Project Report For the Project of Reverse Engineering of Complex Geometry
University of Glamorgan
Faculty of Advanced technology
Project Report
For the Project of
Reverse Engineering of Complex Geometry Components
Submitted by: Md Moonzoor Morshed
Supervisor: Dr. Jafar Jamshidi
University Enrolment Number: 09160906
Submitted on: Sunday, 23 March 2014
Abstract
This research proposes the methodology of Reverse Engineering to repair complex geometry components. The work contains algorithms and techniques of digitizing, assessment analyses, and surface renovation. And tool path production needed for the repair process. Using a 3D non-contact determining system, outputting higher data quality, higher resolution and smoother mesh surfaces in comparison to touch probe and laser scanners digitization is accomplished.
The developed machining strategy facilitates the creation of multi-axis tool paths for removing excess material dumped in restoration process. The projected methodology has been productively executed to repair the geometry of an aero engine component and free-from surfaced parts. With the guidance, the total repair time has been reduced and the consistency of repairing a component has been improved. By using such a cost effective and time saving methodology of maintenance, repair and creation of new elements or parts, any nation or company can improve their profit margin undauntedly.
Abbreviations
CAD Computer Aided Design
CAM Computer Aided Manufacturing
CC Cutter Contact
CL Cutter Location
CMM Coordinate Measuring Machine
CNC Computer Numerical Control
DOF Degree Of Freedom
HP High Pressure
HSM High Speed Machining
ISO International Standards Organization
LE Leading Edge
MCU Machine Control Unit
MIG Metal Inert Gas
MRO Maintenance, Repair and Overhaul
NC Numerical Control
NGV Nozzle Guided Vane
NURBS Non-Uniform Rational B-spline Surface
Pro/E Pro-Engineer
Ra Arithmetic mean roughness
RE Reverse Engineering
RM Rapid Manufacturing
RP Rapid Prototyping
RR
Faculty of Advanced technology
Project Report
For the Project of
Reverse Engineering of Complex Geometry Components
Submitted by: Md Moonzoor Morshed
Supervisor: Dr. Jafar Jamshidi
University Enrolment Number: 09160906
Submitted on: Sunday, 23 March 2014
Abstract
This research proposes the methodology of Reverse Engineering to repair complex geometry components. The work contains algorithms and techniques of digitizing, assessment analyses, and surface renovation. And tool path production needed for the repair process. Using a 3D non-contact determining system, outputting higher data quality, higher resolution and smoother mesh surfaces in comparison to touch probe and laser scanners digitization is accomplished.
The developed machining strategy facilitates the creation of multi-axis tool paths for removing excess material dumped in restoration process. The projected methodology has been productively executed to repair the geometry of an aero engine component and free-from surfaced parts. With the guidance, the total repair time has been reduced and the consistency of repairing a component has been improved. By using such a cost effective and time saving methodology of maintenance, repair and creation of new elements or parts, any nation or company can improve their profit margin undauntedly.
