Maintenance and Parts Fabrication by Reverse Engineering

1999 ◽  
Author(s):  
Sayed M. Metwalli ◽  
M. Alaa E. Radwan ◽  
Osama Abdel-Wehab ◽  
Owaise Shalaby ◽  
Youssria A. Moussa ◽  
...  
Keyword(s):  
Reverse Engineering ◽  
Spare Parts ◽  
Geometrical Configuration ◽  
Proof Of Concept ◽  
Industrial Plants ◽  
Industrial Base ◽  
Skilled Manpower ◽  
Casting Industry ◽  
Major Industry ◽  
Re Methods

Abstract With the collapse of the Eastern block, once Egypt’s major industry supplier for machinery and spare parts, and the lack of skilled manpower, the Egyptian industry is finding it difficult to maintain its machinery and industrial base and to compete with the much more sophisticated and coordinated industries abroad. The cutoff of supply of maintenance parts from the Eastern Block, prompt the use of modern reverse engineering (RE) methods in the capturing the geometrical configuration and fabrication of rare maintenance parts, in support of the Egyptian Industry. This paper demonstrates, as a proof of concept, the use of the technology of RE in the fabrication of parts. The success of the experiment initiated a much wider application to the technology, that of patterns making in support of the casting industry. This will provide an accurate and expeditious means to properly maintain industrial plants and produce compatible spare pails urgently needed.

Teknologi Inokulasi Besi Cor Kelabu FC-250 Untuk Mencegah Pengerasan Pada Dove Tale Produk Ragum Tipe 125

2019 ◽  
Vol 16 (2) ◽  
Author(s):  
Amin Suhadi ◽  
Seodihono
Keyword(s):  
Mechanical Properties ◽  
Cast Iron ◽  
Treatment Process ◽  
Gray Cast Iron ◽  
Spare Parts ◽  
Gray Cast ◽  
Micro Structure ◽  
Control Factors ◽  
Seed Inoculation ◽  
Casting Industry

Production technology of metal casting industry in Indonesia needs to be improved, especially in the manufacturing of spare parts and box engine made of gray cast iron which has various wall thick such as dove tale construction. Microstructure of gray cast iron is influenced by cooling rate during casting, chemical composition and melting treatment process (inoculation). The part which has the thinnest thickness has the fastest cooling therefore, the grain boundary is smaller compared to other section. As a result this part has highest hardness and difficult to be machined. This research is conducted to solve this problem by modifying melting and solidification treatment process. The research starting from micro structure analysis, composition and mechanical properties tests on the product, and then conducting modification treatment through Taguchi method approach. Experimental results obtained show that the best level settings to control factors which affect to the uniformity of the microstructure and mechanical properties in gray cast iron is the addition of seed inoculation super ® 75, as much as 0.25% with the method of inoculation material entering into the Transfer Ladle.Teknologi produksi pada industri pengecoran di Indonesia masih membutuhkan perbaikan terutama dalam pembuatan komponen mesin perkakas dan peralatan pabrik yang terbuat dari besi tuang kelabu yang mempunyai variasi ketebalan yang besar seperti konstruksi ekor burung (dove tale). Pada pengecoran, struktur mikro dari besi tuang kelabu sangat dipengaruhi oleh kecepatan pendinginan, komposisi kimia dan proses perlakuan pada logam cair (inokulasi). Bagian yang mempunyai ukuran paling tipis mempunyai kecepatan pendinigan paling tinggi karena itu ukuran butirnya jauh lebih kecil dari bagian lain, akibatnya bagian ini mempunyai kekerasan lebih tinggi dan sulit dilakukan pengerjaan mesin. Penelitian ini bertujuan untuk memperbaiki hal ini yang terjadi pada dove taledengan cara memodifikasi proses perlakuan pada cairan besi dan proses pendinginan. Penelitian dimulai dari analisa struktur mikro, pengujian komposisi kimia, pengujian sifat mekanis pada produk kemudian dilakukan modifikasi menggunakan pendekatan metode statistik Taguchi. Hasil penelitian menunjukkan bahwa pengaturan terbaik yang dapat diperoleh untuk mendapatkan keseragaman struktur mikro dan sifat mekanis pada pengecoran besi tuang kelabu adalah penambahan seed inoculation super ® 75, sebesar 0.25% dengan metode pemasukan inokulasi kedalam Ladle pengangkut logam cair.Keywords: carbon, micro structure, hardness, inoculation

scholarly journals Use of Reverse Engineering and Additive Printing in the Reconstruction of Gears

