Product Design Innovation Reverse Engineering and Leadership

Dr Om Prakash SinghAsst Prof School of Engineering IIT Mandi

wwwomprakashsinghcom

Our Vision

To become a world class institution toproduce manpower with skills creativity andpassion dedicated to innovation andexcellence with quest for continuousimprovement

Jawaharlal Nehru GovernmentEngineering College Sundernagar

What is an Engineer

bull Engineering is the profession in which knowledge ofthe mathematical and natural sciences gained bystudy experience and practice is applied withjudgement to develop ways to utilize economicallythe materials and forces of nature for the benefit ofmankind

bull Eg Trouble shooting Energy conversion healthsciences aerospace transportation manufacturing

bull In fact almost every type of industry employsmechanical engineers

Engineers make design and productsInterdisciplinary nature

Think out of box

The complex interconnectionbull System level thinking is expected from engineersbull Component level design may not work in productbull Engineers should know how to work together in team

bull Human race survived as it hascontinuously inventedinnovated

bull Species those who have notinnovated became extinct

bull Only innovative companies survive

bull Lost top spot MicrosoftBlackBerry and Nokia

Invention key for survival

bull Invention is absolutely a good thing but even without inventionsa country or company or an individual can still come out ahead

bull After all Japan didnrsquot invent the car or the TV but it certainlyinnovated on them and built world-leading companies andeconomies

A movie on how technology determines who rules whom

bull Movie Planet of the Apes (2001)bull Entire movie is edited to 5 minutesbull Message from the movie

1 A technologically advanced society are the rulers over other species (here Apes rule Human being)

2 Technology changes with time3 Innovation is the key for survival4 After the movie question will be asked

Our Vision

To become a world class institution toproduce manpower with skills creativity andpassion dedicated to innovation andexcellence with quest for continuousimprovement

Jawaharlal Nehru GovernmentEngineering College Sundernagar

What is an Engineer

bull Engineering is the profession in which knowledge ofthe mathematical and natural sciences gained bystudy experience and practice is applied withjudgement to develop ways to utilize economicallythe materials and forces of nature for the benefit ofmankind

bull Eg Trouble shooting Energy conversion healthsciences aerospace transportation manufacturing

bull In fact almost every type of industry employsmechanical engineers

Engineers make design and productsInterdisciplinary nature

Think out of box

The complex interconnectionbull System level thinking is expected from engineersbull Component level design may not work in productbull Engineers should know how to work together in team

bull Human race survived as it hascontinuously inventedinnovated

bull Species those who have notinnovated became extinct

bull Only innovative companies survive

bull Lost top spot MicrosoftBlackBerry and Nokia

Invention key for survival

bull Invention is absolutely a good thing but even without inventionsa country or company or an individual can still come out ahead

bull After all Japan didnrsquot invent the car or the TV but it certainlyinnovated on them and built world-leading companies andeconomies

A movie on how technology determines who rules whom

bull Movie Planet of the Apes (2001)bull Entire movie is edited to 5 minutesbull Message from the movie

1 A technologically advanced society are the rulers over other species (here Apes rule Human being)

2 Technology changes with time3 Innovation is the key for survival4 After the movie question will be asked

What is an Engineer

bull Engineering is the profession in which knowledge ofthe mathematical and natural sciences gained bystudy experience and practice is applied withjudgement to develop ways to utilize economicallythe materials and forces of nature for the benefit ofmankind

bull Eg Trouble shooting Energy conversion healthsciences aerospace transportation manufacturing

bull In fact almost every type of industry employsmechanical engineers

Engineers make design and productsInterdisciplinary nature

Think out of box

The complex interconnectionbull System level thinking is expected from engineersbull Component level design may not work in productbull Engineers should know how to work together in team

bull Human race survived as it hascontinuously inventedinnovated

bull Species those who have notinnovated became extinct

bull Only innovative companies survive

bull Lost top spot MicrosoftBlackBerry and Nokia

Invention key for survival

bull Invention is absolutely a good thing but even without inventionsa country or company or an individual can still come out ahead

bull After all Japan didnrsquot invent the car or the TV but it certainlyinnovated on them and built world-leading companies andeconomies

A movie on how technology determines who rules whom

bull Movie Planet of the Apes (2001)bull Entire movie is edited to 5 minutesbull Message from the movie

1 A technologically advanced society are the rulers over other species (here Apes rule Human being)

2 Technology changes with time3 Innovation is the key for survival4 After the movie question will be asked

Engineers make design and productsInterdisciplinary nature

Think out of box

The complex interconnectionbull System level thinking is expected from engineersbull Component level design may not work in productbull Engineers should know how to work together in team

bull Human race survived as it hascontinuously inventedinnovated

bull Species those who have notinnovated became extinct

bull Only innovative companies survive

bull Lost top spot MicrosoftBlackBerry and Nokia

Invention key for survival

bull Invention is absolutely a good thing but even without inventionsa country or company or an individual can still come out ahead

bull After all Japan didnrsquot invent the car or the TV but it certainlyinnovated on them and built world-leading companies andeconomies

A movie on how technology determines who rules whom

bull Movie Planet of the Apes (2001)bull Entire movie is edited to 5 minutesbull Message from the movie

1 A technologically advanced society are the rulers over other species (here Apes rule Human being)

2 Technology changes with time3 Innovation is the key for survival4 After the movie question will be asked

Think out of box

The complex interconnectionbull System level thinking is expected from engineersbull Component level design may not work in productbull Engineers should know how to work together in team

bull Human race survived as it hascontinuously inventedinnovated

bull Species those who have notinnovated became extinct

bull Only innovative companies survive

bull Lost top spot MicrosoftBlackBerry and Nokia

Invention key for survival

bull Invention is absolutely a good thing but even without inventionsa country or company or an individual can still come out ahead

bull After all Japan didnrsquot invent the car or the TV but it certainlyinnovated on them and built world-leading companies andeconomies

A movie on how technology determines who rules whom

bull Movie Planet of the Apes (2001)bull Entire movie is edited to 5 minutesbull Message from the movie

1 A technologically advanced society are the rulers over other species (here Apes rule Human being)

2 Technology changes with time3 Innovation is the key for survival4 After the movie question will be asked

The complex interconnectionbull System level thinking is expected from engineersbull Component level design may not work in productbull Engineers should know how to work together in team

bull Human race survived as it hascontinuously inventedinnovated

bull Species those who have notinnovated became extinct

bull Only innovative companies survive

bull Lost top spot MicrosoftBlackBerry and Nokia

Invention key for survival

bull Invention is absolutely a good thing but even without inventionsa country or company or an individual can still come out ahead

bull After all Japan didnrsquot invent the car or the TV but it certainlyinnovated on them and built world-leading companies andeconomies

A movie on how technology determines who rules whom

bull Movie Planet of the Apes (2001)bull Entire movie is edited to 5 minutesbull Message from the movie

1 A technologically advanced society are the rulers over other species (here Apes rule Human being)

2 Technology changes with time3 Innovation is the key for survival4 After the movie question will be asked

bull Human race survived as it hascontinuously inventedinnovated

bull Species those who have notinnovated became extinct

bull Only innovative companies survive

bull Lost top spot MicrosoftBlackBerry and Nokia

Invention key for survival

bull Invention is absolutely a good thing but even without inventionsa country or company or an individual can still come out ahead

bull After all Japan didnrsquot invent the car or the TV but it certainlyinnovated on them and built world-leading companies andeconomies

A movie on how technology determines who rules whom

bull Movie Planet of the Apes (2001)bull Entire movie is edited to 5 minutesbull Message from the movie

1 A technologically advanced society are the rulers over other species (here Apes rule Human being)

2 Technology changes with time3 Innovation is the key for survival4 After the movie question will be asked

A movie on how technology determines who rules whom

bull Movie Planet of the Apes (2001)bull Entire movie is edited to 5 minutesbull Message from the movie

1 A technologically advanced society are the rulers over other species (here Apes rule Human being)

2 Technology changes with time3 Innovation is the key for survival4 After the movie question will be asked

What you study as an engg student

bull Forces motion structures statics dynamics kinematics mechanics of solids and fluids

bull Energy thermodynamics heat transfer

bull Materials materials engineering amp processing manufacturing

bull Machines graphics design machine elements controls

bull Economics engineering economic analysis cost engineering

bull Human and Social Studies arts humanities social sciences history government ethics law

bull Overall foundation math physics chemistry biology analysis skills communication skills computation skills

Modern method of production

1 Design2 Prototypes3 Testing4 Mass production

Convectional method of production

1 Design2 CAE3 Prototypes4 Testing5 Mass production

Optimization loop

Optimization loop

Material saving weight reduction

CAE Computer Aided Engineering

More prototypes

Less prototypes

Design Changes and costbull Initial design changes incurs less costbull As the product reaches deployment phase change in design proves very

costlybull Numerical tools such as FEM CFD etc helps in improving designs during

concept stagebull Such tools also helps in investigating failures after the product launched in

the market

Design Changes Process

Combustion

External Aerodynamics of car

External Aerodynamics of bike

Tool cutting process Dragonfly CFD simulation

CFD applications

CFD applications in buildings design

Solar collectors on roofs of industrial buildings

Two time steps in an oxygen uptake simulation of a breathing cycle

Contours and path lines at aninhalation time step

CFD in Biomedical application Predicting breathingcycle

ldquoProgress Towards a Medical Image through CFD Analysis Toolkit forRespiratory Function Assessment on a Clinical Time Scalerdquo The Pennsylvania State University daggerApplied ResearchLaboratory daggerdaggerDepartment of Mechanical Engineering Department of Aerospace Engineering Drexel UniversityDepartment of Biomedical Engineering

Finite Element Analysismedical implants

Processes involved in FEMCFD analysis

bull Geometry pre-processingbull Clean upbull Remove unwanted features

bull Mesh generationbull Boundary conditionsbull Materials element type etc

bull Solutionbull Post processing result visualization bull Reports and decision making

Extracting geometry from medical images

Stack of images from MRI (1mm)

Contour extraction by segmentation (using B-

Splines)

Sample points on extracted geometry

GEOMETRIC PRE-PROCESSING

MR (Magnetic Resonance)

Generating a computational mesh

Constrained optimization procedures are needed to maximize a suitable measure of the grid quality (to avoid triangle distorsion) while keeping the desired accuracy of surface representation

Original grid Optimized grid

GEOMETRIC PRE-PROCESSING

Splines on sections

Design Innovation Center at IIT Mandi

bull Design Studio

bull CFD FEM software HyperWorks

Ansys StarCCM+hellip

bull Prototyping and 3D printing

machines

bull Reverse Engineering

Courses

bull Applied CFD

bull Applied FEM

bull Reverse Engineering

bull Design Practicum

bull CAE based final year projects

Projects based on FEMCFD

1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip

Engines from different automotive companies

XL Super heavy duty 95 marketshare 15 year old engine

Example

Final mass

produced design

Original design

Design changes 35 Prototype design 2

Original mass produced

design

Example of real world problem Multidisciplinary natureCAE driven product design

The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26

bull Rubber dampers are provided between thefins to reduce their vibration

bull High vibration of fins produces undesirablenoise

bull Undesirable noise leads to customerdissatisfaction

bull Proper design of the fins are necessary

bull Rubber dampers add extra cost to thevehicle

Rubber dampers

Two-wheeler engine head

TVS Moped Engine Rubber dampers

bull Reliable engine gt 15 years in the market

bull Holds 95 market share in moped class

bull Lakhs of satisfied customers

bull16 dampers on the cylinder head

If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head

Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz

Radiated noise with and without rubber dampers

Experimental verificationhellip

All 16

dampers

in place

Campbell diagram during gradual acceleration

Noise levels have spread and are higher in magnitude in the 2nd case

All 16

dampers

removed

2nd Stage design of Cylinder Head

Thinner part of the fins are fixed now

1st stage design

Modern method of production

1 Design2 Prototypes3 Testing4 Mass production

Convectional method of production

1 Design2 CAE3 Prototypes4 Testing5 Mass production

Optimization loop

Optimization loop

Material saving weight reduction

CAE Computer Aided Engineering

More prototypes

Less prototypes

Design Changes and costbull Initial design changes incurs less costbull As the product reaches deployment phase change in design proves very

costlybull Numerical tools such as FEM CFD etc helps in improving designs during

concept stagebull Such tools also helps in investigating failures after the product launched in

the market

Design Changes Process

Combustion

External Aerodynamics of car

External Aerodynamics of bike

Tool cutting process Dragonfly CFD simulation

CFD applications

CFD applications in buildings design

Solar collectors on roofs of industrial buildings

Two time steps in an oxygen uptake simulation of a breathing cycle

Contours and path lines at aninhalation time step

CFD in Biomedical application Predicting breathingcycle

ldquoProgress Towards a Medical Image through CFD Analysis Toolkit forRespiratory Function Assessment on a Clinical Time Scalerdquo The Pennsylvania State University daggerApplied ResearchLaboratory daggerdaggerDepartment of Mechanical Engineering Department of Aerospace Engineering Drexel UniversityDepartment of Biomedical Engineering

