UIE 901

Advances in Manufacturing Systems

Prepared by: Mohit Garg Thapar University

What is Reverse Engineering?

n

A systematic methodology for analyzing the design of an existing device or system, either as an approach to study the design or as a prerequisite for re-design.

What is Reverse Engineering ?

Forward Engineering Requirements Design Source Code Behavior Reverse Engineering

Definition
n

Reverse engineeringis theprocessof discovering the technological principles of a device, object, or system through analysis of its structure, function, and operation. It often involves taking something (a mechanical device, electronic component, computer program, or biological, chemical, or organic matter) apart and analyzing its workings in detail to be used in maintenance, or to try to make a new device or program that does the same thing without using or simply duplicating (without understanding) the original.

Reverse Engineering helps us to:

n n

Develop a systematic approach to thinking about the engineering design of devices and systems Acquire a data bank of mechanical design solutions

Reasons for Reverse Engineering

n n

Interfacing. RE can be used when a system is required to interface to another system and how both systems would negotiate is to be established. Such requirements typically exist forinteroperability. Military or commercialespionage. Learning about an enemy's or competitor's latest research by stealing or capturing a prototype and dismantling it. It may result in development of similar product. Improve documentation shortcomingsReverse engineering can be done when documentation of a system for its design, production, operation or maintenance have shortcomings and original designers are not available to improve it. RE of software can provide the most current documentation necessary for understanding the most current state of a software system ObsolescenceIntegrated circuitsoften seem to have been designed on obsolete, proprietary systems, which means that the only way to incorporate the functionality into new technology is to reverse-engineer the existing chip and then re-design it.

n n n

Software Modernization. RE is generally needed in order to understand the 'as is' state of existing or legacy software in order to properly estimate the effort required to migrate system knowledge into a 'to be' state. Much of this may be driven by changing functional, compliance or security requirements. Product Security Analysis.. To examine how a product works, what are specifications of its components, estimate costs and identify potentialpatent infringement. Acquiring sensitive data by disassembling and analysing the design of a system component. Another intent may be to removecopy protection, circumvention of access restrictions. Creation of unlicensed/unapproved duplicates. Academic/learning purposes. RE for learning purposes may be understand the key issues of an unsuccessful design and subsequently improve the design. Competitive technical intelligence (understand what your competitor is actually doing, versus what they say they are doing).

Reverse Engineering for Machines

n

Ascomputer-aided design (CAD) has become more popular, reverse engineering has become a viable method to create a 3D virtual model of an existing physical part for use in 3D CAD,CAM,CAEor other software.The reverse-engineering process involves measuring an object and then reconstructing it as a 3D model. The physical object can be measured using3D scanning technologies likeCMMs,laser scanners,structured light digitizers, orIndustrial CT Scanning (computed tomography). The measured data alone, usually represented as apoint cloud, lacks topological information and is therefore often processed and modeled into a more usable format such as a triangular-faced mesh, a set ofNURBSsurfaces, or aCADmodel. Reverse engineering is also used by businesses to bring existing physical geometry into digital product development environments, to make a digital 3D record of their own products, or to assess competitors' products. It is used to analyse, for instance, how a product works, what it does, and what components it consists of, estimate costs, and identify potentialpatentinfringement, etc. Value engineeringis a related activity also used by businesses. It involves deconstructing and analysing products, but the objective is to find opportunities for cost cutting.

Levels of Analysis in Reverse Engineering

n

System-Wide Analysis Subsystem Dissection Analysis Individual Component Analysis

1) System-Wide Analysis
n n n n

Customer Requirements Engineering Requirements Functional Specifications Prediction of Subsystems and Components

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2) Subsystem Dissection Analysis

n

Document Disassembly Define Subsystems Determine Subsystem Functional Specifications Determine Subsystem Physical/Mathematical Principles

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3) Individual Component Analysis

n

Repeat Dissection Steps to Individual Component Define Component Material Selection and Fabrication Process Suggest Alternative Designs, Systems, Components, and Materials

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Example: Small Kitchen Scale

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Customer s Perspective:
n

Some of the things that the customer might look for in a kitchen scale are the cost of the item and its appearance. Some other factors they would be concerned about how sturdy the device is, the accuracy of the weighing process, and its size. The customer may even ask if he/she is getting quality for the price.

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Engineer s Perspective:
The engineer has a totally different perspective from which he operates. The engineer will be looking at things like the material that the object is made of, the mechanisms that are required, the strength of the materials used, etc. In relation to the kitchen scale: Is the riveting process of the plate to the stem adequate? Are the materials used strong enough to hold one pound of weight? Does the kitchen scale have any sharp edges that could cause injury? What mechanism is necessary to give an accurate reading on the scale?

n n n n

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TOP PLATE

STEM

RIVETS

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Functional Requirements
n n n n n n

The kitchen scale must be able to accommodate 1 pound of food. The plate must be large enough to hold 1 pound of food. The stem must be strong enough to support the plate and the food. The linkage must be designed so that the reading is accurate to the nearest .25 ounce. The read-out must be easily read. The design must lend itself for easy cleaning and sanitizing.

