Reverse Engineer In V2

8/8/2019 Reverse Engineer In V2

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Reverse Engineering1

TABLE OF CONTENTS:

Page No.Subjects

2Abstract

Introduction

4What is Reverse Engineering?5What can Reverse Engineering be used for?5Reasons for reverse engineering a part or product.6The Flow Chart of Reverse Engineering73D scanner3Computer Aided Engineering (CAE)31Computer-aided manufacturing (CAM)

3Rapid prototyping23Manufacturing Process2Computer Numerical Controlled (CNC)

21Example of some RE27Appendix

2References


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Abstract


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Introduction :

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 Reverse engineering.

Forward Engineer:

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.

Reverse Engineer:

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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What is Reverse Engineering?

Reverse Engineering is defined as the analysis of a device or object to determine its structure

or function.

It is also an activity you do to determine how a product works, or to learn the ideas and

technology that were originally used to develop the product.

Reverse engineering also involved using various measuring devices to hand measure the part or

parts and then recreating those dimensions in CAD.

For simple part, it is easy to create a CAD file. But for complex surfaces, it is nearly

impossible.

Reverse engineering is a systematic approach for analyzing the design of existing devices or

systems. You can use it either to study the design process, or as an initial step in the redesign

process, in order to do any of the following:

Observe and assess the mechanisms that make the device work . Dissect and study the inner workings of a mechanical device . Compare the actual device to your observations and suggest improvements

Before you decide to re-engineer a component, be sure to make every effort to obtain existing

technical data. For example, you can proceed with reverse engineering if replacement parts are

required and the associated technical data is either lost, destroyed, non-existent, proprietary, or

incomplete.


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What can Reverse Engineering be used for?

Replicating parts that have no tooling or CAD data.Documenting existing architectural work.Documenting museum pieces.Crime Scene Investigation.Creating digital data of engineering mockups such as clay or wood.Creating 3D data files of the human face or figure.Medical Device fitting.Scaling of artist's model.Packaging design.


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Reasons for reverse engineering a part or product:

The original manufacturer of a product no longer produces a product. There is inadequate documentation of the original design. The original manufacturer no longer exists, but a customer needs the

product.

The original design documentation has been lost or never existed Some bad features of a product need to be designed out. To strengthen the good features of a product based on long-term usage of

the product.

To analyze the good and bad features of competitors' product. To explore new ways to improve product performance and features. To gain competitive benchmarking methods to understand competitor's

products and develop better products.

The original CAD model is not sufficient to support modifications orcurrent manufacturing methods.

The original supplier is unable or unwilling to provide additional parts. The original equipment manufacturers are either unwilling or unable to

supply replacement parts, or demand inflated costs for sole-source parts.

To update obsolete materials or antiquated manufacturing processes withmore current, less-expensive technologies.

Reverse engineering may also be necessary if alternative methods of obtainingtechnical data are more costly than the actual reverse engineering process.

What are the Benefits?

Higher accuracy on complex surfaces vs. hand measuring.Faster process compared to traditional methods.Replicate existing geometry quickly and inexpensively.


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The Flow Chart of Reverse Engineering

CAE

Object

3D Scanning

CAM

CAD modeling

CNC

RP/RT

Products / Mould

Manufacturing

Process

Feature Detect Surface

Reconstruct

CAE


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3D scanner

Reverse engineering of a mechanical component requires a precise digital model

of the objects to be reproduced.

A 3D scanner can be used to digitize free-form or gradually changing shaped

components as well as prismatic geometries whereas a coordinate measuring

machine is usually used only to determine simple dimensions of a highly

prismatic model.

These data points are then processed to create a usable digital model, usually

using specialized reverse engineering software (CAE).

