Recognition of machining features for cast then machined parts

Mechanical parts are typically manufactured using multiple manufacturing processes. Primary processes such as casting realize the primary shape of the part, while secondary processes such as machining generate more detailed shape of the part. This paper presents a feature recognition method to support machining process planning for cast-then-machined parts. From the part model including the specification of machined faces, we generate the starting workpiece for machining, which represents the casting output in sufficient detail to support machining process planning. The starting workpiece is generated by identifying faces to be made by casting followed by machining, then offsetting the part through these faces by a uniform machining thickness to obtain cast faces, and combining the halfspaces induced by machined faces and the halfspaces induced by their bounding cast faces to enclose removal volumes. Machining features are then recognized from the removal volumes using a volume decomposition method called Alternating Sum of Volumes with Partitioning.     

Structural optimization of as-built parts using reverse engineering and evolution strategies

In industry, some parts are prone to failures or their design is simply sub-optimal. In those critical situations, one would like to be able to make changes to the part, making it lighter or improving its mechanical resistance. The problem of as-built parts is that the original computer-aided design (CAD) model is not available or is lost. To optimize them, a reverse engineering process is necessary to capture the shape and topology of the original design. This paper describes how to capture the original design geometry using a semi-automated reverse engineering process based on measurement provided by an optical 3D sensor. Following this reverse engineering process, a Fixed Grid Finite Element method and evolutionary algorithms are used to find the optimum shape that will minimize stress and weight. Several examples of industrial parts are presented. These examples show the advantages and disadvantages of the proposed method in an industrial scenario. Presented at the 7th World Congress on Computational Mechanics, Los Angeles 2006.     

A reverse engineering system for rapid manufacturing of complex objects

This paper presents a reverse engineering system for rapid modeling and manufacturing of products with complex surfaces. The system consists of three main components: a 3D optical digitizing system, a surface reconstruction software and a rapid prototyping machine. The unique features of the 3D optical digitizing system include the use of white-light source, and cost-effective and quick image acquisition. The surface reconstruction process consists of three major steps: (1) range view registration by an iterative closed-form solution, (2) range surface integration by reconstructing an implicit function to update the volumetric grid, and (3) iso-surface extraction by the Marching Cubes algorithm. The modeling software exports models in STL format, which are used as input to an FDM 2000 machine to manufacture products. The examples are included to illustrate the systems and the methods.     

Manufacturing cost estimation for machined parts based on manufacturing features

The purpose of this paper is to present a feature-based cost estimating system for machined parts. Since cost estimation provides designers with valuable information, it must be quick and accurate. In this paper, manufacturing features are classified into four categories. Cost estimation for all features in a category is based on manufacturing activities. Early cost estimations did not consider the manufacturing activity, hence they were not accurate. Machining cost is proportional to machining time, which includes operational time and non-operational time. Operation time includes rough cutting time and finish cutting time. Tool approach time and non-operation time are taken from past experience and approximated for modification into mathematical forms. This paper develops a cost estimation system based on manufacturing features. It is an approximation system which inputs information on machining activities.     

A piecewise hole filling algorithm in reverse engineering

While scanning a complex part in reverse engineering, it is not possible to acquire all part of the scanned surface. Data are inevitably missing due to the complexity of the scanned part or imperfect scanning process. Missing scanned data cause holes in the created triangular mesh, so that a hole-free mesh model is prerequisite for fitting watertight surfaces. Although a number of hole filling algorithms have been investigated, they enable to fill holes only on the smooth regions of a model. They are not always robust in the regions of high curvature. This paper proposes a novel methodology that can automatically fill complex polygonal holes with a piecewise manner. It incrementally splits a complex hole into several simple holes with respect to the 3D shape of the hole boundary, and then it consecutively fills each divided simple hole with planar triangulation method until the entire complex hole is firmly closed. Finally smoothing and subdivision techniques are applied for enhancing the hole triangles. The newly created vertices and triangles are added to their respective lists and the topology information is updated. The method has proven to be robust and effective from the result of test with a variety of complex holes. Examples are given and discussed to validate the methodology.     

Applying knowledge to reverse engineering problems

This paper summarizes a series of recent research results made at Edinburgh University based on projects that apply domain knowledge of standard shapes and relation ships to solve or improve reverse engineering problems. The problems considered are how to enforce known relationships when data fitting, how to extract features even in very noisy data, how to get better shape parameter estimates and how to infer data about unseen features.     

