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BY REVERSE ENGINEERING
ABSTRACT:
This project is about application of reverse engineering. Reverse engineering helps in obtaining
the geometry of part or product which is not available otherwise. Its application makes it possible
to reconstruct the original component with its drawing and manufacturing process. It is used in
various fields but here the main application is related to broken Gear. In this present work a
broken tooth of gear of two wheeler bike has been taken. Currently this part is not available in
the market and drawing of the component does not exist. As the part is no longer available it has
to be made in-house so it will require all activities from designing to rapid prototyping. The
procedure includes various stages which will help understand the different phases of reverse
engineering.
The process starts with understanding the reverse engineering procedure. The part
geometry is first obtained with the help of scanning technology. Then with the use of
SOLIDWORKS SCAN TO 3D option the three-dimensional model of the spur gear is obtained.
Once the CAD model is obtained, the part is analyzed using SOLID WORKS simulation tool by
applying alloy steel material and by varying face width of the Gear. The stresses induced will be
low as the face width of gear increases. After the analysis, the pattern of the part is obtained
using Rapid prototyping machine. This can be used for Machining/ casting of the original part.
In todays intensely competitive global market, product enterprises are constantly seeking
new ways to shorten lead times for new product developments that meet all customer
expectations. In general, product enterprise has invested in CAD/CAM, rapid prototyping, and a
range of new technologies that provide business benefits. Reverse engineering (RE) is now
considered one of the technologies that provide business benefits in shortening the product
development cycle. Figure 1.1 below depicts how RE allows the possibilities of closing the loop
between what is as designed and what is actually manufactured.
development cycle times. In the intensely competitive global market, manufacturers are
constantly seeking new ways to shorten lead times to market a new product. Rapid product
development (RPD) refers to recently developed technologies and techniques that assist
manufacturers and designers in meeting the demands of shortened product development time.
For example, injection-molding companies need to shorten tool and die
Generating data to create dental or surgical prosthetics, tissue engineered body parts, or for
surgical planning.
Documentation and reproduction of crime scenes.
The above list is not exhaustive and there are many more reasons for using reverse
engineering, than documented above.
Phase 1
Scanning:
This phase is involved with the scanning strategyselecting the correct scanning technique,
preparing the part to be scanned, and performing the actual scanning to capture information that
describes all geometric features of the part such as steps, slots, pockets, and holes. Threedimensional scanners are employed to scan the part geometry, producing clouds of points, which
define the surface geometry. These scanning devices are available as dedicated tools or as addons to the existing computer numerically controlled (CNC) machine tools. There are two distinct
types of scanners, contact and noncontact.
a. Contact Scanners
These devices employ contact probes that automatically follow the contours of a physical surface
.In the current market place, contact probe.
scanning devices are based on CMM technologies, with a tolerance range of +0.01 to 0.02 mm.
However, depending on the size of the part scanned, contact methods can be slow because each
point is generated sequentially at the tip of the probe. Tactile device probes must deflect to
register a point; hence, a degree of contact pressure is maintained during the scanning process.
This contact pressure limits the use of contact devices because soft, tactile materials such as
rubber cannot be easily or accurately scanned.
b. Noncontact Scanners:
A variety of noncontact scanning technologies available on the market capture data with no
physical part contact. Noncontact devices use lasers, optics, and charge-coupled device (CCD)
sensors to capture point data, as shown in Figure. Although these devices capture large amounts
of data in a relatively short space of time, there are a number of issues related to this scanning
technology.
The typical tolerance of noncontact scanning is within 0.025 to 0.2 mm.
Some noncontact systems have problems generating data describing surfaces, which are
parallel to the axis of the laser (Figure 1.6).
Noncontact devices employ light within the data capture process. This creates problems when
the light impinges on shiny surfaces, and hence some surfaces must be prepared with a
temporary coating of fine powder before scanning.
These issues restrict the use of remote sensing devices to areas in engineering, where the
accuracy of the information generated is secondary to the speed of data capture. However, as
research and laser development in optical technology continue, the accuracy of the commercially
available noncontact scanning device is beginning to improve.
The output of the scanning phase is point cloud data sets in the most convenient format.