Definition:

A 3D scanner is a device that analyzes a real-world object or environment

to collect data on its shape and possibly its appearance. The collected data

can then be used to construct digital, three dimensional models
http://en.wikipedia.org/wiki/Reverse_engineeringhttp://en.wikipedia.org/wiki/Coordinate_measuring_machinehttp://en.wikipedia.org/wiki/Coordinate_measuring_machinehttp://en.wikipedia.org/wiki/Three_dimensional_modelhttp://en.wikipedia.org/wiki/Three_dimensional_modelhttp://en.wikipedia.org/wiki/Coordinate_measuring_machinehttp://en.wikipedia.org/wiki/Coordinate_measuring_machinehttp://en.wikipedia.org/wiki/Reverse_engineering


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Technology

3D Laser Scanning or 3D Laser Scanners can generally be categorized into three

main categories - laser triangulation, time of flight and phase shift.

These laser scanning techniques are typically used independently but can also be

used in combination to create a more versatile scanning system.

There are also numerous other laser scanning technologies that are hybrids and/or

combinations of other 3D scanning technologies.

Laser triangulation is accomplished by projecting a laser line or pointonto an object and then capturing its reflection with a sensor located at a

known distance from the laser's source. The resulting reflection angle can

be interpreted to yield 3D measurements of the part.

Time of flight laser scanners emit a pulse of laser light that is reflected

off of the object to be scanned. The resulting reflection is detected with asensor and the time that elapses between emission and detection yields the

distance to the object since the speed of the laser light is precisely known.

Phase shift laser scanners work by comparing the phase shift in thereflected laser light to a standard phase, which is also captured for

comparison. This is similar to time of flight detection except that the phase

of the reflected laser light further refines the distance detection, similar to

the vernier scale on a caliper.


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3D scanner areas covered include:

Human body scanner. Face scanning. Automated part scanner. Industrial tracking. Building measurement. Animal measurement. Medical applications. Automatic inspection.


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Computer Aided Engineering (CAE)

In todays competitive environment, companies are constantly facing the pressureto produce differentiated products that are low cost, high quality, and satisfy

customer demands.

Traditional design and analysis tools require too much time and effort from

engineers who must rely heavily on physical prototyping, educated guesses, a

handbook, and their experience to validate their design.

CAE is the use of information technology to support engineers in tasks such as

analysis, simulation, design, manufacture, planning, diagnosis, and repair.

Definition:

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.

Also used computers in modeling engineering factors, processes, or systems,

such as heat transfer, liquid- and gas flows, stresses and strains.
http://en.wikipedia.org/wiki/Information_technologyhttp://en.wikipedia.org/wiki/Engineerhttp://en.wikipedia.org/wiki/Analysishttp://en.wikipedia.org/wiki/Computer_simulationhttp://en.wikipedia.org/wiki/Designhttp://en.wikipedia.org/wiki/Manufacturehttp://www.businessdictionary.com/definition/computer.htmlhttp://www.investorwords.com/3082/modeling.htmlhttp://www.businessdictionary.com/definition/engineering.htmlhttp://www.businessdictionary.com/definition/factor.htmlhttp://www.businessdictionary.com/definition/system.htmlhttp://www.businessdictionary.com/definition/transfer.htmlhttp://www.investorwords.com/7640/gas.htmlhttp://www.businessdictionary.com/definition/flow.htmlhttp://www.businessdictionary.com/definition/strain.htmlhttp://www.businessdictionary.com/definition/strain.htmlhttp://www.businessdictionary.com/definition/flow.htmlhttp://www.investorwords.com/7640/gas.htmlhttp://www.businessdictionary.com/definition/transfer.htmlhttp://www.businessdictionary.com/definition/system.htmlhttp://www.businessdictionary.com/definition/factor.htmlhttp://www.businessdictionary.com/definition/engineering.htmlhttp://www.investorwords.com/3082/modeling.htmlhttp://www.businessdictionary.com/definition/computer.htmlhttp://en.wikipedia.org/wiki/Manufacturehttp://en.wikipedia.org/wiki/Designhttp://en.wikipedia.org/wiki/Computer_simulationhttp://en.wikipedia.org/wiki/Analysishttp://en.wikipedia.org/wiki/Engineerhttp://en.wikipedia.org/wiki/Information_technology


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CAE software is used on various types of computers:

Mainframes and super minis. Grid-based computers. Engineering workstations. Personal computer.

