
4. www.rsleads.com/404tp-170

5. www.revworks.com

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