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Reverse Engineering

An Industrial Perspective

herausgegeben von: Vinesh Raja, Kiran J. Fernandes

Verlag: Springer London

Buchreihe : Springer Series in Advanced Manufacturing

Enthalten in: Springer Professional "Wirtschaft+Technik" , Springer Professional "Technik" , Springer Professional "Wirtschaft"

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Über dieses Buch

Congratulations and thank you for reading this book! You hold in your hand perhaps the first book solely written on mechanical reverse engineering from an industry perspective. The motivation for this book originates from the needs of today’s global industry. We recall an incident during one of our industrial trips to a local manufact- ing company. The office secretary was photocopying documents for this me- ing, when the manufacturing manager remarked, “Wouldn’t it be nice if I could do the same with mechanical parts, it would save me and my team a lot of time and money. ” “Have you not heard of reverse engineering?” we asked him. “- verse engineering, isn’t that something to do with programming computers?” “No,” we replied. “Reverse engineering (RE) refers to creating a computer-aided design (CAD) model from an existing physical object, which can be used as a design tool for producing a copy of an object, extracting the design concept of an existing model, or reengineering an existing part. ” His eyes lit up. Such sit- tions are not uncommon in today’s manufacturing arena. With globalization and trade liberalization, manufacturing companies face increasing competition from goods and services produced in lower wage eco- mies. Countries in the West cannot compete against low wages and must the- fore depend on raising innovation and best practices to create better products.

Inhaltsverzeichnis

Frontmatter

1. Introduction to Reverse Engineering

Abstract

This chapter introduces readers to the term reverse engineering (RE), and to the associated techniques that can be used for scanning physical parts. In addition, the chapter presents the process of reverse engineering and the strategy for scanning and converting the scanned data into a 3-D surface or solid model.

Vinesh Raja

2. Methodologies and Techniques for Reverse Engineering–The Potential for Automation with 3-D Laser Scanners

Abstract

In this chapter, we present methodologies and technologies for automating reverse engineering (RE) through digital imaging and computer vision. We begin this chapter with a definition of RE in terms of generating computer-aided design (CAD) models from existing objects and components. We use the term computer-aided reverse engineering (CARE) to describe this process. With this definition, we present a brief overview of the traditional approach to RE using coordinate measuring machines (CMMs). Then, we begin the main focus of the chapter where we explore digital imaging and computer vision as an alternative to CMMs. This exploration begins with data acquisition, where we present laser-based range scanners as a promising approach. For these scanners, we explain and highlight differences in data resolution and scanning rates and contrast those to CMM performance. Next, we present a processing pipeline for creating CAD models using these scanners. This processing includes tasks such as view registration, surface integration, patch reconstruction, model fitting, noise removal, and other functions. This chapter explains these topics to help the reader understand their importance in designing an RE imaging system and the impact that various parameters have on modeling accuracy.

David Page, Andreas Koschan, Mongi Abidi

3. Reverse Engineering–Hardware and Software

Abstract

Reverse engineering (RE) is generally defined as a process of analyzing an object or existing system (hardware and software) to identify its components and their interrelationships and to investigate how it works to redesign or produce a copy without access to the design from which it was originally produced (Wikipedia, 2005). In areas related to 3-D graphics and modeling, RE technology is used for reconstructing 3-D models of an object in different geometric formats.

D.T. Pham, L.C. Hieu

4. Selecting a Reverse Engineering System

Abstract

In recent years, the market for systems to generate geometric representations of physical objects has exploded in size and complexity, as has the number of potential applications. Applications range from scanning the bodies and tracking the motion of actors for computer animated films through surveying buildings, plants, and landscape, medical applications from brain and prenatal scans to rapid prototyping of prosthetic devices and models of the patient for rehearsal of surgery, to the more conventional engineering applications of inspection, reverse engineering of obsolete parts, measurement of deformation on crash testing, and so on. Each application has unique requirements.