A typical CAE program is made up of a number of

mathematical models (Numerical theories)like Finite element method, Boundary

element method, Finite difference method and encoded by algorithms written in a

programming language.

CAE allows for many more iterations of the analysis-design cycle than was

possible by hand computation, especially when the CAE is coupled with

optimization systems that drive this cycle automatically.

The benefits are translated into improved productivity and quality of design.


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CAE areas covered include:

Stress analysis on components and assemblies using FEA (Finite ElementAnalysis).

Thermal and fluid flow analysis Computational fluid dynamics (CFD). Kinematics. Mechanical event simulation (MES). Analysis tools for process simulation for operations such as casting,

molding, and die press forming.

Optimization of the product or process.

In general, there are three phases in any computer-aided engineering task:

Pre-processing defining the model and environmental factors to beapplied to it. (typically a finite element model, but facet, voxel and thin

sheet methods are also used)

Analysis solver (usually performed on high powered computers) Post-processing of results (using visualization tools)

This cycle is iterated, often many times, either manually or with the use of

commercial optimization software.
http://en.wikipedia.org/wiki/Stress_analysishttp://en.wikipedia.org/wiki/Finite_Element_Analysishttp://en.wikipedia.org/wiki/Finite_Element_Analysishttp://en.wikipedia.org/wiki/Computational_fluid_dynamicshttp://en.wikipedia.org/wiki/Kinematicshttp://en.wikipedia.org/wiki/Castinghttp://en.wikipedia.org/wiki/Molding_(process)http://en.wikipedia.org/wiki/Multidisciplinary_design_optimizationhttp://en.wikipedia.org/wiki/Voxelhttp://en.wikipedia.org/wiki/Multidisciplinary_design_optimization#Commercial_MDO_Toolshttp://en.wikipedia.org/wiki/Multidisciplinary_design_optimization#Commercial_MDO_Toolshttp://en.wikipedia.org/wiki/Voxelhttp://en.wikipedia.org/wiki/Multidisciplinary_design_optimizationhttp://en.wikipedia.org/wiki/Molding_(process)http://en.wikipedia.org/wiki/Castinghttp://en.wikipedia.org/wiki/Kinematicshttp://en.wikipedia.org/wiki/Computational_fluid_dynamicshttp://en.wikipedia.org/wiki/Finite_Element_Analysishttp://en.wikipedia.org/wiki/Finite_Element_Analysishttp://en.wikipedia.org/wiki/Stress_analysis


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Key Benefits of CAE:

Ease 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.

Scalability gives you the flexibility to buy what you need today and

upgrade capabilities anytime.

Some CAE software:


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Computer Aided Manufacturing (CAM)

Its primary purpose is to create a faster production process and components and

tooling with more precise dimensions and material consistency, which in some

cases, uses only the required amount of raw material (thus minimizing waste),

while simultaneously reducing energy consumption.

CAM is a programming tool that makes it possible to manufacture physical

models using computer-aided design (CAD) programs.

CAM creates real life versions of components designed within a software

package.

Definition:

is the use ofcomputer-based software tools that assist engineers and machinists

in manufacturing or prototyping product components and tooling.

