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MAN 547
Reverse Engineering in Mechanical Design
Dr. Mohamed Badran
Department of Mechanical Engineering
Reverse Engineering-Hardware and Software
Reference
• Raja, Vinesh and Kiran J. Fernandes. “Reverse
Engineering: An industrial Perspective”
Springer, 2008.
MAN 547 Dr. Mohamed Badran 2
Introduction: RE Hardware
RE Hardware is used for RE data acquisition
Collection of geometric data that represent a physical object.
RE data acquisition technologies:
– Contact
– Noncontact
– Destructive
RE data acquisition output:
– 2-D cross-sectional images
– Point clouds
MAN 547 Dr. Mohamed Badran 3
Introduction: RE Software
RE Software is used to transform the RE data acquired
into 3-D geometric models.
Two types of 3-D data are generated which are:
– Polygons
STL , VRML, or DXF format (RP, laser milling, 3-D graphics,
simulation and animation)
– NURBS (non-uniform rational B-splines)
Surface or solids (CAD, manufacturing and engineering CAD-CAM-
CAE)
MAN 547 Dr. Mohamed Badran 4
Contact Methods
Contacts methods digitizes a surface employing:
– Sensing devices with mechanical arms
– Coordinate measurement machines (CMM)
– Computer numerical control (CNC) machines
Data collection techniques:
– Point to point sensing
with touch-trigger probes.
– Analogue sensing with
scanning probes.
MAN 547 Dr. Mohamed Badran 5
Contact Methods: Point to point
sensing
A touch trigger probe is used that is installed on a CMM or on an
articulated mechanical arm.
MAN 547 Dr. Mohamed Badran 6
Contact Methods: Point to point
sensing
MAN 547 Dr. Mohamed Badran 7
Contact Methods : Analogue sensing
• Scanning probe provides continuous deflection output combined
with the machine position to derive the location of the surface
• Scanning speed > 3 times Point to point
MAN 547 Dr. Mohamed Badran 8
Contact Methods : Analogue sensing
MAN 547 Dr. Mohamed Badran 9
Contact Methods
Advantages:
• High accuracy
• Low cost
• Ability to measure deep slots and pockets
• Insensitivity to color or transparency
Disadvantages:
• Slow data collection
• Distortion of soft objects by the probe
MAN 547 Dr. Mohamed Badran 10
NonContact Methods
Project energy source onto an object, then either the transmitted or
the reflected energy is observed.
Calculation of geometric data by:
• Triangulation
• Time of flight
• Wave interference information
• Image processing algorithm
MAN 547 Dr. Mohamed Badran 11
NonContact Methods
Advantages:
• No physical contact
• Fast digitizing of substantial volumes
• Good accuracy and resolution for common applications
• Ability to detect colors
• Ability to scan highly detailed objects
Disadvantages:
• Limitations for colored, transparent or reflective surfaces
• Lower accuracy
MAN 547 Dr. Mohamed Badran 12
NonContact Methods Classification via
data acquisition technique
MAN 547 Dr. Mohamed Badran 13
NonContact Methods: Optical
Triangulation
MAN 547 Dr. Mohamed Badran 14
NonContact Methods: Optical
Structured light
MAN 547 Dr. Mohamed Badran 15
NonContact Methods: Optical
Structured light
MAN 547 Dr. Mohamed Badran 16
NonContact Methods: Optical
Interferometry (moir Effects)
MAN 547 Dr. Mohamed Badran 17
e
NonContact Methods: Optical
Time of flight
MAN 547 Dr. Mohamed Badran 18
NonContact Methods: Optical
Passive methods
• Shape from shading
• Shape from stereo
• Shape from motion
• Shape from focus/defocus
• Shape from Silhouette, and volumetric reconstruction
MAN 547 Dr. Mohamed Badran 19
NonContact Methods: Optical
Coherent laser radar
MAN 547 Dr. Mohamed Badran 20
NonContact Methods:Nonoptical
Acoustic (active sonar)
Microwave radar
MAN 547 Dr. Mohamed Badran 21
NonContact Methods: Transitive
Computerized tomography (CT)
Computerized axial tomography (CAT)
Computerized transaxial tomography ( CTAT)
Digital axial tomography (DAT)
MAN 547 Dr. Mohamed Badran 22
Destructive Method
• 2-D slice images of the part are gathered by destroying the part
layer by layer.
• Applicable for small and complex objects (internal and external
features)
• Components:
CNC milling + CCD Camera
• Acceptable accuracy
• layer thickness 0.0127-0.254 mm
• repeatability ±0.0127 mm
• Any machinable object
• Destruction of part (disadvantage)
MAN 547 Dr. Mohamed Badran 23
Destructive Method
• 2-D slice images of the part are gathered by destroying the part
layer by layer.
