Reason for choosing topic
The automotive industry in Vietnam is experiencing rapid growth, prompting increased demands from the government, manufacturers, and consumers A significant concern has been the supply of spare parts, which faced challenges during the Covid-19 pandemic due to transportation restrictions impacting manufacturing To bolster domestic production, the government has implemented various policies aimed at strengthening the automotive sector in recent years Additionally, there is a high demand for skilled labor in this industry, leading universities to expand their automotive programs However, the high cost of equipping these programs with necessary study materials remains a significant challenge.
Mechanical design is significantly enhanced by advanced computer software, with leading programs like SolidWorks and Inventor being essential tools for modern engineers Proficiency in these applications is crucial, as they provide detailed 3D visualization of designs Beyond individual part creation, these programs facilitate the assembly process, allowing engineers to estimate, design, and simulate their products effectively.
From these conditions mentioned above, we decided to use CAD programs, and apply reverse design engineering to build a 3D model, which can be simulated on the computer.
Topic research purpose and goals
Topic research purpose
Understanding the Top-down design engineering and applying it in the project
Applying reverse engineering software to design and manufacture parts in the automotive field
Build a database about learning models in the school’s practice workshop and support for study purposes in the future.
Topic research goals
Applying Geomagic Design X to build an original 3D file from the real models
Building the exact geometry of the 3D models by using the Solidworks Part module from the original file
Assembling these parts into a complete component of the engine on the computer
Simulation of the assembly process.
Research objects
In the topic APPLIED REVERSE DESIGN ENGINEERING IN
Our team is dedicated to researching automotive mechanical assemblies, with a particular emphasis on high-pressure diesel pump components This study aims to deepen our understanding of their design and functionality Additionally, the role of CAD software programmers is crucial to this project, as their expertise in application is integral to our research efforts.
Research area
Researching REVERSE ENGINEERING theory fundamental, the origin and development of this engineering
Overall researching the design process
Studying how to use the equipment (Laser scanners) and software programmers (Geomagic Design X, Solidworks,…) which support the project
Studying assembly simulation (Solidworks Assembly module) to show and apply the project for further study purposes
Estimate result
Getting the best quality 3D file after scanning and processing with the Geomagic Design X
Building the geometries of 3D models that exact to the real models
Assembly can work without confliction
Easily understanding when watching the simulation
Being a base for the further project such as building a 3D library of components in the engine for education purposes
Scope of the study
Learn about the theoretical basis of reverse engineering, the formation and development of this method affecting the development of the world economy
Studying the overall design process since then to have a specific view that can be applied to the research of the topic
Learn about how to approach using equipment and software for direct prototyping with machine parts in cars
Learn about the application of reverse engineering in a variety of fields.
Research methods
There are many scientific research methods such as:
Data collection method qualitative method
Methods of analysis and synthesis
Applied reverse design engineering in automotive mechanical assemblies simulation offers significant practical applications and enhancements Utilizing experimental methods is essential for effectively conducting research and achieving meaningful improvements in this field.
Structure of the thesis
For the topic of APPLIED REVERSE DESIGN ENGINEERING IN AUTOMOTIVE MECHANICAL ASSEMBLIES’ SIMULATION, there are 7 main parts:
Overview
Foreign scientific studies on reverse engineering methods
1.1.1 Reverse Engineering in Modeling of Aircraft Propeller Blade - First Step to Product Optimization
Modern propeller planes are increasingly utilizing fiber-reinforced composite propellers, replacing traditional aluminum options Despite this shift, aluminum propellers remain prevalent in military aircraft due to their reliability, strength, and integrity Conducting research or modifications on aluminum propellers is challenging without accurate CAD data.
- Similar techniques for creating CAD models using laser scanners can be applied to build precise geometric models for other aircraft parts
- Reverse engineering-based 3D CAD geometry reconstruction could provide a viable alternative to aerodynamics that make curves, profiles, and very complex geometries to duplicate
The generated CAD model will facilitate structural and kinetic analysis, while also enabling CFD analysis of the entire wing and its spoiler to determine aerodynamic load (pressure) distribution across various flight conditions.
The aerodynamic load calculated can be utilized to assess the strength and stiffness of a structure through Finite Element Analysis (FEA) Following this, actual Computer-Aided Design (CAD), FEA, and Computational Fluid Dynamics (CFD) data are obtained via comprehensive computational analysis and reverse engineering.
1.1.2 Reverse Engineering and Topology Optimization for Weight
The optimal design strategy for minimizing the weight of the bell crank, inspired by the Louis Christen Road Racing F1 Sidecar, utilizes reverse engineering to develop a 3D model of this crucial mechanical component The bell crank serves a vital role in converting the motion of links at an angle, functioning as a connection between the spring and damper on one end and the push/pull rod on the other.
* The 3D bell crank model has been converted to:
- The finite element (FE) model is used to describe vibration eigenvalues
- Response to stimulus using the Lanczos iterative method in the Abaqus software
* The crank part of the bell is also tested by:
- Use a laser vibrating meter to capture the natural frequencies and corresponding vibration mode shapes The test results are used to validate the FE model
The topology optimization process analyzes the structure with a focus on minimizing weight while adhering to constraints related to stiffness and strain energy The result of this optimization is an enhanced design, which is subsequently transformed back into a 3D model.
- It is then built to create a physical prototype to verify and validate the design using
FE analysis and lab experiments, and then compare with the original part
The study demonstrates that the optimized design successfully reduced weight by approximately 3% while enhancing the natural frequency by 2% Additionally, it achieved a 4% reduction in maximum principal distortion and a 16.5% decrease in maximum von Mises stress compared to the original design These findings confirm the effectiveness of the proposed method in optimizing topology for a lightweight yet robust structure.
* In this paper, a design optimization method is described combining:
- Non-destructive measurement technique by laser vibrating meter
- A reverse engineering technique for 3D modeling
1.1.3 Reverse Engineering of Automotive Parts Applying Laser Scanning and Structured Light Techniques
This research paper aims to reproduce automotive spare parts through reverse engineering
The procedure is as follows:
- Laser scanning is the use of a CCD camera to record the configuration of a laser beam as it passes through an object
The newly developed 3D models will enhance the IRIS 3D part database, aiming to facilitate a partial CAD and reconstruction of the original design for future applications.