Early Use of CAM:

The first commercial applications of CAM were in large companies in the

automotive and aerospace industries for example UNISURF in 1971 at Renault

for car body design and tooling.
http://en.wikipedia.org/wiki/Computer-aided_designhttp://en.wikipedia.org/wiki/Computerhttp://en.wikipedia.org/wiki/Softwarehttp://en.wikipedia.org/wiki/Machinistshttp://en.wikipedia.org/wiki/Manufacturinghttp://en.wikipedia.org/wiki/Prototypinghttp://en.wikipedia.org/wiki/Tool_and_die_makerhttp://en.wikipedia.org/wiki/UNISURFhttp://en.wikipedia.org/wiki/Renaulthttp://en.wikipedia.org/wiki/Renaulthttp://en.wikipedia.org/wiki/UNISURFhttp://en.wikipedia.org/wiki/Tool_and_die_makerhttp://en.wikipedia.org/wiki/Prototypinghttp://en.wikipedia.org/wiki/Manufacturinghttp://en.wikipedia.org/wiki/Machinistshttp://en.wikipedia.org/wiki/Softwarehttp://en.wikipedia.org/wiki/Computerhttp://en.wikipedia.org/wiki/Computer-aided_design


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Overview:

Traditionally, CAM has been considered as a numerical control (NC)

programming tool wherein three-dimensional (3D) models of components

generated in CAD software are used to generate CNC code to drive numerically

controlled machine tools.

As with other Computer-Aided technologies, CAM does not eliminate the need

for skilled professionals such as Manufacturing Engineers and NC Programmers.

CAM, in fact, both leverages the value of the most skilled manufacturing

professionals through advanced productivity tools, while building the skills of

new professionals through visualization, simulation and optimization tools.

CAM is a process just like the rest of the steps in CNC. You need to do certain

things before it spits out the tool paths and then the G-Code. These things you

need to define change with the type of CAM you are using and the CAM

program you are using. They are all similar, but a bit different.

Typical areas of concern:

High Speed Machining, including streamlining of tool paths Multi-function Machining 5 Axis Machining Ease of Use

Here are the CAM Steps:

Define Material . Define Stock Size. Define Coordinates. Define Tool . Define Feeds and Speeds. Simulate Machining . Post Process .
http://en.wikipedia.org/wiki/Numerical_controlhttp://en.wikipedia.org/wiki/Computer_aided_designhttp://en.wikipedia.org/wiki/CNChttp://en.wikipedia.org/wiki/Machine_toolhttp://en.wikipedia.org/wiki/Multiaxis_machininghttp://en.wikipedia.org/wiki/Multiaxis_machininghttp://en.wikipedia.org/wiki/Machine_toolhttp://en.wikipedia.org/wiki/CNChttp://en.wikipedia.org/wiki/Computer_aided_designhttp://en.wikipedia.org/wiki/Numerical_control


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Rapid Prototyping

The first techniques for rapid prototyping became available in the late 1980s and

were used to produce models and prototype parts. Today, they are used for a

much wider range of applications and are even used to manufacture production-

quality parts in relatively small numbers. Some sculptors use the technology to

produce complex shapes for fine arts exhibitions.

There are different forms of Rapid Prototyping available depending upon the

needs. One can differentiate between them by the methods these systems employto make the layers. Following are few of the main types of Rapid Prototyping.

Definition:

Rapid prototyping is the automatic construction of physical objects using additive

manufacturing technology.
http://en.wikipedia.org/wiki/Model_%28physical%29http://en.wikipedia.org/wiki/Prototypehttp://en.wikipedia.org/wiki/Manufacturehttp://en.wikipedia.org/wiki/Sculptorhttp://en.wikipedia.org/wiki/Fine_artshttp://en.wikipedia.org/wiki/Exhibitionhttp://en.wikipedia.org/wiki/Exhibitionhttp://en.wikipedia.org/wiki/Fine_artshttp://en.wikipedia.org/wiki/Sculptorhttp://en.wikipedia.org/wiki/Manufacturehttp://en.wikipedia.org/wiki/Prototypehttp://en.wikipedia.org/wiki/Model_%28physical%29


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Stereo lithography (SLA):

Stereo lithography uses UV ray to solidify liquid acrylic polymer layer by layer

on a moving platform and after many layers, the prototype in the preferred form

is formed. This process is carried on in a VAT, a device that is filling up with

photo curable liquid acrylate polymer.