Typically, the RE software provides a variety of output formats such as raw (X, Y, Z values
separated by space or commas).
part. The RE software allows the user to compare the two data sets (as designed to as
manufactured). This process is also used for inspecting manufactured parts. Reverse engineering
can also be used to scan existing hip joints and to design new artificial hips joint around patientspecific pelvic data. This creates the opportunity for customized artificial joints for each patient.
The output of this phase is geometric model in one of the proprietary formats such as IGES,
VDA, STL, DXF, OBJ, VRML, ISO G Code, etc.
A typical two-stage gear reduction box is been used to understand the design process. The design
sequence is similar for variations of this particular transmission system.
1.2 TRANSMISSION
The term power transmission is defined as the movement of energy from a source to an output
device that performs work. In mechanical power transmissions, a device is interposed between a
source of power and a specific application for the purpose of adapting one to the other. Most
mechanical transmissions function as rotary speed changers; the ratio of the output speed to the
input speed may be constant (as in a gearbox) or variable. On variable-speed transmissions the
speeds may be variable in discrete steps or they may be continuously variable within a range.
The need for a transmission in an automobile is a consequence of the characteristics of the
internal combustion engine. Engines typically operate over a range of 600 to about
7000revolutions per minute (though this varies, and is typically less for diesel engines), while the
car's wheels rotate between 0 rpm and around 1800 rpm.
The most common use of power transmission is in motor vehicles, where the transmission adapts
the output of the internal combustion engine to the drive wheels. Such engines need to operate at
a relatively high rotational speed, which is inappropriate for starting, stopping, and slower travel.
Furthermore, the engine provides its highest torque and power outputs unevenly resulting in a
torque band and a power band. Often the greatest torque is required when the vehicle is moving
from rest or traveling slowly, while maximum power is needed at high speed. Therefore, a
system that transforms the engine's output so that it can supply high torque at low speeds, but
also operate at highway speeds with the motor still operating within its limits, is required.
Transmissions perform this transformation.
The transmission reduces the higher engine speed to the slower wheel speed, increasing torque in
the process. Transmissions are also used on pedal bicycles, fixed machines, and anywhere
rotational speed and torque must be adapted.
Many applications require the availability of multiple gear ratios. Often, this is to ease the
starting and stopping of a mechanical system, though another important need is that of
maintaining good fuel efficiency.
Manual Transmission
Automatic Transmission
Semi-automatic transmission.
cut spur gear sets spin freely, and must be synchronized by the operator matching engine revs to
road speed, to avoid noisy and damaging clashing of the gears.
The
synchronized/synchromesh systems, where typically diagonal cut helical (or sometimes either
straight-cut, or double-helical) gear sets are constantly "meshed" together, and a dog clutch is
used for changing gears. On synchromesh boxes, friction cones or "synchro-rings" are used in
addition to the dog clutch to closely match the rotational speeds of the two sides of the
(declutched) transmission before making a full mechanical engagement.
Manual transmissions are the most common type. They are cheaper, lighter, usually give
better performance, and fuel efficiency. It is customary for new drivers to learn, and be tested, on
a car with a manual gear change.
Some manual transmissions have an extremely low ratio for first gear, called a creeper
gear or granny gear. Such gears are usually not synchronized. This feature is common on pickup
trucks tailored to trailer-towing, farming, or construction-site work. During normal on-road use,
the truck is usually driven without using the creeper gear at all, and second gear is used from a
standing start.
1.3.2 Semi-automatic
A hybrid form of transmission where the integrated control system handles manipulation of the
clutch automatically, but the driver can still - and may be required to - take manual control of
gear selection. This is sometimes called a "clutchless manual," or "automated manual"
transmission. Many of these transmissions allow the driver to fully delegate gear shifting choice
to the control system, which then effectively acts as if it was a regular automatic transmission.
They are generally designed using manual transmission "internals", and when used in passenger
cars, have synchromesh operated helical constant mesh gear sets.
Early semi-automatic systems used a variety of mechanical and hydraulic systems - including
centrifugal clutches, torque converters, electro-mechanical (and even electrostatic) and
servo/solenoid controlled clutches - and control schemes automatic declutching when moving
the gearstick, pre-selector controls, centrifugal clutches with drum-sequential shift requiring the
driver to lift the throttle for a successful shift, etc. -and some were little more than regular lockup torque converter automatics with manual gear selection.
