Reverse engineering applications for recovery of broken or worn parts and re-manufacturing: Three case studies

Damaged or broken parts are generally too expensive to replace, or are no longer available. RE can be defined as: ‘Systematic evaluation of a product with the purpose of replication. This involves design of a new part, copy of an existing part, recovery of a damaged or broken part, improvement of model precision and inspection of a numerical model. Advantages of the technique include immediate feedback, data reduction, direct generation of geometry and higher precision of the final product. This paper shows some possibilities of use and benefit from utilising the RE-methodologies and techniques in production process, especially in the case when exists parts without 3D-CAD support.This paper, which defines obtaining CAD data step by step from damaged three different parts to reproduce or make a new design for some recoveries, has not get any technical drawings. When these parts had been recovered, some problems occurred. These problems have been solved by referring to some practical approaches. Establishing continuity across curve and surface patches is an important concept in the free form surface modeling. The CAD models were recovered and reconstructed to consider parametric and geometric continuity. The iso-phote method was used for surface continuity analysis. Hence, in this work, not only occurring problems but also solving methods were explained. Firstly, CAD models are created from damaged and broken parts by data digitization method by using CMM and the process was explored in detailed. Later, CAD models that had been obtained earlier are transferred into CAM module of the software and G codes are taken by the NC post-processor, and finally, the parts are manufactured by means of CNC milling machine. Additionally, this paper presents a review of the part digitization techniques available for reverse engineering.     

Reverse engineering in the design of turbine blades – a case study in applying the MAMDP

This paper presents a case study on the reverse engineering of turbine blades used in nuclear power generators. Reverse engineering has been widely recognised as a crucial step in the product design cycle. However, major problems with current reverse engineering technology are the inefficient surface reconstruction process, lack of digitising accuracy control in the data digitisation process, and bottlenecks resulted from huge amounts of digitised surface points in the surface modeling process. Moreover, under this limitation, modern concurrent engineering concepts are difficult to implement to obtain optimal product design. This study applies a developed reverse engineering approach – the modified adaptive model-based digitizing process (MAMDP) to the 3D geometric design of turbine blades. The approach integrates surface digitising and modeling processes of turbine blades into a single surface reconstruction process. Using the approach, accurate product CAD models can be efficiently generated and the product design cycle of turbine blades can be successfully linked.     

Robust uniform triangulation algorithm for computer aided design

This paper presents a new robust uniform triangulation algorithm that can be used in CAD/CAM systems to generate and visualize geometry of 3D models. Typically, in CAD/CAM systems 3D geometry consists of 3D surfaces presented by the parametric equations (e.g. surface of revolution, NURBS surfaces) which are defined on a two dimensional domain. Conventional triangulation algorithms (e.g. ear clipping, Voronoi-Delaunay triangulation) do not provide desired quality and high level of accuracy (challenging tasks) for 3D geometry. The approach developed in this paper combines lattice tessellation and conventional triangulation techniques and allows CAD/CAM systems to obtain the required surface quality and accuracy. The algorithm uses a Cartesian lattice to divide the parametric domain into adjacent rectangular cells. These cells are used to generate polygons that are further triangulated to obtain accurate surface representation. The algorithm allows users to control the triangle distribution intensity by adjusting the lattice density. Once triangulated, the 3D model can be used not only for rendering but also in various manufacturing and design applications. The approach presented in this paper can be used to triangulate any parametric surface given in S(u,v) form, e.g. NURBS surfaces, surfaces of revolution, and produces good quality triangulation which can be used in CAD/CAM and computer graphics applications.     

Comparative study of different digitization techniques and their accuracy

The various manufacturers of digitization systems speak of the effectiveness and accuracy of their tools under optimal conditions, but actual experimentation with simple or complex objects and different materials yields results that on occasions refute the effectiveness of those systems. In order to help choose a digitization system on the basis of its accuracy and the quality of the distribution of points and triangular meshes, in the field of reverse engineering, we compared five digitization techniques (three versions of the laser scanner, a fringe projection version and an X-ray version): (1) an ordered point cloud obtained with a laser incorporated in a CMM, (2) a disordered point cloud obtained with a manual laser the position of which is determined with a Krypton Camera, (3) an Exascan manual laser with targets, (4) an ordered point cloud obtained by high precision Computerized Tomography (CT) and (5) an Atos fringe projection scanner with targets. Each of the three calibrated pieces (a sphere, a cylinder and a gauge block) was measured five times by the five digitization systems to confirm the accuracy of the measurement. A comparison was also made of the meshes generated by the five software packages (Focus-Inspection, Metris, VxScan, Mimics and Atos) of the five digitization systems for the three calibrated pieces and two more complex pieces (a bone and an automobile window winder pulley) to determine meshing quality. Finally, all the pieces were meshed by triangulation in the Catia V5 DSE (Digitized Shape Editor) module in order to test the quality of the points distribution.     