- 1 In this project, some achievements were made to model selected parts of the body using two different systems, with two different techniques
- Using a laser-based triangulation and structured lighting system which has various benefits that make both systems ideal for 3D reconstruction
- The triangle-based system has no ambient light issues affecting data collection 3D CAD modeling can continue to be improved
- Models should show little occluded or missing data and have data free of noise and surface anomalies caused by surface reflections or object positioning
The two techniques modeled parts using different methods, the post-processing of the data was similar
1.1.4 Reverse Engineering in Mechanical Component
* Project on reverse engineering application Reverse engineering helps:
- Get the shape of a part or product that is not available
This component is currently unavailable in the market due to its age, and there are no existing drawings for it As a result, it must be custom manufactured, necessitating a complete process that includes design and rapid prototyping.
- The first part of the geometry is obtained with the help of scanning technology.,
- With the use of various soft ceramics, a three-dimensional image of the damaged impeller is obtained
After acquiring the image, the part undergoes optimization through CAD software Once the optimized geometry is achieved, a pattern of the part is created using a rapid prototyping machine, which can then be utilized for casting the original component.
- Reverse engineering can be used for worn or damaged parts where availability is an issue, in cases such as not having any prior documentation or drawings available
- Provides digital data for CAD CAM & CAE applications Since the underlying data is recovered using the Reverse Engineering process, it can be further used for different processes
- Obtain the CAD model of the component, which can be used for analysis and design optimization
Reverse engineering is advantageous for product development from a market perspective, and when combined with rapid prototyping, it enables the creation of models that facilitate the manufacturing of the original product Additionally, rapid prototyping enhances visualization and comprehension of the final product.
Domestic scientific research articles on reverse engineering methods
1.2.1 Reverse engineering and 3D printing technology in supporting craniofacial surgery
Recent research highlights a significant demand for craniofacial surgery, with annual procedures totaling 1,000 to 1,200, which only meets 10-15% of the actual need In recent years, the medical field has leveraged reverse engineering (RE) and medical image-based modeling technologies to create 3D models of patients' anatomical structures using computed tomography (CT) and magnetic resonance imaging (MRI) These RE techniques and imaging devices facilitate comprehensive internal and external scanning, enabling accurate data acquisition of anatomical features The resulting 3D models have diverse applications in medicine, enhancing surgical training, preoperative planning, diagnosis, and treatment.
* The results of RE application in craniofacial surgery have shown advantages such as:
Reducing surgery time to 40-60 minutes enhances anesthesiology expertise, minimizing unforeseen risks during procedures This efficiency not only alleviates fatigue for the surgical team but also lowers the costs associated with supplies and medications used in the anesthesia process.
Surgeons visualize the craniometrical injury and prepare the necessary graft for assembly They utilize an intuitive model for consultation, ensuring optimal surgical options are considered.
Autologous bone grafting utilizes additional bone harvested from the patient's own body as grafting material This technique allows the surgeon to accurately assess the size of the graft, enabling precise cuts and minimizing the need for multiple incisions during the procedure.
After surgery and recovery, patients experience improved aesthetics with a cortical structure resembling that of a healthy individual, boosting their satisfaction and confidence This article explores the integration of medical image processing, reverse engineering, and 3D printing technologies to create precise biomedical 3D models for skull and facial surgeries These advancements enhance the accuracy of surgical graft design and manufacturing, reduce potential errors during procedures, and shorten anesthesia, surgery, and recovery times for patients Furthermore, 3D models facilitate preoperative planning, allow for surgical rehearsals, test innovative medical techniques, and contribute to medical research and the training of healthcare professionals in surgical practices.
1.2.2 Reverse engineering for re-export of worn-out machine parts based on 3D scan data
The study highlights the crucial reasons for re-exporting worn and damaged machine parts, emphasizing the impact of uncontrolled variations in failure conditions, including wear degree, structural failures, and complex geometries.
Remanufacturing critical machine components that experience wear or failure presents a sustainable solution for minimizing environmental impact and financial costs by extending their lifespan The effectiveness of this process is influenced by the extent of variation in failure conditions, including wear, damage, size, and structure While manual repairs can restore components to their original shape, they often require significant time and effort, and the quality may not match that of new products.
The Reverse Engineering (RE) method transforms existing physical products into detailed drawings and remanufactured parts Utilizing 3D digital test equipment, the model's point cloud data set is analyzed to reconstruct the CAD model through 3D geometry modeling This process enables the identification and localization of failure points in mechanical components Central to RE technology are the testing equipment and process software, with widely used tools including PIX 30 DOT, ATOS, and MCAx scanners Key application software for RE technology comprises Geomagic Studio, SiemensNX, Pro/E, and the Point Cloud Function Module.
This paper introduces a reverse engineering method for reconstructing 3D CAD geometry of worn and damaged machine parts in need of remanufacturing Utilizing point cloud data from laser scans, the approach involves filtering noise, extracting features, and simplifying data to create highly accurate geometric models This technique is particularly effective for reproducing screw air compressor components The successful remanufacturing of these damaged parts highlights a growing trend in the industry towards economic efficiency through equipment reuse and emphasizes the future potential of reverse engineering and rapid prototyping.
1.2.3 Development of reverse engineering process of metal parts in the
The article highlights the significance of Reverse Engineering (RE) technology, particularly through the use of 3D scanners and Additive Manufacturing (AM), which are prevalent in various industries, including defense and civil sectors RE plays a crucial role in verifying geometrical accuracy and validating part measurements A notable example is Fain Models and colleagues, who utilized the NVision Scanner to produce replicas of fighter jet ejection seats for flight training equipment, achieving substantial cost savings compared to traditional prototyping or large-scale projects.
MSI company utilized 3D scanning technology to develop CAD models of B52 aircraft engine components, enabling alternative manufacturing solutions Additionally, RE technology was implemented to ensure high-precision inspections during the production of specialized parts, including turbine blades for aircraft engines.