Finite Element Analysismedical implants

Processes involved in FEMCFD analysis

bull Geometry pre-processingbull Clean upbull Remove unwanted features

bull Mesh generationbull Boundary conditionsbull Materials element type etc

bull Solutionbull Post processing result visualization bull Reports and decision making

Extracting geometry from medical images

Stack of images from MRI (1mm)

Contour extraction by segmentation (using B-

Splines)

Sample points on extracted geometry

GEOMETRIC PRE-PROCESSING

MR (Magnetic Resonance)

Generating a computational mesh

Constrained optimization procedures are needed to maximize a suitable measure of the grid quality (to avoid triangle distorsion) while keeping the desired accuracy of surface representation

Original grid Optimized grid

GEOMETRIC PRE-PROCESSING

Splines on sections

Design Innovation Center at IIT Mandi

bull Design Studio

bull CFD FEM software HyperWorks

Ansys StarCCM+hellip

bull Prototyping and 3D printing

machines

bull Reverse Engineering

Courses

bull Applied CFD

bull Applied FEM

bull Reverse Engineering

bull Design Practicum

bull CAE based final year projects

Projects based on FEMCFD

1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip

Engines from different automotive companies

XL Super heavy duty 95 marketshare 15 year old engine

Example

Final mass

produced design

Original design

Design changes 35 Prototype design 2

Original mass produced

design

Example of real world problem Multidisciplinary natureCAE driven product design

The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26

bull Rubber dampers are provided between thefins to reduce their vibration

bull High vibration of fins produces undesirablenoise

bull Undesirable noise leads to customerdissatisfaction

bull Proper design of the fins are necessary

bull Rubber dampers add extra cost to thevehicle

Rubber dampers

Two-wheeler engine head

TVS Moped Engine Rubber dampers

bull Reliable engine gt 15 years in the market

bull Holds 95 market share in moped class

bull Lakhs of satisfied customers

bull16 dampers on the cylinder head

If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head

Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz

Radiated noise with and without rubber dampers

Experimental verificationhellip

All 16

dampers

in place

Campbell diagram during gradual acceleration

Noise levels have spread and are higher in magnitude in the 2nd case

All 16

dampers

removed

2nd Stage design of Cylinder Head

Thinner part of the fins are fixed now

1st stage design

Design Changes and costbull Initial design changes incurs less costbull As the product reaches deployment phase change in design proves very

costlybull Numerical tools such as FEM CFD etc helps in improving designs during

concept stagebull Such tools also helps in investigating failures after the product launched in

the market

Design Changes Process

Combustion

External Aerodynamics of car

External Aerodynamics of bike

Tool cutting process Dragonfly CFD simulation

CFD applications

CFD applications in buildings design

Solar collectors on roofs of industrial buildings

Two time steps in an oxygen uptake simulation of a breathing cycle

Contours and path lines at aninhalation time step

CFD in Biomedical application Predicting breathingcycle

ldquoProgress Towards a Medical Image through CFD Analysis Toolkit forRespiratory Function Assessment on a Clinical Time Scalerdquo The Pennsylvania State University daggerApplied ResearchLaboratory daggerdaggerDepartment of Mechanical Engineering Department of Aerospace Engineering Drexel UniversityDepartment of Biomedical Engineering

Finite Element Analysismedical implants

Processes involved in FEMCFD analysis

bull Geometry pre-processingbull Clean upbull Remove unwanted features

bull Mesh generationbull Boundary conditionsbull Materials element type etc

bull Solutionbull Post processing result visualization bull Reports and decision making

Extracting geometry from medical images

Stack of images from MRI (1mm)

Contour extraction by segmentation (using B-

Splines)

Sample points on extracted geometry

GEOMETRIC PRE-PROCESSING

MR (Magnetic Resonance)

Generating a computational mesh

Constrained optimization procedures are needed to maximize a suitable measure of the grid quality (to avoid triangle distorsion) while keeping the desired accuracy of surface representation

Original grid Optimized grid

GEOMETRIC PRE-PROCESSING

Splines on sections

Design Innovation Center at IIT Mandi

bull Design Studio

bull CFD FEM software HyperWorks

Ansys StarCCM+hellip

bull Prototyping and 3D printing

machines

bull Reverse Engineering

Courses

bull Applied CFD

bull Applied FEM

bull Reverse Engineering

bull Design Practicum

bull CAE based final year projects

Projects based on FEMCFD

1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip

Engines from different automotive companies

XL Super heavy duty 95 marketshare 15 year old engine

Example

Final mass

produced design

Original design

Design changes 35 Prototype design 2

Original mass produced

design

Example of real world problem Multidisciplinary natureCAE driven product design

The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26

bull Rubber dampers are provided between thefins to reduce their vibration

bull High vibration of fins produces undesirablenoise

bull Undesirable noise leads to customerdissatisfaction

bull Proper design of the fins are necessary

bull Rubber dampers add extra cost to thevehicle

Rubber dampers

Two-wheeler engine head

TVS Moped Engine Rubber dampers

bull Reliable engine gt 15 years in the market

bull Holds 95 market share in moped class

bull Lakhs of satisfied customers

bull16 dampers on the cylinder head

If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head

Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz

Radiated noise with and without rubber dampers

Experimental verificationhellip

All 16

dampers

in place

Campbell diagram during gradual acceleration

Noise levels have spread and are higher in magnitude in the 2nd case

All 16

dampers

removed

2nd Stage design of Cylinder Head

Thinner part of the fins are fixed now

1st stage design

Design Changes Process

Combustion

External Aerodynamics of car

External Aerodynamics of bike

Tool cutting process Dragonfly CFD simulation

CFD applications

CFD applications in buildings design

Solar collectors on roofs of industrial buildings

Two time steps in an oxygen uptake simulation of a breathing cycle

Contours and path lines at aninhalation time step

CFD in Biomedical application Predicting breathingcycle

ldquoProgress Towards a Medical Image through CFD Analysis Toolkit forRespiratory Function Assessment on a Clinical Time Scalerdquo The Pennsylvania State University daggerApplied ResearchLaboratory daggerdaggerDepartment of Mechanical Engineering Department of Aerospace Engineering Drexel UniversityDepartment of Biomedical Engineering

Finite Element Analysismedical implants

Processes involved in FEMCFD analysis

bull Geometry pre-processingbull Clean upbull Remove unwanted features

bull Mesh generationbull Boundary conditionsbull Materials element type etc

bull Solutionbull Post processing result visualization bull Reports and decision making

Extracting geometry from medical images

Stack of images from MRI (1mm)

Contour extraction by segmentation (using B-

Splines)

Sample points on extracted geometry

GEOMETRIC PRE-PROCESSING

MR (Magnetic Resonance)

Generating a computational mesh

Constrained optimization procedures are needed to maximize a suitable measure of the grid quality (to avoid triangle distorsion) while keeping the desired accuracy of surface representation

Original grid Optimized grid

GEOMETRIC PRE-PROCESSING

Splines on sections

Design Innovation Center at IIT Mandi

bull Design Studio

bull CFD FEM software HyperWorks

Ansys StarCCM+hellip

bull Prototyping and 3D printing

machines

bull Reverse Engineering

Courses

bull Applied CFD

bull Applied FEM

bull Reverse Engineering

bull Design Practicum

bull CAE based final year projects

Projects based on FEMCFD

1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip

Engines from different automotive companies

XL Super heavy duty 95 marketshare 15 year old engine

Example

Final mass

produced design

Original design

Design changes 35 Prototype design 2

Original mass produced

design

Example of real world problem Multidisciplinary natureCAE driven product design

The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26

bull Rubber dampers are provided between thefins to reduce their vibration

bull High vibration of fins produces undesirablenoise

bull Undesirable noise leads to customerdissatisfaction

bull Proper design of the fins are necessary

bull Rubber dampers add extra cost to thevehicle

Rubber dampers

Two-wheeler engine head

TVS Moped Engine Rubber dampers

bull Reliable engine gt 15 years in the market

bull Holds 95 market share in moped class

bull Lakhs of satisfied customers

bull16 dampers on the cylinder head

If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head

Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz

Radiated noise with and without rubber dampers

Experimental verificationhellip

All 16

dampers

in place

Campbell diagram during gradual acceleration

Noise levels have spread and are higher in magnitude in the 2nd case

All 16

dampers

removed

2nd Stage design of Cylinder Head

Thinner part of the fins are fixed now

1st stage design

Combustion

External Aerodynamics of car

External Aerodynamics of bike

Tool cutting process Dragonfly CFD simulation

CFD applications

CFD applications in buildings design

Solar collectors on roofs of industrial buildings

Two time steps in an oxygen uptake simulation of a breathing cycle

Contours and path lines at aninhalation time step

CFD in Biomedical application Predicting breathingcycle

ldquoProgress Towards a Medical Image through CFD Analysis Toolkit forRespiratory Function Assessment on a Clinical Time Scalerdquo The Pennsylvania State University daggerApplied ResearchLaboratory daggerdaggerDepartment of Mechanical Engineering Department of Aerospace Engineering Drexel UniversityDepartment of Biomedical Engineering

Finite Element Analysismedical implants

Processes involved in FEMCFD analysis

bull Geometry pre-processingbull Clean upbull Remove unwanted features

bull Mesh generationbull Boundary conditionsbull Materials element type etc

bull Solutionbull Post processing result visualization bull Reports and decision making

Extracting geometry from medical images

Stack of images from MRI (1mm)

Contour extraction by segmentation (using B-

Splines)

Sample points on extracted geometry

GEOMETRIC PRE-PROCESSING

MR (Magnetic Resonance)

Generating a computational mesh

Constrained optimization procedures are needed to maximize a suitable measure of the grid quality (to avoid triangle distorsion) while keeping the desired accuracy of surface representation