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SPRING MECHANISM

SPRING NUT

THREADED PIN

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LINK 2

LINK 3

LINK 1

BOTTOM

READOUT

COVER

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Bicycle Reverse Engineering

Let s say we are trying to get a quick start in the bicycle business. We could buy a bunch of new bikes and reverse engineer them to:

n n

learn how to build them ourselves (without paying royalties for the design) improve on existing designs if possible another reason for reverse engineering - need to replace a part for which you have no drawing or technical information

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Bicycle Construction and Design

from ref. 4, used by permission of Rodale Press, 1994, all rights reserved

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Look at one simple subsystem frame tubing

n

There are lots of possibilities (variables) for even this simple element n material (steel, aluminum, titanium, composite, ...) n cross section shape n shape (square, round, oval or other) n hollow or solid n constant cross section, or variable n How do you handle all this information and make a proper choice ?

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Design Process
1. My first step in design - ASK QUESTIONS n intended use of product n desired or important performance qualities n for bike - low weight, riding efficiency, comfort, durability, low cost ... n potential failure modes n how does the part fit into overall system 2. Identify design variables (things you as the designer can specify) make a list here

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Design Process - continued

3.Quantify the performance qualities in terms of the design
variables

4. Identify the constraints based on potential failure modes and performance qualities

5. Formulate a measure of the design s goodness

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Design Process - continued

6. Apply an appropriate design method for choosing the
actual values of the design variables and then iterate n Trial and error (OK for simple problems) n Past experience (extrapolation or interpolation) n Numerical optimization methods ( a necessity if the number of design variables and constraints are large)

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Back to the Tube

Let s assume that the most important qualities of this tube are its: n Low Flexibility (= high stiffness) n Low Weight (as light as possible) n High Bending and Crush Strength n Long Life Design Variables: n Material n Wall thickness n Joining method (weld, glue, braze)

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Bike Tubing
plain gage tube

Better tubes are thicker at ends to give greater strength at joints. How are these made?

single-butted tube

double-butted tube

triple-butted tube
from ref. 4, used by permission of Rodale Press, 1994, all rights reserved

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Materials Issues.....
n n n

Why was aluminum used? What are its advantages and disadvantages? Other possibilities: n Steels n Low Carbon, High Carbon, Chrome-molybdenum, Stainless ... n Titanium n Magnesium n Carbon fiber composite (Carbon Fiber, Kevlar)

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Important Material Properties

n n n n n n n

Weight (density) Stiffness (elastic modulus) Strength (tensile strength, endurance limit) Impact resistance (hardness) Corrosion resistance Joining Recycling potential

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Material Properties Comparison

Material Aluminum 6061 T6 7075 T6 Steel 1040 HR (med carbon) 1040 CD 4140 HR (chrome/moly) 4140 CD Graphite/Epoxy* Elastic Yield Tensile Density Brinell Cost Modulus Strength Strength lb/in3 Hardness $/lb Mpsi Kpsi Kpsi 10 10 30 30 30 30 1-20 40 72 42 71 63 90 N/A 45 82 76 85 90 102 30-200 .10 .10 .283 .283 .283 .283 .06 95 150 149 170 187 223

HR = Hot Rolled CD=Cold Drawn * Actual properties depend on the amount of reinforcing material
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Stages in Reverse Engineering

Stage 1: Evaluation and Verification Stage 2: Technical Data Generation Stage 3: Design Verification Stage 4: Project Implementation

Stage 1: Evaluation and Verification

The primary steps in Stage 1 are as follows: Visual and dimensional inspection Discrepancy review versus available data Failure analysis Quality evaluation report Stage 1 report Go/no-go decision

Stage 2: Technical Data Generation

The second stage, disassembly or decompilation of the original product, is the most time-consuming aspect of the project. In this stage, reverse engineers attempt to construct a characterization of the system by accumulating all of the technical data and instructions of how the product works. The objective is to develop a complete and unrestricted technical data package which will be sufficient for both fabrication and procurement of the part in the future. The engineering drawing defines the configuration of the component, and the technical package contains all additional inspection and quality assurance requirements to manufacture the part.

Stage 3: Design Verification

In the third stage of reverse engineering, reverse engineers try to verify that the data generated by disassembly or decompilation is an accurate reconstruction the original system. The design generated in stage 2 is verified by testing of a preliminary technical data package (PTDP) on one or many levels. The verification method requires two separate operations to be conducted, yet the outcome is dependent on the completeness of the data to achieve success in both areas. The two operations are prototype fabrication and prototype testing. Engineers verify the accuracy and validity of their designs by testing the system, creating prototypes, and experimenting with the results.

Stage 4: Project Implementation

The final stage of the reverse engineering process is the introduction of a new product into the marketplace. With the inclusion of all test, inspection and quality assurance reports, the data have completely become the complete technical data package (CTDP). The delivery of prototypes, the engineering and the economic summary, and the CTDP with procurement requirements form the final TDP. These new products are often innovations of the original product with competitive designs, features, or capabilities. These products may also be adaptations of the original product for use with other integrated systems, such as different platforms of computer operating systems.

Advantages
o o o o o o How a product or system was formed and how it works What it is made of and what it can do Costs and the possibility of benefiting from an existing device without infringing on its patent The creation of a digital 3D model or recording will enable a company to make an honest assessment of its products The 3D rendering made possible by MicroScribe will enable the company to examine and evaluate the products being offered by its competitors. By using this process, a company will be able to discover the possibility of cutting production costs by analyzing how many devices work and improving on it.

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