The research paper outlines the reverse engineering process, which begins with a virtual reality prototype and specialized equipment to obtain 3D data This data is subsequently processed to create a solid CAD model of the part The final stage, after developing the 3D CAD model, mirrors the traditional engineering cycle.
The author team utilized Turbine for sample scanning and product redesign, employing Geomagic Design X software to process point cloud data and create a new 3D model Throughout the design process, they assessed the error between the reconstructed data and the scanned data, ensuring that adjustments kept the error within acceptable limits This paper outlines the detailed reverse engineering process of the TV3-117 engine turbine wing from the Mi- helicopter.
The 3D model of the 17 and Mi-172 helicopters serves as a high-quality input for the metal 3D printing process, which requires additional research to assess its performance in high-temperature environments, particularly due to turbine engine characteristics While the details may be incomplete, the article also suggests an enhanced technological process aimed at improving product quality following the technology loop.
Basis of R&D theory
Overview of reverse engineering technology
2.1.1 Introduction to reverse engineering technology
In manufacturing, the traditional production cycle involves a designer conceptualizing a product, outlining its design, and then calculating and testing it to finalize the manufacturing method This established approach has been utilized for centuries However, since the 1990s, reverse engineering has gained traction due to advancements in computer technology and 3-D design software Unlike traditional methods that rely on design ideas for prototyping, reverse engineering begins by scanning sample products to gather prototyping data and conduct product inspections This systematic approach aims to analyze existing devices or systems to understand their functionality and the original ideas and technologies behind their development.
It can be used to study the design process or as the first step in the redesign process, to do any of the following:
- Observe and evaluate the mechanisms that make the device work
Analysis and study of the internal functioning of a mechanical device Compare actual equipment with observations, judgments, and suggestions for improvement
Figure 2 1 Overview of reverse engineering
Reverse Engineering (RE) has gained popularity in recent years, but its application in product development dates back several decades It involves the process of replicating an object, component, or finished product without relying on drawings, documentation, or computer models.
Reverse engineering is the method of replicating a manufactured product by converting its physical form into 3D CAD data This process involves scanning and digitizing objects into points, curves, and surfaces, enabling precise reproduction of the original item.
Reverse engineering is a systematic technique used by designers and fabricators to evaluate existing products and competitors, facilitating the reinvention or enhancement of new ideas This process involves creating design models from current products, enabling technical analysis and the reconstruction of the product in its original or modified form.
2.1.3 Advantages and disadvantages of reverse engineering technology
- Allows fast and accurate design of designs with high geometric complexity or free surface patterns (shaping rules unknown) Build prototypes without blueprints
- The accuracy is a lot higher than using manual measurements
- Check the quality of the product by comparing the CAD model with the product, thereby adjusting the model or technological parameters to create a satisfactory product
- Recycling and creating product parts, molds, products at a reasonable cost and time
- Reduced manufacturing time leads to high productivity => shortens production time
- products to market => high economic efficiency
Recent advancements have led to the development of automatic devices for measuring 3D coordinates, alongside the application of reverse engineering techniques in various sectors such as enterprises, research institutes, and universities However, the high cost of this equipment poses challenges, necessitating a prolonged and ongoing process of improvement for effective implementation of these innovative technical solutions.
- Modern technology is needed as video scanners
- Do not reverse engineer the product if the product's procurement contract
- Remember to do reverse engineering using only part of the data.
Reverse engineering process
The process begins with a sample of the original or damaged physical part, which is digitized and processed using specialized equipment and software to create a precise CAD model Once the CAD model is obtained, the subsequent stages mirror the production cycle, involving calculation, analysis, and optimization through CAE/CAM software This is followed by technology preparation (CAPP) for rapid prototyping or CNC machining programming, culminating in a reality check before the part is mass-produced.
Reverse engineering for automation typically involves three key stages: first, sampling or surface digitization using coordinate scanning equipment; second, processing the collected data and creating design models with CAD software; and finally, applying these models in practical applications.
Phase 1: Sampling is the stage of digitizing the sample surface by means of coordinate scanning equipment The types of coordinate scanning equipment are selected according to the shape of the part, accuracy requirements, part materials, part dimensions The two most common types of coordinate scanning devices today are non-contact measuring devices and contact measuring devices Typical of these 2 types of machines are laser scanners and coordinate measuring machines (CMM) In this phase, the coordinate measuring device will pick up data about the object's geometric shape in the form of coordinates of points (x, y, z), which will then gather points on the object's surface described as "point clouds"
Phase 2: Next is the data processing and modeling phase, this stage uses 2 software: grid creation software (capable of automatically overlaying all data points) and 3D modeling software (capable of modeling curves, curved side NURBS, building a CAD design model from a point grid model through user interaction with the software's interface)
Phase 3: In the application phase, the design model can be refined and optimized by CAE analysis methods or moved to the mold design stage for the product and finally export design data in the form of technical drawings Design data can be directly used for production by transferring CAD models to CAM software for CNC machining programming or switching to STL data for rapid prototyping In addition to serving the manufacturing design, the reverse design process is also used to check and evaluate the accuracy between the processed product and the prototype
- Stage 1 Object Digitization: The Reverse Engineering process usually begins with digitization In which the subject undergoes contact measurement (CMM) or irradiation measurement (3D scanning)
Stage 2 of data processing involves converting the coordinate values obtained from the measurement process in the X, Y, and Z axes into a file format compatible with 3D software It is essential to filter out measurement data that falls outside the permitted range and present the remaining data visually This refined data can then be utilized to create CAD models directly.
- Stage 3: Creating a 3D model: There are 2 ways to create a 3D CAD model from measurement data, using free-form modelling
- pre-generated from measurement data; then the CAD model is created from
- Stage 5: Surface Mode: Surface CAD 3D model
In Phase 1 of styling, professional artists generate a variety of innovative designs based on the initial concept Subsequently, company departments convene to review and select the most suitable sketches, discarding those that do not align with the established basic criteria.