Original grid Optimized grid

GEOMETRIC PRE-PROCESSING

Splines on sections

Design Innovation Center at IIT Mandi

bull Design Studio

bull CFD FEM software HyperWorks

Ansys StarCCM+hellip

bull Prototyping and 3D printing

machines

bull Reverse Engineering

Courses

bull Applied CFD

bull Applied FEM

bull Reverse Engineering

bull Design Practicum

bull CAE based final year projects

Projects based on FEMCFD

1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip

Engines from different automotive companies

XL Super heavy duty 95 marketshare 15 year old engine

Example

Final mass

produced design

Original design

Design changes 35 Prototype design 2

Original mass produced

design

Example of real world problem Multidisciplinary natureCAE driven product design

The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26

bull Rubber dampers are provided between thefins to reduce their vibration

bull High vibration of fins produces undesirablenoise

bull Undesirable noise leads to customerdissatisfaction

bull Proper design of the fins are necessary

bull Rubber dampers add extra cost to thevehicle

Rubber dampers

Two-wheeler engine head

TVS Moped Engine Rubber dampers

bull Reliable engine gt 15 years in the market

bull Holds 95 market share in moped class

bull Lakhs of satisfied customers

bull16 dampers on the cylinder head

If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head

Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz

Radiated noise with and without rubber dampers

Experimental verificationhellip

All 16

dampers

in place

Campbell diagram during gradual acceleration

Noise levels have spread and are higher in magnitude in the 2nd case

All 16

dampers

removed

2nd Stage design of Cylinder Head

Thinner part of the fins are fixed now

1st stage design

CFD applications in buildings design

Solar collectors on roofs of industrial buildings

Two time steps in an oxygen uptake simulation of a breathing cycle

Contours and path lines at aninhalation time step

CFD in Biomedical application Predicting breathingcycle

ldquoProgress Towards a Medical Image through CFD Analysis Toolkit forRespiratory Function Assessment on a Clinical Time Scalerdquo The Pennsylvania State University daggerApplied ResearchLaboratory daggerdaggerDepartment of Mechanical Engineering Department of Aerospace Engineering Drexel UniversityDepartment of Biomedical Engineering

Finite Element Analysismedical implants

Processes involved in FEMCFD analysis

bull Geometry pre-processingbull Clean upbull Remove unwanted features

bull Mesh generationbull Boundary conditionsbull Materials element type etc

bull Solutionbull Post processing result visualization bull Reports and decision making

Extracting geometry from medical images

Stack of images from MRI (1mm)

Contour extraction by segmentation (using B-

Splines)

Sample points on extracted geometry

GEOMETRIC PRE-PROCESSING

MR (Magnetic Resonance)

Generating a computational mesh

Constrained optimization procedures are needed to maximize a suitable measure of the grid quality (to avoid triangle distorsion) while keeping the desired accuracy of surface representation

Original grid Optimized grid

GEOMETRIC PRE-PROCESSING

Splines on sections

Design Innovation Center at IIT Mandi

bull Design Studio

bull CFD FEM software HyperWorks

Ansys StarCCM+hellip

bull Prototyping and 3D printing

machines

bull Reverse Engineering

Courses

bull Applied CFD

bull Applied FEM

bull Reverse Engineering

bull Design Practicum

bull CAE based final year projects

Projects based on FEMCFD

1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip

Engines from different automotive companies

XL Super heavy duty 95 marketshare 15 year old engine

Example

Final mass

produced design

Original design

Design changes 35 Prototype design 2

Original mass produced

design

Example of real world problem Multidisciplinary natureCAE driven product design

The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26

bull Rubber dampers are provided between thefins to reduce their vibration

bull High vibration of fins produces undesirablenoise

bull Undesirable noise leads to customerdissatisfaction

bull Proper design of the fins are necessary

bull Rubber dampers add extra cost to thevehicle

Rubber dampers

Two-wheeler engine head

TVS Moped Engine Rubber dampers

bull Reliable engine gt 15 years in the market

bull Holds 95 market share in moped class

bull Lakhs of satisfied customers

bull16 dampers on the cylinder head

If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head

Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz

Radiated noise with and without rubber dampers

Experimental verificationhellip

All 16

dampers

in place

Campbell diagram during gradual acceleration

Noise levels have spread and are higher in magnitude in the 2nd case

All 16

dampers

removed

2nd Stage design of Cylinder Head

Thinner part of the fins are fixed now

1st stage design

Two time steps in an oxygen uptake simulation of a breathing cycle

Contours and path lines at aninhalation time step

CFD in Biomedical application Predicting breathingcycle

ldquoProgress Towards a Medical Image through CFD Analysis Toolkit forRespiratory Function Assessment on a Clinical Time Scalerdquo The Pennsylvania State University daggerApplied ResearchLaboratory daggerdaggerDepartment of Mechanical Engineering Department of Aerospace Engineering Drexel UniversityDepartment of Biomedical Engineering

Finite Element Analysismedical implants

Processes involved in FEMCFD analysis

bull Geometry pre-processingbull Clean upbull Remove unwanted features

bull Mesh generationbull Boundary conditionsbull Materials element type etc

bull Solutionbull Post processing result visualization bull Reports and decision making

Extracting geometry from medical images

Stack of images from MRI (1mm)

Contour extraction by segmentation (using B-

Splines)

Sample points on extracted geometry

GEOMETRIC PRE-PROCESSING

MR (Magnetic Resonance)

Generating a computational mesh

Constrained optimization procedures are needed to maximize a suitable measure of the grid quality (to avoid triangle distorsion) while keeping the desired accuracy of surface representation

Original grid Optimized grid

GEOMETRIC PRE-PROCESSING

Splines on sections

Design Innovation Center at IIT Mandi

bull Design Studio

bull CFD FEM software HyperWorks

Ansys StarCCM+hellip

bull Prototyping and 3D printing

machines

bull Reverse Engineering

Courses

bull Applied CFD

bull Applied FEM

bull Reverse Engineering

bull Design Practicum

bull CAE based final year projects

Projects based on FEMCFD

1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip

Engines from different automotive companies

XL Super heavy duty 95 marketshare 15 year old engine

Example

Final mass

produced design

Original design

Design changes 35 Prototype design 2

Original mass produced

design

Example of real world problem Multidisciplinary natureCAE driven product design

The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26

bull Rubber dampers are provided between thefins to reduce their vibration

bull High vibration of fins produces undesirablenoise

bull Undesirable noise leads to customerdissatisfaction

bull Proper design of the fins are necessary

bull Rubber dampers add extra cost to thevehicle

Rubber dampers

Two-wheeler engine head

TVS Moped Engine Rubber dampers

bull Reliable engine gt 15 years in the market

bull Holds 95 market share in moped class

bull Lakhs of satisfied customers

bull16 dampers on the cylinder head

If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head

Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz

Radiated noise with and without rubber dampers

Experimental verificationhellip

All 16

dampers

in place

Campbell diagram during gradual acceleration

Noise levels have spread and are higher in magnitude in the 2nd case

All 16

dampers

removed

2nd Stage design of Cylinder Head

Thinner part of the fins are fixed now

1st stage design

Finite Element Analysismedical implants

Processes involved in FEMCFD analysis

bull Geometry pre-processingbull Clean upbull Remove unwanted features

bull Mesh generationbull Boundary conditionsbull Materials element type etc

bull Solutionbull Post processing result visualization bull Reports and decision making

Extracting geometry from medical images

Stack of images from MRI (1mm)

Contour extraction by segmentation (using B-

Splines)

Sample points on extracted geometry

GEOMETRIC PRE-PROCESSING

MR (Magnetic Resonance)

Generating a computational mesh

Constrained optimization procedures are needed to maximize a suitable measure of the grid quality (to avoid triangle distorsion) while keeping the desired accuracy of surface representation

Original grid Optimized grid

GEOMETRIC PRE-PROCESSING

Splines on sections

Design Innovation Center at IIT Mandi

bull Design Studio

bull CFD FEM software HyperWorks

Ansys StarCCM+hellip

bull Prototyping and 3D printing

machines

bull Reverse Engineering

Courses

bull Applied CFD

bull Applied FEM

bull Reverse Engineering

bull Design Practicum

bull CAE based final year projects

Projects based on FEMCFD

1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip

Engines from different automotive companies

XL Super heavy duty 95 marketshare 15 year old engine

Example

Final mass

produced design

Original design

Design changes 35 Prototype design 2

Original mass produced

design

Example of real world problem Multidisciplinary natureCAE driven product design

The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26

bull Rubber dampers are provided between thefins to reduce their vibration

bull High vibration of fins produces undesirablenoise

bull Undesirable noise leads to customerdissatisfaction

bull Proper design of the fins are necessary

bull Rubber dampers add extra cost to thevehicle

Rubber dampers

Two-wheeler engine head

TVS Moped Engine Rubber dampers

bull Reliable engine gt 15 years in the market

bull Holds 95 market share in moped class

bull Lakhs of satisfied customers

bull16 dampers on the cylinder head

If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head

Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz

Radiated noise with and without rubber dampers

Experimental verificationhellip

All 16

dampers

in place

Campbell diagram during gradual acceleration

Noise levels have spread and are higher in magnitude in the 2nd case

All 16

dampers

removed

2nd Stage design of Cylinder Head

Thinner part of the fins are fixed now

1st stage design

Processes involved in FEMCFD analysis

bull Geometry pre-processingbull Clean upbull Remove unwanted features

bull Mesh generationbull Boundary conditionsbull Materials element type etc

bull Solutionbull Post processing result visualization bull Reports and decision making

Extracting geometry from medical images

Stack of images from MRI (1mm)

Contour extraction by segmentation (using B-

Splines)

Sample points on extracted geometry

GEOMETRIC PRE-PROCESSING

MR (Magnetic Resonance)

Generating a computational mesh

Constrained optimization procedures are needed to maximize a suitable measure of the grid quality (to avoid triangle distorsion) while keeping the desired accuracy of surface representation

Original grid Optimized grid

GEOMETRIC PRE-PROCESSING

Splines on sections

Design Innovation Center at IIT Mandi

bull Design Studio

bull CFD FEM software HyperWorks

Ansys StarCCM+hellip

bull Prototyping and 3D printing

machines

bull Reverse Engineering

Courses

bull Applied CFD

bull Applied FEM

bull Reverse Engineering

bull Design Practicum

bull CAE based final year projects

Projects based on FEMCFD

1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip

Engines from different automotive companies

XL Super heavy duty 95 marketshare 15 year old engine

Example

Final mass

produced design

Original design

Design changes 35 Prototype design 2

Original mass produced

design

Example of real world problem Multidisciplinary natureCAE driven product design

The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26

bull Rubber dampers are provided between thefins to reduce their vibration

bull High vibration of fins produces undesirablenoise

bull Undesirable noise leads to customerdissatisfaction

bull Proper design of the fins are necessary

bull Rubber dampers add extra cost to thevehicle

Rubber dampers

Two-wheeler engine head

TVS Moped Engine Rubber dampers

bull Reliable engine gt 15 years in the market

bull Holds 95 market share in moped class

bull Lakhs of satisfied customers

bull16 dampers on the cylinder head

If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head

Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz

Radiated noise with and without rubber dampers

Experimental verificationhellip

All 16

dampers

in place

Campbell diagram during gradual acceleration

Noise levels have spread and are higher in magnitude in the 2nd case

All 16

dampers

removed

2nd Stage design of Cylinder Head

Thinner part of the fins are fixed now

1st stage design

Extracting geometry from medical images

Stack of images from MRI (1mm)

Contour extraction by segmentation (using B-

Splines)

Sample points on extracted geometry

GEOMETRIC PRE-PROCESSING

MR (Magnetic Resonance)

Generating a computational mesh

Constrained optimization procedures are needed to maximize a suitable measure of the grid quality (to avoid triangle distorsion) while keeping the desired accuracy of surface representation