Most modern implementations, however, are standard or slightly modified manual transmissions
(and very occasionally modified automaticseven including a few cases of CVTs with "fake"
fixed gear ratios), with servo-controlled clutching and shifting under command of the central
engine computer. These are intended as a combined replacement option both for more expensive
and less efficient "normal" automatic systems, and for drivers who prefer manual shift but are no
longer able to operate a clutch, and users are encouraged to leave the shift lever in fully
automatic "drive" most of the time, only engaging manual-sequential mode for sporty driving or
when otherwise strictly necessary.
1.3.3 Automatic
These primarily use hydraulics to select gears, depending on pressure exerted by fluid within the
transmission assembly. Rather than using a clutch to engage the transmission, a fluid flywheel, or
torque converter is placed in between the engine and transmission. It is possible for the driver to
control the number of gears in use or select reverse, though precise control of which gear is in
use may or may not be possible.
Automatic transmissions are easy to use. However, in the past, automatic transmissions of
this type have had a number of problems; they were complex and expensive, sometimes had
reliability problems (which sometimes caused more expenses in repair), have often been less
fuel-efficient than their manual counterparts (due to "slippage" in the torque converter), and their
shift time was slower than a manual making them uncompetitive for racing. With the
advancement of modern automatic transmissions this has changed.
Attempts to improve fuel efficiency of automatic transmissions include the use of torque
converters that lock up beyond a certain speed or in higher gear ratios, eliminating power loss,
and overdrive gears that automatically actuate above certain speeds. In older transmissions, both
technologies could be intrusive, when conditions are such that they repeatedly cut in and out as
speed and such load factors as grade or wind vary slightly.Current computerized transmissions
possess complex programming that both maximizes fuel efficiency and eliminates intrusiveness.
This is due mainly to electronic rather than mechanical advances, though improvements in CVT
technology and the use of automatic clutches have also helped.
The above figure shows the spur gearing, with parallel axes; bevel gearing, with intersecting axes
and, in rare instances, spur-bevel and flat spur gearing; and screw drives (worm gears, hypoid
gears, and screws), with overlapping axes. Rack-and-gear drive is a special type of gear drive
which transforms rotary motion into translatory motion or vice versa. Most machines and
mechanisms use external gearingthat is, gears with teeth on their outer surface. Internal
gearing, in which case one gear has teeth cut into its inner surface, is used less frequently.
The power transmission chains are made of steel and hardened to reduce wear. These chains are
classified into three categories (a) Block chain (b) Roller chain (c) Inverted tooth chain (silent
chain) Out of these three categories roller chain shown in Figure (b) is most commonly used.
The construction of this type of chain is shown in the figure. The roller is made of steel and then
hardened to reduce the wear. A good roller chain is quiter in operation as compared to the block
chain and it has lesser wear. The block chain is shown in Figure (a). It is used for low speed
drive. The inverted tooth chain is shown in Figures (c) and (d). It is also called as silent chain
because it runs very quietly even at higher speeds.
Flat and round belts, as a rule, are used singly in a drive, while several V-belts (usually no more
than eight) can be used together.
Flat-belt drives are simple and convenient. They permit the use of ordinary pulleys with smooth
surfaces, and they can be operated at speeds as high as 4050 m/sec and more. However, they are
bulky in design and low in strength, and their tension ratio usually does not exceed 5. V-belt
drives provide improved attachment of the belt to the pulleys, permit shortening of the center
distances, and allow a decrease in the size of the drive and an increase in the tension ratio (up to
10-15). Round-belt drives are now rare and are used only in mechanisms of low power, such as
those in sewing machines.
this can be generalized for any number of gears in the train as:
Gears :
Gear is a part, as a disk, wheel, or section of a shaft, having cut teeth of such form, size and
spacing that they mesh with teeth in another part to transmit or receive force and motion
The gears in a transmission are analogous to the wheels in a pulley. An advantage of gears is that
the teeth of a gear prevent slipping.