- Phase 2 Clay Modeling: Derived from the available or nearly identical base frame, balanced, and properly positioned
Creating a standing drum and a steering wheel perpendicular to the axle is essential in the prototyping process, where artisans skillfully apply clay to the frame This clay can sometimes be substituted with wood or plaster, allowing for a visually striking prototype that facilitates easy editing During this phase, various departments—including design, sales, research, customer care, production, and the board of directors—collaborate to observe, evaluate, and provide feedback The design team works with the prototyping department to adjust the model size for optimal usability, while the business team collaborates with manufacturers to assess preliminary production costs and market suitability Additionally, the customer service team incorporates insights from past customer feedback, and the board compiles all opinions to guide necessary modifications to the prototype.
- Phase 3 Digitization of Prototype products by 3D Scan method:
Using 3D scanning devices to scan the profile of the prototype product and collect data * STL (Polygon Mesh – polygon mesh) Then use specialized software to edit grid data (Geomagic Studio)
Phase 4 of reverse engineering involves utilizing 3D scan data alongside specialized software like Rapid Form XO to create a comprehensive 3D model of a car's body This process unfolds in three key stages: initially, the overall design is transformed into a Surface object, followed by the development of a fragmentation plan for each component based on its specific function, and concluding with the design of assembly positions and the thickening of plates, resulting in a Solid object.
Product => Digitization => Design model => Prototyping and testing => Products
1 Scan stage: use the scanner to conduct a detailed 3D scan The result is the set of points (point clouds) that make up the detail
2 This is the stage of digitizing the sample surface using various types of coordinate scanning devices The types of coordinate scanning equipment are selected according to the shape of the part, accuracy requirements, part materials, part size
Phase 2: Data processing on the software
The data processing and modeling phase involves entering point cloud data, minimizing interference, and reducing the number of points This stage produces a refined set of point cloud data, seamlessly integrated from scans and free of errors, utilizing two key software tools: grid creation software, which automatically overlays the grid across all data points, and 3D modeling software, which allows for the modeling of curves and NURBS, enabling users to create CAD design models from point grid models through interactive software engagement.
Currently, there are some popular software used for reverse engineering such as Geomagic Design X, Solidworks, Catia
Step 1: Edit the data grid, point cloud
Step 2: Simplify the triangle grid by reducing the number of triangles and optimizing the vertex position and how to connect the sides of each triangle in the grid so that the geometric characteristics do not change
Step 3: Split the grid and cut off the excess to create a smooth surface as you like
The application phase involves polygonization from point cloud data, leading to the creation of NURBS surfaces or STL outputs for rapid prototyping These outputs can be fine-tuned and optimized using CAE analysis before being transferred to the mold design stage The design data is then exported as technical drawings, which can be directly utilized in the production segment by converting CAD models to CAM software for CNC machining or switching to STL for rapid prototyping Additionally, the reverse design process is employed to assess and ensure the accuracy of the final product compared to the prototype.
To guarantee safety and precision in manufacturing, it is essential to test design parts for durability beforehand to minimize risks By utilizing theoretical calculations alongside a detailed software model created through reverse fabrication techniques, we can perform endurance tests on the components.
Measurement method
The primary types of coordinate scanning devices used today are non-contact measuring devices, such as laser scanners (e.g., Faro and ATOS – GOM), and contact measuring devices like coordinate measuring machines (CMM) The data collected from these scans is subsequently converted into a grid format, specifically the STL file format, for further analysis.
A coordinate measuring machine (CMM) is an essential tool for measuring the geometry of objects by detecting specific points on their surfaces using various types of probes, such as mechanical, optical, laser, and white light The probe's position can be adjusted either manually by the operator or automatically via a computer, with measurements typically referenced in a three-dimensional Cartesian coordinate system (XYZ axes) Many CMMs also offer the capability to control the probe's angle, enabling the measurement of hard-to-reach surfaces.
Typical 3D "bridge" CMM allows the probe to be moved along three axes; X, Y and
Z, are orthogonal to each other in the three-dimensional Cartesian coordinate system
Each axis of a Coordinate Measuring Machine (CMM) is equipped with a sensor that accurately monitors the probe's position, typically with micrometer precision When the probe detects a specific location on an object, it samples three position sensors to measure a point on the surface This process generates a "point cloud" that represents the areas of interest and is repeated by moving the probe as needed CMMs are commonly used in manufacturing and assembly to ensure parts meet design specifications, with point clouds analyzed through regression algorithms to identify features Measurements can be collected either manually by an operator or automatically through Direct Computer Control (DCC), making automated CMMs a specialized type of industrial robot capable of repeatedly measuring identical parts.
- The scanning mechanism can take three different forms:
A sliding table system features robust arms that maintain a constant perpendicular position, with shafts gliding along rails, making it particularly effective for flat profiles and simple convex curves Equipped with an articulated arm and a rigid frame, this system incorporates a high-precision angle sensor to determine the arm head's position The intricate calculations for wrist rotation and joint hinge angles allow for precise probing into crevices and internal spaces.
A combination of both methods can be used, such as an articulated arm suspended on a portable table, to map large objects to internal niches or overlapping surfaces
The machine operates on the principle of measuring each point on the object, ensuring high accuracy with a precision range of 0.1 to 0.5 micrometers This stroke-based operation allows for an impressive accuracy level of up to ten thousand.
- High automation: can be automated in the whole measurement process
- The result is that the files have many standard formats such as IGS, STP, STL, suitable for 3D design software.10
- Easy to handle measurement results: measurement results are a set of favorable curve lines that create sides on 3D design software
- Diverse measuring heads are suitable for measuring objects
- It is possible to determine the size, shape, position, and orientation of the object in a jig placed on a machine using a reference system The result is a reduction in measurement errors
- Limit the measurement of narrow angles, sharp edges, smaller in size than the radius of the measuring head
- The measurement speed is not high: only 10 to 1000 points per minute is much slower than laser scanning technology
- Limited size of objects to be measured
- The machine size is large, bulky and takes up a lot of installation space
- Not suitable for reverse engineering technology
A non-contact, non-destructive technology utilizes laser light to digitally capture the shape of physical objects This process generates a point cloud that precisely represents the surface profile of the object being scanned.