Original grid Optimized grid

GEOMETRIC PRE-PROCESSING

Splines on sections

Design Innovation Center at IIT Mandi

bull Design Studio

bull CFD FEM software HyperWorks

Ansys StarCCM+hellip

bull Prototyping and 3D printing

machines

bull Reverse Engineering

Courses

bull Applied CFD

bull Applied FEM

bull Reverse Engineering

bull Design Practicum

bull CAE based final year projects

Projects based on FEMCFD

1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip

Engines from different automotive companies

XL Super heavy duty 95 marketshare 15 year old engine

Example

Final mass

produced design

Original design

Design changes 35 Prototype design 2

Original mass produced

design

Example of real world problem Multidisciplinary natureCAE driven product design

The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26

bull Rubber dampers are provided between thefins to reduce their vibration

bull High vibration of fins produces undesirablenoise

bull Undesirable noise leads to customerdissatisfaction

bull Proper design of the fins are necessary

bull Rubber dampers add extra cost to thevehicle

Rubber dampers

Two-wheeler engine head

TVS Moped Engine Rubber dampers

bull Reliable engine gt 15 years in the market

bull Holds 95 market share in moped class

bull Lakhs of satisfied customers

bull16 dampers on the cylinder head

If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head

Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz

Radiated noise with and without rubber dampers

Experimental verificationhellip

All 16

dampers

in place

Campbell diagram during gradual acceleration

Noise levels have spread and are higher in magnitude in the 2nd case

All 16

dampers

removed

2nd Stage design of Cylinder Head

Thinner part of the fins are fixed now

1st stage design

Generating a computational mesh

Constrained optimization procedures are needed to maximize a suitable measure of the grid quality (to avoid triangle distorsion) while keeping the desired accuracy of surface representation

Original grid Optimized grid

GEOMETRIC PRE-PROCESSING

Splines on sections

Design Innovation Center at IIT Mandi

bull Design Studio

bull CFD FEM software HyperWorks

Ansys StarCCM+hellip

bull Prototyping and 3D printing

machines

bull Reverse Engineering

Courses

bull Applied CFD

bull Applied FEM

bull Reverse Engineering

bull Design Practicum

bull CAE based final year projects

Projects based on FEMCFD

1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip

Engines from different automotive companies

XL Super heavy duty 95 marketshare 15 year old engine

Example

Final mass

produced design

Original design

Design changes 35 Prototype design 2

Original mass produced

design

Example of real world problem Multidisciplinary natureCAE driven product design

The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26

bull Rubber dampers are provided between thefins to reduce their vibration

bull High vibration of fins produces undesirablenoise

bull Undesirable noise leads to customerdissatisfaction

bull Proper design of the fins are necessary

bull Rubber dampers add extra cost to thevehicle

Rubber dampers

Two-wheeler engine head

TVS Moped Engine Rubber dampers

bull Reliable engine gt 15 years in the market

bull Holds 95 market share in moped class

bull Lakhs of satisfied customers

bull16 dampers on the cylinder head

If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head

Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz

Radiated noise with and without rubber dampers

Experimental verificationhellip

All 16

dampers

in place

Campbell diagram during gradual acceleration

Noise levels have spread and are higher in magnitude in the 2nd case

All 16

dampers

removed

2nd Stage design of Cylinder Head

Thinner part of the fins are fixed now

1st stage design

Design Innovation Center at IIT Mandi

bull Design Studio

bull CFD FEM software HyperWorks

Ansys StarCCM+hellip

bull Prototyping and 3D printing

machines

bull Reverse Engineering

Courses

bull Applied CFD

bull Applied FEM

bull Reverse Engineering

bull Design Practicum

bull CAE based final year projects

Projects based on FEMCFD

1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip

Engines from different automotive companies

XL Super heavy duty 95 marketshare 15 year old engine

Example

Final mass

produced design

Original design

Design changes 35 Prototype design 2

Original mass produced

design

Example of real world problem Multidisciplinary natureCAE driven product design

The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26

bull Rubber dampers are provided between thefins to reduce their vibration

bull High vibration of fins produces undesirablenoise

bull Undesirable noise leads to customerdissatisfaction

bull Proper design of the fins are necessary

bull Rubber dampers add extra cost to thevehicle

Rubber dampers

Two-wheeler engine head

TVS Moped Engine Rubber dampers

bull Reliable engine gt 15 years in the market

bull Holds 95 market share in moped class

bull Lakhs of satisfied customers

bull16 dampers on the cylinder head

If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head

Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz

Radiated noise with and without rubber dampers

Experimental verificationhellip

All 16

dampers

in place

Campbell diagram during gradual acceleration

Noise levels have spread and are higher in magnitude in the 2nd case

All 16

dampers

removed

2nd Stage design of Cylinder Head

Thinner part of the fins are fixed now

1st stage design

Projects based on FEMCFD

1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip

Engines from different automotive companies

XL Super heavy duty 95 marketshare 15 year old engine

Example

Final mass

produced design

Original design

Design changes 35 Prototype design 2

Original mass produced

design

Example of real world problem Multidisciplinary natureCAE driven product design

The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26

bull Rubber dampers are provided between thefins to reduce their vibration

bull High vibration of fins produces undesirablenoise

bull Undesirable noise leads to customerdissatisfaction

bull Proper design of the fins are necessary

bull Rubber dampers add extra cost to thevehicle

Rubber dampers

Two-wheeler engine head

TVS Moped Engine Rubber dampers

bull Reliable engine gt 15 years in the market

bull Holds 95 market share in moped class

bull Lakhs of satisfied customers

bull16 dampers on the cylinder head

If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head

Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz

Radiated noise with and without rubber dampers

Experimental verificationhellip

All 16

dampers

in place

Campbell diagram during gradual acceleration

Noise levels have spread and are higher in magnitude in the 2nd case

All 16

dampers

removed

2nd Stage design of Cylinder Head

Thinner part of the fins are fixed now

1st stage design

Engines from different automotive companies

XL Super heavy duty 95 marketshare 15 year old engine

Example

Final mass

produced design

Original design

Design changes 35 Prototype design 2

Original mass produced

design

Example of real world problem Multidisciplinary natureCAE driven product design

The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26

bull Rubber dampers are provided between thefins to reduce their vibration

bull High vibration of fins produces undesirablenoise

bull Undesirable noise leads to customerdissatisfaction

bull Proper design of the fins are necessary

bull Rubber dampers add extra cost to thevehicle

Rubber dampers

Two-wheeler engine head

TVS Moped Engine Rubber dampers

bull Reliable engine gt 15 years in the market

bull Holds 95 market share in moped class

bull Lakhs of satisfied customers

bull16 dampers on the cylinder head

If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head

Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz

Radiated noise with and without rubber dampers

Experimental verificationhellip

All 16

dampers

in place

Campbell diagram during gradual acceleration

Noise levels have spread and are higher in magnitude in the 2nd case

All 16

dampers

removed

2nd Stage design of Cylinder Head

Thinner part of the fins are fixed now

1st stage design

Final mass

produced design

Original design

Design changes 35 Prototype design 2

Original mass produced

design

Example of real world problem Multidisciplinary natureCAE driven product design

The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26

bull Rubber dampers are provided between thefins to reduce their vibration

bull High vibration of fins produces undesirablenoise

bull Undesirable noise leads to customerdissatisfaction

bull Proper design of the fins are necessary

bull Rubber dampers add extra cost to thevehicle

Rubber dampers

Two-wheeler engine head

TVS Moped Engine Rubber dampers

bull Reliable engine gt 15 years in the market

bull Holds 95 market share in moped class

bull Lakhs of satisfied customers

bull16 dampers on the cylinder head

If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head

Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz

Radiated noise with and without rubber dampers

Experimental verificationhellip

All 16

dampers

in place

Campbell diagram during gradual acceleration

Noise levels have spread and are higher in magnitude in the 2nd case

All 16

dampers

removed

2nd Stage design of Cylinder Head

Thinner part of the fins are fixed now

1st stage design

bull Rubber dampers are provided between thefins to reduce their vibration

bull High vibration of fins produces undesirablenoise

bull Undesirable noise leads to customerdissatisfaction

bull Proper design of the fins are necessary

bull Rubber dampers add extra cost to thevehicle

Rubber dampers

Two-wheeler engine head

TVS Moped Engine Rubber dampers

bull Reliable engine gt 15 years in the market

bull Holds 95 market share in moped class

bull Lakhs of satisfied customers

bull16 dampers on the cylinder head

If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head

Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz

Radiated noise with and without rubber dampers

Experimental verificationhellip

All 16

dampers

in place

Campbell diagram during gradual acceleration

Noise levels have spread and are higher in magnitude in the 2nd case

All 16

dampers

removed

2nd Stage design of Cylinder Head

Thinner part of the fins are fixed now

1st stage design

Two-wheeler engine head

TVS Moped Engine Rubber dampers

bull Reliable engine gt 15 years in the market

bull Holds 95 market share in moped class

bull Lakhs of satisfied customers

bull16 dampers on the cylinder head

If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head

Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz

Radiated noise with and without rubber dampers

Experimental verificationhellip

All 16

dampers

in place

Campbell diagram during gradual acceleration

Noise levels have spread and are higher in magnitude in the 2nd case

All 16

dampers

removed

2nd Stage design of Cylinder Head

Thinner part of the fins are fixed now

1st stage design

Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz

Radiated noise with and without rubber dampers

Experimental verificationhellip

All 16

dampers

in place

Campbell diagram during gradual acceleration

Noise levels have spread and are higher in magnitude in the 2nd case

All 16

dampers

removed

2nd Stage design of Cylinder Head

Thinner part of the fins are fixed now

1st stage design

Experimental verificationhellip

All 16

dampers

in place

Campbell diagram during gradual acceleration

Noise levels have spread and are higher in magnitude in the 2nd case

All 16

dampers

removed

2nd Stage design of Cylinder Head

Thinner part of the fins are fixed now

1st stage design

2nd Stage design of Cylinder Head

Thinner part of the fins are fixed now

1st stage design

It was observed that the new head design may notbe feasible from manufacturing point of view