The common thread in all these applications is that the starting point is the gathering of accurate x-y-z data over the surface of the object, and then from this, the construction of a geometric model in a computer system that can then be used in a variety of ways. Because of the wide variety of systems and applications, finding the right system for a particular application becomes difficult. This chapter offers a structured process for system selection which should lead to a sound system purchase. The different approaches to each stage of the reverse engineering process are classified and discussed, as are the pros and cons of each. Because the author has no links to any particular vendor, the chapter does not attempt to endorse or recommend any one approach or any one system. Each has a realm of application for which, given the constraints of cost, accuracy, and speed, it may be the best solution. The trick is to match the application requirements with the unique set of capabilities of a system!

John Keast

5. Introduction to Rapid Prototyping

Abstract

The term rapid prototyping (RP) refers to a class of technologies that are used to produce physical objects layer-by-layer directly from computer-aided design (CAD) data. These techniques allow designers to produce tangible prototypes of their designs quickly, rather than just two-dimensional pictures. Besides visual aids for communicating ideas with coworkers or customers, these prototypes can be used to test various aspects of their design, such as wind tunnel tests and dimensional checks. In addition to the production of prototypes, rapid prototyping techniques can also be used to produce molds or mold inserts (rapid tooling) and even fully functional end-use parts (rapid manufacturing). Because these are nonprototyping applications, rapid prototyping is often referred to as solid free-form fabrication or layered manufacturing. For small series and complex parts, these techniques are often the best manufacturing processes available. They are not a solution to every part fabrication problem. After all, CNC technology and injection molding are economical, widely understood, available, and offer wide material selection.

In rapid prototyping, the term “rapid” is relative; it aims at the automated step from CAD data to machine, rather than at the speed of the techniques. Depending on the dimensions of the object, production times can be as long as a few days, especially with complex parts or when long cooling times are required. This may seem slow, but it is still much faster than the time required by traditional production techniques, such as machining. This relatively fast production allows analyzing parts in a very early stage of designing, which decreases the resulting design cost. The costs can also be reduced because rapid prototyping processes are fully automated. and therefore, need the skill of individual craftsmen for no more than finishing the part.

Eef Moeskopf, Frits Feenstra

6. Relationship Between Reverse Engineering and Rapid Prototyping

Abstract

In recent years, advanced reverse engineering (RE) techniques have been developed to convert point cloud data, obtained through digitization (by contact or noncontact scanning), into CAD models either in NURBS or STL (triangular mesh) format. These CAD models can be subsequently used for fabrication by using either conventional material removal methods (e.g., milling) or material incremental methods, i.e., rapid prototyping (RP). On the other hand, as a nonconventional fabrication method, RP has been gaining greater popularity in industry recently due to its capability of creating three-dimensional (3-D) parts with complex geometries. Typically, the CAD model in the STL format is first sliced into 2-D layers before RP fabrication can be carried out. The fabrication efficiency and accuracy are directly affected by the thickness of the layers.

Recently, there has been much research on developing adaptive slicing techniques to determine the minimum number of layers required under an allowable shape error. Unrtil now, the modeling algorithms developed in RE and adaptive slicing algorithms in RP are quite capable of handling problems in their own domains. When using RP to fabricate a part based on its point cloud data, the RE modeling and RP slicing algorithms are used sequentially. This, however, can result in serious problems in error control because in either of the two processes, shape error is controlled within the given tolerance band independently. Therefore, the shape error between the finally fabricated part and the original point cloud data cannot be controlled effectively. To solve this problem, the RE modeling process and the RP slicing process must be integrated by following a model-for-RP approach.

This chapter focuses on issues in RE for direct RP by describing an innovative modeling method that slices the point cloud directly along the part building direction and generates a layer-based model (RP model) that can be used directly for fabrication by RP techniques. With this method, the integration of RE and RP in shape-error control can be effectively achieved. Furthermore, the slicing algorithm is also adaptive; thus the RP model generated has a minimum number of layers. Issues discussed include cloud data filtering, 2-D curve generation from point cloud data, and optimal layer thickness. Finally, the efficacy of the algorithms is demonstrated by several case studies.