Figure 2 8 Atos Gom Inspect scanner
An active scanner utilizes various sources such as light, ultrasound, or x-rays to emit signals that probe an object or environment, detecting the reflected light or radiation that passes through the target.
A 3D scanner is a device that captures data about the shape and surface characteristics, such as color, of real-world objects This data is utilized to create digital holographic models.
Sampling time is rapid, allowing for the sampling of large-sized objects This technique is effective for sampling soft materials like plastics, foams, and waxes, as well as deformed objects, without causing any distortion or damage to the samples being measured.
- Not affected by ambient light when shooting with blue light The machine has a compact structure, simple mounting
- High resolution: The resolution of laser scanning is much higher than that of CMM meters CMM is only accurate to a limited number of proximity positions
- the measuring head but cannot be accurate and complete the whole product So, the laser scan gives a more complete surface metric of the CMM
The accuracy is not as high as the contact measurement method
– When measuring some glossy or transparent objects, it must be coated on the surface with a layer of paint or powder, which leads to errors
Scanning samples that are either too small or too deep presents challenges, necessitating the use of specific methods tailored to each case Each technique has distinct advantages and disadvantages, allowing for the possibility of combining methods to maximize efficiency A practical approach involves digitizing samples with a contactless scanner and subsequently verifying accuracy using a contact coordinate meter.
Common types of 3D scanners
Figure 2 9 Atos Gom inspect compact 5M
ATOS 5 features a powerful light source that delivers highly accurate data for a variety of applications, including manual operations and automation in mold manufacturing, tool production, and plastic injection parts, as well as metal molding GOM scanners provide exceptional sharpness, enabling precise visualization of intricate details such as small patterns, reinforced tendons, tendon structures, tiny arcs, and folded edges in sheet processing.
- High-intensity LED light source
ATOS 5 is focused on development for industrial applications
Meets the ability to provide highly accurate 3D data in short measurement time, even under some unfavorable measurement conditions
The 3D measurement data provided by ATOS 5 offers users comprehensive control over production processes and quality assurance, enabling the visualization of potential errors to expedite production With a robust light source, ATOS 5 ensures highly accurate data for various applications, including manual and automated uses, from mold and tool manufacturing to plastic injection and metal molding parts.
Data from GOM scanners show very high sharpness, such as accurately displaying the smallest patterns, reinforced tendon and tendon structures, very small arcs, or folding edges in sheet processing
MOBILE SCANNING MEASUREMENT scans plastic parts applied in the molding industry THE AIRCRAFT'S WINGS CHECK THE SUSPENSION DETAILS OF THE AIRCRAFT
Car Check the entire body
* Introduction: The 3D API scanner has outstanding accuracy and speed Can scan difficult high-contrast surfaces easily
The blue laser diagonal makes it easy and flexible to scan in any direction
- 200,000 points per second with a score range of 70% and an accuracy of 50u Integrated contact tracing enables CMM machine measurement for internal and external features
Contact probes fitted with RFID chips enable automatic style recognition
Flexible software – iScan3D can be used with any measuring software common point clouds
To prevent issues during the transition between device operators in partial test data, it is essential to focus on specific manufacturing applications These applications include factory production measurement, prototype part inspection and identification, high-precision reverse engineering, large body assembly, and the inspection of fixed parts, grooves, gaps, molds, mold niches, and surface contours Ensuring accurate alignment in these processes is critical for maintaining efficiency and quality in manufacturing.
Application of reverse engineering technology
Reverse engineering significantly reduces study time and enables the reconstruction of discontinued products, turning innovative ideas into reality This technology is widely utilized across various industries, including automotive, motorcycle, aerospace, shipbuilding, mold manufacturing, medical fields, architecture, and art.
The superiority of reverse engineering technology is to model many details (including highly complex details) quickly and accurately to meet the diverse needs of the market in many fields:
In the art world, reverse engineering technology plays a crucial role in replicating and analyzing the intricate details of masterpieces in painting and sculpture Skilled stylists utilize materials like clay, plastic, and wood to create products that reflect the high aesthetic standards of these works However, since original masterpieces are the creations of a select few artists, the demand for such art often outstrips supply, necessitating the production of similar items in various styles To fulfill this market demand, obtaining a CAD model of the desired product is essential, and this can only be achieved through reverse engineering technology With advanced equipment and computer assistance, we can generate CAD data that closely mirrors the original models crafted by artists, ensuring precision with minimal tolerances.
Figure 2 11 Reverse engineering in Art
In the automotive industry, reverse engineering technology is essential for replacing parts that manufacturers no longer supply or for creating innovative designs when original design materials are lost or unavailable This approach is particularly useful for products with complex shapes, such as those resembling humanoids or animals, where precise replication is challenging.
Figure 2 12 Reverse engineering in automotive engineering
Reverse engineering technology plays a crucial role in archaeology by enabling the restoration of prehistoric organisms' shapes from ancient fossils found in soil, rock, or ice, all while preserving the integrity of the specimens Additionally, this innovative approach facilitates the reconstruction of ancient statues and the restoration of historically significant architecture and art that have suffered destruction over time.
Figure 2 13 Reverse engineering in archaeology
Reverse engineering technology in medicine enables the rapid creation of customized body parts tailored to individual patients This innovative approach effectively addresses defects and damages caused by accidents or congenital issues, including bones, joints, molars, and cranial fragments.
Figure 2 14 Reverse engineering in medicine
Software that supports reverse engineering
Geomagic Design X is a powerful reverse engineering software that transforms polygon (Cloud Point) data from 3D scanners into CAD data It seamlessly integrates CAD software, serving as a vital link between the scanning process and the design of automotive components, home appliances, and various manufacturing applications.
Geomagic Design X reverse engineering software allows converting file formats including SolidWorks, Creo, NX, Inventor, AutoCAD, Catia and others
Integrate point clouds, grids, surfaces, and samples within a single application to enhance your CAD software This allows for the creation of root models featuring comprehensive feature trees, which are essential for effective design modeling.
