Reverse Engineering

Presented by-Dattaprasad Pokale

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What is Reverse Engineering?

• 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.

• In this, existing product is redesigned to improve and broaden its functions, add quality functions and to increase its useful life.

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Why reverse engineering ? • The original producer no longer produces the product,

but the customers still requires the product or old product needed to be repaired.

• There is inadequate documentation of the product.• Problems of the existing product are needed to be

solved• To replace the time consuming or defective or costly

process of manufacturing.• This means reverse engineering is efficient approach to

significantly reduce the product development cycle.

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Reasons for Reverse Engineering

•Military or commercial espionage•Creation of unlicensed/unapproved duplicates•Improve documentation shortcomings•Obsolescence•Software modernization•Product security analysis•Bug fixing•Academic/learning purposes •Competitive technical intelligence•Saving money•Repurposing

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Reverse Engineering Methodology

Investigation, Prediction and Hypothesis

Concrete Experience: Function & Form

Design Models

Design Analysis

Parametric Redesign

Adaptive Redesign

Original Redesign

Reverse Engineering

Modeling & Analysis

Redesign

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Parametric Redesign• Optimize design parameters• Perform sensitivity analysis and tolerance design• Build and test prototype

Adaptive Redesign• Recommend new subsystems• Search for inventive solutions• Analyze force flows and component combinations• Build and test prototype

Original Redesign• Develop new functional structure• Choose alternatives• Verify design concepts• Build and test prototype

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System-Wide AnalysisCustomer Requirements

1. Compact

2. Light in weight

3. Easy to operate

4. Good in design

Functional Specifications

Engineering Requirements

1. Material performance

2. Operable at any condition

3. Harmless to user

Prediction of Subsystems and Components

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Digitizing• Collecting data from physical part.• Used when drawing of object is not available.• Aim is to generate a 3D mapping of the product in

the form of CAD file.• This requires acquisition of surface data, which is

large number of points on the product surface.• For this two types of processes are used: contact and

non contact method.

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Discretization method 1. Contact method

• Requires contact between the component surface & a measuring tool.

• Uses Coordinate Measuring Machine (CMM), electromagnetic digitizer or sonic digitizers to get desired coordinates.

2. Non contact method• Uses light as the main

tool• Uses white light or laser

scanners to scan 3D objects to generate CAD design.

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Manipulation of data• Basically, after completion of this a CAD model of

product is obtained.• Used to fit a geometry to the large number of points

obtained from digitizing.• The surface can be mathematically defined as

algebraic or parametric surface.• Surface fitting techniques can be of two types:

interpolation and approximation techniques.

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Surface fitting techniques 1.Interpolation technique

• Surface to be fitted passes through all the data points.

• Used when the data points are accurately measured without any errors.

2.Approximation technique

• Surface represents a generalized or best fit to the data points.

• Used when large number of data points are to be fitted.

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Generation of functional part

• The geometric model obtained, can be used as the basis for variety of operations.

• Operations such as automated process planning, automated manufacturing, automated dimensional inspection and automated tolerance analysis.

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Advantages of reverse engineering

• RE typically starts with measuring an existing object, so that a solid model can be deduced in order to make use of the advantages of CAD/CAM/CAE technologies.

• CAD models are used for manufacturing or rapid prototyping applications.

• Hence we can work on a product without having prior knowledge of the technology involved.

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Advantages of reverse engineering

Cost saving for developing new products.

Lesser maintenance costs

Quality improvement

Competitive advantages

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Applications• Manufacturing Field: To create a 3D virtual model of

an existing physical part for use in 3D CAD, CAM, CAE or other software and to analyze the working of a product.

• Medical Field: Imaging, modeling and replication (as a physical model) of a patient's bone structure

• Software engineering: To detect and neutralize viruses and malware.

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References

[1] Durupt A., Remy S. and Ducellier G (2010), Knowledge Based Reverse Engineering- An Approach for Reverse Engineering of a Mechanical Part, ASME Journal of Computing and Information Science in Engineering, 10, pp.044501-1.

[2] Lefever D. D. and Wood K. L. (1996), Design for Assembly Technique in Reverse Engineering and Redesign, ASME Design Theory and Methodology Conference, pp. 78712-1063.

[3] Shooter Steven (2008), Reverse Engineering to Design Forward, American Society for Engineering Education, pp.2008- 1170.

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