Autonomous weld seam identification and localisation using eye-in-hand stereo vision for robotic arc welding

One of the main difficulties in using robotic welding in low to medium volume manufacturing or repair work is the time taken to programme the robot to weld a new part. It is often cheaper and more efficient to weld the parts manually. This paper presents a method for the automatic identification and location of welding seams for robotic welding using computer vision. The use of computer vision in welding faces some difficult challenges such as poor contrast, textureless images, reflections and imperfections on the surface of the steel such as scratches. The methods developed in the paper enables the robust identification of narrow weld seams for ferrous materials combined with reliable image matching and triangulation through the use of 2D homography. The proposed algorithms are validated through experiments using an industrial welding robot in a workshop environment. The results show that this method can provide a 3D Cartesian accuracy of within ±1 mm which is acceptable in most robotic arc welding applications.     

A study of a reverse engineering system based on vision sensor for free-form surfaces

Reverse engineering can quickly create a CAD model of a new product, in which, the sensor, sampling planning and surface reconstruction are three crucial elements. In this paper, a reverse engineering system involving a new vision sensor, an improved sampling planning module and a fine surface reconstruction module is developed. A characteristic of the proposed sensor is strong linearity between output and input, obtained by the structure optimization when a simple lens replaces the asperic lens. Back propagation (BP) neural network error compensation heightens accuracy. To increase efficiency of digitization, an improved sampling planning approach is proposed; it is based on surface curvature and tangent line slope of a measured point. In surface reconstruction, a new adaptive extracting approach based on curvature of surface reconstructs the non-uniform rational B-spline (NURBS) surface for the scattered data. The accompanying reverse engineering experiment proves the proposed system to be reliable and efficient.     

Improving three-dimensional point reconstruction from image correspondences using surface curvatures

Recovering three-dimensional (3D) points from image correspondences is an important and fundamental task in computer vision. Traditionally, the task is completed by triangulation whose accuracy has its limitation in some applications. In this paper, we present a framework that incorporates surface characteristics such as Gaussian and mean curvatures into 3D point reconstruction to enhance the reconstruction accuracy. A Gaussian and mean curvature estimation scheme suitable to the proposed framework is also introduced in this paper. Based on this estimation scheme and the proposed framework, the 3D point recovery from image correspondences is formulated as an optimization problem with the surface curvatures modeled as soft constraints. To analyze the performance of proposed 3D reconstruction approach, we generated some synthetic data, including the points on the surfaces of a plane, a cylinder and a sphere, to test the approach. The experimental results demonstrated that the proposed framework can indeed improve the accuracy of 3D point reconstruction. Some real-image data were also tested and the results also confirm this point.     

一种基于模型融合的CMM实施过程建模方法

提出了一种基于模型融合的CMM实施过程建模方法．该方法使用软件过程工程元模型SPEM建立CMM过程模型CPM和企业过程模型EPM，通过融合CPM和EPM来获得CMM实施过程模型CIPM．文中利用带标记的有向图描述过程模型。给出了模型融合方法，并进行了一致性证明．最后通过一个过程模型融合原型工具和实例说明了方法的应用情况．     

Extension of surface reconstruction algorithm to the global stitching and repairing of STL models

In the design of complex parts involving free-form or sculptured surfaces, the design is usually represented by a B-rep model. But in production involving rapid prototyping (RP) or solid machining, the B-rep model is often converted to the popular STL model. Due to defects such as topological and geometric errors in the B-rep model, the resulting STL model may contain gaps, overlaps, and inconsistent orientations. This paper presents the extension of a surface reconstruction algorithm to the global stitching of STL models for RP and solid machining applications. The model to be stitched may come from the digitization of physical objects by 3D laser scanners, or the triangulation of trimmed surfaces of a B-rep model. Systematic procedures have been developed for each of these two different but equally important cases. The result shows that the proposed method can robustly and effectively solve the global stitching problem for very complex STL models.     