Direct 3D scanner control over the most popular devices and full integration with Geomagic Capture scanners
Live Transfer supports bright data transfer of other popular CAD software such as Solidworks, Catia, NX, Inventor,
- Ability to merge data and cloud points efficiently, process and refine, creating powerful grid structures
Compatible with over 60 file formats including polygon grid, point cloud, and CAD Easy-to-use grid editing tool for quick patching, smoothing, and optimization
The ability to automatically overlay and create blocks as parametric elements from superior scan data
- Accuracy AnalyzerTM feature automatically compares and evaluates surfaces, blocks, the cross section compared to the original scan data is highly accurate
Create sharp design images with the Add-in that comes with Key shot
Creating intricate freeform shapes can be challenging with traditional CAD tools, but Geomagic Design X simplifies this process By starting with a physical model and scanning it, the software automatically processes the 3D scan to produce a seamless, high-quality surface Its advanced editing features enable users to make precise adjustments, making Geomagic Design X a favored choice among professionals in the automotive, aerospace, medical, and equipment sectors This innovative software significantly enhances productivity and saves time in design workflows.
SolidWorks is a highly trusted 3D design software favored by engineers due to its robust features and integration of diverse support tools Its applications span various industries, including construction, pipeline design, architecture, and interior design.
Through many versions, Solidworks has made many outstanding strides in terms of features, performance as well as meeting the expectations of professional 3D drawing design for engineering and industrial industries
Solidworks offers intuitive 3D CAD design solutions that enable users to efficiently create parametric 3D models while optimizing their workflow Additionally, it allows for the reuse of 2D drawing data, facilitating seamless conversion to 3D models, making it a powerful tool for designers.
Above all, the software features 3D modeling from photographs and this will shorten the time for creative activities, innovation, or development of unique products
- Powerful tools, quick processing of designs
Compared to technical design software such as Inventor, Catia, Solidworks is
"slightly" more "in terms of fast processing features - compact designs from basic to intensive smoothly
Above all, with Solidworks 2013 version and above, for drawings with many complex details, the machine still operates smoothly, without lag when operating
- Design and assemble parts into finished products
Solidworks offers a significant advantage in designing 3D detailed drawings, allowing users to assemble components into a complete block This feature enables the creation of unique products by freely designing and combining various parts.
Since Solidworks 2019, the software has introduced enhanced features for handling large assembly files, enabling faster loading speeds and efficient data export for quick viewing of drawings.
Solidworks features an intuitive resizing tool that customizes dimensions based on user preferences Additionally, the software includes capabilities for recording surface roughness, dimensional tolerances, and geometric specifications, enhancing its functionality for precision design.
In addition, users can create perpendicular projections of assemblies in a scale and position you decide without much impact on the drawing size
This software package is ideal for users of SOLIDWORKS Standard or Professional seeking an affordable structural simulation solution It offers essential simulation benefits, including linear stress analysis, time-based motion analysis, and fatigue analysis, making it a valuable tool for enhancing design efficiency and performance.
SOLIDWORKS Simulation Standard software enables engineers to integrate virtual simulation into their design processes by providing intuitive and powerful solutions
It also includes the Trend Tracker Productivity Tool that allows designers to highlight optimal design changes while they work by providing visual feedback on the impact of the design
* ProEngineer is software of Parametric Technology, Corp Partly
Soft design according to parameters, has many very strong features in the field
CAD/CAM/CAE, it gives us capabilities such as:
Direct modeling of solid objects
Create modules using design concepts and elements
- Kinetic simulation, mechanical structural dynamics
Pro/ENGINEER has evolved through various versions, including Pro/Engineer 2000, 2001, and the Wildfire series (2.0, 3.0, 4.0, 5.0), as well as Creo Elements/Pro 5.0 and Creo Parametric 1.0 and 2.0 This software is recognized for its power, flexibility, and user-friendliness, with up to 75% of users reporting satisfaction.
Pro/Engineer has become the dominant choice among Vietnamese mechanical designers, particularly in mold design, machine design, and precision mechanical processing Its design environment is unmatched by any other software available in the market.
Pro/E is a versatile CAD software that seamlessly integrates solid and surface modeling, enabling designers to accurately convey their product concepts Its capability to import designs from other software facilitates a smooth workflow, while the Import DataDoctor tool assists in editing any template issues Once the design is complete, Pro/E allows for easy export to AutoCAD or other formats, streamlining the printing process.
* The modules work on the software
- Pro/Design: This module allows users to design any product according to methods such as: Free design (Style), graph method
- Pro/Assembly: This module facilitates easy detailed setup into the system and under the system It supports assembly and assembly of groups, conflict situation resolution, design changes
The Pro/Manufacturing module features advanced machining process simulation, comprehensive error reporting, and efficient NC data export in CL data format It includes a robust Pro/Mold Design elements library, enabling users to create molds ranging from simple to complex designs This module also facilitates the simulation of mold separation and the testing of product pressing, enhancing the overall efficiency and accuracy of the mold design process.
- Pro/Mechanical: The module helps simulate collision problems, stress testing, transfer, linear and nonlinear pellets, identify and estimate the ability to destroy materials
The Pro/Plastic Advisor module enhances analysis and simulation of heat transfer issues, leveraging the advanced capabilities of Pro Engineer This robust CAD/CAM/CAE software excels in modeling intricate designs, including excavators, vehicles, and hull profiles, while offering significant assembly capacity and optimal design efficiency.
2.6.4 Software that supports reverse engineering
Reverse engineering applications provide an efficient technical solution for designers and manufacturers to swiftly create high-precision designs, making it an ideal choice for underdeveloped countries with limited scientific and technological resources The significance of researching reverse engineering in design is underscored by its substantial impact, prompting numerous software companies to integrate reverse engineering features into their design applications, including popular platforms like Solidworks, Inventor, NX, and Catia.