A framework for 3D model reconstruction in reverse engineering

We present a framework for 3D model reconstruction, which has potential applications to a spectrum of engineering problems with impacts on rapid design and prototyping, shape analysis, and virtual reality. The framework, composed of four main components, provides a systematic solution to reconstruct geometric model from the surface mesh of an existing object. First, the input mesh is pre-processed to filter out noise. Second, the mesh is partitioned into segments to obtain individual geometric feature patches. Then, two integrated solutions, namely solid feature based strategy and surface feature based strategy, are exploited to reconstruct primitive features from the segmented feature patches. Finally, the modeling operations, such as solid boolean and surface trimming operations, are performed to “assemble” the primitive features into the final model. The concepts of “feature”, “constraint” and “modeling history” are introduced into the entire reconstruction process so that the design intents are retrieved and exhibited in the final model with geometrical accuracy, topological consistency and flexible editability. A variety of industrial parts have been tested to illustrate the effectiveness and robustness of our framework.     

STEP-based product modeling system for remote collaborative reverse engineering

Production of high-quality products with lower cost and shorter time-to-market is an important challenge in the face of increased global competition, and reverse engineering plays an important role in accelerating product and process development. With the advent of new technologies such as network, multimedia and product data exchange standard STEP (STandard for Exchange of Product model data), there are many advantages to adopt these technologies to enhance the competitiveness of an enterprise. In this paper, a product information recording module for reverse engineering is developed to enhance the performance of product development. A STEP development tool, ST-Developer, and Visual C++ were used to develop this module, which can be used to record key information expeditiously during a collaborative process, and can also be used for further exchange of information, or as the basis for manufacturability evaluation. In this paper, the developed STEP-based information recording system is further integrated with the conventional Computer Supported Cooperative Work methods such as videoconferencing and application-sharing to form a remote collaborative reverse engineering system, which can provides a new strategy for an enterprise to speed up the product development cycle, reducing production cost, as well as sharing knowledge and experience.     

A comprehensive process of reverse engineering from 3D meshes to CAD models

In an industrial context, most manufactured objects are designed using CAD (Computer-Aided Design) software. For visualization, data exchange or manufacturing applications, the geometric model has to be discretized into a 3D mesh composed of a finite number of vertices and edges. However, the initial model may sometimes be lost or unavailable. In other cases, the 3D discrete representation may be modified, e.g. after numerical simulation, and no longer corresponds to the initial model. A retro-engineering method is then required to reconstruct a 3D continuous representation from the discrete one.In this paper, we present an automatic and comprehensive retro-engineering process dedicated mainly to 3D meshes obtained initially by mechanical object discretization. First, several improvements in automatic detection of geometric primitives from a 3D mesh are presented. Then a new formalism is introduced to define the topology of the object and compute the intersections between primitives. The proposed method is validated on 3D industrial meshes.     

MoDisco: A model driven reverse engineering framework

ContextMost companies, independently of their size and activity type, are facing the problem of managing, maintaining and/or replacing (part of) their existing software systems. These legacy systems are often large applications playing a critical role in the company’s information system and with a non-negligible impact on its daily operations. Improving their comprehension (e.g., architecture, features, enforced rules, handled data) is a key point when dealing with their evolution/modernization.ObjectiveThe process of obtaining useful higher-level representations of (legacy) systems is called reverse engineering (RE), and remains a complex goal to achieve. So-called Model Driven Reverse Engineering (MDRE) has been proposed to enhance more traditional RE processes. However, generic and extensible MDRE solutions potentially addressing several kinds of scenarios relying on different legacy technologies are still missing or incomplete. This paper proposes to make a step in this direction.MethodMDRE is the application of Model Driven Engineering (MDE) principles and techniques to RE in order to generate relevant model-based views on legacy systems, thus facilitating their understanding and manipulation. In this context, MDRE is practically used in order to (1) discover initial models from the legacy artifacts composing a given system and (2) understand (process) these models to generate relevant views (i.e., derived models) on this system.ResultsCapitalizing on the different MDRE practices and our previous experience (e.g., in real modernization projects), this paper introduces and details the MoDisco open source MDRE framework. It also presents the underlying MDRE global methodology and architecture accompanying this proposed tooling.ConclusionMoDisco is intended to make easier the design and building of model-based solutions dedicated to legacy systems RE. As an empirical evidence of its relevance and usability, we report on its successful application in real industrial projects and on the concrete experience we gained from that.     