Gears are the most common means used for power transmission
They can be applied between two shafts which are
Parallel Collinear
Perpendicular and intersecting
Perpendicular and nonintersecting
Inclined at any arbitrary angle
Classification of gears
Limitations: Spur gears generally cannot be used when a direction change between the two shafts is
required.
Advantages: Helical gears can be used on non parallel and even perpendicular shafts, and can
carry higher loads than can spur gears.
Perhaps the most well-known application of a rack is the rack and pinion steering system used on
many cars in the past.
Figure : Gear from two wheeler bike which has broken teeth
In this thesis we are producing the Gear C of shaft 2 nd of Hero bike.The below shown figures are
the Gear C of 29 teeth.
The Gear has been scanned in a Roland Model lpx-600 laser scanner .
The Roland Model lpx-600 laser scanner is a medium sized scanner used to scan object of
maximum height of around 150 mm and diameter of 120 mm. It operates with interface of
computer with software Dr. Picza which helps in setting up the scanning parameters and also
shows the scanning process. It stores the scanned file in .stl format. The scanner is shown in fig.
SOLID WORKS
Solid Works is mechanical design automation software that takes advantage of the familiar
Microsoft Windows graphical user interface.
It is an easy-to-learn tool which makes it possible for mechanical designers to quickly sketch
ideas, experiment with features and dimensions, and produce models and detailed drawings.
A Solid Works model consists of parts, assemblies, and drawings.
Typically, we begin with a sketch, create a base feature, and then add more features to
the model. (One can also begin with an imported surface or solid geometry).
We are free to refine our design by adding, changing, or reordering features.
Associativity between parts, assemblies, and drawings assures that changes made to one
Design intent is how the creator of the part wants it to respond to changes and updates. For
example, you would want the hole at the top of a beverage can to stay at the top surface,
regardless of the height or size of the can. Solid Works allows you to specify that the hole is a
feature on the top surface, and will then honor your design intent no matter what the height you
later gave to the can.several factors contribute to how we capture design intent are Automatic
relations,Equations,added relations and dimensioning.
Features refer to the building blocks of the part. They are the shapes and operations that construct
the part. Shape-based features typically begin with a 2D or 3D sketch of shapes such as bosses,
holes, slots, etc. This shape is then extruded or cut to add or remove material from the part.
Operation-based features are not sketch-based, and include features such as fillets, chamfers,
shells, applying draft to the faces of a part, etc.
Building a model in Solid Works usually starts with a 2D sketch (although 3D sketches are
available for power users). The sketch consists of geometry such as points, lines, arcs, conics
(except the hyperbola), and splines. Dimensions are added to the sketch to define the size and
location of the geometry. Relations are used to define attributes such as tangency, parallelism,
perpendicularity, and concentricity. The parametric nature of Solid Works means that the
dimensions and relations drive the geometry, not the other way around. The dimensions in the
sketch can be controlled independently, or by relationships to other parameters inside or outside
of the sketch.
Several ways a part can be builded like
1. Layer-cake approach :
The layer-cake approach builds the part one piece at a time, adding each layer, orfeature, onto
the previous one.
2. Potters wheel approach :
The potters wheel approach builds the part as a single revolved feature.As a single sketch
representing the cross section includes all the information and dimensions necessary to make the
part as one feature.
3. Manufacturing approach :
The manufacturing approach to modeling mimics the way the part would be manufactured. For
example, if the stepped shaft was turned a lathe ,we would start with a piece of bar stock and
remove material using a series of cuts.
In an assembly, the analogue to sketch relations is mates. Just as sketch relations define
conditions such as tangency, parallelism, and concentricity with respect to sketch geometry,
assembly mates define equivalent relations with respect to the individual parts or components,
allowing the easy construction of assemblies. Solid Works also includes additional advanced
mating features such as gear and cam follower mates, which allow modelled gear assemblies to
accurately reproduce the rotational movement of an actual gear train.
Finally, drawings can be created either from parts or assemblies. Views are automatically
generated from the solid model, and notes, dimensions and tolerances can then be easily added to
the drawing as needed. The drawing module includes most paper sizes and standards.
A Solid Works model consists of parts, assemblies, and drawings.
(1) Part: Individual components are drawn in the form of part drawings.