Stereo lithography is one of the most used forms of rapid prototyping because of

accuracy (Tolerances= 0.0125mm), less time taken (depends upon the size and

complication of the part) and where parts details are fine and their geometry is to

difficult to machined.


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Fused Deposition Modeling (FDM)

Fused deposition modeling also referred as FDM, is a rapid prototype technology

commonly used to convert CAD drawings into physical parts.

FDM works on an "additive" principle which extrudes material in layers. Plastic

or wax is melted and liquefied in the extrusion head and extruded through a

nozzle. The nozzle is made to move over a trail identified by the CAD design to

produce part. This way single layer is extruded and then it is dropped to extrude

the next layer on top of the first until the entire prototype is built, with one layer

at a time.


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Selective Laser Sintering (SLS)

Selective laser sintering (SLS) is an additive manufacturing technique that uses a

high power laser (for example, a carbon dioxide laser) to fuse small particles of

plastic, metal (Direct Metal Laser Sintering), ceramic, or glass powders into a

mass representing a desired 3-dimensional object.

The laser selectively fuses powdered material by scanning cross-sections

generated from a 3-D digital description of the part (for example from a CAD file

or scan data) on the surface of a powder bed.

After each cross-section is scanned, the powder bed is lowered by one layer

thickness, a new layer of material is applied on top, and the process is repeated

until the part is completed.
http://en.wikipedia.org/wiki/Laserhttp://en.wikipedia.org/wiki/Carbon_dioxide_laserhttp://en.wikipedia.org/wiki/Plastichttp://en.wikipedia.org/wiki/Metalhttp://en.wikipedia.org/wiki/Direct_Metal_Laser_Sinteringhttp://en.wikipedia.org/wiki/Ceramichttp://en.wikipedia.org/wiki/Glasshttp://en.wikipedia.org/wiki/Computer-aided_designhttp://en.wikipedia.org/wiki/Computer-aided_designhttp://en.wikipedia.org/wiki/Glasshttp://en.wikipedia.org/wiki/Ceramichttp://en.wikipedia.org/wiki/Direct_Metal_Laser_Sinteringhttp://en.wikipedia.org/wiki/Metalhttp://en.wikipedia.org/wiki/Plastichttp://en.wikipedia.org/wiki/Carbon_dioxide_laserhttp://en.wikipedia.org/wiki/Laser


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MANUFACTURING PROCESS

Casting :

Casting is a manufacturing process by which a liquid material is usually poured

into a mold, which contains a hollow cavity of the desired shape, and then

allowed to solidify. The solidified part is also known as a casting, which is

ejected or broken out of the mold to complete the process. Casting materials are

usually metals or various cold setting materials that cure after mixing two or

more components together; examples are epoxy, concrete, plaster and clay.

Casting is most often used for making complex shapes that would be otherwise

difficult or uneconomical to make by other methods.

Casting is a 6000 year old process. The oldest surviving casting is a copper frog

from 3200 BC .
http://en.wikipedia.org/wiki/Manufacturinghttp://en.wikipedia.org/wiki/Manufacturing


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Turning :

Turning is the process whereby a single point cutting tool is parallel to the

surface. It can be done manually, in a traditional form of lathe, which frequently

requires continuous supervision by the operator, or by using a computer

controlled and automated lathe which does not. This type of machine tool is

referred to as having computer numerical control, better known as CNC. and is

commonly used with many other types ofmachine tool besides the lathe.
http://en.wikipedia.org/wiki/Computer_numerical_controlhttp://en.wikipedia.org/wiki/Machine_toolhttp://en.wikipedia.org/wiki/Machine_toolhttp://en.wikipedia.org/wiki/Computer_numerical_control


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Grinding :

Grinding is a machining process that uses an abrasive wheel as the cutting tool.

A wide variety of machines are used for grinding.

They include:

Hand-cranked knife-sharpening stones. Handheld power tools such as angle grinders and die grinders. Various kinds of expensive industrial machine tools called grinding

machines.

