Computer-aided reverse engineering for rapid replacement of parts

Abstract

Indigenous product development using conventional means involves a relatively long lead time and cost, especially for replacing worn out and broken parts. This paper presents methodologies and technologies for computer-aided reverse engineering, illustrated by a reallife case study of an aluminium alloy separator body of a hydraulic filter assembly for the special army vehicle. It involved reconstruction of part geometry using 3-D scanning, material identification using spectrometry, casting process optimisation using simulation software, and fabrication of prototype and tooling using rapid prototyping systems. It was found that the fabrication of wax patterns directly from reverse-engineered CAD data in a suitable rapid prototyping system (such as thermojet), followed by conventional investment casting, gives a reliable and economic route for rapid development of one-off intricate parts for the replacement purpose.