(2) Assembly: The individual parts are assembled in this region.
(3) Drawings: This contains detailed information of the assembly.
Figure : Example of a solid created from scanned data of a hand, using the Surface
Wizard's Automatic creation.
Direct mesh referencing is useful for very complex surfaces, such as consumer products.
The Mesh Prep and Surface Wizards guide you through the ScanTo3D process
Mesh Boundaries
Mesh boundaries form along boundary edges. ScanTo3D can create boundary curves only
along boundary edges. Boundary edges are commonly found on meshes that represent
surfaces or have large holes in them.
Automatic Creation
Automatically create solids based on the desired amount of detail.
Figure : Model before surface extractionModel after extracting two cylindrical and two b-spline
surfaces
When you extract surfaces, you might see salient sub-meshes (arrows), which are transitions
between primary mesh regions. Transition regions usually show a large variation in geometry,
such as curvature. You usually do not convert salient sub-meshes as surfaces during guided
surface creation, but instead you create these surfaces later in Solid works.
Surface creation is complete. To recreate the surfaces with more control, click
to return to
Figure : Solid model created from the extracted surfaces using Untrim, Trim, Extend,Knit,
and Thicken tools.
Exporting files :
After you import a mesh or cloud point file into a Solid works document using ScanTo3D, We
export the document as another file type that contains the mesh or cloud point data.
1.
2.
ScanTo3D (*.xyz)
ScanTo3D (*.wrl).
ScanTo3D (*.stl).
ScanTo3D (*.3ds)
ScanTo3D (*.iges)
The scanned file is imported in solid works software which helps to extract geometry from
the .stl file or point cloud data shown in figure below to Solid geometry.
Increasing the global smoothness then entering into surface wizard manager for adjusting surface
resolution.
The drawings are generated for the Gear model and the following dimensions are obtained.
symbol
parameter
Gear
Module
1.79 2mm
Face width
8.5mm
No. of teeth
29
52mm
Profile
Solid Works Simulation is a design analysis system fully integrated with Solid works. Solid
Works Simulation provides simulation solutions for linear and nonlinear static, frequency,
buckling, thermal, fatigue, pressure vessel, drop test, linear and nonlinear dynamic, and
optimization analyses.
Powered by fast and accurate solvers, Solid works Simulation enables you to solve large
problems intuitively while you design. Solid works Simulation comes in two bundles: Solid
works Simulation Professional and Solid works Simulation Premium to satisfy your analysis
needs. Solid works Simulation shortens time to market by saving time and effort in searching for
the optimum design.
Benefits of Simulation:
After building your model, you need to make sure that it performs efficiently in the field. In the
absence of analysis tools, this task can only be answered by performing expensive and timeconsuming product development cycles. A product development cycle typically includes the
following steps:
1. Building your model.
2. Building a prototype of the design.
3. Testing the prototype in the field.
4. Evaluating the results of the field tests.
5. Modifying the design based on the field test results.
This process continues until a satisfactory solution is reached. Analysis can help you accomplish
the following tasks:
Reduce cost by simulating the testing of your model on the computer instead of
expensive field tests.
Improve products by quickly testing many concepts and scenarios before making a final
decision, giving you more time to think of new designs.
Elements share common points called nodes. The process of dividing the model into small pieces
is called meshing.
The behavior of each element is well-known under all possible support and load scenarios. The
finite element method uses elements with different shapes.
The response at any point in an element is interpolated from the response at the element nodes.
Each node is fully described by a number of parameters depending on the analysis type and the
element used. For example, the temperature of a node fully describes its response in thermal
analysis. For structural analyses, the response of a node is described, in general, by three
translations and three rotations. These are called degrees of freedom (DOFs). Analysis using
FEM is called Finite Element Analysis (FEA).
A tetrahedral element. Red dots represent nodes. Edges of an element can be curved or straight.
The software formulates the equations governing the behavior of each element taking into
consideration its connectivity to other elements. These equations relate the response to known
material properties, restraints, and loads.
Next, the program organizes the equations into a large set of simultaneous algebraic equations
and solves for the unknowns.
In stress analysis, for example, the solver finds the displacements at each node and then the
program calculates strains and finally stresses.