Y.F. Zhang, Y.S. Wong, H.T. Loh

7. Reverse Engineering in the Automotive Industry

Abstract

Ford Motor Company celebrated its 100-year anniversary in 2003. Looking back over the decades, automakers have seen five influential trends in automotive design:

• the invention of the horseless carriage itself, a reengineering of a proven design;

• the speed and productivity of Henry Ford’s mass production system, which was reengineered from the Chicago meatpacking industry;

• an attempt by Alfred Sloan, president of General Motors, to appeal to individual customers’ desires by offering a greater variety of product models within the limits of mass production;

• the use of a wide variety of quality assurance methods to produce standard and exchangeable parts to reduce manufacturing costs; and

• attempting to fulfill the customer’s desire to have it all–the economy of mass production, design options to fit an individual’s taste and needs, and the highest possible quality.

Ping Fu

8. Reverse Engineering in the Aerospace Industry

Abstract

December 17, 2003 marked the 100th anniversary of the Wright brothers’ first successful airplane flight–the first time a heavier-than-air vehicle with an engine successfully propelled itself into flight. Aviation has come a long way since 1903. We’ve broken the sound barrier; we can fly more than 500 people on a single jumbo jet; and we’ve landed on the moon. All in less than a century!

Ping Fu

9. Reverse Engineering in the Medical Device Industry

Abstract

Since the advent of computer-aided design (CAD), researchers have tried to create products in digital form. But, despite major advances in mechanical CAD, 99% of the things we use or treasure in our daily lives do not have manufacturable digital representations. Nowhere has this problem been more of an obstacle to progress than in the medical device market.

Ping Fu

10. Legal Aspects of Reverse Engineering

Abstract

With the current eruption of technological development, technology is advancing at a rapid rate. The legal world is beginning to realize a need for concomitant advancement. Laws must keep pace with technological development. The copyright laws that currently govern the development of computer software, for example, are still quite ambiguous. There is debate over the scope of the law as well as difficulty in applying the law. In the light of conflicting case law, it is troublesome for attorneys to give clients advice as to whether particular software development techniques violate copyright laws or carry other legal consequences (Behrens and Levary 1998).

C.Brian Beherens, Reuven R. Levary

11. Barriers to Adopting Reverse Engineering

Abstract

This chapter presents a study of the barriers to adopting reverse engineering technology. Previous literature suggests that various factors play a role in adopting technology; however, there is little research into the factors affecting the adoption of RE technology in particular. This chapter investigates the forms of barriers that affect the adoption of RE technology in manufacturing firms. A three-phase factor analysis approach (FAA) is used to investigate these “critical” factors.

Kiran Jude Fernandez

Backmatter

Titel: Reverse Engineering
herausgegeben von: Vinesh Raja
Kiran J. Fernandes
Verlag: Springer London
Electronic ISBN: 978-1-84628-856-2
Print ISBN: 978-1-84628-855-5
DOI: https://doi.org/10.1007/978-1-84628-856-2

Springer Professional

Über dieses Buch

Inhaltsverzeichnis

Frontmatter

1. Introduction to Reverse Engineering

2. Methodologies and Techniques for Reverse Engineering–The Potential for Automation with 3-D Laser Scanners

3. Reverse Engineering–Hardware and Software

4. Selecting a Reverse Engineering System

5. Introduction to Rapid Prototyping

6. Relationship Between Reverse Engineering and Rapid Prototyping

7. Reverse Engineering in the Automotive Industry

8. Reverse Engineering in the Aerospace Industry

9. Reverse Engineering in the Medical Device Industry

10. Legal Aspects of Reverse Engineering

11. Barriers to Adopting Reverse Engineering

Backmatter

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