What are the processes involved in reverse engineering and how to start it?
Well, the first step is to either have the object you want to reverse engineer/copy/replicate or a sufficient amount of data with dimensions and properties.
The next step is to understand how the parts are assembled and connected and based on that, make a decision on the way you will create all the required parts. I know at least seven different ways to create a round tube. I always use that method which allows me to use it within the assembly. Sometimes it's welding profile (structural member, sometimes it's a revolved boss feature, sometimes an extruded boss, sometimes it's made as a loft, or use a thickening feature...) it all depends on what you want to do with it later... If it's a sheet metal, you can create a drawing, boss extrude, edge flange, or make a solid and bend and rip edges... There are many ways to get the job done...
If by reverse engineering you mean make a model or models of already existing parts and or assemblies, then this is the technique I use. If the components are assemblies, then you pretty much have to take the assembly apart. From there you start your model of each part. It helps to have knowledge of machining and or manufacturing techniques, as I like to build my model in the same manner as it would be manufactured. As far as the part, it simply becomes a method of measurements. Micrometers, calipers, Coordinate Measuring machine, 3D scanners, Optical comparators, and so on. To give you an example, download the "0-1 micrometer" that I modeled. It was "reverse engineered" from a DoAll micrometer that I won as a prize about 47 years ago. Most all the measurements I needed were taken with a digital caliper.
Here is a link to the file...
Hope this helps...
Dear sir, i ll agree with u if suppose u got an die casting component n dey had ask u to model d same for plastic component den whic are all the things to be consider? n wt all d input u need in tat case?
By "plastic component" are you are referring to an "Injection Molded" plastic part, that perform s the same function as the die cast one.
That being the case, die cast parts and injection molded plastic parts are very similar.
There is not enough room here to get into all the detail in "designing plastic parts". There are many, many books on that subject. One such book is the "Injection Molding Handbook" by Rosato and Rosato.
But, just to give you some idea regarding injection molding... First thing to consider is material type. Knowing the application, with a broad knowledge of plastic materials is key. Next would be geometry. Wall thickness is critical, and is driven by the material type, and the structure. The rule for wall thickness is "uniform wall throughout". This is generally never achievable but is the guideline to follow. The idea is to avoid heavy sections. One of the key characters of injection molding is dealing with material shrinkage. This alone is a complex area and requires much thought and consideration, as variations within the geometry and type of material will generate various shrink rates.
I could go on and on, but hope this helps you with the concept. As far as just the part, if it is die cast now, and you want it to be injection molded then in the end the parts will probably be very similar. It's the details that are critical.
If you are not versed in injection molding, then a good book with lots of schooling will help. Regardless, my suggestion is work with a reputable "Custom Molder", who should be able to help you with material selection, part design, and mold design. I am attaching a link to get you to the Molder that I was previously employed by (I am retired now). I see you are in India, so probably not a good match up, but there is a lot of knowledge to gain by exploring the web site.
Hope this helps...
ya.... sir thank u very much for ur kind information abt... n i ll let u knw 1 thing tat earlier i 'd worked in injection mould designing but now recently 'm working on product designing.. i ask dis doubt bcoz in future i may come across such prob so... anyway thank u very much sir...
3D scanning is best way to reverse engineer parts into your CAD software, especially on complex parts. The more complex the part, the more you will benefit from 3D scanning. I would love to sell you a 3D scanner, but I don't recommend jumping into doing that right away. If you have parts that you need to reverse engineer, I would recommend using 3D scanning services. This will help you by getting your project done quickly and by giving you a chance to better understand the capabilities and benefits of using a 3D scanner before you commit to the cost of purchasing your own equipment.
There is a video on our website that shows our 3d scanning / reverse engineering capabilities.