The software offers the following types of studies:
Study type
Study icon
Static
Frequency
Harmonic
Buckling
Random Vibration
Thermal
Response Spectrum
Design Study
Drop Test
Nonlinear Static
Fatigue
Nonlinear Dynamic
Analysis Steps :
The steps needed to perform an analysis depend on the study type. You complete a study by
performing the following steps:
The program automatically creates a mixed mesh when different geometries (solid, shell,
structural members etc.) exist in the model.
Mesh the model to divide the model into many small pieces called elements. Fatigue and
optimization studies use the meshes in referenced studies.
View results.
3. Frequency analysis :
If the design is subjected to dynamic environments, static studies cannot be used to
evaluate the response. Frequency studies can help you avoid resonance and design
vibration isolation systems. They also form the basis for evaluating the response of linear
dynamic systems where the response of a system to a dynamic environment is assumed to
be equal to the summation of the contributions of the modes considered in the analysis.
4. Dynamic analysis :
Dynamic analysis includes:
5. Buckling analysis :
Used to calculate the buckling loads and determine the buckling mode shape. Both linear
(Eigen value) buckling and nonlinear buckling analyses are possible.
Gear analysis can be performed using analytical methods which required a number of
assumption and simplifications which aim at getting the maximum stress values only but
gear analyses are multidisciplinary including calculations related to the tooth stresses .In this
work, an attempt will been made to analyze bending stress to resist bending of helical gears, as
both affect transmission error. Due to the progress of computer technology many researchers
tended to use numerical Methods to develop theoretical models to calculate the effect of
whatever is studied. numerical methods are capable of providing more truthful solution since
they require very lessrestrictive assumptions. However, the developed model and its solution
method must e selected attentively to ensure that the results are more acceptable and its
computational time is reasonable. The dimension of the model have been arrived at by theoretical
methods. The stress generated of the tooth have been analyzed for materials. Finally the results
obtained by theoretical analysis, AGMA calculations and finite element analysis are compared to
check the correctness.
This procedure is based on the principle of differential geometry that pertains to envelopes of
curves and surfaces.
The above equation is lewis bending equation to calculate bending stresses developed in gears.
Where
Cv =
Where v =
= 4.396m/sec, D= 56mm
D= diameter of gear
N=speed .rpm =1500 rpm
Cv =
= 0.577
Bending stress(b)
(Mpa)
8.5
50.7
10.5
41.04
12.5
34.4
14.5
29.7
Static 1
Analysis type
Static
Mesh type
Solid Mesh
Thermal Effect:
On
Thermal option
298 Kelvin
Off
Solver type
FFEPlus
Inplane Effect:
Off
Soft Spring:
Off
Inertial Relief:
Off
Automatic
Large displacement
Off
On
Friction
Off
Off
Result folder
Units :
Unit system:
SI (MKS)
Length/Displacement
mm
Temperature
Kelvin
Angular velocity
Rad/sec
Pressure/Stress
N/m^2
Material Properties :
Model Reference
Properties
Name:
Model type:
Alloy Steel
Linear Elastic
Isotropic
Default failure
criterion:
Yield strength:
6.20422e+008
N/m^2
Tensile
strength:
7.23826e+008
N/m^2
Elastic
modulus:
2.1e+011 N/m^2
Poisson's ratio:
Mass density:
Shear modulus:
Thermal
expansion
coefficient:
0.28
7700 kg/m^3
7.9e+010 N/m^2
1.3e-005 /Kelvin
Components
SolidBody 1(Fillet8)
(srinivas gear)
Fixture
name
Fixture Image
Fixture Details
Entities:
Type:
6 face(s)
Fixed Geometry
Fixed-1
Resultant Forces
Components
Resultant
Reaction force(N)
443.107
-197.792
-0.00437104
485.248
Reaction
Moment(N.m)
Load
name
Load Image
Load Details
Entities:
Type:
Force-1
Value:
Phase Angle:
Units:
1 face(s)
Apply normal force
500 N
0
deg
Mesh Information :
Mesh type
Solid Mesh
Mesher Used:
Standard mesh
Automatic Transition:
Off
Off
Jacobian points
4 Points
Element Size
2.7397 mm
Tolerance
0.136985 mm
Mesh Quality
High
27167
Total Elements
16148
15.563
83.9
0.142
% of distorted elements(Jacobian)
00:00:12
Computer name:
Srinivas-PC
Name
Type
Min
Max
Stress1
30.9186 N/m^2
4.7972e+007 N/m^2
Node: 10906
Node: 1280
Name
Type
Min
Max
A factor of safety less than 1 at a location indicates that the material at that location has failed.A
factor of safety of 1 at a location indicates that the material at that location has just started to fail.
