Papers by Keyword: Reverse Engineering

Abstract: Remanufacturing by casting of end-of-life (EoL) components can be challenging as it requires specific molds/cores, machinery and tooling. The use of 3D scanning technology and rapid casting processes can produce high-quality, efficient components. However, error propagation during the manufacturing process can significantly affect the dimensional accuracy of the final product. In this study, the dimensions of a case study part were evaluated at the main stages of the rapid hybrid low-pressure sand casting (LPSC) process, from the initial CAD model to the final casting, to identify the main causes of final 3D surface deviation. The casting design was optimized using coupled thermal and fluid-flow FE computations for two suitable casting orientations: horizontal (H) and vertical (V). After the 3D sand-mold printing process, an optical 3D scanner was used to extract surface data from each printed mold part. 3D surface deviations caused by the printing process were evaluated by comparing the individual mold components to their original CAD models using GOM Inspect Pro^® software. The final castings were also compared to the initial CAD models for both orientations to quantify the overall 3D surface deviations resulting from the rapid LPSC process chain, including 3D printing, liquid metal shrinkage and contraction during solidification and cooling. The results provide a foundation for improving dimensional accuracy of one-off replacement components produced by the hybrid LPSC process.

Abstract: A tissue processor is a device that automatically processes tissue into several steps for histological studies in medical or biological laboratories. One of the stages of this device is embedding, where the tissue is inserted into a vessel that is heated to a stable temperature of 60 to 80°C so that the paraffin remains liquid during this process. The handling of tissue specimens is a crucial aspect of ensuring an accurate diagnosis of the tissue. However, due to its high cost, it can affect scientific development that requires tissue processing. Reverse engineering is one of the methods commonly used to develop a tool at a lower price; one way is to change the essential components used while still maintaining the device's primary function. This research aims to develop a heater controller for a tissue processor using STM8 and LM35 analog sensors equipped with a Kalman filter. The design of the Kalman filter will be determined based on its component equations. The measurement and variance constant values will be simulated and analysed in MATLAB for the most suitable parameter value. Afterwards, the proposed design will be conducted using the Arduino Integrated Development Environment (IDE) to reduce the noise in the LM35 sensor reading and then saved using ArduSpreadsheet. The simulation and implementation results provide evidence that the proposed Kalman filter effectively filters signals contaminated with noise, even in the presence of high data variations that may occur in sensor readings. In testing, it is necessary to pay attention to the ratio that can reduce noise while keeping the characteristics of the sensor itself. Numerous investigations have explored various ratios, recommending an appropriate ratio of 100. Based on the implementation of this ratio with measurement constant (R) 10 and variance constant (Q) 0.1, resulted in a 0.29°C mean error and stable sensor readings.

Abstract: This paper integrates reverse engineering and circular economy concepts in the remanufacturing of shoe plain bearings for a tubular ball mill used in the mining industry. The developed procedure covers a range of steps including diverse bearing cleaning methods, the definition of various inspection techniques, and the selection of the ideal sacrificial material through spectrometry tests and bibliographic references. It also encompasses the determination of deformation and stress on the shoe plain bearings during normal operation, followed by the remanufacturing process, which involves adding sacrificial material to the substrate and machining it using a CNC machine. Quality control testing of the remanufactured bearings was conducted according to international standards. A comparative financial cost-benefit analysis was also performed between new and remanufactured shoe plain bearings. The results of this analysis provide the company with a solid foundation for decision-making in both the economic and logistical aspects of shoe plain bearings, thereby promoting a more sustainable and efficient management of industrial assets.

Abstract: The article analyzed modern trends in mechanical engineering technology, especially focused on methods of software control of the accuracy of machining processes through technological primitives, which was first introduced into technological science by the author of the article. For formation of accuracy operation programs was used by means of synthesis of technological primitives of the conformity table . The correlation was installed between automated draft of technological operations and conduct of their accuracy. In the given automated system except operating conditions of cutting calculation of elastic deformations of technological systems, forecasting cutting accuracy, construction of cutting surface topography and determination the programes of operating process accuracy.

Abstract: In times when companies must respond efficiently to market demands, reverse engineering plays a fundamental role. Although design processes are commonly developed with digital workflows, in reverse engineering different and independent phases with bottlenecks between them are involved. The present work addresses the challenge of establishing a continuous and efficient data flow between the three-dimensional digitized data obtained with 3D scanning and the automatic generation of NC toolpaths. A methodology is developed for the generation and optimization of NC toolpaths directly from the 3D point cloud data obtained through the three-dimensional scanning of pre-existing geometries. The methodology consists of an algorithm developed with Grasshopper, a script for visual programming in Rhino’s interface. It does not only attempt to reconstruct the three-dimensional geometry of the scanned part but also, it directly generates the tool paths and optimizes them with evolutionary optimization algorithms that are integrated in the methodology. A case study is developed for TMU-SIO TOWGTAI machining center with the proposed methodology. Finally, the obtained results and the efficiency of the methodology are analyzed and presented.