2020 ◽  
Vol 3 (1) ◽  
pp. 274-284
Author(s):  
Dorota Palka
Keyword(s):  
3D Printing ◽  
Reverse Engineering ◽  
Fused Deposition Modeling ◽  
Rapid Development ◽  
Spare Parts ◽  
Common Element ◽  
Practical Application ◽  
Computer Aided Manufacturing ◽  
Fused Deposition ◽  
Computer Aided

AbstractDespite the very rapid technological development, the general concept of mechanical devices has not changed. Still, the most common element of these devices are gears, whose range of use is very wide. There are both technological and historical considerations for the reconstruction of gears and other elements. In particular, this applies to spare parts for technical facilities that are not available on the market or service costs are too high. Contemporary reconstruction is called Reverse Engineering, which offers tools that allow transformation of an existing object through a virtual model into the final real product. Modern production engineering is based on innovative CAD – Computer Aided Designed design methods and computer-aided manufacturing technologies, CAM – Computer Aided Manufacturing. The rapid development of 3D CAD systems has led to the development of solutions to obtain the designed object, already at the development stage. Such a solution is the Rapid Prototyping method, designed for fast, precise and repeatable production of machine components. Widespread use and growing interest in the use of additive printing influenced the development of this technology. The purpose of the article is to present the practical application of the Reverse Engineering method and 3D printing in the reconstruction of gears. The object of research is the real gear, which has been reconstructed using Reverse Engineering and 3D printing. The article presents the basic assumptions of the methods used and the methodology for conducting reconstruction work. FDM (Fused Deposition Modeling) technology was used for the research. The results obtained are a real example of the practical application of the presented methods. At the same time, they create great opportunities for their wider use.

The Power of Insulation in the Citrus Industry

2007 ◽  
Author(s):  
Ronald L. King
Keyword(s):  
Construction Industry ◽  
Return On Investment ◽  
Special Design ◽  
Insulation System ◽  
Citrus Industry ◽  
Industrial Plants ◽  
Computer Chips ◽  
Important Time ◽  
Corrosion Under Insulation ◽  
Major Industry

Insulation is a forgotten technology that can provide an unrivaled return on investment. The Citrus Industry is not an exception. Insulation is the ‘Rodney Dangerfield’ of the construction industry: It receives very little respect and is taken for granted. Insulation is a powerful resource when designed, applied, and maintained properly. Yet, this technology is often forgotten or put on the bottom of the list and ignored. A recent survey conducted by the National Insulation Association of more than 160 industrial plants, manufacturing, engineering, and architectural firms found that: • Most had no idea of the payback period, rate of return, with the use of insulation, nor a method to quantify costs versus savings • Many acknowledged that numerous areas of insulation were in serious need of repair • The majority did not understand that insulation had any real environmental “tie in” • Some did not consider additional insulation necessary: “the plant is working fine” • Many could not relate corrosion under insulation to having anything to do with the insulation • Most acknowledged their specifications were outdated • Many confirmed they did not have a dedicated job function to address insulation specifications or anyone who was the “insulation champion” • Many did not think of insulation as a system or requiring any special design review or technical consideration That survey confirmed the ‘Rodney Dangerfield’ characterization and formed the basis for the foundation of a major industry educational and awareness initiative. The benefits of insulation are in many cases invisible and long lasting. This technology is not some mysterious myth. Possibly it is misunderstood and under appreciated due to lack of knowledge. Calculating the operational benefits and the return on investment can be relatively simple. However, an insulation system does not have any moving parts, computer chips, or fancy gauges, and it is certainly not sexy. Maybe that is why in many circles insulation is not an exciting topic of discussion, even though it is a time tested and proven technology that can often provide an annual return on investment greater than 100%. There has not been a more important time in recent history than now to think about insulation differently. The Citrus Industry is not immune to that thought process. Paper published with permission.