2nd stage cylinder head

Further design

changes and

analysis

Experimental verification Campbell diagram

Existing head with rubber dampers 3rd stage head without rubber dampers

bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head

Noise level comparison

Computational Fluid Dynamic analysis

Temperature distribution

1st stage cylinder head 3rd stage cylinder head

bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass

production

bull Among many benefits few advantages are listed below

1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment

2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits

3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging

4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins

5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine

6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature

Costs and environmental impact

Life cycle cost benefit

Each rubber damper cost = Rs 1

Total cost dampers = 16 x 1 = Rs 16

Additional benefit = Rs 4

Total saving = Rs (16 + 4) = Rs 20vehicle

Sales = 70000 vehiclesmonth

Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth

Benefityear = 12 x 14 lakh = 168 Croreyear

Life cycle benefit = 10 x 168 crore = 168 crore

Product life cycle Competitors upper hand

3D printing technology Innovation in manufacturing

Recent news headlines on 3D printing technology

How 3D Printing Is Revolutionizing Surgery

How 3D printing works

Further design

changes and

analysis

Experimental verification Campbell diagram

Existing head with rubber dampers 3rd stage head without rubber dampers

bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head

Noise level comparison

Computational Fluid Dynamic analysis

Temperature distribution

1st stage cylinder head 3rd stage cylinder head

bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass

production

bull Among many benefits few advantages are listed below

1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment

2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits

3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging

4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins

5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine

6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature

Costs and environmental impact

Life cycle cost benefit

Each rubber damper cost = Rs 1

Total cost dampers = 16 x 1 = Rs 16

Additional benefit = Rs 4

Total saving = Rs (16 + 4) = Rs 20vehicle

Sales = 70000 vehiclesmonth

Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth

Benefityear = 12 x 14 lakh = 168 Croreyear

Life cycle benefit = 10 x 168 crore = 168 crore

Product life cycle Competitors upper hand

3D printing technology Innovation in manufacturing

Recent news headlines on 3D printing technology

How 3D Printing Is Revolutionizing Surgery

How 3D printing works

Experimental verification Campbell diagram

Existing head with rubber dampers 3rd stage head without rubber dampers

bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head

Noise level comparison

Computational Fluid Dynamic analysis

Temperature distribution

1st stage cylinder head 3rd stage cylinder head

bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass

production

bull Among many benefits few advantages are listed below

1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment

2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits

3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging

4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins

5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine

6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature

Costs and environmental impact

Life cycle cost benefit

Each rubber damper cost = Rs 1

Total cost dampers = 16 x 1 = Rs 16

Additional benefit = Rs 4

Total saving = Rs (16 + 4) = Rs 20vehicle

Sales = 70000 vehiclesmonth

Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth

Benefityear = 12 x 14 lakh = 168 Croreyear

Life cycle benefit = 10 x 168 crore = 168 crore

Product life cycle Competitors upper hand

3D printing technology Innovation in manufacturing

Recent news headlines on 3D printing technology

How 3D Printing Is Revolutionizing Surgery

How 3D printing works

Noise level comparison

Computational Fluid Dynamic analysis

Temperature distribution

1st stage cylinder head 3rd stage cylinder head

bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass

production

bull Among many benefits few advantages are listed below

1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment

2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits

3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging

4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins

5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine

6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature

Costs and environmental impact

Life cycle cost benefit

Each rubber damper cost = Rs 1

Total cost dampers = 16 x 1 = Rs 16

Additional benefit = Rs 4

Total saving = Rs (16 + 4) = Rs 20vehicle

Sales = 70000 vehiclesmonth

Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth

Benefityear = 12 x 14 lakh = 168 Croreyear

Life cycle benefit = 10 x 168 crore = 168 crore

Product life cycle Competitors upper hand

3D printing technology Innovation in manufacturing

Recent news headlines on 3D printing technology

How 3D Printing Is Revolutionizing Surgery

How 3D printing works

Computational Fluid Dynamic analysis

Temperature distribution

1st stage cylinder head 3rd stage cylinder head

bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass

production

bull Among many benefits few advantages are listed below

1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment

2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits

3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging

4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins

5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine

6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature

Costs and environmental impact

Life cycle cost benefit

Each rubber damper cost = Rs 1

Total cost dampers = 16 x 1 = Rs 16

Additional benefit = Rs 4

Total saving = Rs (16 + 4) = Rs 20vehicle

Sales = 70000 vehiclesmonth

Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth

Benefityear = 12 x 14 lakh = 168 Croreyear

Life cycle benefit = 10 x 168 crore = 168 crore

Product life cycle Competitors upper hand

3D printing technology Innovation in manufacturing

Recent news headlines on 3D printing technology

How 3D Printing Is Revolutionizing Surgery

How 3D printing works

Temperature distribution

1st stage cylinder head 3rd stage cylinder head

bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass

production

bull Among many benefits few advantages are listed below

1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment

2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits

3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging

4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins

5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine

6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature

Costs and environmental impact

Life cycle cost benefit

Each rubber damper cost = Rs 1

Total cost dampers = 16 x 1 = Rs 16

Additional benefit = Rs 4

Total saving = Rs (16 + 4) = Rs 20vehicle

Sales = 70000 vehiclesmonth

Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth

Benefityear = 12 x 14 lakh = 168 Croreyear

Life cycle benefit = 10 x 168 crore = 168 crore

Product life cycle Competitors upper hand

3D printing technology Innovation in manufacturing

Recent news headlines on 3D printing technology

How 3D Printing Is Revolutionizing Surgery

How 3D printing works

bull Among many benefits few advantages are listed below

1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment

2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits

3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging

4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins

5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine

6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature

Costs and environmental impact

Life cycle cost benefit

Each rubber damper cost = Rs 1

Total cost dampers = 16 x 1 = Rs 16

Additional benefit = Rs 4

Total saving = Rs (16 + 4) = Rs 20vehicle

Sales = 70000 vehiclesmonth

Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth

Benefityear = 12 x 14 lakh = 168 Croreyear

Life cycle benefit = 10 x 168 crore = 168 crore

Product life cycle Competitors upper hand

3D printing technology Innovation in manufacturing

Recent news headlines on 3D printing technology

How 3D Printing Is Revolutionizing Surgery

How 3D printing works

Life cycle cost benefit

Each rubber damper cost = Rs 1

Total cost dampers = 16 x 1 = Rs 16

Additional benefit = Rs 4

Total saving = Rs (16 + 4) = Rs 20vehicle

Sales = 70000 vehiclesmonth

Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth

Benefityear = 12 x 14 lakh = 168 Croreyear

Life cycle benefit = 10 x 168 crore = 168 crore

Product life cycle Competitors upper hand

3D printing technology Innovation in manufacturing

Recent news headlines on 3D printing technology

How 3D Printing Is Revolutionizing Surgery

How 3D printing works

Product life cycle Competitors upper hand

3D printing technology Innovation in manufacturing

Recent news headlines on 3D printing technology

How 3D Printing Is Revolutionizing Surgery

How 3D printing works

3D printing technology Innovation in manufacturing

Recent news headlines on 3D printing technology

How 3D Printing Is Revolutionizing Surgery

How 3D printing works

Recent news headlines on 3D printing technology

How 3D Printing Is Revolutionizing Surgery

How 3D printing works

How 3D printing works

3D printed parts in space

Misuse of 3D printing technology Making gun

3D printing machine by IIT Mandi students

A movie on how technology can save our life

bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie

1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)

2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages

3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc

Misuse of 3D printing technology Making gun

3D printing machine by IIT Mandi students

A movie on how technology can save our life

bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie

1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)

2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages

3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc

3D printing machine by IIT Mandi students

A movie on how technology can save our life

bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie

1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)

2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages

3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc

A movie on how technology can save our life

bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie

1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)

2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages

3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc

Be an entrepreneur उदयमी उदयोगपति

Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer

You work for others

Options for an engineers

Can you work for yourself for your passion

Definition of Entrepreneur

ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo

News headlines

bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand

bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh

bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip

Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup

Yes we can

bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea

How India can become a developed nation

bull How India can become a developed countrybull Oath for the Students

httpswwwyoutubecomwatchv=ZkBEq5dk7BI

Definition of Entrepreneur

ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo

News headlines

bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand

bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh

bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip

Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup

Yes we can

bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea

How India can become a developed nation

bull How India can become a developed countrybull Oath for the Students

httpswwwyoutubecomwatchv=ZkBEq5dk7BI

News headlines

bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand

bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh

bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip

Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup

Yes we can

bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea

How India can become a developed nation

bull How India can become a developed countrybull Oath for the Students

httpswwwyoutubecomwatchv=ZkBEq5dk7BI

Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup

Yes we can

bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea

How India can become a developed nation

bull How India can become a developed countrybull Oath for the Students

httpswwwyoutubecomwatchv=ZkBEq5dk7BI

bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea

How India can become a developed nation

bull How India can become a developed countrybull Oath for the Students

httpswwwyoutubecomwatchv=ZkBEq5dk7BI

bull How India can become a developed countrybull Oath for the Students

httpswwwyoutubecomwatchv=ZkBEq5dk7BI

When broken from INSIDE its life When broken from OUTSIDE its death

Life or death it depends on you

bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind

bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together

in success and failurebull A leadership qualities can be developed with patience practicehellip

What are the qualities of a leader

Be a leader

APJ Abdul Kalam speaks on leadership with Arnab Goswami

bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together

in success and failurebull A leadership qualities can be developed with patience practicehellip