Software reverse engineering: A case study

This paper presents lessons learned from an experiment to reverse engineer a program. A reverse engineering process was used as part of a project to develop an Ada implementation of a Fortran program and upgrade the existing documentation. To accomplish this, design information was extracted from the Fortran source code and entered into a software development environment. The extracted design information was used to implement a new version of the program written in Ada. This experiment revealed issues about recovering design information, such as, separating design details from implementation details, dealing with incomplete or erroneous information, traceability of information between implementation and recovered design, and re-engineering. The reverse engineering process used to recover the design, and the experience gained during the study are reported.     

A reverse engineering method based on haptic volume removing

This paper presents a new reverse engineering methodology that is based on haptic volume removing. When a physical object is to be digitized, it is first buried in a piece of virtual clay that is generated with the help of a fixture. Now digitizing the physical object is by simply chipping away the virtual clay with a position tracker that is attached to a haptic device PHANToM^®. While chipping away the clay, the user can see on the computer monitor what is emerging and at the same time feel the chipping force from the haptic device. By so doing, reverse engineering is seamlessly integrated into haptic volume sculpting that is now widely used for conceptual design. Furthermore, the proposed method has eliminated the need to merge point clouds that are digitized from different views using current digitizers. The virtual clay volume is represented by a spatial run-length encoding scheme. A prototype system has been developed to demonstrate the feasibility of the proposed new method through a case study. The strengths and weaknesses of the presented method are analyzed and the applicability is discussed.     

An algorithm for filling complex holes in reverse engineering

The existence of holes in meshes makes it difficult for mesh operations, especially when comes to model rebuilding, rapid prototyping and finite element analysis. Existing hole-filling algorithms are capable of filling holes on small and smooth regions of a model. For large holes with complex boundaries or in curved region, they may not result in satisfactory results. This paper proposes an algorithm which first split the holes into flatter ones and then split the complex holes based the concept of edge expansion. It incrementally splits a complex hole into simple ones by respecting the 3D shape of its boundary and the neighboring meshes, and then fills each resulting simple hole with planar triangulation. The proposed algorithm works well for a variety of complex holes and can better preserve the detailed features of the original mesh.     

Motorcycle graph enumeration from quadrilateral meshes for reverse engineering

Recently proposed quad-meshing techniques allow the generation of high-quality semi-regular quadrilateral meshes. This paper outlines the generation of quadrilateral segments using such meshes. Quadrilateral segments are advantageous in reverse engineering because they do not require surface trimming or surface parameterization. The motorcycle graph algorithm of Eppstein et al. produces the motorcycle graph of a given quadrilateral mesh consisting of quadrilateral segments. These graphs are preferable to base complexes, because the mesh can be represented with a smaller number of segments, as T-joints (where the intersection of two neighboring segments does not involve the whole edge or the vertex) are allowed in quadrilateral segmentation.The proposed approach in this study enumerates all motorcycle graphs of a given quadrilateral mesh and optimum graph for reverse engineering is then selected. Due to the high computational cost of enumerating all these graphs, the mesh is cut into several sub-meshes whose motorcycle graphs are enumerated separately. The optimum graph is then selected based on a cost function that produces low values for graphs whose edges trace a large number of highly curved regions in the model. By applying several successive enumeration steps for each sub-mesh, a motorcycle graph for the given mesh is found. We also outline a method for the extraction of feature curves (sets of highly curved edges) and their integration into the proposed algorithm. Quadrilateral segments generated using the proposed techniques are validated by B-spline surfaces.     

Machining feature-based similarity assessment algorithms for prismatic machined parts

This paper presents algorithms for identifying machined parts in a database that are similar to a given query part based on machining features. In this paper we only consider parts that are machined on 3-axis machining centers. We utilize reduced feature vectors consisting of machining feature access directions, feature types, feature volumes, feature dimensional tolerances and feature group cardinality as a basis for assessing shape similarity. We have defined a distance function between two sets of reduced feature vectors to assess the similarity between them from the machining effort point of view. To assess the similarity between the two parts, one set of reduced feature vectors is transformed in space using rigid body transformations with respect to the other set such that the distance between them is minimized. The distance between the two sets of aligned reduced feature vectors is used as a measure of similarity between the two parts. The existing machined parts are rank ordered based on the value of the distance with respect to the query part. The cost of previously machined parts that have a very small distance from the query part can be used as a basis for estimating the cost of machining the new part.     