Object scanning
Set up scanning device
Carefully read the instructions for use before proceeding with the installation of the machine All contents and specifications of the GOM INSPECT IMPACT 5M scanner are in the accompanying catalog
1 Read the instructions for use
2 Watch video instructions for installing the scanner on YouTube with the keywords: setup, Gom inspect,
3 Set the full drive for each type of lens before calibration is carried out
4 Fully prepare supporting equipment before scanning: turntables, stickers, clay, …
To ensure accurate scanning results, select a stable, horizontal surface to prevent tilting and potential device falls A flat plane not only facilitates a quick and reliable calibration process but also minimizes errors, leading to more precise sample scans.
The primary extension cord features two plugs, with one end connecting the lens and camera power Additionally, it includes a connector for the lens that plugs directly into the computer's USB drive, while the opposite end connects to the power supply.
*Note: check the bottom of the computer for instructions on the compatible plug position for the scanner and the USB software copyright
The scanner set includes 3 sets of lenses for different distances and sizes of objects to be scanned:
- 300/MV150: scan objects that are small and need high detail
- 300/MV300: scan medium sized objects
* Note: each set of lenses when it comes to the calibration process will have a different balance board, it is necessary to choose the appropriate one
* Do not mix lenses with each other, which will cause the calibration to fail and the subject will not be scanned
To utilize a small set of lenses, it is essential to install the appropriate driver, while large and medium lenses come with drivers readily available for device calibration.
Open the software with the icon on the desktop or the taskbar
Then the main screen appears with options:
- open the program's sample file
- see instructions to use the program
To begin, select "open new file" if you don't already have a scanned document This action will direct you to the main workspace In the upper left corner, click on "set up" to adjust the lens settings and calibrate the scanner for optimal performance.
At this setup step, it is necessary to adhere to the specifications required by the software for each type of lens
To begin, set the specifications for the lens being used, selecting initial set points between 300mm and 790mm based on the lens type After making these selections, click 'Next' for each item, and finalize the alignment by adjusting two lasers to ensure the lens is oriented correctly at the center (+) of the measurement target.
Step 2 Adjust focus for the lens
To set up the projector, mount the lens and choose the correct 90-degree angle, either straight down or across the plane After configuring each setting, click 'Next' to proceed If needed, use the hexagon tool to loosen the Focus key ring and adjust it until the image on the computer screen is clear.
Step 3 Adjust the intensity of blue light for the center lens
The central lens body features a single rotation mechanism that allows users to adjust the intensity of the scanned light Following the software instructions, users should modify the light intensity until the software indicates the optimal setting is achieved Once the desired intensity is confirmed, the control ring should be locked to finalize the adjustment process.
Once the ideal light intensity is established, scanning objects at varying heights may result in overly harsh or insufficient lighting To address this issue without compromising image quality, we can customize the lighting in two effective ways.
- Re-adjust the light intensity with the control ring on the lens again
- Check the box that automatically adjusts the exposure on the scanning software
- Separate exposure adjustment for 2 side lenses on scanning software
Step 4 Adjust the aperture for each lens:
Perform aperture corrections for each lens like the above
In this stage, we adjust the aperture ring on all three lenses to ensure that the colors displayed on the software's heat panel for the right lens match closely with those of the other lenses.
Figure 3 12 Adjust right camera aperture
When adjusting light from blue-violet to orange-green, it's crucial to find the optimal intensity Excessively high blue-violet levels indicate that the light is too weak, while a shift to a white hue suggests that the light source is burning out.
In this step, users need to use a calibration board specific to each type of lens
- Small balance plate: for MV150 lens kit
- Medium balance plate: for MV300 lens kit
- Large balance plate: used for MV600 lens kit
To ensure optimal performance, the panel must be positioned vertically at a 90-degree angle to the lens, maintaining the appropriate distance as recommended by the software for each lens type and calibration panel.
Calibrating the scanner involves 10 to 20 steps, varying based on the lens set used The software provides precise guidance on the angle and distance for placing the scale board, ensuring accurate adjustments Simply follow the software's recommendations for optimal calibration results.
In the initial phase, the machine must calibrate the board at a right angle to the camera and lens, with the primary adjustment focusing on the distance of the table's position.
In the advanced phase of operation, the machine must accurately measure the tilt angles of the scale Users are required to navigate long distances around the machine while also positioning themselves at the correct angles as dictated by the software.
After the complete weighing period, we can conduct a sample scan
Install the machine on the leg and fasten the fixing pin Place the turntable in a flat position and fit the scanner range
Stick positioning points around the scanner so the machine can scan and stitch the scan fields together at the final stage
To start a new project, navigate to the software page and select the "NEW FILE" option In the main interface, choose to display a single camera for a clearer view of the scan results.
Reverse design
Import raw file (with extension STL)
After scanning process have been completed, the scan file will be export as a mesh file which has extension “ STL.”
The shortage of scan data
However, this file is not a completely useable because it has many shortages in geometry From this file, we import into the Geomagic DX
Step 1: Clicking on button “Import”
Position of the “Insert” button
Step 2: An Import box will appear, select the needed file to import, then click on the button “Run mesh buildup wizard”
Step 3: Picking up the model
Step 4: Deleting the unnecessary details
Step 5: Merging the data, fill holes
Run the Mesh Buildup Wizard
After running this setup, the mesh become clearly to reversed design However, the software cannot fix all surfaces that do not have enough data
Figure 4 8 Mesh Build up Overview the object after run Mesh Buildup Wizard
Figure 4 9 Overview the objectThe hole cannot be filled
Divide the region for the model
The mesh is already established, but it is essential to segment the data into distinct regions This tool assists in categorizing the mesh into regions that exhibit similar properties.
“plane”, “cone”, “cylinder”, … This function can be used to create new surface when we design
Choosing button “Auto Segment” for this step
Figure 4 10 Auto Segment Position of “Auto-Segment” button
Select the level of “Sensitivity”
The varying levels of "Sensitivity" will result in the release of different numbers of regions; selecting "More" increases the number of regions, indicating a more detailed mesh grouping.
The mesh after divide into many regions
After that, the program will return a model which is divided into many regions
If the region fails to meet the designer's requirements, we can adjust the mesh using the "Split" or "Merge" functions Since the model is appropriate for the next section, no additional steps are necessary.