What are the qualities of a leader

Be a leader

APJ Abdul Kalam speaks on leadership with Arnab Goswami

Be a leader

APJ Abdul Kalam speaks on leadership with Arnab Goswami

Yoursquore the future of India we look towards you to solve our society problems

Reverse Engineering

Khul Ja Sim-Sim

Forward Engineering

Concept Engineering

a product Product

Reverse Engineering

Product Reverse

Engineering Concept

Reverse Engineering

ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo

- Dym amp Little

ldquoHow does it do thatrdquo

ldquoWhy would you want to do thatrdquo

ldquoSometimes the best way to advance

is in reverserdquo By Eldad Eilam

Why Reverse Engineering

In general the product is defined as

bull a ldquothing produced by labor or effortrdquo or

bull the ldquoresult of an act or a processrdquo

Example Fan Computers Software Pen Clock Bottle

etc

What is a Product

Who make product

bull Entrepreneurs

bull Engineers

bull Designers

bull Students

bull hellip

Why make product

bull Earn money

bull Get recognition

bull Social service

bull Personal satisfaction

bull hellip

Startup company by IIT studentsbull Company name IdeaForge

bull NETRA is a completely autonomous Unmanned

Aerial Vehicle ndash for Intelligence Surveillance

and Reconnaissance of moving and fixed

targets

bull NETRA streams you real time video of the

target area with spotless clarity

bull Helped Nepal during Earthquake saved many

life

bull Initially struggled lots of failure in designs

Unmanned aerial vehicles are the best way to

access risky terrain especially cracked

buildings during an earthquake Here rescue

officials are inspecting a ramshackled building

in the 2015 Nepal earthquake Image

ideaForge

Video

Reverse Engineering

Khul Ja Sim-Sim

Forward Engineering

Concept Engineering

a product Product

Reverse Engineering

Product Reverse

Engineering Concept

Reverse Engineering

ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo

- Dym amp Little

ldquoHow does it do thatrdquo

ldquoWhy would you want to do thatrdquo

ldquoSometimes the best way to advance

is in reverserdquo By Eldad Eilam

Why Reverse Engineering

In general the product is defined as

bull a ldquothing produced by labor or effortrdquo or

bull the ldquoresult of an act or a processrdquo

Example Fan Computers Software Pen Clock Bottle

etc

What is a Product

Who make product

bull Entrepreneurs

bull Engineers

bull Designers

bull Students

bull hellip

Why make product

bull Earn money

bull Get recognition

bull Social service

bull Personal satisfaction

bull hellip

Startup company by IIT studentsbull Company name IdeaForge

bull NETRA is a completely autonomous Unmanned

Aerial Vehicle ndash for Intelligence Surveillance

and Reconnaissance of moving and fixed

targets

bull NETRA streams you real time video of the

target area with spotless clarity

bull Helped Nepal during Earthquake saved many

life

bull Initially struggled lots of failure in designs

Unmanned aerial vehicles are the best way to

access risky terrain especially cracked

buildings during an earthquake Here rescue

officials are inspecting a ramshackled building

in the 2015 Nepal earthquake Image

ideaForge

Video

Forward Engineering

Concept Engineering

a product Product

Reverse Engineering

Product Reverse

Engineering Concept

Reverse Engineering

ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo

- Dym amp Little

ldquoHow does it do thatrdquo

ldquoWhy would you want to do thatrdquo

ldquoSometimes the best way to advance

is in reverserdquo By Eldad Eilam

Why Reverse Engineering

In general the product is defined as

bull a ldquothing produced by labor or effortrdquo or

bull the ldquoresult of an act or a processrdquo

Example Fan Computers Software Pen Clock Bottle

etc

What is a Product

Who make product

bull Entrepreneurs

bull Engineers

bull Designers

bull Students

bull hellip

Why make product

bull Earn money

bull Get recognition

bull Social service

bull Personal satisfaction

bull hellip

Startup company by IIT studentsbull Company name IdeaForge

bull NETRA is a completely autonomous Unmanned

Aerial Vehicle ndash for Intelligence Surveillance

and Reconnaissance of moving and fixed

targets

bull NETRA streams you real time video of the

target area with spotless clarity

bull Helped Nepal during Earthquake saved many

life

bull Initially struggled lots of failure in designs

Unmanned aerial vehicles are the best way to

access risky terrain especially cracked

buildings during an earthquake Here rescue

officials are inspecting a ramshackled building

in the 2015 Nepal earthquake Image

ideaForge

Video

Reverse Engineering

ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo

- Dym amp Little

ldquoHow does it do thatrdquo

ldquoWhy would you want to do thatrdquo

ldquoSometimes the best way to advance

is in reverserdquo By Eldad Eilam

Why Reverse Engineering

In general the product is defined as

bull a ldquothing produced by labor or effortrdquo or

bull the ldquoresult of an act or a processrdquo

Example Fan Computers Software Pen Clock Bottle

etc

What is a Product

Who make product

bull Entrepreneurs

bull Engineers

bull Designers

bull Students

bull hellip

Why make product

bull Earn money

bull Get recognition

bull Social service

bull Personal satisfaction

bull hellip

Startup company by IIT studentsbull Company name IdeaForge

bull NETRA is a completely autonomous Unmanned

Aerial Vehicle ndash for Intelligence Surveillance

and Reconnaissance of moving and fixed

targets

bull NETRA streams you real time video of the

target area with spotless clarity

bull Helped Nepal during Earthquake saved many

life

bull Initially struggled lots of failure in designs

Unmanned aerial vehicles are the best way to

access risky terrain especially cracked

buildings during an earthquake Here rescue

officials are inspecting a ramshackled building

in the 2015 Nepal earthquake Image

ideaForge

Video

ldquoSometimes the best way to advance

is in reverserdquo By Eldad Eilam

Why Reverse Engineering

In general the product is defined as

bull a ldquothing produced by labor or effortrdquo or

bull the ldquoresult of an act or a processrdquo

Example Fan Computers Software Pen Clock Bottle

etc

What is a Product

Who make product

bull Entrepreneurs

bull Engineers

bull Designers

bull Students

bull hellip

Why make product

bull Earn money

bull Get recognition

bull Social service

bull Personal satisfaction

bull hellip

Startup company by IIT studentsbull Company name IdeaForge

bull NETRA is a completely autonomous Unmanned

Aerial Vehicle ndash for Intelligence Surveillance

and Reconnaissance of moving and fixed

targets

bull NETRA streams you real time video of the

target area with spotless clarity

bull Helped Nepal during Earthquake saved many

life

bull Initially struggled lots of failure in designs

Unmanned aerial vehicles are the best way to

access risky terrain especially cracked

buildings during an earthquake Here rescue

officials are inspecting a ramshackled building

in the 2015 Nepal earthquake Image

ideaForge

Video

In general the product is defined as

bull a ldquothing produced by labor or effortrdquo or

bull the ldquoresult of an act or a processrdquo

Example Fan Computers Software Pen Clock Bottle

etc

What is a Product

Who make product

bull Entrepreneurs

bull Engineers

bull Designers

bull Students

bull hellip

Why make product

bull Earn money

bull Get recognition

bull Social service

bull Personal satisfaction

bull hellip

Startup company by IIT studentsbull Company name IdeaForge

bull NETRA is a completely autonomous Unmanned

Aerial Vehicle ndash for Intelligence Surveillance

and Reconnaissance of moving and fixed

targets

bull NETRA streams you real time video of the

target area with spotless clarity

bull Helped Nepal during Earthquake saved many

life

bull Initially struggled lots of failure in designs

Unmanned aerial vehicles are the best way to

access risky terrain especially cracked

buildings during an earthquake Here rescue

officials are inspecting a ramshackled building

in the 2015 Nepal earthquake Image

ideaForge

Video

Who make product

bull Entrepreneurs

bull Engineers

bull Designers

bull Students

bull hellip

Why make product

bull Earn money

bull Get recognition

bull Social service

bull Personal satisfaction

bull hellip

Startup company by IIT studentsbull Company name IdeaForge

bull NETRA is a completely autonomous Unmanned

Aerial Vehicle ndash for Intelligence Surveillance

and Reconnaissance of moving and fixed

targets

bull NETRA streams you real time video of the

target area with spotless clarity

bull Helped Nepal during Earthquake saved many

life

bull Initially struggled lots of failure in designs

Unmanned aerial vehicles are the best way to

access risky terrain especially cracked

buildings during an earthquake Here rescue

officials are inspecting a ramshackled building

in the 2015 Nepal earthquake Image

ideaForge

Video

Startup company by IIT studentsbull Company name IdeaForge

bull NETRA is a completely autonomous Unmanned

Aerial Vehicle ndash for Intelligence Surveillance

and Reconnaissance of moving and fixed

targets

bull NETRA streams you real time video of the

target area with spotless clarity

bull Helped Nepal during Earthquake saved many

life

bull Initially struggled lots of failure in designs

Unmanned aerial vehicles are the best way to

access risky terrain especially cracked

buildings during an earthquake Here rescue

officials are inspecting a ramshackled building

in the 2015 Nepal earthquake Image

ideaForge

Video

If you want to design a bird like machine

you have to study the bird first

Reverse Engineering

Gain insight into our own design problem bylooking at how other people have addressed thesame issues