An approach to recognize interacting features from B-Rep CAD models of prismatic machined parts using a hybrid (graph and rule based) technique

This paper presents a new hybrid (graph + rule based) approach for recognizing the interacting features from B-Rep CAD models of prismatic machined parts. The developed algorithm considers variable topology features and handles both adjacent and volumetric feature interactions to provide a single interpretation for the latter. The input CAD part model in B-Rep format is preprocessed to create the adjacency graphs for faces and features of associated topological entities and compute their attributes. The developed FR system initially recognizes all varieties of the simple and stepped holes with flat and conical bottoms from the feature graphs. A new concept of Base Explicit Feature Graphs and No-base Explicit Feature Graphs has been proposed which essentially delineates between features having planar base face like pockets, blind slots, etc. and those without planar base faces like passages, 3D features, conical bottom features, etc. Based on the structure of the explicit feature graphs, geometric reasoning rules are formulated to recognize the interacting feature types. Extracted data has been post-processed to compute the feature attributes and their parent-child relationships which are written into a STEP like native feature file format. The FR system was extensively tested with several standard benchmark components and was found to be robust and consistent. The extracted feature file can be used for integration with various downstream applications like CAPP.     

Analysis of digitized 3D mesh curvature histograms for reverse engineering

Today, it has become more frequent and reasonably easy to digitize the surface of 3D objects. However, the obtained results are often inaccurate and noisy. In this paper, we present an efficient method to analyze a curvature histogram from a digitized 3D surface using a real object. Moreover, we propose to use the curvature histogram analysis for many steps of a reverse engineering process, which can be used to retrieve a CAD model from a digitized one for example. Our objective is to design a fast and fully automated method, which is seldom seen in reverse engineering. Experimental results applied on digitized 3D meshes show the efficiency and the robustness of our proposed method.     

Thermoforming mould design using a reverse engineering approach

Thermoforming is commonly used to produce shaped plastic sheets for packaging consumer products. The conventional method of designing and making thermoforming moulds is laborious and time consuming. A method based on a reverse engineering approach and thermoforming feature concept is proposed. The method involves the use of a self-developed device to digitise the surface of a product. A CAD model that corresponds to the thermoforming mould of the product is then constructed by using the digitised data. The construction of the mould surface is based on the concept of a defined set of thermoforming mould features. A modified Laplacian smoothing technique is applied to process the digitised data for generating the thermoforming mould surfaces. Several examples are used to explain the working principle and demonstrate the viability of the proposed method.     

An integrated approach of reverse engineering aided remanufacturing process for worn components

The worn mechanical components/parts arrived in the remanufacturing system exhibit highly uncontrolled variabilities in failure conditions as well as structures and shape complexities. With the aid of reverse engineering (RE) technologies, a quick and accurate acquisition of the damaged areas of the worn part is attainable and thereby facilitates remanufacturing operations necessary to bring the parts back to like-new conditions. In this paper, a reverse engineering based approach is proposed to aid the remanufacturing processes of worn parts. The proposed approach integrates 3D surface data collection, nominal model reconstruction, fine registration, extraction of additive/subtractive repair, tool path generation and actual machining process, seeking to improve the reliability and efficiency of manual repair process. For nominal model reconstruction, a Prominent Cross-Section algorithm embedded with curvature constraint is proposed to automatically identify the boundary of the part's damaged area and thereby eliminate the defective point clouds from the reconstruction process. With the nominal reconstruction model and the 3D model of the worn part, a modified ICP algorithm integrating curvature and distance constraints is proposed to achieve a best-fit position of the two models by automatically identifying and eliminating the unreliable corresponding pairs through iterations. The proposed approach is demonstrated through remanufacturing of two different mechanical components and is approved to be efficient and effective.     

Three-dimensional optical measurements and reverse engineering for automotive applications

The paper describes a very special and suggestive example of optical three-dimensional (3D) acquisition, reverse engineering and rapid prototyping of a historic automobile, a Ferrari 250 Mille Miglia, performed primarily using an optical 3D whole-field digitiser based on the projection of incoherent light (OPL-3D, developed in our laboratory). The entire process consists in the acquisition, the point cloud alignment, the triangle model definition, the NURBS creation, the production of the STL file, and finally the generation of a scaled replica of the car.The process, apart from the importance of the application to a unique, prestigious historic racing car, demonstrates the ease of application of the optical system to the gauging and the reverse engineering of large surfaces, as automobile body press parts and full-size clays, with high accuracy and reduced processing time, for design and restyling applications.