Set up new alignment, new coordination for the model
In Technical Drawing, the observation orientation is crucial as it serves as a universal language for engineers to interpret drawings effectively However, it is important to note that the object's orientation may not always be optimized for design purposes.
Figure 4 13 Front viewFront view
So that, we need to set up new alignment, transfer to new coordination
At this step, we have two options “Align Wizard” or “Interactive Alignment”
Basically, understanding that, in the “Align Wizard”, the software will offer us several of selections for a new coordination We simply choosing the one which suitable for our design orientation
“Align Wizard” with options for a new coordination
Figure 4 18 Result Result after we apply one of these offers above
The "Interactive Alignment" option involves manually setting up an alignment, which may require significant preparation time The following steps will guide you through the setup process.
Step 1: Choosing a region which is suitable, then select “Surface Primitive” to build a new plane based on the surface of the suitable region Ticking on the selection
“Extract Specific Shape”, then choose the “plane” type at the box “Shape to Create”
Notice that for clearly view, we should hide References planes by tick the eye symbol of the “Ref Planes” at the model tree
Step 2: Drawing reference lines for two other planes Select to the plane have just been created, then choose “Mesh Sketch” Next, we set up for the sketch Choose the section polyline by offset from the base plane This step will help us define the direction of observation which we want
Figure 4 20 Mesh SketchChoosing “Mesh Sketch” to draw Sketch base on the profile of the mesh
Offset a section from the base plane to find the suitable profile
Step 3: Defining two lines that will extrude to be a plane These lines must be defined that perpendicular with each other
Define two lines which will be based to extrude planes
Step 4: Extruding lines for new planes Choosing “Extrude” button from tab “Create
To create a surface, select the desired profile from the predefined lines, with the offset direction automatically set to normal to the base plane Various extrusion types exist, but in this instance, we will apply the "Blind" option, extending up to a distance of 25 mm.
Figure 4 23 Extruding lines for new planes Extrude Surface
Figure 4 24 Extrude Surface Result with three plane which are used to define new Alignment
Figure 4 25 Result with three planesChecking with the mesh position
Step 5: Defining new Alignment Choosing “Interactive Alignment”, then select the mesh for “Moving Entities” Next, at each line “Plane”, “Vector”, “Position”, pick a plane for each At the scene on the right-hand side, that will show the new place for your mesh after setting up
Choosing plane for new Alignment
Step 6: Checking again for the observation direction and delete unneeded plane
Figure 4 27 Checking observation directionChecking new Alignment, and remove old plane
The "Align Wizard" method provides users with a quick and easy solution for aligning objects, particularly for rotating shapes like cylinders and spheres However, it may not fully align with the modeler's intent, as the available options are not clearly comparable to other methods.
The "Interactive Alignment" method involves manually establishing new coordination, allowing the modeler to manage the alignment based on their skills However, in certain instances, creating a base plane requires the user to possess advanced CAD processing abilities to ensure accurate positioning.
Reverse design based on the mesh model
After optimizing the requirements, we will construct a robust solid model derived from the processed mesh This section focuses on redrawing the geometry from the mesh, utilizing various methods to create a solid body By combining these techniques, we can directly generate a 3D model from the mesh with a tolerance of approximately 100 micrometers The complexity of the part will guide our planning for the model-building process.
Figure 4 32 Build a solid model Redraw geometry from the mesh
Figure 4 33 Comparing section geometry Comparing section geometry from mesh and the Solid body
Figure 4 34 Tools to build modelTools to build model from Sketch
Figure 4 35 Tools to build model Features when built a Solid body
Figure 4 36 FeaturesCompare the Tolerance between Scan data and the Solid body
Result after reverse design process
After completing the assembly process, we encountered issues with the 3D model due to a lack of experience and insufficient scan data Notably, the geometry of certain components, such as the control rack, control sleeve, and helix plunger, did not match the actual model Additionally, parts with varying internal dimensions, like the housing and outlet port, posed significant scanning challenges To address these discrepancies, we resorted to manual measurements using a vernier caliper; however, this method only provided general dimensions rather than optimized geometry for the model We also took care to measure the connections between parts to ensure that their tolerances did not conflict.
Below here is the image of parts in the PF pump assembly:
Figure 4 42 Cam head Isometric view
Figure 4 43 Cam head Front view
Figure 4 44 Cam head Top view
Figure 4 45 Return Spring Isometric view
Figure 4 46 Return Spring Front view
Figure 4 47 Return Spring Right view
Figure 4 48 Return Spring Top view
Figure 4 49 Bottom Spring Seat Isometric view
Figure 4 50 Bottom Spring Seat Front view
Figure 4 51 Bottom Spring Seat Right view
Figure 4 52 Bottom Spring Seat Top view
Figure 4 53 Upper Spring Seat Isometric view
Figure 4 54 Upper Spring Seat Front view
Figure 4 55 Upper Spring Seat Top view
Figure 4 56 Helix Plunger Isometric view
Figure 4 57 Helix Plunger Front view
Figure 4 58 Helix Plunger Right view
Figure 4 59 Helix Plunger Top view
Figure 4 60 Control Sleeve Isometric view
Figure 4 61 Control Sleeve Front view
Figure 4 62 Control Sleeve Right view
Figure 4 63 Control Sleeve Top view
Figure 4 64 Control Rack Isometric view
Figure 4 65 Control Rack Front view
Figure 4 66 Control Rack Right view
Figure 4 67 Control Rack Top view
Figure 4 72 Delivery Valve Housing Isometric view
Figure 4 73 Delivery Valve Housing Front view
Figure 4 74 Delivery Valve Housing Top view
Figure 4 75 Delivery Valve Piston Isometric view
Figure 4 76 Delivery Valve Piston Front view
Figure 4 77 Delivery Valve Piston Top view
Figure 4 78 Delivery Valve Spring Isometric view
Figure 4 79 Delivery Valve Spring Front view
Figure 4 80 Outlet Port Isometric view
Figure 4 81 Outlet Port Front view
Figure 4 82 Outlet Port top view