Restrictions

ndash Expensive designs

ndash Protected by copyrights and patents

ndash May be the competitorrsquos design

ndash Design may not work very well

ndash Design may be copied difficult to copy knowledge

Reasons for reverse engineering

Interfacing

Military or

commercial

espionage

ObsolescenceBug fixing

Saving money

(Value Engineering

Competitive

technical

intelligence

Creation of

unlicensed

unapproved

duplicates

Software

modernization

Reverse Engineering

Reasons for reverse engineering a part or product

1 The original manufacturer of a product no longer produces a product

2 There is inadequate documentation of the original design

3 The original manufacturer no longer exists but a customer needs the product

4 The original design documentation has been lost or never existed

5 Some bad features of a product need to be designed out For example

excessive wear might indicate where a product should be improved

6 To strengthen the good features of a product based on long-term usage of the

product

7 To analyze the good and bad features of competitors product

8 To explore new avenues to improve product performance and features

9 To gain competitive benchmarking methods to understand competitors

products and develop better products

10The original CAD model is not sufficient to support modifications or current

manufacturing methods

11The original supplier is unable or unwilling to provide additional parts

12The original equipment manufacturers are either unwilling or unable to supply

replacement parts or demand inflated costs for sole-source parts

13To update obsolete materials or antiquated manufacturing processes with more

current less-expensive technologies

Reverse Engineering for military applications

World war II Jerry can

bull British and American forces noticed

that the Germans had gasoline cans

with an excellent design

bull They reverse-engineered copies of

those cans

Reverse Engineering for military applications

World war II Panzerschreck

bull The Germans captured an American Bazooka during World War

II and reverse engineered it to create the larger Panzerschreck

bull See how the need of mask removed in improved design

Improved designOriginal design

Reverse Engineering for military applications

World war II Tupolev Tu-4

bull Three American B-29 bombers on missions over Japan were

forced to land in the USSR

bull The Soviets who did not have a similar strategic bomber decided

to copy the B-29

bull Within a few years they had developed the Tu-4 a near-perfect

copy

Tupolev Tu-4B-29 bombers

Reverse Engineering for military applications

World war II K-13R-3S missile

K-13 Short-range infrared homing air-to-

air missile developed by the Soviet Union

An AIM-9E Sidewinder missile on

display at the National Air and

Space Museum

bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible

after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile

became lodged within the airframe and the pilot returned to base with what

Russian scientists would describe as a university course in missile development

Investigation Prediction and Hypothesis

Concrete Experience Function amp Form

Design Models

Design Analysis

Parametric

Redesign

Adaptive

Redesign

Original

Redesign

Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin

Reverse

Engineering

Modeling amp

Analysis

Redesign

Product (re)design begins with Reverse

Engineering Methodology

1 Investigation Prediction and Hypothesis

bull Develop black box model

bull Use Experience product

bull List assumed working principles

bull Perform economic feasibility of redesign

bull State process description or activity

diagram

Reverse Engineering Methodology

Car Crash

Reasons for reverse engineering

Interfacing

Military or

commercial

espionage

ObsolescenceBug fixing

Saving money

(Value Engineering

Competitive

technical

intelligence

Creation of

unlicensed

unapproved

duplicates

Software

modernization

Reverse Engineering

Reasons for reverse engineering a part or product

1 The original manufacturer of a product no longer produces a product

2 There is inadequate documentation of the original design

3 The original manufacturer no longer exists but a customer needs the product

4 The original design documentation has been lost or never existed

5 Some bad features of a product need to be designed out For example

excessive wear might indicate where a product should be improved

6 To strengthen the good features of a product based on long-term usage of the

product

7 To analyze the good and bad features of competitors product

8 To explore new avenues to improve product performance and features

9 To gain competitive benchmarking methods to understand competitors

products and develop better products

10The original CAD model is not sufficient to support modifications or current

manufacturing methods

11The original supplier is unable or unwilling to provide additional parts

12The original equipment manufacturers are either unwilling or unable to supply

replacement parts or demand inflated costs for sole-source parts

13To update obsolete materials or antiquated manufacturing processes with more

current less-expensive technologies

Reverse Engineering for military applications

World war II Jerry can

bull British and American forces noticed

that the Germans had gasoline cans

with an excellent design

bull They reverse-engineered copies of

those cans

Reverse Engineering for military applications

World war II Panzerschreck

bull The Germans captured an American Bazooka during World War

II and reverse engineered it to create the larger Panzerschreck

bull See how the need of mask removed in improved design

Improved designOriginal design

Reverse Engineering for military applications

World war II Tupolev Tu-4

bull Three American B-29 bombers on missions over Japan were

forced to land in the USSR

bull The Soviets who did not have a similar strategic bomber decided

to copy the B-29

bull Within a few years they had developed the Tu-4 a near-perfect

copy

Tupolev Tu-4B-29 bombers

Reverse Engineering for military applications

World war II K-13R-3S missile

K-13 Short-range infrared homing air-to-

air missile developed by the Soviet Union

An AIM-9E Sidewinder missile on

display at the National Air and

Space Museum

bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible

after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile

became lodged within the airframe and the pilot returned to base with what

Russian scientists would describe as a university course in missile development

Investigation Prediction and Hypothesis

Concrete Experience Function amp Form

Design Models

Design Analysis

Parametric

Redesign

Adaptive

Redesign

Original

Redesign

Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin

Reverse

Engineering

Modeling amp

Analysis

Redesign

Product (re)design begins with Reverse

Engineering Methodology

1 Investigation Prediction and Hypothesis

bull Develop black box model

bull Use Experience product

bull List assumed working principles

bull Perform economic feasibility of redesign

bull State process description or activity

diagram

Reverse Engineering Methodology

Car Crash

Reasons for reverse engineering a part or product

1 The original manufacturer of a product no longer produces a product

2 There is inadequate documentation of the original design

3 The original manufacturer no longer exists but a customer needs the product

4 The original design documentation has been lost or never existed

5 Some bad features of a product need to be designed out For example

excessive wear might indicate where a product should be improved

6 To strengthen the good features of a product based on long-term usage of the

product

7 To analyze the good and bad features of competitors product

8 To explore new avenues to improve product performance and features

9 To gain competitive benchmarking methods to understand competitors

products and develop better products

10The original CAD model is not sufficient to support modifications or current

manufacturing methods

11The original supplier is unable or unwilling to provide additional parts

12The original equipment manufacturers are either unwilling or unable to supply

replacement parts or demand inflated costs for sole-source parts

13To update obsolete materials or antiquated manufacturing processes with more

current less-expensive technologies

Reverse Engineering for military applications

World war II Jerry can

bull British and American forces noticed

that the Germans had gasoline cans

with an excellent design

bull They reverse-engineered copies of

those cans

Reverse Engineering for military applications

World war II Panzerschreck

bull The Germans captured an American Bazooka during World War

II and reverse engineered it to create the larger Panzerschreck

bull See how the need of mask removed in improved design

Improved designOriginal design

Reverse Engineering for military applications

World war II Tupolev Tu-4

bull Three American B-29 bombers on missions over Japan were

forced to land in the USSR

bull The Soviets who did not have a similar strategic bomber decided

to copy the B-29

bull Within a few years they had developed the Tu-4 a near-perfect

copy

Tupolev Tu-4B-29 bombers

Reverse Engineering for military applications

World war II K-13R-3S missile

K-13 Short-range infrared homing air-to-

air missile developed by the Soviet Union

An AIM-9E Sidewinder missile on

display at the National Air and

Space Museum

bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible

after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile

became lodged within the airframe and the pilot returned to base with what

Russian scientists would describe as a university course in missile development

Investigation Prediction and Hypothesis

Concrete Experience Function amp Form

Design Models

Design Analysis

Parametric

Redesign

Adaptive

Redesign

Original

Redesign

Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin

Reverse

Engineering

Modeling amp

Analysis

Redesign

Product (re)design begins with Reverse

Engineering Methodology

1 Investigation Prediction and Hypothesis

bull Develop black box model

bull Use Experience product

bull List assumed working principles

bull Perform economic feasibility of redesign

bull State process description or activity

diagram

Reverse Engineering Methodology

Car Crash

Reverse Engineering for military applications

World war II Jerry can

bull British and American forces noticed

that the Germans had gasoline cans

with an excellent design

bull They reverse-engineered copies of

those cans

Reverse Engineering for military applications

World war II Panzerschreck

bull The Germans captured an American Bazooka during World War

II and reverse engineered it to create the larger Panzerschreck

bull See how the need of mask removed in improved design

Improved designOriginal design

Reverse Engineering for military applications

World war II Tupolev Tu-4

bull Three American B-29 bombers on missions over Japan were

forced to land in the USSR

bull The Soviets who did not have a similar strategic bomber decided

to copy the B-29

bull Within a few years they had developed the Tu-4 a near-perfect

copy

Tupolev Tu-4B-29 bombers

Reverse Engineering for military applications

World war II K-13R-3S missile

K-13 Short-range infrared homing air-to-

air missile developed by the Soviet Union

An AIM-9E Sidewinder missile on

display at the National Air and

Space Museum

bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible

after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile

became lodged within the airframe and the pilot returned to base with what

Russian scientists would describe as a university course in missile development

Investigation Prediction and Hypothesis

Concrete Experience Function amp Form

Design Models

Design Analysis

Parametric

Redesign

Adaptive

Redesign

Original

Redesign

Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin

Reverse

Engineering

Modeling amp

Analysis

Redesign

Product (re)design begins with Reverse

Engineering Methodology

1 Investigation Prediction and Hypothesis

bull Develop black box model

bull Use Experience product

bull List assumed working principles

bull Perform economic feasibility of redesign

bull State process description or activity

diagram

Reverse Engineering Methodology

Car Crash

Reverse Engineering for military applications

World war II Panzerschreck

bull The Germans captured an American Bazooka during World War

II and reverse engineered it to create the larger Panzerschreck

bull See how the need of mask removed in improved design

Improved designOriginal design

Reverse Engineering for military applications

World war II Tupolev Tu-4

bull Three American B-29 bombers on missions over Japan were

forced to land in the USSR

bull The Soviets who did not have a similar strategic bomber decided

to copy the B-29

bull Within a few years they had developed the Tu-4 a near-perfect

copy

Tupolev Tu-4B-29 bombers

Reverse Engineering for military applications

World war II K-13R-3S missile

K-13 Short-range infrared homing air-to-

air missile developed by the Soviet Union

An AIM-9E Sidewinder missile on

display at the National Air and

Space Museum

bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible

after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile

became lodged within the airframe and the pilot returned to base with what

Russian scientists would describe as a university course in missile development

Investigation Prediction and Hypothesis

Concrete Experience Function amp Form

Design Models

Design Analysis

Parametric

Redesign

Adaptive

Redesign

Original

Redesign

Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin

Reverse

Engineering

Modeling amp

Analysis

Redesign

Product (re)design begins with Reverse

Engineering Methodology

1 Investigation Prediction and Hypothesis

bull Develop black box model

bull Use Experience product

bull List assumed working principles

bull Perform economic feasibility of redesign

bull State process description or activity

diagram

Reverse Engineering Methodology

Car Crash

Reverse Engineering for military applications

World war II Tupolev Tu-4

bull Three American B-29 bombers on missions over Japan were

forced to land in the USSR

bull The Soviets who did not have a similar strategic bomber decided

to copy the B-29

bull Within a few years they had developed the Tu-4 a near-perfect

copy

Tupolev Tu-4B-29 bombers

Reverse Engineering for military applications

World war II K-13R-3S missile

K-13 Short-range infrared homing air-to-

air missile developed by the Soviet Union

An AIM-9E Sidewinder missile on

display at the National Air and

Space Museum

bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible

after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile

became lodged within the airframe and the pilot returned to base with what

Russian scientists would describe as a university course in missile development

Investigation Prediction and Hypothesis

Concrete Experience Function amp Form

Design Models

Design Analysis

Parametric

Redesign

Adaptive

Redesign

Original

Redesign

Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin

Reverse

Engineering

Modeling amp

Analysis

Redesign

Product (re)design begins with Reverse

Engineering Methodology

1 Investigation Prediction and Hypothesis

bull Develop black box model

bull Use Experience product

bull List assumed working principles

bull Perform economic feasibility of redesign

bull State process description or activity

diagram

Reverse Engineering Methodology

Car Crash

Reverse Engineering for military applications

World war II K-13R-3S missile

K-13 Short-range infrared homing air-to-

air missile developed by the Soviet Union

An AIM-9E Sidewinder missile on

display at the National Air and

Space Museum

bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible

after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile

became lodged within the airframe and the pilot returned to base with what

Russian scientists would describe as a university course in missile development

Investigation Prediction and Hypothesis

Concrete Experience Function amp Form

Design Models

Design Analysis

Parametric

Redesign

Adaptive

Redesign

Original

Redesign

Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin

Reverse

Engineering

Modeling amp

Analysis

Redesign

Product (re)design begins with Reverse

Engineering Methodology

1 Investigation Prediction and Hypothesis

bull Develop black box model

bull Use Experience product

bull List assumed working principles

bull Perform economic feasibility of redesign

bull State process description or activity

diagram

Reverse Engineering Methodology

Car Crash

Investigation Prediction and Hypothesis

Concrete Experience Function amp Form

Design Models

Design Analysis

Parametric

Redesign

Adaptive

Redesign

Original

Redesign

Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin

Reverse

Engineering

Modeling amp

Analysis

Redesign

Product (re)design begins with Reverse

Engineering Methodology

1 Investigation Prediction and Hypothesis

bull Develop black box model

bull Use Experience product

bull List assumed working principles

bull Perform economic feasibility of redesign

bull State process description or activity

diagram

Reverse Engineering Methodology

Car Crash

1 Investigation Prediction and Hypothesis

bull Develop black box model

bull Use Experience product

bull List assumed working principles

bull Perform economic feasibility of redesign

bull State process description or activity

diagram

Reverse Engineering Methodology

Car Crash

Car Crash

Engine Oil consumption measurement

Drain capDipstick

Example

Method Advantages Disadvantages

Drain amp

measure

Simple and economical

No complicated equipment

required

No skilled labor required

Error in measurement

Approx 25 hrs to run

Impossible to drain all oil practically

Increase in viscosity due to degradation increases

time of drain

Tracer

Radioactive

Sulfur

Measurement time ndash order of

minutes

Transient effects can be measured

Very costly equipment and special handling

procedures for radioactive material

Secondary measurements and calibration of air

and fuel flow

Oil deposited on piston valves and exhaust after

treatment devices not accounted for in final

measurement

Smart Oil

Consumption

Meter

Level sensor to gauge level of oil in

crankcase

Measurement time of the order of

hours

Accuracy of level sensor is of concern

Requires addition of new oil

Suitable for diesel engines

Transient effects cannot be measured

New Method

Cheap to build and use

Portable

Run time of the order of hours

Pump flow characteristics can be

studied

Addition of new oil not required

Accuracy of the scale

Vibrations need to be handled better

Leakages have to be monitored

Comparison of various oil consumption measurement techniques

Engine Oil consumption measurement methods

Glass tube

Metal stand

Metal scale

Slider

Tube

Tube

Engine

Engine stand

Crankcase

Dipstick

Drain cap

1 Investigation Prediction and Hypothesis

Example Engine oil measurement

75

8

85

9

95

10

105

11

1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600

Lev

el o

f oil

(cm

)

Volume in crankcase (ml)

45

42

37 372

6

52

46

44

3

35

4

45

5

55

6

65

0 20 40 60 80 100 120

Oil

Co

ns

um

pti

on

(m

lh

)Time (hours)

New Method

Drain amp Measure

Example Engine oil measurement

Calibration and measurement

2 Concrete Experience Function and Form

bull Plan and execute product disassembly

bull Group defined systems and components together

bull Experiment with product components

bull Develop free body diagrams

bull Identify function sharing and compatibility

bull Transform to engineering specs and metrics

Reverse Engineering MethodologyRE

3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test

parametersbull Ethical issuesbull IPR issues

Reverse Engineering Methodology

4 Design Analysis

bull Calibrate model

bull Create engineering analysis simulation or optimization

bull Create experiment and testing procedures

Reverse Engineering Methodology

5 Parametric Redesign

bull Optimize design parameters

bull Perform sensitivity analysis and tolerance design

bull Build and test prototype

Reverse Engineering Methodology

Parametric design Prototypes testing

6 Adaptive Redesign

ndash Recommend new subsystems

ndash Search for inventive solutions

ndash Analyze force flows and component combinations

ndash Build and test prototype

Reverse Engineering Methodology

7 Original Redesign

ndash Develop new functional structure

ndash Choose alternatives

ndash Verify design concepts

ndash Build and test prototype

Reverse Engineering Methodology

System Level Design

bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together

bull This concept is known as System Level Design

System Level Design

System = Components + Connections

bull Components

ndash Physical - pick-up measure draw on CAD

ndash Functional - flowcharts difficult to define

bull Connections

ndash Fundamental - intended design

ndash Incidental - created by physical proximity of components (vibration heat transfer etc)

System Level Design

Method Advantages Disadvantages

Drain amp

measure

Simple and economical

No complicated equipment

required

No skilled labor required

Error in measurement

Approx 25 hrs to run

Impossible to drain all oil practically

Increase in viscosity due to degradation increases

time of drain

Tracer

Radioactive

Sulfur

Measurement time ndash order of

minutes

Transient effects can be measured

Very costly equipment and special handling

procedures for radioactive material

Secondary measurements and calibration of air

and fuel flow

Oil deposited on piston valves and exhaust after

treatment devices not accounted for in final

measurement

Smart Oil

Consumption

Meter

Level sensor to gauge level of oil in

crankcase

Measurement time of the order of

hours

Accuracy of level sensor is of concern

Requires addition of new oil

Suitable for diesel engines

Transient effects cannot be measured

New Method

Cheap to build and use

Portable

Run time of the order of hours

Pump flow characteristics can be

studied

Addition of new oil not required

Accuracy of the scale

Vibrations need to be handled better

Leakages have to be monitored

Comparison of various oil consumption measurement techniques

Engine Oil consumption measurement methods

Glass tube

Metal stand

Metal scale

Slider

Tube

Tube

Engine

Engine stand

Crankcase

Dipstick

Drain cap

1 Investigation Prediction and Hypothesis

Example Engine oil measurement

75

8

85

9

95

10

105

11

1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600

Lev

el o

f oil

(cm

)

Volume in crankcase (ml)