scholarly journals Service experiences Maglev vehicles Shanghai

2018 ◽  
Vol 4 (3) ◽  
pp. 65-71 ◽  
Author(s):  
Reinhard Rampelmann ◽  
Reiner Köhler
Keyword(s):  
Lead Time ◽  
High Speed ◽  
Spare Parts ◽  
Industrial Base ◽  
Maglev Vehicle ◽  
Commercial Operation ◽  
Great Availability ◽  
Adaptive Development ◽  
Intelligent Diagnostics ◽  
Service Experiences

In the late 1990s thyssenkrupp Transrapid GmbH successfully qualified the Maglev Vehicle TR08 and obtained the type approval certificate. Based on that design, in 2001-2003 three five-car vehicles for the first commercial high speed Maglev Line in Shanghai have been manufactured and set into operation. The VIP-Run took place over 15 years ago and the commercial operation has been running for almost 15 years at great availability. The Transrapid system concept of small autonomous redundant electronics based modules facilitates significantly smooth maintenance - diagnosis, testing and system inspection. Thanks to intelligent diagnostics, the use of easily interchangeable plug-in units, the dimensioning of the spare parts inventory according to the expected failure rates and the replenishment lead time, the maintenance efforts are still within the forecast range at the beginning of the project. Furthermore, the maintenance concept is essentially unchanged since the beginning. There are no special materials that are subject to a potential shortage or price leap, but all according to normal industrial base. Thanks to the low level of stress to components on board, most electrical and electronic units are still on-board as original equipment, which are 15 years old and at no end of life is visible. But in case of repair or replacement, the challenge is the adaptation to the volatile market of electronic components. This includes the necessary lead-time for adaptive development and qualification, which has to be considered. On the side of the vehicle supplier, a small smart team of electronics experts is managing obsolescence and compensates discontinuation. The paper tells how it works and appreciates trustful cooperation of the supplier in Europe with the operator in China.

scholarly journals Reverse engineering and CAD-CAM approach for manufacturing of spare parts. Case study

2018 ◽  
Vol Volume XXVII (XVII), 2018/1 (1) ◽  
Author(s):  
Iulian Stănăşel ◽  
Florin Blaga ◽  
Traian Buidoş ◽  
Dan Crăciun
Keyword(s):  
Reverse Engineering ◽  
Spare Parts ◽  
Cad Cam

On the Classification of Fitting Problems for Single Patch Free-Form Surfaces in Reverse Engineering

2001 ◽  
Author(s):  
Mohammed M. Shalaby ◽  
Ashraf O. Nassef ◽  
Sayed M. Metwalli
Keyword(s):  
Reverse Engineering ◽  
Geometric Modeling ◽  
Linear Optimization ◽  
Optimization Methods ◽  
Industrial Applications ◽  
Spare Parts ◽  
Free Form ◽  
Modeling Techniques ◽  
Free Form Surfaces ◽  
Die And Mold

Abstract The design and manufacture of free-form surfaces increased in industrial applications, especially for the re-manufacture of spare parts, or in the die and mold industry. Reverse engineering has become the status quo technique in reproducing parts whose original designs are no longer existing or for parts, which assume slightly different shapes after manufacturing as in the case of die and mold industry. Laser scanners have been used extensively in sampling points from parts surfaces. The sampled points are then fitted with a free-form surface using one of the geometric modeling techniques such as Bezier or B-Spline surfaces. Since Non-Uniform Rational B-Splines (NURBS) is the most general form of geometric modeling techniques, this paper presents the possible formulations of the fitting problem optimization and presents some guidelines of the choice of the independent NURBS parameters, once the control points are evaluated using least squares fitting. The work shows that the use of NURBS weights can provide better improvements for the significant reduction of the fitting error, rather than the widely used knot values. In addition the work shows that parts with semi planar surfaces do not need further refinement using non-linear optimization methods.

scholarly journals Reverse engineering methodology as a way of steam turbine blades designing for Loviisa Nuclear Power

2019 ◽  
Vol 137 ◽  
pp. 01002
Author(s):  
Radosław Bondyra ◽  
Krzysztof Dominiczak ◽  
Jacek Matuszak
Keyword(s):  
Power Plant ◽  
Reverse Engineering ◽  
Steam Turbine ◽  
Nuclear Power ◽  
Turbine Blades ◽  
Selection Criterion ◽  
Spare Parts ◽  
Cost Competitiveness ◽  
Last Stage ◽  
Lp Turbine