The bench grinders often found in residential garages and basements.Grinding practice is a large and diverse area ofmanufacturing and tool making. It

can produce very fine finishes and very accurate dimensions; yet in mass

production contexts it can also rough out large volumes of metal quite rapidly. Itis usually better suited to the machining of very hard materials than is "regular"

machining (that is, cutting larger chips with cutting tools such as tool bits or

milling cutters), and until recent decades it was the only practical way to machine

such materials as hardened steels. Compared to "regular" machining, it is usually

better suited to taking very shallow cuts, such as reducing a shaft's diameter by

half a thou.
http://en.wikipedia.org/wiki/Machininghttp://en.wikipedia.org/wiki/Grinding_wheelhttp://en.wikipedia.org/wiki/Cutting_tool_%28metalworking%29http://en.wikipedia.org/wiki/Power_toolhttp://en.wikipedia.org/wiki/Angle_grinderhttp://en.wikipedia.org/wiki/Die_grinderhttp://en.wikipedia.org/wiki/Machine_toolhttp://en.wikipedia.org/wiki/Grinding_machinehttp://en.wikipedia.org/wiki/Grinding_machinehttp://en.wikipedia.org/wiki/Bench_grinderhttp://en.wikipedia.org/wiki/Manufacturinghttp://en.wikipedia.org/wiki/Tool_and_die_makerhttp://en.wikipedia.org/wiki/Hardnesshttp://en.wikipedia.org/wiki/Tool_bithttp://en.wikipedia.org/wiki/Milling_cutterhttp://en.wikipedia.org/wiki/Thou_%28length%29http://en.wikipedia.org/wiki/Thou_%28length%29http://en.wikipedia.org/wiki/Milling_cutterhttp://en.wikipedia.org/wiki/Tool_bithttp://en.wikipedia.org/wiki/Hardnesshttp://en.wikipedia.org/wiki/Tool_and_die_makerhttp://en.wikipedia.org/wiki/Manufacturinghttp://en.wikipedia.org/wiki/Bench_grinderhttp://en.wikipedia.org/wiki/Grinding_machinehttp://en.wikipedia.org/wiki/Grinding_machinehttp://en.wikipedia.org/wiki/Machine_toolhttp://en.wikipedia.org/wiki/Die_grinderhttp://en.wikipedia.org/wiki/Angle_grinderhttp://en.wikipedia.org/wiki/Power_toolhttp://en.wikipedia.org/wiki/Cutting_tool_%28metalworking%29http://en.wikipedia.org/wiki/Grinding_wheelhttp://en.wikipedia.org/wiki/Machining


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Technically, grinding is a subset of cutting, as grinding is a true metal cutting

process. Each grain of abrasive functions as a microscopic single-point cutting

edge (although of high negative rake angle), and shears a tiny chip that isanalogous to what would conventionally be called a "cut" chip (turning, milling,

drilling, tapping, etc.). However, among people who work in the machining

fields, the term cutting is often understood to refer to the macroscopic cutting

operations, and grinding is often mentally categorized as a "separate" process.

This is why the terms are usually used in contradistinction in shop-floor practice,

even though technically grinding is a subset of cutting.


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Milling:

Milling machine is a machine tool used for the shaping of metal and other solid

materials.

Milling machines exist in two basic forms: horizontal and vertical, which terms

refer to the orientation of the cutting tool spindle. Unlike a drill press, in which

the work piece is held stationary and the drill is moved vertically to penetrate the

material, milling also involves movement of the work piece against the rotating

cutter, the latter of which is able to cut on its flanks as well as its tip. Work piece

and cutter movement are precisely controlled to less than 0.001 inches (.025

millimeters), usually by means of precision ground slides and lead screws or

analogous technology. Milling machines may be manually operated,

mechanically automated, or digitally automated via computer numerical control

(CNC).