MLP neural network models of CMM measuring processes

The objective of this study is to show how a multi-layer perceptron (MLP) neural network can be used to model a CMM measuring process. To date, most MLP-based process models have been established for process mean only. An innovative approach is proposed to model simultaneously the mean and the variation of a CMM process using one integrated MLP architecture. Therefore, the MLP-based model obtained captures not only the process mean but also the process variation information. Selected issues related to neural network training are also discussed. Specifically, the guideline that was proposed by Mirchandani and Cao (1989) for selecting a number of hidden neurons is tested to determine the effects of the number of hidden neurons. The performances of two different learning algorithms - back-propagation with momentum factor (BPM) and the Fletcher-Reeves (FR) algorithm - are studied in terms of CPU time, training error, and generalization error.     

Modeling customer satisfaction for new product development using a PSO-based ANFIS approach

When developing new products, it is important to understand customer perception towards consumer products. It is because the success of new products is heavily dependent on the associated customer satisfaction level. If customers are satisfied with a new product, the chance of the product being successful in marketplaces would be higher. Various approaches have been attempted to model the relationship between customer satisfaction and design attributes of products. In this paper, a particle swarm optimization (PSO) based ANFIS approach to modeling customer satisfaction is proposed for improving the modeling accuracy. In the approach, PSO is employed to determine the parameters of an ANFIS from which better customer satisfaction models in terms of modeling accuracy can be generated. A notebook computer design is used as an example to illustrate the approach. To evaluate the effectiveness of the proposed approach, modeling results based on the proposed approach are compared with those based on the fuzzy regression (FR), ANFIS and genetic algorithm (GA)-based ANFIS approaches. The comparisons indicate that the proposed approach can effectively generate customer satisfaction models and that their modeling results outperform those based on the other three methods in terms of mean absolute errors and variance of errors.     

A crenellated-target-based calibration method for laser triangulation sensors integration in articulated measurement arms

This work presents a method for integrating laser triangulation sensors (LTS) in articulated arm coordinate measuring machines (AACMM). First, the kinematic parameters of the AACMM are identified using a passive self-centering probe and a multipose optimization algorithm based in point and length constrains. Then, by means of a single calibration gauge object, a one-step calibration method to obtain both intrinsic – laser plane, CCD sensor and camera geometry – and extrinsic parameters related to AACMM main frame has been developed, allowing the integration of LTS and AACMM mathematical models without the need of additional optimization methods after the previous sensor calibration, usually done in a coordinate measuring machine (CMM) before the assembly of the sensor in the arm. Experimental tests for accuracy and repeatability show the suitable performance of this method. The technique presented is easily generalizable for LTSs integration in robot arms and CMMs.     

An haptic-based immersive environment for shape analysis and modelling

Currently, the design of aesthetic products is a process that requires a set of activities where digital models and physical mockups play a key role. Typically, these are modified (and built) several times before reaching the desired design, increasing the development time and, consequently, the final product cost. In this paper, we present an innovative design environment for computer-aided design (CAD) surface analysis. Our system relies on a direct visuo-haptic display system, which enables users to visualize models using a stereoscopic view, and allows the evaluation of sectional curves using touch. Profile curves are rendered using an haptic device that deforms a plastic strip, thanks to a set of actuators, to reproduce the curvature of the shape co-located with the virtual model. By touching the strip, users are able to evaluate shape characteristics, such as curvature or discontinuities (rendered using sound), and to assess the surface quality. We believe that future computer-aided systems (CAS)/CAD systems based on our approach will contribute in improving the design process at industrial level. Moreover, these will allow companies to reduce the product development time by reducing the number of physical mockups necessary for the product design evaluation and by increasing the quality of the final product, allowing a wider exploration and comparative evaluation of alternatives in the given time.     

A new approach to quality function deployment planning with financial consideration