Abstract: Reverse engineering, or the creation of models from physical objects, is increasingly being used in many industries including manufacturing, automotive design, and computer animation. The presented work focuses on the issue of data preparation for reverse engineering. The aim of the thesis is to map the issues of working with the Zeiss LineScan optical sensor on a 3D coordinate measuring machine in the metrology laboratory of the Regional Institute of Technology at the University of West Bohemia. The aim of the work was to map the software setting options supplied by the sensor manufacturer. The sensor can obtain clouds of three types of points: RSL (Raw Scan Lines - measured points, directly recorded by the scanner, without further adjustments), GSL (Gridded Scan Lines - points reduced and grouped into a grid of a given step), and QSP (Qualified Surface points - compressed and grouped points into a given grid). The evaluation of the experiment revealed the ideal setting for the specified measurement conditions. Reference objects with nominal lengths of 100 mm and 500 mm were chosen. The data required for evaluating each sensor setting were obtained through a series of measurements of these objects. The output of the experiment is a comparison of each option for setting up the scanning method. GSL points with a step setting of 0.1 mm were evaluated as the most suitable setting for measuring objects with similar shapes. They showed stable deviations within the selected tolerance of ± 0.03 mm for all measurement variations. RSL and QSP points, on the other hand, showed less stability of deviations across the measurements.

Abstract: In the last 40 years CAD engineering has taken a considerable advantage in all domains. This has been imposed by the changes that have occurred in most of the environments with which engineering interacts in general, as well as by the technological advancement that has made the use of computers that have become increasingly efficient and are now indispensable to the technology [1]. The tendency of this period was consumer because prices fell as a consequence of globalization, the technique evolved, the standards became very rigorous, and the laws began to protect the consumer more.

Abstract: Characterizing a fruit’s mechanical behavior is an important step towards reducing economic losses due to bruising. Several 3D scanning technologies allow to obtain the external geometry of a fruit, but no easily accessible tools exist for the acquisition of the geometry of internal structures such as the core. We propose a low-cost destructive method for tomographic reconstruction of a fruit from scanned slices. A method for overcoming the difficulties in registering the different images is also presented.

Abstract: One of the main shortcomings of individualized training in the use of computer aided design (CAD), and computer aided manufacturing (CAM) tools is that students lack a sound and broad understanding of the type of tools, and their specific and integrated applications in industrial manufacturing. This study aimed to design an integrated curricular training programme in computer aided tools for the design and manufacture of mechanical components based on reverse engineering techniques. By using real products that students can see and touch, a scanned copy is obtained for subsequent reconstruction into a virtual three-dimensional model using the software for optimizing the point cloud, meshing, and creating both the surface and solid. Once the virtual three-dimensional model has been obtained, it is exported to a solid modelling CAD (3D-CAD) software for modification according to the geometrical requirements. The next step is for students to manufacture a component using rapid prototyping techniques, which allow them to visualize, analyse, and inspect a component to optimize its design. The use of computer aided manufacturing software enables students to design and plan machining operations virtually to obtain a computer numeric control (CNC) program for the manufacture of a component with a CNC machine tool. Finally, students perform a quality control of the component by employing a range of measurement techniques. This training program is integrated into the subjects of the mechanical engineering degree, where students can work with these tools in line with an intergraded curriculum.

Abstract: This research aimed to develop the formulation of natural rubber filled with carbon black, silica and calcium carbonate for rubber calf nipple application. The reverse engineering was performed on the calf nipple product to analyze the rubber type and component by using Soxhlet extraction, thermogravimetric analysis (TGA) and Fourier transform infrared spectroscopy (FTIR) techniques. Furthermore, mechanical properties were examined to act as benchmark for the rubber compound design. The results showed that rubber component in the nipple product was natural rubber, whereas two filler types revealed as carbon black and calcium carbonate with 10 and 35 of the total weight. In addition, rubber nipple showed the hardness of 46±1 Shore A and tensile strength of 5.3±0.60 MPa. From the investigation of the properties of developed rubber compounds in this work, it was found that the mechanical properties depended on type and content of filler. The required mechanical properties of vulcanizates were achieved at 20 phr of carbon black (N330), 20 phr of silica and 120 phr of calcium carbonate.