This article concerns a reverse engineering-based design process of last stage blade (LSB) for other original equipment manufacturer (oOEM). For Loviisa Power Plant (Finland) GE designed and delivered a set of oOEM LSBs to be fit into existing low pressure (LP) turbine module steam path. Although cost competitiveness is a one of major selection criterion for steam turbine spare parts components supplier, diversification of suppliers is also a strategic for power plant owner. Considered here is a process of reengineering of oOEM LSB and all relevant challenges related to this process especially management of geometry deviations between reverse-engineered and oOEM blade. In this article, there are a design steps described taken to qualify reverse-engineered design. Moreover, a manufacturing process of the LSB is shown.

scholarly journals Issues related to an attempt to recreate the geometry of a non-standard spur gear

2021 ◽  
Vol 1199 (1) ◽  
pp. 012105
Author(s):  
K Konecki ◽  
D Wojtkowiak ◽  
K Talaśka ◽  
A Kołodziej ◽  
G Domek
Keyword(s):  
Reverse Engineering ◽  
Test Object ◽  
Spur Gear ◽  
Spare Parts ◽  
Geometric Parameters ◽  
Design And Technology ◽  
Involute Gear ◽  
Modern Machine ◽  
Selection Of ◽  
Made In

Abstract Modern machine manufacturers are making the design and technology of their products more and more complicated. This is to protect against a frequently used practice at customers, i.e. making extra parts on your own. This is because entrepreneurs often cannot afford to order expensive original spare parts and - using reverse engineering - prepare working drawings and commission the components to be made in their own machine park or externally from local suppliers. However, the matter is more complex in the case of gears, which so far have been designed on the basis of the selection of standard geometric parameters. A small modification of one or more of these parameters is enough and it becomes very difficult to recreate the geometry of such a gear. This paper presents the issues related to the reverse engineering of a spur involute gear with very non-standard parameters m = 4.98, α = 26.325 °, x = 0.0695, y = 0.795, c* = 0.383. Further metrological steps were proposed that should be taken to correctly identify at least the fact that the test object is not a part produced by standard modular tools (Fellows cutter, Maag rack cutter, worm cutter, etc.). The work also includes short graphical analyzes of the recreated geometry.

scholarly journals Reverse engineering and CAD-CAM approach for manufacturing of spare parts. Case study

2018 ◽  
Vol 184 ◽  
pp. 03004
Author(s):  
Iulian Stănăşel ◽  
Florin Blaga ◽  
Traian Buidoş ◽  
Dan Crăciun
Keyword(s):  
Reverse Engineering ◽  
Complex Shape ◽  
Product Information ◽  
Spare Part ◽  
Spare Parts ◽  
Virtual Manufacturing ◽  
Cnc Machine Tools ◽  
Cnc Machine ◽  
Cad Cam

Reverse engineering represents a method to retrieve information from an existing product, information which are then used for designing a new product or to reproduce it in order to make spare parts. In this paper is presented a case study on making a spare part of complex shape from a worn part. There are presented the stages of acquisition of data by scanning, the use of reverse engineering for the realization of the 3D model, the virtual manufacturing and then the machining of the workpiece CNC machine tools.

scholarly journals Determination of ordering acceptance using decision support system on metal casting industry in sub-district of Ceper Klaten

2019 ◽  
Vol 1 (2) ◽  
Author(s):  
Ahmad Muhsin ◽  
Muafi Muafi ◽  
Fuad Hasyim ◽  
Rizqi Adhyka Kusumawati
Keyword(s):  
Support System ◽  
System Analysis ◽  
System Development ◽  
Spare Parts ◽  
Test Method ◽  
Metal Casting ◽  
Corporate Managers ◽  
Central Java ◽  
Casting Industry ◽  
Analysis System

The largest center of metal casting industry in Indonesia is located in sub-district of Ceper, Klaten, Central Java. The companies of this region open orders for manufacturing engine spare parts and any other engineering needs. The research aims to provide a media accelerating the process of estimation and decision making on product ordering acceptance in the form of Decision Suppprt System (DSS). The method used in this research was System Development Life Cycle (SDLC) encompassing system analysis, system design, and system implementation. The contrive of application used basic programming language with visual Studio Community 2017 software and Microsoft Access basic database software. The testing result of Decission Support System on consumer ordering acceptance using alpha test method and black box test showed that the application program is proper to use and in accordance to the needs of corporate managers to take decision on ordering acceptance.

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