A factor of safety greater than 1 at a location indicates that the material at that location is safe.
So our design is safe for given loading condition.
Name
Type
Min
Max
Stress1
3.92889 N/m^2
4.02837e+007
N/m^2
Node: 11761
Node: 19002
Name
Type
Min
Max
Name
Type
Min
Max
Displacement1
URES: Resultant
Displacement
0 mm
0.00248392 mm
Node: 674
Node: 1646
Name
Type
Min
Max
Strain1
5.21391e-011
0.000142769
Element: 5529
Element: 5826
Name
Type
Min
Max
Displacement1
URES: Resultant
Displacement
0 mm
0.00248392 mm
Node: 674
Node: 1646
Name
Type
Min
Max
Factor of Safety1
Automatic
15.4013
1.57913e+008
Node: 19002
Node: 11761
Name
Type
Min
Max
Stress1
15.9894 N/m^2
2.92143e+007
N/m^2
Node: 23297
Node: 1113
Name
Type
Min
Max
Displacement1
URES: Resultant
Displacement
0 mm
0.00171887 mm
Node: 617
Node: 1464
Name
Type
Min
Max
Strain1
5.93542e-011
7.72139e-005
Element: 5036
Element: 13711
Name
Type
Min
Max
Factor of Safety1
Automatic
21.237
3.88021e+007
Node: 1113
Node: 23297
Name
Type
Min
Max
Stress1
14.9038 N/m^2
2.57757e+007
N/m^2
Node: 24243
Node: 14953
Name
Type
Min
Max
Displacement1
URES: Resultant
Displacement
0 mm
0.00206972 mm
Node: 643
Node: 1548
Name
Type
Min
Max
Strain1
3.18208e-011
9.05585e-005
Element: 5186
Element: 12900
Name
Type
Min
Max
Factor of Safety1
Automatic
24.07
4.16285e+007
Node: 14953
Node: 24243
Bending
Bending
stresses Mpa
(lewis equation)
stresses Mpa
(static analysis)
8.5
50.7
47.2
10.5
41.04
40.2
12.5
34.4
29.2
14.5
29.7
25.2
Rapid Prototyping (RP) can be defined as a group of techniques used to quickly fabricate
a scale model of a part or assembly using three-dimensional computer aided design (CAD) data.
What is commonly considered to be the first RP technique, Stereo-lithography, was developed by
3D Systems of Valencia, CA, USA. The company was founded in 1986, and since then, a number
of different RP techniques have become available.
Rapid Prototyping has also been referred to as solid free-form manufacturing; computer
automated manufacturing, and layered manufacturing. RP has obvious use as a vehicle for
visualization. In addition, RP models can be used for testing, such as when an airfoil shape is put
into a wind tunnel. RP models can be used to create male models for tooling, such as silicone
rubber molds and investment casts. In some cases, the RP part can be the final part, but typically
the RP material is not strong or accurate enough. When the RP material is suitable, highly
convoluted shapes (including parts nested within parts) can be produced because of the nature of
RP.
There is a multitude of experimental RP methodologies either in development or used by
small groups of individuals. This section will focus on RP techniques that are currently
commercially available, including Stereo-lithography (SLA), Selective Laser Sintering (SLS),
Laminated Object Manufacturing (LOM), Fused Deposition Modeling (FDM), 3D printing,
and Ink Jet printing techniques
Why Rapid Prototyping ?
The reasons of Rapid Prototyping are
A CAD model is constructed, and then converted to STL format. The resolution can be
set to minimize stair stepping.
2.
The RP machine processes the .STL file by creating sliced layers of the model.
3.
The first layer of the physical model is created. The model is then lowered by the
thickness of the next layer, and the process is repeated until completion of the model.
