REVERSEE ENGINEERING

Transcription

1 International Journal of Mechanical Engineering and Technology (IJMET) Volume 8, Issue 7, July 2017, pp , Article ID: IJMET_08_07_032 Available online at aeme/ijm MET/issues.as asp?jtype=ijm MET&VType=8&IType= =7 ISSN Print: and ISSN Online: IAEME Publication Scopus Indexed DESIGN AND FABRICATION OF THERMOSTAT VALVE FOR MARATHI ALTO VEHICLE USING REVERSEE ENGINEERING P. Jeyaraman Department of Mechanical Engineering, K. Arun Kumar Department of Mechanical Engineering, B.R. Aravindh Raj Department of Mechanical Engineering, I. Saran Raj Department of Mechanical Engineering, M. Saleem Department of Aeronautical Engineering, ABSTRACT Indigenous product development using conventional means involves a relatively long lead-time and cost, especially for replacing worn-out and broken parts. This project work presents methodologies and technologies for computer-aided reverse engineering, illustrated by a real-life case study of an aluminum-alloy thermostatt of a MARUTHI ALTO vehicle. It involved reconstruction of part geometry using 3D scanning, coordinate measuring machine (CMM) and casting process optimization using simulation software, and fabrication of prototype and tooling using rapid prototyping systems. Critical dimensions of thermostat valve v are measured using coordinate measuring machine (CMM). Model was created with help of dimensions measured and by slight modified for the improvement in temperature control from Computer Aided Design (CAD) data. After this modified componentt model convert into STL file then prototype model was created by Rapid prototyping and Tooling (RPT) in 3D viper SLA system. 275

2 Design and Fabrication of Thermostat Valve for Marathi Alto Vehicle using Reverse Engineering Key words: Reverse Engineering, CAD data, Co ordinate Measuring Machine, Rapid Prototyping. Cite this Article: P. Jeyaraman, K. Arun Kumar, B.R. Aravindh Raj, I. Saran Raj and M. Saleem. Design and Fabrication of Thermostat Valve for Marathi Alto Vehicle using Reverse Engineering. International Journal of Mechanical Engineering and Technology, 8(7), 2017, pp INTRODUCTION Reverse engineering has a long history as an accepted practice. What it means, broadly speaking, is the process of extracting know-how or knowledge from a human-made artifact.1 Lawyers and economists have endorsed reverse engineering as an appropriate way to obtain such information, even if the intention is to make a product that will draw customers away from the maker of the reverse-engineered product.2 Given this acceptance, it may be surprising that reverse engineering has been under siege in the past few decades. 2. REVERSE ENGINEERING IN TRADITIONAL MANUFACTURING INDUSTRIES Reverse engineering is generally a lawful way to acquire know-how about manufactured products. Reverse engineering may be undertaken for many purposes. We concentrate in this Part on reverse engineering be taken for the purpose of making a competing product because this is the most common and most economically significant reason to reverse engineer in this industrial context. We argue that legal rules favoring the reverse engineering of manufactured products have been economically sound because an innovator is nevertheless protected in two ways: by the costliness of reverse engineering and by lead time due to difficulties of reverse engineering. If technological advances transform reverse engineering so that it becomes a very cheap and rapid way to make a Competing product, innovators may not be able to recoup their R&D expenses, and hence some regulation may be justified. An example discussed below is the plug-molding of boat hulls. 3. AN ECONOMIC PERSPECTIVE ON REVERSE ENGINEERING The economic effects of reverse engineering depend on a number of factors, including the purpose for which it is undertaken, the industrial context within which it occurs, how much it costs, how long it takes, whether licensing is a viable alternative, and how the reverse engineer uses information learned in the reverse engineering process. We argue that a legal right to reverse-engineer does not typically threaten an innovative manufacturer because the manufacturer generally has two forms of protection against competitors who reverse-engineer: lead-time before reverse engineers cans enter45 and costliness of reverse engineering. Lead time serves the same function as a short-lived intellectual property right. Costliness may prevent reverse engineering entirely, especially if the innovator licenses others as a strategy for preventing unlicensed entry. Provided that the cost of reverse engineering is high enough, such licensing will be on terms that permit the innovator to recoup its R&D expenses, while at the same time constraining the exercise of market power in order to dissuade other potential entrants. Our economic assessment of reverse engineering recognizes that this activity is only one step in what is typically a fourstage development process. The first stage of a second comer s development process is an awareness stage. This involves a firm s recognition that another firm has introduced a product into the market that is potentially worth the time, expense, and effort of reverse engineering. 276 com