Milling machines can perform a vast number of operations, some very complex,

such as slot and keyway cutting, planning, drilling, die sinking, rebating, routing,

etc. Cutting fluid is often pumped to the cutting site to cool and lubricate the cut,

and to sluice away the resulting swarf.
http://en.wikipedia.org/wiki/Drill#Drill_presshttp://en.wikipedia.org/wiki/Leadscrewhttp://en.wikipedia.org/wiki/Computer_numerical_controlhttp://en.wikipedia.org/wiki/Computer_numerical_controlhttp://en.wikipedia.org/wiki/Leadscrewhttp://en.wikipedia.org/wiki/Drill#Drill_press


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Shaper :

A shaper is a machine tool used for shaping or surfacing metal and other

material.

Shapers have been largely superseded by milling machines or grinding

machines in modern industrial practice. The basic function of a shaper

machine is still sound and tooling for them is minimal and very cheap to

reproduce. They can be invaluable for jobbing or repair shops where only one

or a few pieces are required to be produced and the alternative methods are

cost or tooling intensive. The mechanically operated machines are simple and

robust in construction, making their repair and upkeep easily achievable.


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Forging :

Forging is the term for shaping metal by using localized compressive forces.

Cold forging is done at room temperature or near room temperature. Hot

forging is done at a high temperature, which makes metal easier to shape and

less likely to fracture.

Warm forging is done at intermediate temperature between room temperature

and hot forging temperatures.

Forged parts can range in weight from less than a kilogram to 170 metric tons.

Forged parts usually require further processing to achieve a finished part.


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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.

First a design is drawn using design software, then it is processed by the

computer and manufactured using the CNC machine.

CNC machines can be extremely large or medium size. and can classified by the

number of axis.

CNC is an important manufacturing process for rapidly prototyping an object.


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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.

Performing actions like turning on and off, rapid positioning moves, controlled feed moves in

straight lines and arcs, selecting tools, turning coolant on and off, and setting spindle speeds.

While G-Code can be directly programmed into a text file and read by the mill, it is more

common to use Computer-Aided Manufacturing (CAM) programs, like Pro/Engineer, to write

G-Code over a much easier to use user-interface.


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RE Example: Turbine Blade render

As we see in flow graph we follow the steps until we reach the final product.

3D scanning :

In 3D scanning there is many feature need to cheek it like :

Accuracy. Resolution. Type of scanner suitable for this application.

Feature

Name Faro arm Konica

Minolta

VIVID 9i

Z scanner 600 Z scanner 800

Accuracy. Up to 35 microns Up to 50 microns Up to 80 microns Up to 40 microns

Resolution. - - 0.1 mm in Z 0.05 mm in XYZ


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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)

CAM &Manufacturing Process:

There is many type of manufacturing process can be used :

Manufacturing process Cost Quantity Quality

Casting low high low

Forging medium low low

Forming high low low

CNC high high high
http://en.wikipedia.org/wiki/Computational_fluid_dynamicshttp://en.wikipedia.org/wiki/Computational_fluid_dynamics


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Analysis

3D scanning :

select (Z scanner 800)

CAE:

Use (Ansys) for stress analysis and fluid flow analysis.

Rapid prototyping:

Chose FDM and create the part.

CAM &Manufacturing Process:

Chose CNC for low quantity and for high quantity casting .


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References www.ems-usa.com www.metropolisdesign.com www.wikipedia.org www.cadworks.us www.absolutegeometries.com http://3dscanningtechnologies.com www.david-laserscanner.com
http://www.ems-usa.com/http://www.ems-usa.com/http://www.metropolisdesign.com/http://www.wikipedia.org/http://www.wikipedia.org/http://www.cadworks.us/http://www.cadworks.us/http://www.absolutegeometries.com/http://www.absolutegeometries.com/http://3dscanningtechnologies.com/http://www.david-laserscanner.com/http://www.david-laserscanner.com/http://3dscanningtechnologies.com/http://www.absolutegeometries.com/http://www.cadworks.us/http://www.wikipedia.org/http://www.metropolisdesign.com/http://www.ems-usa.com/


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Appendix:


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Konica Minolta VIVID 9i

The Konica Minolta VIVID 9i in the most advanced scanner in the VIVID line of

3D laser scanners. The VIVID 9i is truly a jack of all trades, able to scan objects

ranging from very small to very large - all with incredible accuracy and precision.