4.
The model and any supports are removed. The surface of the model is then finished and
cleaned
STEREO-LITHOGRAPHY
The implementation shown is used by 3D Systems and some foreign manufacturers. A moveable
table, or elevator (A), initially is placed at a position just below the surface of a vat (B) filled
with liquid photopolymer resin (C). This material has the property that when light of the correct
color strikes it, it turns from a liquid to a solid. The most common photopolymer materials used
require an ultraviolet light, but resins that work with visible light are also utilized. The system is
sealed to prevent the escape of fumes from the resin.
Profiles of object cross sections are cut from paper using a CO2 laser as shown in Fig. 2. The
paper is unwound from a feed roll (A) onto the stack and bonded to the previous layer using a
heated roller (B). The roller melts a plastic coating on the bottom side of the paper to create the
bond. The profiles are traced by an optics system that is mounted to an X-Y stage (C). The
process generates considerable smoke. Either a chimney or a charcoal filtration system is
required (E) and the build chamber must be sealed.
After cutting the geometric features of a layer is completed, the excess paper is cut away to
separate the layer from the web. The extra paper of the web is wound on a take-up roll (D). The
method is self-supporting for overhangs and undercuts. Areas of cross sections which are to be
removed in the final object are heavily cross-hatched with the laser to facilitate removal.
FDM is the second most widely used rapid prototyping technology, after stereolithography. A plastic filament, approximately 1/16 inch in diameter, is unwound from a coil (A)
and supplies material to an extrusion nozzle (B). Some configurations of the machinery have
used plastic pellets fed from a hopper rather than a filament. The nozzle is heated to melt the
plastic and has a mechanism which allows the flow of the melted plastic to be controlled. The
nozzle is mounted to a mechanical stage (C) which can be moved in horizontal and vertical
directions
As the nozzle is moved over the table (D) in the required geometry, it deposits a thin bead of
extruded plastic to form each layer. The plastic hardens immediately after being squirted from
the nozzle and bonds to the layer below. The entire system is contained within an oven chamber
which is held at a temperature just below the melting point of the plastic. Thus, only a small
amount of additional thermal energy needs to be supplied by the extrusion nozzle to cause the
plastic to melt. This provides much better control of the process.
The system was developed at MIT and is shown schematically in Fig. 6. The method is
very reminiscent of selective laser sintering, except that the laser is replaced by an inkjet head.
The multi-channel jetting head (A) deposits a liquid adhesive compound onto the top layer of a
bed of powder object material (B). The particles of the powder become bonded in the areas
where the adhesive is deposited.
Once a layer is completed the piston (C) moves down by the thickness of a layer. As in selective
laser sintering, the powder supply system (E) is similar in function to the build cylinder In this
case the piston moves upward incrementally to supply powder for the process and the roller (D)
spreads and compresses the powder on the top of the build cylinder. The process is repeated until
the entire object is completed within the powder bed.
Technical Specifications :
Technical Data :
TABLE NO 1 :
Effective building volume
Support structure
not necessary
Laser type
CO2, 30W
Precision optics
F-theta lens
Power supply
16 A
2 Kw
Nitrogen generator
integrated (optional)
Dimensions :
TABLE NO 2 :
Weight
Data preparation :
TABLE NO 3 :
PC
Software
CAD interface
Network
Ethernet
Certification
CE
CONCLUSIONS
Reverse engineering helps in obtaining the geometry of part or product which is not available
otherwise. Its application makes it possible to reconstruct the original component with its
drawing and manufacturing process. It is used in various fields but here the main application is
related to broken Gear.
The process starts with understanding the reverse engineering procedure. The part
geometry is first obtained with the help of scanning technology. Then with the use of
SOLIDWORKS SCAN TO 3D option the three-dimensional model of the spur gear is
obtained.
In theory of Gear, we are considering that the load is acting at one point and the stress is
calculated. The calculation of maximum stresses in a gear at tooth root is three
dimensional problems. The accurate evaluation of stress state is complex task. The
in this work the maximum bending stress decreases with increasing face width.
After the analysis, the pattern of the part is obtained using Rapid prototyping machine
{Fused depositing machine}.
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