Computer-Aided Reverse Engineering for Rapid Replacement Parts: A Case Study

Indigenous product development using conventional means involves a relatively long lead-time and cost, especially for replacing worn-out and broken parts. This paper presents methodologies and technologies for computer-aided reverse engineering, illustrated by a real-life case study of an aluminium-alloy separator body of a hydraulic filter assembly for a special army vehicle. It involved reconstruction of part geometry using 3D scanning, material identification using spectrometry, casting process optimisation using simulation software, and fabrication of prototype and tooling using rapid prototyping systems. It was found that the fabrication of wax patterns directly from reverse engineered CAD data in a suitable RP system (such as Thermojet), followed by conventional investment casting, gives a reliable and economic route for rapid development of one-off intricate parts for replacement purpose.