A Case study on

Reverse Engineering
A real-life case study of a gear wheel of a rotating machinery

Presented by
Eng. Taha S. Sherif
ASME Journal Author
Assistant Lecturer, faculty of engineering, Menoufia University
Reverse Engineering Concept

Reverse Classic
Eng. Eng.
 Reverse Engineering (RE)
➢ The operation of acquiring a geometric CAD model by scanning or
Definition

digitizing given products or parts [4].

➢ The process of digitally capturing the physical entities of a component.
➢ RE is the method of reproducing new geometry from an existing part by
digitizing and editing an existing CAD data of part [6].

To give a demonstration of reverse engineering of parts whose geometric,

material, and manufacturing information is misplaced or not available
Aim

(drawings) and to replace broken, damaged and warn out parts to reduce
financial and production loss to the industry.

The three steps of data in reverse engineering activities connect to the

Steps

1) CAD model generation,

2) material identification, and
3) rapid manufacturing.
 Experimental Process for Replacement of Damaged Parts
Basically, the experimental process of work of reconstruction of the damaged part
consists of the three step procedure. The process can be
1. 3D scanning of damaged machine parts
2. Reconstruction of damaged area of parts using CAD soft ware.
3. Rapid prototyping of new created parts

Fig. 1 Process of reconstruction

of the damaged part.
 1. 3D scanning of damaged machine parts
The scan for a Virtual Model (damaged part) is carried out using a 3D scanner.
3D scanner is a device that analyses a real world object or environment to on its shape
and possibly its appearance [7].
Generally, these scanning processes differ in many aspects but the basic and digitalizing steps
remain the same.
It involve three main steps [8]:
• Exploration (acquisition of points)
• Manual or automatic alignment; and
• Fusion or processing of the geometrical points pack for conversion into solid state.
Usually, there are two ways of scanning, contact based and noncontact based.
 Contact Based Scanning Technique

In contact based type, measuring is done by physical contact between surface being
measured and measuring instrument to get as many dimensions as possible. The
easiest measurement process comprises manual measurement of a part’ s dimensions. A
coordinate measuring machine is the best and accurate approach in contact
based type. This machine captures point-to -point data of measurement.

Non-contact Based Scanning Technique

The device capture the data of part without any contact between them in non-contact
based type. It can be sub-divided into: Active and passive technique. The phenomenon
of. The point data is captured using lasers, optics, X-rays and charge-coupled device
structured lighting and reflection is used in the active technology (CCD) sensors in
non-contact scanners Other types of infrared radiation are also used [9].
 2. Formation of Modified Model
A transfer of 3D point´s cloud data from 3D Scanner into 3D CAD software

Modifications and reconstruction of scanned surface of part from scanner and formation new CAD model.

‘.stl’ file—file format accepted as universally for data transfer between 3D CAD software [11].

After the number operations for modification in damaged model in CAD software, the final new modified 3D
model is formed which is base for further operations.

The CAD software which can be used further modification and reconstruction for a damaged part CATIA
V5, SolidWorks, Geomagic Design X, Ansys SpaceClaim [12].
 3. Rapid Prototyping (RP)

Rapid prototyping can be defined as an additive process based on the philosophy of layered
technology in which cross-sectional layers are deposited one after other by plastic, wax or
paper to create part [13].

The CAD model is sliced into the cross-sectional layers of parts and printed using one of RP
technology available [14].

All techniques involves the same basic step process:

(i) Conversion of the CAD model to STL format,
(ii) Slicing the part STL file into cross-sectional layers nearly 0.01–0.7 mm thin,
(iii) Construction of the layers of the model one after another as sliced, and
(iv) Post processing such as cleaning and curing [15].

A variety of rapid prototyping technologies have emerged.

Fused Deposition Manufacturing (FDM) is process used in work as RP technique [16].
 Fused Deposition Manufacturing (FDM)

❑ In FDM, through a fine nozzle a model material is extruded out as filament and deposited
as initial position set by software.
❑ A thin cross-sectional slice of part is laid down with filament by nozzle on platform in
movement X–Y plane.
❑ For the next layer deposition platform moved down relative to nozzle and next layer is
deposited on previous one.
❑ Bonding between two slices takes place due hotness of extruded filament.
❑ Support structure is built by second nozzle with different material for part where needed.
As layer by layer the part is completed, it is post processed and support material is
removed [17].

A solid 3D printed model is formed which serve as masterpiece for casting or molding process
for further production new parts [18].
 Case Study: Gear Wheel of Rotating Machinery
Damage of machine parts is a serious concern in the production. It affects production flow
and causes financial losses due machine failure or fault.

A gear wheel in a rotating machinery was selected to examine the application of computer
aided reverse engineering technologies for rapid development of one-off complex parts
required for replacement process.
This replacement part has not any technical data or manufacturing drawings available with it.

The study involved three steps as follows:

STEP 1—3D scanning of damaged machine parts
STEP 2—Reconstruction of damaged area of parts using CAD software
STEP 3—Rapid Prototyping of new created parts.
Fig. 2 Diagram of broken and damaged area of gear wheel
 3D Scanning of Damaged Gear Wheel
A CAD model generation of damaged or broken gear wheel is the first step.
For obtaining the geometry of damaged body part, Range Vision 3D Scanner is used as 3D
scanning device .
Smart scanners can scan with markers that make alignment automatically and simplifies the
scanning process.
Part is prepared by spraying developer spray which create a coat white color and markers
are stick to part and turning table as suitable as shown in Fig. 3.