3 P. Jeyaraman, K. Arun Kumar, B.R. Aravindh Raj, I. Saran Raj and M. Saleem In some markets, recognition happens very rapidly; in others, it may take some time, during which the innovator can begin to recoup its R&D costs by selling its product and establishing goodwill with its customer base. Second is the reverse engineering stage. This begins when a second comer obtains the innovator s product and starts to disassemble and analyze it to discern of what and how it was made may be costly, time-consuming, and difficult, although this varies considerably, depending mainly on how readily the innovator s product will yield the know-how required to make it when confronted by a determined and skilled reverse engineer. However, a reverse engineer will generally spend less time and money to discern this know-how than the initialnnovator spent in developing it, in part becausee the reversee engineer is able to avoid wasteful expenditures investigating approaches that do not work,51and in part because advances in technology typically reduce the costs of rediscovery over time. Third is the implementation stage. After reverse-engineering the innovator s product, a second comer must take the know-how obtained. 4. EXPERIMENTAL PROCEDURE In my case, I have selected the Thermostat component which is aluminiumm based casting. By adopting reverse engineering g concept, the considered component is to be made by rapid prototyping concept such as Fused deposition modeling. Since the component having complex geometries it cannot be duplicated as it is.so by using Coordinate measuring machine (CMM) the dimensions of component is taken. The dimensionss are taken the following are below: Coordinate measuring machine This Coordinate measuring machine available in kalasalingam university, krishnankoil. It is having the 2.5 um high precision (Swiss made), Pneumatic controller 4 bar systems. Figure 1 Coordinate measuring machine Cylindricity Conical surface; Inclination Height Polar coordinates; U V Squareness XY Ref length Parallelism; ZX XZ Table 1 Dimensions mm

4 Design and Fabrication of Thermostat Valve for Marathi Alto Vehicle using Reverse Engineering The above dimensions are taken by using CMM. The component is modelled by using Pro-E software. This software is used because of the ease of modelling and able to convert prt file in to.stl file. The Rapid prototype machine only able to make a product only, if the modelled component is of.stl format. 5. MODELLING PROCEDURE Using the Pro-E software, the component is modelled in Part Module. Then Part file is converted to STL File (stereolithiography).the modelled component is attached with this Figure 2 Existing component default view The Above component is modeled by taking the dimensionn taken using CMM After the component is modeled in pro-e prototype machine. part module, this part file is converted to STL file which will compatible with Rapid Figure 3 Convert STL format The stl file is to be transferred from Pro-E to Fused deposition machine so that accurate replica of the component is made without any hurdles. The raw material of component to be made is ABS. The component to be obtained is finally modeled in ANSYSS.By applying loads and Boundary conditions, the deformation is to be noted.if the deformation is within limit, the component to be made by reversed engineering concept willl be successful. 278

5 P. Jeyaraman, K. Arun Kumar, B.R. Aravindh Raj, I. Saran Raj and M. Saleem 6. DRAFTING OF COMPONENT Figure 4 Modified component default view Figure 5 Modified component model 7. RAPID PROTOTYPING Rapid manufacturing techniques enable complex shaped parts to t be produced directly from a computer model without conventional part specific tooling or machining. There are two routes for fabricating the part: (1) direct route in which the part is produced in plastic, resin or paper directly from the CAD data using a suitable rapid prototyping (RP) system, and(2) indirect route in which the RP parts can be used as masters for fabricating the tooling through a suitable rapid tooling (RT) method using epoxy, polyurethanee or silicone rubber. The parts produced by direct or indirect route in resin, paper, plastic or wax material can be used as a pattern or mould for sand casting or investment casting as appropriate. Thiss enables producing near net shape metal parts, which can be machined to final dimension and tolerances. The CNC program required for the machining can also be generated directly from the CAD model of the part using CAM software. 8. DIRECT ROUTES: RAPID PROTOTYPING The Rapid Prototyping (RP) technology is an additive process based on the philosophy of fabricating the cross-sectional layers of paper, wax or plastic on top of each other to create a physical part4. The sections are generated from a 3D CAD model of the part and then 279

