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U.S. ARMY TANK AUTOMOTIVE RESEARCH, DEVELOPMENT AND ENGINEERING CENTER

Reverse Engineering Re-definedRequirements

TARDEC

25 AUG 2015

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Presented by: Kim HankeTARDEC SIE CSI/EST

Distribution A approved for Public Release; distribution Unlimited, per AR 380-5. OPSEC Review conducted per AR 530-1 OPSEC#27140

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• What is R/E……..• Questions to Ask

– What does the Customer really need?– How do I select the provider of services

• Assumptions– Identify and share your assumptions with the R/E Team

• Types of Reverse Engineering– The Current OEM is out of Business or No Longer supplies this part– We have parts and no drawings (supplied as Urgent Need)– We have drawings but no 3D CAD Data to use as reference– We need the entire Vehicle for future integration efforts

• Cautions– How to interpret the data I have received

• Validation– How do I check the R/E items– Training

Agenda

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What is Reverse Engineering • Merriam-Webster

• :to study the parts of (something) to see how it was made and how it works so that you can make something that is like it

Reverse Engineering

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Decision of Support:TARDEC / CSI

PLDM / IndustryDepot

Reverse Engineering Steps to Success

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What does the Customer really need or want?• What is the information going to be used for?• Reference to create something new?• Reference to integrate something new?• To make new parts?• To evaluate current systems through Modeling & Simulation,

Virtual Testing• To solicit a new supplier for a current part?• To solicit a new supplier for a obsolete part?• To solicit suppliers for competition?• The Government owns the drawings but not the 3D data for

evaluation, integration or manufacturing.• What is available to start with?• What level of detail is needed?

From the questions above decisions can be made to identify• Levels vary from basic 3D point cloud data to a complete 3D

parametric model, with individual parametric components, containing weld information, wire routing, material type and evaluation of manufactured process and more

• Discussions between customer and our experienced team will help determine which level is necessary to achieve goal

Questions to Ask

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The Customer and Team need to understand the types of Reverse Engineering and what is gained from each type.

Types of Reverse Engineering • 3D Visual Model

• 3D Point Cloud Model completed for viewing• Basic CAD Model

• Material, weight, and part information defined. CAD model has volume, but limited modification ability. (Known as a “dumb solid”)

• Parametric CAD Model• CAD model completely modifiable – change size, shape,

thickness, add or remove holes, cut sections, calculate mass.

• Kinematic Model• Develop kinematic model

• Data & Information for “Blast Simulation and Analysis”• Data and Information for “Technical Data Package creation”

Types of Reverse Engineering

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Reverse Engineering Decision Tree

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How to how to interpret the data I have created or received.

Use the process flow to review the data received with an experienced designer and the collector of the data.

Ensure that what you needed is what you have received

Ensure that what you have received can be used for what you need.• You may to need to review with:

• Modeling & Simulation Team• Manufacturing• Contracting

Cautions

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Validate and Verify what you have received is what you needed and is accurate.

Comparison and Test• Conduct the scan process in reverse

• Created data to object used• Test the build process if parts are going to be made

• Reliefs in part, spring back for parts, mold flow for plastic for example

• The Reverse Engineering effort is only the start what the effort will be used for will need to tested and verified then refined.

Results• Refinement to the validation or test results is an opportunity

for process improvement• Comparison studies and result differences are an

opportunity for additional training.

Validation

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Disassembly, Storage, and Reassembly• In order to ensure complete, accurate scan data, all significant

surfaces of a part must be scanned Therefore, disassembly may be required

• Amount of disassembly to be determined by customer’s project requirements

• Vehicle can be completely disassembled, down to bare chassis, if necessary

• Part storage system, including space allocation, will be tailored per project requirements, then implemented and utilized throughout duration of project. All data will be backed up and stored on an external hard drive

• At the conclusion of project, vehicle will be reassembled back to original “as received” condition

Process Overview Step 1

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3D Point Cloud Model• First step in reverse engineering• Scan to gather geometric data and produce three dimensional

point cloud model• Useful for visual aid – basically, a three dimensional picture• Cannot be modified, separated or analyzed• Point cloud data can be used as a CAD model assembly template

for assembling multiple components – from a small assembly up to a complete vehicle, interior and exterior

Process Overview Step 2

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3D Surface Model• Data post processed and saved into customer specified CAD software

(Pro E, Creo, Solidworks, etc.)• CAD parameters added to CAD model per customer requirements• Part information available – material, weight, part number, etc.

(metadata)• Also known as “dumb solid” – limited modification ability

3D Parametric Model• Features of each part model rebuilt from surface data to form a solid,

parametric model• Part completely modifiable, enabling the ability to change size,

shape, and thickness, add or remove holes, etc., quickly and easily• CAD model data verified to physical part to ensure accuracy• Ability to cut sections, create subassemblies, and calculate mass

Process Overview Step 3 & 4

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Assembled Cad Model• Part models inserted into Vehicle Model with proper location and

orientation• Allows the ability to make virtual vehicle modifications:

add/remove parts, interchange sub systems, upgrade armor• Electrical wire harness routing or space claim can be added• Ability to repurpose vehicle for new and evolving mission package

needs

Process Overview Step 5

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Additional BenefitsFully processed, parametric data provides the ability to perform additional follow-on activities:

• FEA: Surfaces can be meshed to perform FEA calculations for finding component displacements, strains, and stresses under internal and external loads

• Blast simulation analysis: Welds can be located and identified, using X-ray equipment, if necessary. The welds can then be added to the CAD model indicated by callouts and annotations

• Kinematics can be applied to various components for motion analysis, interference checking, & troubleshooting

• Technical Data Package can be created from this level of data. TDP can include such items as engineering drawings, product information, process specifications, quality assurance, technical manuals, and more.

Additional Benefits (Step 6)