Quality function deployment (QFD) is becoming a widely used customer-oriented approach and tool in product design. Taking into account the financial factors and uncertainties in the product design process, this paper deals with a fuzzy formulation combined with a genetic-based interactive approach to QFD planning. By introducing new concepts of planned degree, actual achieved degree, actual primary costs required and actual planned costs, two types of fuzzy optimisation models are discussed in this paper. These models consider not only the overall customer satisfaction, but also the enterprise satisfaction with the costs committed to the product. With the interactive approach, the best balance between enterprise satisfaction and overall customer satisfaction can be obtained, and the preferred solutions under different business criteria can be achieved through human–computer interaction.Scope and PurposeQuality function deployment (QFD) that originated in Japan in the late 1960s is a concept and mechanism for translating the ‘voice of customer’ into product through various stages of product planning, engineering and manufacturing. It has become a widely used customer-oriented approach to facilitating product design by analysing customer requirements (CRs). Determination of the target levels for the technical attributes (TAs) of a product with a view to achieving a high level of overall customer satisfaction is an important activity in product design and development.Traditional methods for QFD planning are mainly subjective, ad hoc and heuristic. They can hardly achieve global optimisation, and most of these models barely take into consideration the correlation between TAs. Moreover, most of these methods are technically one-sided without considering the design budget. However, the financial factor is also an important factor and should not be neglected in QFD planning. In addition, owing to uncertainties involved in the decision process, these deterministic methods could not formulate and solve it effectively.Taking into consideration the financial factors and uncertainties in the product design process, this paper deals with fuzzy formulation combined with a genetic-based interactive approach to QFD planning. By introducing new concepts of planned degree, actual achieved degree, actual primary costs required and actual planned costs, two types of fuzzy optimisation models are discussed in this paper. These models consider not only the overall customer satisfaction, but also the enterprise satisfaction with the costs committed to the product. With the interactive approach, the best balance between enterprise satisfaction and overall customer satisfaction can be obtained, and the preferred solutions under different business criteria can be achieved through human–computer interaction.     

软件生命周期模型与CMM实施*

对于采用不同软件生命周期模型的项目在实施CMM 当中遇到的实际问题及其产生机理进行了深入分析,并提出初步的解决方案,主要涉及:采用迭代式生命周期模型的项目在实施需求管理过程域的部分内容时难以满足CMM 的要求,建议通过扩展基线的概念,采用分步基线化、分块基线化的方法予以处理;软件产品工程过程域的内容更多地针对瀑布模型,针对迭代式生命周期的内容较少,因而在实际使用迭代式生命周期模型时,工程活动不能局限于CMM 的内容.建议对CMM 中的工作产品与迭代式生命周期模型中的工作产品进行映射,并采用迭代式生命周期模型中的方法和概念作为替代实践以符合软件产品工程过程域的要求.     

Analytical derivatives technology for structural shape design

The ability to perform and evaluate the effect of shape changes on the stress and modal responses of components is an important ingredient in the “design” of aircraft engine components. The classical design of experiments (DOE)-based approach that is motivated from statistics (for physical experiments) is one of the possible approaches for the evaluation of the component response with respect to design parameters [Myers, Montgomery. Response surface methodology, process and product optimization using design of experiments. John Wiley and Sons, NY (1995)]. As the underlying physical model used for the component response is deterministic and understood through a computer simulation model, one needs to re-think the use of the classical DOE techniques for this class of problems. In this paper, we explore an alternate sensitivity-analysis-based technique where a deterministic parametric response is constructed using exact derivatives of the complex finite-element (FE)-based computer models to design parameters. The method is based on a discrete sensitivity analysis formulation using semi-automatic differentiation (Griewank, SIAM (2000), ADIFOR, Automatic Differentiation of FORTRAN codes ) to compute the Taylor series or its Pade equivalent for finite-element-based responses. Shape design or optimization in the context of finite element modeling is challenging because the evaluation of the response for different shape requires the need for a meshing consistent with the new geometry. This paper examines the differences in the nature and performance (accuracy and efficiency) of the analytical derivatives approach against other existing approaches with validation on several benchmark structural applications. The use of analytical derivatives for parametric analysis is demonstrated to have accuracy benefits on certain classes of shape applications.     

Computer-aided appearance design based on BRDF measurements

This paper presents a comprehensive and efficient framework for computer-aided appearance design based on BRDF (bidirectional reflectance distribution function) measurements. It covers all stages of a new product development including acquisition, processing and modeling of reflectance data, interactive rendering and evaluation of material appearance, and manufacturing operations. The proposed method eliminates the need of making a real physical prototype by providing a reliable surface appearance design process in which he/she can faithfully simulate the final surface appearance in the early design stage of a product. In addition, it enables us to manufacture the coating surface the same as the computer simulated surface from the known coating specification. The accuracy test between a real sample and the computer simulated one demonstrates that the proposed method satisfies an acceptable level of accuracy for industrial applications. A case study has been conducted to evaluate the user preference on the surface appearance of a digital handheld device which contains a combination of different coating surfaces. The case study successfully demonstrates that the user preference can be identified using the proposed method while changing the combination of different coating surfaces represented by BRDFs considering factors such as surrounding environments and age groups.