45

42

37 372

6

52

46

44

3

35

4

45

5

55

6

65

0 20 40 60 80 100 120

Oil

Co

ns

um

pti

on

(m

lh

)Time (hours)

New Method

Drain amp Measure

Example Engine oil measurement

Calibration and measurement

2 Concrete Experience Function and Form

bull Plan and execute product disassembly

bull Group defined systems and components together

bull Experiment with product components

bull Develop free body diagrams

bull Identify function sharing and compatibility

bull Transform to engineering specs and metrics

Reverse Engineering MethodologyRE

3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test

parametersbull Ethical issuesbull IPR issues

Reverse Engineering Methodology

4 Design Analysis

bull Calibrate model

bull Create engineering analysis simulation or optimization

bull Create experiment and testing procedures

Reverse Engineering Methodology

5 Parametric Redesign

bull Optimize design parameters

bull Perform sensitivity analysis and tolerance design

bull Build and test prototype

Reverse Engineering Methodology

Parametric design Prototypes testing

6 Adaptive Redesign

ndash Recommend new subsystems

ndash Search for inventive solutions

ndash Analyze force flows and component combinations

ndash Build and test prototype

Reverse Engineering Methodology

7 Original Redesign

ndash Develop new functional structure

ndash Choose alternatives

ndash Verify design concepts

ndash Build and test prototype

Reverse Engineering Methodology

System Level Design

bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together

bull This concept is known as System Level Design

System Level Design

System = Components + Connections

bull Components

ndash Physical - pick-up measure draw on CAD

ndash Functional - flowcharts difficult to define

bull Connections

ndash Fundamental - intended design

ndash Incidental - created by physical proximity of components (vibration heat transfer etc)

System Level Design

Glass tube

Metal stand

Metal scale

Slider

Tube

Tube

Engine

Engine stand

Crankcase

Dipstick

Drain cap

1 Investigation Prediction and Hypothesis

Example Engine oil measurement

75

8

85

9

95

10

105

11

1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600

Lev

el o

f oil

(cm

)

Volume in crankcase (ml)

45

42

37 372

6

52

46

44

3

35

4

45

5

55

6

65

0 20 40 60 80 100 120

Oil

Co

ns

um

pti

on

(m

lh

)Time (hours)

New Method

Drain amp Measure

Example Engine oil measurement

Calibration and measurement

2 Concrete Experience Function and Form

bull Plan and execute product disassembly

bull Group defined systems and components together

bull Experiment with product components

bull Develop free body diagrams

bull Identify function sharing and compatibility

bull Transform to engineering specs and metrics

Reverse Engineering MethodologyRE

3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test

parametersbull Ethical issuesbull IPR issues

Reverse Engineering Methodology

4 Design Analysis

bull Calibrate model

bull Create engineering analysis simulation or optimization

bull Create experiment and testing procedures

Reverse Engineering Methodology

5 Parametric Redesign

bull Optimize design parameters

bull Perform sensitivity analysis and tolerance design

bull Build and test prototype

Reverse Engineering Methodology

Parametric design Prototypes testing

6 Adaptive Redesign

ndash Recommend new subsystems

ndash Search for inventive solutions

ndash Analyze force flows and component combinations

ndash Build and test prototype

Reverse Engineering Methodology

7 Original Redesign

ndash Develop new functional structure

ndash Choose alternatives

ndash Verify design concepts

ndash Build and test prototype

Reverse Engineering Methodology

System Level Design

bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together

bull This concept is known as System Level Design

System Level Design

System = Components + Connections

bull Components

ndash Physical - pick-up measure draw on CAD

ndash Functional - flowcharts difficult to define

bull Connections

ndash Fundamental - intended design

ndash Incidental - created by physical proximity of components (vibration heat transfer etc)

System Level Design

75

8

85

9

95

10

105

11

1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600

Lev

el o

f oil

(cm

)

Volume in crankcase (ml)

45

42

37 372

6

52

46

44

3

35

4

45

5

55

6

65

0 20 40 60 80 100 120

Oil

Co

ns

um

pti

on

(m

lh

)Time (hours)

New Method

Drain amp Measure

Example Engine oil measurement

Calibration and measurement

2 Concrete Experience Function and Form

bull Plan and execute product disassembly

bull Group defined systems and components together

bull Experiment with product components

bull Develop free body diagrams

bull Identify function sharing and compatibility

bull Transform to engineering specs and metrics

Reverse Engineering MethodologyRE

3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test

parametersbull Ethical issuesbull IPR issues

Reverse Engineering Methodology

4 Design Analysis

bull Calibrate model

bull Create engineering analysis simulation or optimization

bull Create experiment and testing procedures

Reverse Engineering Methodology

5 Parametric Redesign

bull Optimize design parameters

bull Perform sensitivity analysis and tolerance design

bull Build and test prototype

Reverse Engineering Methodology

Parametric design Prototypes testing

6 Adaptive Redesign

ndash Recommend new subsystems

ndash Search for inventive solutions

ndash Analyze force flows and component combinations

ndash Build and test prototype

Reverse Engineering Methodology

7 Original Redesign

ndash Develop new functional structure

ndash Choose alternatives

ndash Verify design concepts

ndash Build and test prototype

Reverse Engineering Methodology

System Level Design

bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together

bull This concept is known as System Level Design

System Level Design

System = Components + Connections

bull Components

ndash Physical - pick-up measure draw on CAD

ndash Functional - flowcharts difficult to define

bull Connections

ndash Fundamental - intended design

ndash Incidental - created by physical proximity of components (vibration heat transfer etc)

System Level Design

2 Concrete Experience Function and Form

bull Plan and execute product disassembly

bull Group defined systems and components together

bull Experiment with product components

bull Develop free body diagrams

bull Identify function sharing and compatibility

bull Transform to engineering specs and metrics

Reverse Engineering MethodologyRE

3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test

parametersbull Ethical issuesbull IPR issues

Reverse Engineering Methodology

4 Design Analysis

bull Calibrate model

bull Create engineering analysis simulation or optimization

bull Create experiment and testing procedures

Reverse Engineering Methodology

5 Parametric Redesign

bull Optimize design parameters

bull Perform sensitivity analysis and tolerance design

bull Build and test prototype

Reverse Engineering Methodology

Parametric design Prototypes testing

6 Adaptive Redesign

ndash Recommend new subsystems

ndash Search for inventive solutions

ndash Analyze force flows and component combinations

ndash Build and test prototype

Reverse Engineering Methodology

7 Original Redesign

ndash Develop new functional structure

ndash Choose alternatives

ndash Verify design concepts

ndash Build and test prototype

Reverse Engineering Methodology

System Level Design

bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together

bull This concept is known as System Level Design

System Level Design

System = Components + Connections

bull Components

ndash Physical - pick-up measure draw on CAD

ndash Functional - flowcharts difficult to define

bull Connections

ndash Fundamental - intended design

ndash Incidental - created by physical proximity of components (vibration heat transfer etc)

System Level Design

3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test

parametersbull Ethical issuesbull IPR issues

Reverse Engineering Methodology

4 Design Analysis

bull Calibrate model

bull Create engineering analysis simulation or optimization

bull Create experiment and testing procedures

Reverse Engineering Methodology

5 Parametric Redesign

bull Optimize design parameters

bull Perform sensitivity analysis and tolerance design

bull Build and test prototype

Reverse Engineering Methodology

Parametric design Prototypes testing

6 Adaptive Redesign

ndash Recommend new subsystems

ndash Search for inventive solutions

ndash Analyze force flows and component combinations

ndash Build and test prototype

Reverse Engineering Methodology

7 Original Redesign

ndash Develop new functional structure

ndash Choose alternatives

ndash Verify design concepts

ndash Build and test prototype

Reverse Engineering Methodology

System Level Design

bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together

bull This concept is known as System Level Design

System Level Design

System = Components + Connections

bull Components

ndash Physical - pick-up measure draw on CAD

ndash Functional - flowcharts difficult to define

bull Connections

ndash Fundamental - intended design

ndash Incidental - created by physical proximity of components (vibration heat transfer etc)

System Level Design

4 Design Analysis

bull Calibrate model

bull Create engineering analysis simulation or optimization

bull Create experiment and testing procedures

Reverse Engineering Methodology

5 Parametric Redesign

bull Optimize design parameters

bull Perform sensitivity analysis and tolerance design

bull Build and test prototype

Reverse Engineering Methodology

Parametric design Prototypes testing

6 Adaptive Redesign

ndash Recommend new subsystems

ndash Search for inventive solutions

ndash Analyze force flows and component combinations

ndash Build and test prototype

Reverse Engineering Methodology

7 Original Redesign

ndash Develop new functional structure

ndash Choose alternatives

ndash Verify design concepts

ndash Build and test prototype

Reverse Engineering Methodology

System Level Design

bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together

bull This concept is known as System Level Design

System Level Design

System = Components + Connections

bull Components

ndash Physical - pick-up measure draw on CAD

ndash Functional - flowcharts difficult to define

bull Connections

ndash Fundamental - intended design

ndash Incidental - created by physical proximity of components (vibration heat transfer etc)

System Level Design

5 Parametric Redesign

bull Optimize design parameters

bull Perform sensitivity analysis and tolerance design

bull Build and test prototype

Reverse Engineering Methodology

Parametric design Prototypes testing

6 Adaptive Redesign

ndash Recommend new subsystems

ndash Search for inventive solutions

ndash Analyze force flows and component combinations

ndash Build and test prototype

Reverse Engineering Methodology

7 Original Redesign

ndash Develop new functional structure

ndash Choose alternatives

ndash Verify design concepts

ndash Build and test prototype

Reverse Engineering Methodology

System Level Design

bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together

bull This concept is known as System Level Design

System Level Design

System = Components + Connections

bull Components

ndash Physical - pick-up measure draw on CAD

ndash Functional - flowcharts difficult to define

bull Connections

ndash Fundamental - intended design

ndash Incidental - created by physical proximity of components (vibration heat transfer etc)

System Level Design

6 Adaptive Redesign

ndash Recommend new subsystems

ndash Search for inventive solutions

ndash Analyze force flows and component combinations

ndash Build and test prototype

Reverse Engineering Methodology

7 Original Redesign

ndash Develop new functional structure

ndash Choose alternatives

ndash Verify design concepts

ndash Build and test prototype

Reverse Engineering Methodology

System Level Design

bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together

bull This concept is known as System Level Design

System Level Design

System = Components + Connections

bull Components

ndash Physical - pick-up measure draw on CAD

ndash Functional - flowcharts difficult to define

bull Connections

ndash Fundamental - intended design

ndash Incidental - created by physical proximity of components (vibration heat transfer etc)

System Level Design

7 Original Redesign

ndash Develop new functional structure

ndash Choose alternatives

ndash Verify design concepts

ndash Build and test prototype

Reverse Engineering Methodology

System Level Design

bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together

bull This concept is known as System Level Design

System Level Design

System = Components + Connections

bull Components

ndash Physical - pick-up measure draw on CAD

ndash Functional - flowcharts difficult to define

bull Connections

ndash Fundamental - intended design

ndash Incidental - created by physical proximity of components (vibration heat transfer etc)

System Level Design

System Level Design

bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together

bull This concept is known as System Level Design

System Level Design

System = Components + Connections

bull Components

ndash Physical - pick-up measure draw on CAD

ndash Functional - flowcharts difficult to define

bull Connections

ndash Fundamental - intended design

ndash Incidental - created by physical proximity of components (vibration heat transfer etc)

System Level Design

System Level Design

System = Components + Connections

bull Components

ndash Physical - pick-up measure draw on CAD

ndash Functional - flowcharts difficult to define

bull Connections

ndash Fundamental - intended design

ndash Incidental - created by physical proximity of components (vibration heat transfer etc)

System Level Design

System Level Design