The project of gear with scanned markers is created in the RangeVision Smart ScanCenter.
After the first scan shot rotate the table slightly and Scan the object in the next position.

In this way by taking necessary scanned shots for complete scanning of part by rotating
table is to be done and ScanMerge is opened for further processing of the cloud points of
scanned part.
Fig. 3 Scanning arrangement
After the global registration editing of scanned part is done selection mode (rectangle, brush
or lacco) and unwanted part deleted using proper selection mode as shown in Fig. 4.
Function for filling gaps allows to automatically fill the gaps on unscanned area, remaining on
the model. Use this feature only for closed models, scanned from all sides.

Fig. 4 After completion of scanning in RangeVision ScanMerge

After the end of the work on processing scan data save the results. The model can now
be exported in one of the following formats: stl, obj, ply. Figure 5 shows STL model of
new part is reconstructed (Fig. 6).

Fig. 5 Final .stl file of gear wheel

 Reconstruction of Broken and Damaged Area of Gear Wheel
For further modifications on cloud points scanned data, CATIA V5 is used as editing CAD
software. In the CATIA V5, there is specialized module for the .stl file

Fig. 6 Representation of reconstruction damaged area of parts workflow

Editing and modifications can be done easily. Mainly, the basic three module of CATIA
software are used as (i) Digitized Shape Editor (ii) Generative Shape Design (iii) Quick Surface
Reconstruction. The reconstruction process of part goes through the following steps to get the
final product as soli d 3D model as shown in Fig. 7.

Fig. 7 Import .stl file CATIA V5

Fig. 8 Mesh generation, optimization with planar sections curves
❑ The alignment of the gear wheel is according to the coordinate axes and X– Y plane by the
‘Align by Best Fit’ tool in the module.
❑ Scanned point cloud data is then used for mesh creation on scanned point by ‘Mesh
Creation’ tool in the module by generating 3D mesh on points.
❑ As generated mesh contains large number triangles in formed mesh of part, it creates lot
of trouble during the editing of wheel.
❑ The optimization of triangles is done using ‘Mesh Optimization’ tool in module.
❑ This optimization by to 90% causes reduction and simplified mesh file of gear wheel to be
modified.
❑ The generated meshed gear wheel contains corrupted triangles, duplicated triangles, non-
manifold edges, inconsistent orientation, and non-manifold vertices and noise in the mesh
as shown in Fig. 8.
❑ ‘Mesh Cleaner’ is the tool used for Data clean up and noise removal from mesh file of
gear.
❑ The hole is filled using the ‘Fill Holes’ tool easily.
As cleaned mesh file of gear wheel is created, ‘Planar Sections’ tool created curves along the
scanned mesh on planes along different axis at suitable distance as per given.
❑ The planar sections are created along X-axis, Y-axis and Z-axis also. With ‘Curve From Scan’
tool, create the curves from planar sections for modifications on this curves. This gives us
complete structure of damaged and broken part as wireframe structure.
❑ As the wire frame type structure is formed, Generative Shape Design module in CATIA is used
for further modifications in the broken area and damaged teeth of gear wheel.
❑ So broken area is shown, the reconstruction of curve can be done, joining new area with
suitable lines and circles, the unwanted part deleted.
❑ The gear teeth profile from curves which is generated on scanned gear wheel is newly created
as shown in Fig. 9 and the profile projection of gear teeth is done to second limit of the gear
by angle 7° and a complete single teeth is created of gear as wireframe structure
Fig. 9 Gear teeth profile creation along curves Fig. 10 Wireframe structure of gear
As single teeth is created of gear wheel, the whole is structure is rotated around 360° and
total gear teeth profile of wheel is created in wireframe structure .
The complete reconstructed new wireframe model is generate d from scanned gear wheel as
shown in Fig. 10.

The process of surface generation along the wireframe structure is done and surface 3D
model is generated in Generative Shape Design module.

As Surface geometry of new modified gear wheel is created. It is converted to the solid 3D
model as shown in Fig. 11 and part verification is done to avoid any mistake in the
modifications and reconstruction of damaged and broken area.
Solid 3 D model of new gear wheel can be export ed in various fi le form at as per the
requirement for further processes like STL, IGES, STEP, etc. fi le format. It is export ed in STL
file for rapid proto typing of new 3D model as shown in Fig. 12.

Fig. 11 CAD model of gear wheel Fig. 12 STL model of gear

 Rapid Prototyping of New Create d Parts
‘uPrint SE Plus’ is used as RP machine which made by US based company ‘Strasys’ which uses
FDM Technology to build in real ABS plus thermoplastic.
The .stl file of gear wheel model is imported to the CATLYST EX build preparation software.
CATLYST EX software slices and positions a 3D CAD file and generates a route to extrude ABS
material and calculates any need of support material to the model (Fig. 13).

Fig. 13 3D printed model of gear

Inside the uPrint SE plus printer as printing is started, 3D model of gear wheel is
created layer by layer as seen. The time required for model of gear is 7 h 24 min.

As the process of printing of new model is completed, support material is to be

broken away or dissolves it in solution cleaning solution for support (water and
detergent), and the solid gear wheel model is ready to use for further process
(Table 1)
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