Abbreviations
CAD Computer Aided Design
CAM Computer Aided Manufacturing
CC Cutter Contact
CL Cutter Location
CMM Coordinate Measuring Machine
CNC Computer Numerical Control
DOF Degree Of Freedom
HP High Pressure
HSM High Speed Machining
ISO International Standards Organization
LE Leading Edge
MCU Machine Control Unit
MIG Metal Inert Gas
MRO Maintenance, Repair and Overhaul
NC Numerical Control
NGV Nozzle Guided Vane
NURBS Non-Uniform Rational B-spline Surface
Pro/E Pro-Engineer
Ra Arithmetic mean roughness
RE Reverse Engineering
RM Rapid Manufacturing
RP Rapid Prototyping
RR
References: 1. Galetto, M. & Vezzetti, E., 2006. Reverse engineering of free-form surfaces-A methodology for threshold definition in selective sampling. International Journal of Machine Tools and Manufacture, 10(46), pp. 1079-1086. 2. Gao, J., Yilmaz, O. & Gindy, N., 2004. An integrated repair system for complex geometry parts. Second International Conference on Manufacturing Research, ICMR2004, Issue 7-9 September, pp. 99-104. 3. Haibin, X. Y. X. Z. a. W., 2001. Research on integrated reverse engineering technology for forming sheet metal with a freeform surface. J.of Materials Processing Technology, 2-3(112), pp. 153-156. 4. Huang, C. a. M. S., 1994. Reverse engineering of planar parts using machine vision. Int. Journal of Computers & Industrial Engineering, 2(26), pp. 369-379. 5. Ingle, K. A., 1994. Reverse engineering. Michigan: McGraw-Hill. 7. K.L. Chui, W. K. C. a. K. Y., 2007. Direct 5-axis tool-path generation from point cloud input using 3D biarc fitting, Hong Kong: The Hong Kong Polytechnic University. 8. Lo, C.-C., 1999. Real-time generation and control of cutter path for 5-axis CNC machining. International Journal of Machine Tools and Manufacture, 3(39), pp. 471-488. 9. Ming-Lun, C. D.-F. F., 1996. Reconstruction technique in reverse engineering,Industrial Technology. (ICIT apos96) Proceedings of the IEEE International Conference, Issue 2-6 Dec., p. 3741. 10. Vosselman, G. & Mass, H.-G., 2010. Airborn and Terrestrial Laser Scaning. Caithes, GB, 336 p, Whitt. 11. Wang, W., 2010. Reverse Engineering: Technology of Reinvention. Florida: CRC Press. 13. Yu-Shen Pi-Qiang Yu, H. Z. J.-G. S. a. K. R., 2006. Automatic least-squares projection of points onto point clouds with applications in reverse engineering. J. of Computer Aided Design, 12(38), pp. 1251-1263. 2. Boehm, B. W. 1979. Guidelines for verifying and validating software requirements and design specifications. In Euro IFIP 79, ed. P. A. Samet, 711–719. Amsterdam: North-Holland Publishing Company. 3. Chikofsky, E. J., and Cross, J. H., II. 1990, January. Reverse engineering and design recovery: A taxonomy. IEEE software. Washington, DC: IEEE Computer Society, 7:13–17. 4. Francis, P. H. 1988. Project Management. In Tool and Manufacturing Engineers Handbook volume 5–Manufacturing Management, ed. R. F. Veilleux and L. W. Petro, 17–20. Dearborn: SME. 5. Fu, P. 2008. Reverse engineering in the medical device industry. In Reverse engineering: An industry perspective, ed. V. Raja and K. J. Fernandes, 177–93. Berlin: Springer. 6. MIL-HDBK-115A. 2006. US Army Reverse Engineering Handbook (Guidelines and Procedures). 6. Redstone Arsenal: US Army Aviation and Missle Command. Gao J, Folkes J, Yilmaz O, Gindy NNZ (2005) Investigation of a 3D Non-contact Measurement based Blade Repair Integration System. Aircr Eng Aerosp Technol 77(1):P34–P41 7 8. US ARMY, 1987, reverse engineering handbook (mil-hdbk, 115me) guidelines and procedures. 9. Dix B (2004) Aerofoil machining and polishing combined into a single automated process. Int J Aircr Eng Aerosp Technol 76(5) 10 11. Cavlab quality inspection services website, 2005, (www.cavlab.com/reverse engineering .html) 12 13. Lawguru F.A.Q website, 1999, (www.lawguru.com/FAQ/19.14.html) 14 17. Matteson, Donna and Kulibert, Rich and Matteson, Dustin and Oswego, Sunny, 2005, Learning through reverse engineering, (www.oswego.edu /dmstteson/reng.ppt) 18 19. http://www.airliners.net/photo/Russia—Air/Tupolev-Tu4/1297549/&sid=53544687ba303b720943707110073baf accessed January 12, 2010.With permission.