• Applicable for small and complex objects (internal and external
features)
• Components:
CNC milling + CCD Camera
• Acceptable accuracy
• layer thickness 0.0127-0.254 mm
• repeatability ±0.0127 mm
• Any machinable object
• Destruction of part (disadvantage)
MAN 547 Dr. Mohamed Badran 24

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MAN 547_Reverse Engineering-Hardware and Software.pptx

  • 1. MAN 547 Reverse Engineering in Mechanical Design Dr. Mohamed Badran Department of Mechanical Engineering Reverse Engineering-Hardware and Software
  • 2. Reference • Raja, Vinesh and Kiran J. Fernandes. “Reverse Engineering: An industrial Perspective” Springer, 2008. MAN 547 Dr. Mohamed Badran 2
  • 3. Introduction: RE Hardware RE Hardware is used for RE data acquisition Collection of geometric data that represent a physical object. RE data acquisition technologies: – Contact – Noncontact – Destructive RE data acquisition output: – 2-D cross-sectional images – Point clouds MAN 547 Dr. Mohamed Badran 3
  • 4. Introduction: RE Software RE Software is used to transform the RE data acquired into 3-D geometric models. Two types of 3-D data are generated which are: – Polygons STL , VRML, or DXF format (RP, laser milling, 3-D graphics, simulation and animation) – NURBS (non-uniform rational B-splines) Surface or solids (CAD, manufacturing and engineering CAD-CAM- CAE) MAN 547 Dr. Mohamed Badran 4
  • 5. Contact Methods Contacts methods digitizes a surface employing: – Sensing devices with mechanical arms – Coordinate measurement machines (CMM) – Computer numerical control (CNC) machines Data collection techniques: – Point to point sensing with touch-trigger probes. – Analogue sensing with scanning probes. MAN 547 Dr. Mohamed Badran 5
  • 6. Contact Methods: Point to point sensing A touch trigger probe is used that is installed on a CMM or on an articulated mechanical arm. MAN 547 Dr. Mohamed Badran 6
  • 7. Contact Methods: Point to point sensing MAN 547 Dr. Mohamed Badran 7
  • 8. Contact Methods : Analogue sensing • Scanning probe provides continuous deflection output combined with the machine position to derive the location of the surface • Scanning speed > 3 times Point to point MAN 547 Dr. Mohamed Badran 8
  • 9. Contact Methods : Analogue sensing MAN 547 Dr. Mohamed Badran 9
  • 10. Contact Methods Advantages: • High accuracy • Low cost • Ability to measure deep slots and pockets • Insensitivity to color or transparency Disadvantages: • Slow data collection • Distortion of soft objects by the probe MAN 547 Dr. Mohamed Badran 10
  • 11. NonContact Methods Project energy source onto an object, then either the transmitted or the reflected energy is observed. Calculation of geometric data by: • Triangulation • Time of flight • Wave interference information • Image processing algorithm MAN 547 Dr. Mohamed Badran 11
  • 12. NonContact Methods Advantages: • No physical contact • Fast digitizing of substantial volumes • Good accuracy and resolution for common applications • Ability to detect colors • Ability to scan highly detailed objects Disadvantages: • Limitations for colored, transparent or reflective surfaces • Lower accuracy MAN 547 Dr. Mohamed Badran 12
  • 13. NonContact Methods Classification via data acquisition technique MAN 547 Dr. Mohamed Badran 13
  • 15. NonContact Methods: Optical Structured light MAN 547 Dr. Mohamed Badran 15
  • 16. NonContact Methods: Optical Structured light MAN 547 Dr. Mohamed Badran 16
  • 17. NonContact Methods: Optical Interferometry (moir Effects) MAN 547 Dr. Mohamed Badran 17 e
  • 18. NonContact Methods: Optical Time of flight MAN 547 Dr. Mohamed Badran 18
  • 19. NonContact Methods: Optical Passive methods • Shape from shading • Shape from stereo • Shape from motion • Shape from focus/defocus • Shape from Silhouette, and volumetric reconstruction MAN 547 Dr. Mohamed Badran 19
  • 20. NonContact Methods: Optical Coherent laser radar MAN 547 Dr. Mohamed Badran 20
  • 21. NonContact Methods:Nonoptical Acoustic (active sonar) Microwave radar MAN 547 Dr. Mohamed Badran 21
  • 22. NonContact Methods: Transitive Computerized tomography (CT) Computerized axial tomography (CAT) Computerized transaxial tomography ( CTAT) Digital axial tomography (DAT) MAN 547 Dr. Mohamed Badran 22
  • 23. Destructive Method • 2-D slice images of the part are gathered by destroying the part layer by layer. • Applicable for small and complex objects (internal and external features) • Components: CNC milling + CCD Camera • Acceptable accuracy • layer thickness 0.0127-0.254 mm • repeatability ±0.0127 mm • Any machinable object • Destruction of part (disadvantage) MAN 547 Dr. Mohamed Badran 23
  • 24. Destructive Method • 2-D slice images of the part are gathered by destroying the part layer by layer. • Applicable for small and complex objects (internal and external features) • Components: CNC milling + CCD Camera • Acceptable accuracy • layer thickness 0.0127-0.254 mm • repeatability ±0.0127 mm • Any machinable object • Destruction of part (disadvantage) MAN 547 Dr. Mohamed Badran 24