The tripod-mounted, all-purpose VIVID 9i offers portability, adaptability, and

quality scanning for a wide variety of applications.

Why the 9i?

The VIVID 9i, combined with the PSC-1 Photogrammetry system,

results in a highly accurate scanning system capable of precisely

capturing surface data of what would have been impossible with many

other scanners. The VIVID 9i offers the versatility and accuracy you

need to get the job done.

Key Features

Accuracy of 50 microns (0.002inches).

Turntable accessory. Captures color detail. Photogrammetry PSC-1 system. Three interchangeable lenses.

Benefits

Ideal for inspection. Great for scanning small parts. Use for texture mapping /

visualization.

Removes tolerance stack. Use for wide range of object size

The VIVID 910 is the perfect solution for non-intensive engineering projects

such as:

Faces, bodies, life, etc. Architecture. Sculptures. Artwork.


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With the introduction of the EXA scan laser

scanner from Handy scan 3D; the handheld 3D

laser scanner market gets a new option with

increased resolution and accuracy. This turns

the Handy scan 3D product line into a viableoption for scanning highly detailed surfaces and small objects in many fields such as

aerospace, automotive, consumer products and more.

The EXA scan 3D laser scanner is equipped with a third high definition camera which greatly

increases the scanning resolution as well as the data acquisition accuracy.

Why the Handy scan 3D EXA scan?

The Handy scan 3D EXA scan boasts a number of unique features that help differentiate itself

from other scanning systems. Being an upgrade to the Handy scan 3D REV scan, the EXAscan laser scanner has many of the same features and benefits. The EXA scan also boasts a

new automatic multi-resolution function enabling it to automatically set the optimum

resolution based on the type of surface it is scanning.

Key Features

3 Cameras. Automatic multi-resolution function. Self positioning (does not require an arm). User friendly and ergonomic design. Plug-and-play. Portable scanner system. Versatile use.

Benefits

2x the resolution of the REV scan. 20% increase in accuracy from the REV scan. Easily accesses hard-to-scan areas. Easy to learn - virtually no learning curve. Quickly sets up for scanning. Highly mobile. Use for wide range of object size.

You will see the most benefit with the EXA scan if your projects involve:

Low to medium curvature parts. Free form shapes. Reverse engineering/modeling. Objects ranging in size from a breadbox to a typical car.


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Handheld scanners have long requiredexternal tracking devices such as robotic arms to

track their position. This makes even handheld

scanners difficult to work with at times due to the

cumbersome nature of these devices.

The versatile REV scan from Handy scan 3D is the first truly portable handheld laser scanner,

requiring nothing more than a user and laptop to operate. Call us today to find out how the

REV scan can help you discover the possibilities that 3D laser scanning has to offer.

Why the Handy scan 3D REV scan?

The Handy scan 3D REV scan boasts a number of unique features that help differentiate itself

from other scanning systems. Being the first self-positioning handheld scanner in the market,

the Handy scan 3D's REV scan offers quality scanning for many different applications.

Key Features

Self positioning (does not require an arm). User friendly and ergonomic design. Plug-and-play. Portable scanner system. Versatile use.

Benefits

Easily accesses hard-to-scan areas. Easy to learn - virtually no learning curve. Quickly sets up for scanning. Highly mobile. Use for wide range of object size.

You will see the most benefit with the REV scan if your projects involve:

Large or low curvature parts. Less emphasis on scan resolution. Free form shapes. Reverse engineering. Objects ranging in size from a breadbox to a typical car.


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Reverse Engineer In V2

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Transcript of Reverse Engineer In V2