6 Design and Fabrication of Thermostat Valve for Marathi Alto Vehicle using Reverse Engineering fabricated using one of the several RP techniques available. All techniques employ the same basic four four-step step process: (1) convert the CAD model to STL format, (2) slice the STL file into cross-sectional sectional layers about 0.01 to 0.7 mm thin, (3) construct the layers of the model one a top another, and (4) post processing such as cleaning and curing. Major issues involved in these steps are briefly described below. 9. CONVERSION TO STL FORMAT FORMAT Figure 6 FDM machine Using one of several techniques, the RP machines build one layer at a time from polymers, paper or powdered metal. The machines are autonomous, needing no human intervention during layer construction. There are four major rapid prototyping techniques, each with unique strength strengths: s: selective liquid solidification, semi-liquid semi liquid deposition, sheet laminating and powder binding5.the Stereolithography (SLA) developed by 3D Systems, Inc. uses photosensitive resins cured with an ultraviolet laser. The SLA Quick Cast is a variation of the Stereo lithography process giving a hollow honeycomb structure of polymeric material. 10. VIPER SLA SYSTEM This Viper SLA system with RP model process is available at PSG tech Coimbatore. It is having the 3D viper system. Figure 7 Viper SLA system asp 280 com

7 Applications P. Jeyaraman, K. Arun Kumar, B.R. Aravindh Raj, I. Saran Raj and M. Saleem Small to medium-sized prototype, concept and communication models Investment casting patterns Parts with extremely fine details such as jewelry and electronic connectors Hearing aids Viper SLA System Process Using one of several techniques, the RP machines build one layer l at a time from polymers, paper or powderedd metal. The machines are autonomous, needing no human intervention during layer construction. There are four major rapid prototyping techniques, each with unique strengths: selective liquid solidification, semi-liquid deposition, sheet laminating and powder binding5.the stereo lithography (SLA) developed by 3D Systems, Inc. uses photosensitive resins cured with an ultraviolet laser. The SLA Quick Cast is a variation of the stereo lithography process giving a hollow honeycomb structure of polymeric material. Figure 8 Viper SLA system with RP model This Viper SLA system with RP model process is conducted at PSG tech Coimbatore. There are three types of RPT machine is there. This model has been produced by 3D Viper SLA system. It is one of the rapid prototyping and tooling machine. This model made on ABS plastic material. Figure 9 Prototype model made by ABS 281

8 Design and Fabrication of Thermostat Valve for Marathi Alto Vehicle using Reverse Engineering 11. CONCLUSIONS There is an increasing interest in reverse engineering of parts whose drawings (geometric, material and manufacturing details) are not available, especially those required one-off or in a few numbers, such as for replacement of broken and worn-out parts. It is facilitated by the availability of technologies such as non-contact scanning, rapid tool manufacturing (using rapid prototyping and rapid tooling methods) and process parameter optimization through simulation. This investigation focused on integrating these technologies, to achieve a dramatic reduction in manufacturing time and associated costs for one-off products. REFERENCES [1] D.K.PAL, Computer Aided Reverse Engineering for rapid replacement parts, Defence Science Journal, DRDO, New Delhi, [2] Charalampos Danilidis Katherina Eben, A functional analysis approach for product reengineering,triz Conference,2009. [3] Pasquelo Corba, Michele Germani, Ferruccio Mandorli, Aesthetic and Functional analysis for product model validation in reverse engineering application, Elsevier Publication, Italy, March [4] Ngozi Sherry Ali, Reverse Engineering of Automotive Parts Applying Laser Scanning and Structured Light Techniques, May [5] Alrashdan A.; Motavalli, S. & Fallahi, B., Automatic segmentation of digitized data for reverse engineering applications. IIE transactions, Jan 2000, 32(1), 59. [6] Akarte, M.M. and Ravi, B., RP/RT Route Selection for Casting Pattern Development, Manufacturing Technology, Proc. of 19th AIMTDR Conf, 2000, [7] M. M. Akarte, B. Ravi, 2000, RP/RT Route Selection for Casting Pattern Development, Maufacturing Technology, Proceedings of 19th AIMTDR Conference, pp , [8] B. Mueller, and D. Kochan, Laminated Object Manufacturing for Rapid Prototyping and Pattern Making in Foundry Industry, Computers in Industry, 1, pp , [9] W. Wang, J. G. Conley, and H. W. Stoll, Rapid Tooling for Sand Casting using Laminated Object Manufacturing process, Rapid Prototyping Journal, 3, pp , [10] B. Sushila, K. Karthik, and P. Radhakrishnan, Rapid Tooling for casting-a case study on application of Rapid Prototyping processes, Indian Foundry Journal, 11, pp , [11] Abdul Razzaque Ansari and Prashant Kumar Rana, CFD Analysis of Aerodynam ic Design of Maruti Alto Car. International Journal of Mechanical Engineering and Technology, 8(3), 2017, pp [12] Shweta Matey, Deep R Prajapati, Kunjan Shinde, Abhi shek Mhaske and Aniket Prabhu, Design and Fabrication of Electric Bike, International Journal of Mechanical Engineering and Technology, 8(3), 2017, pp com