Simulation in Reverse Engineering
For the past few years, I have been in constant contact with manufacturers who did not pay any attention to simulation when designing and building a product. What I kept hearing from them was “We do not need simulation in reverse engineering!” And this is how I explained it to them …
Why should we still use simulation even if we do reverse engineering?!
1- Knowledge of product design & development
In fact, it should be noted that the main part of the reverse engineering process is the analysis of the design philosophy and how to achieve the final product. Most of the time, this process ends only with 3D modeling in CAD software and using point cloud devices and measuring equipment (such as calipers, 3D scanners, etc.), material analysis, and in the best case, analysis of manufacturing methods and heat treatment. In fact, this series of reverse engineering measures can not be applied. Rather, all these steps are just copying. The reverse engineering process is completed when, in addition to product design, the necessary analysis is performed to properly understand the behavior and performance of the entire machine, the details of component design and selection of materials and methods are examined and design information is codified. It can be said that the boundary between copying and reverse engineering is defined at the boundary of the development. A product that has been copied and its design details have not been examined will not become a better product. But if the mechanism and performance of a device are properly analyzed according to its components and the information obtained is codified, the design engineer will gain knowledge that allows for optimizing the design and providing better products in later stages.
2- Preventing human errors
Copying ignores the human error that exists in the final product when measuring and taking data, analyzing materials, and producing parts. While in reverse engineering, every part and wherever it is used, it is necessary to evaluate its quality, performance, and safety using simulation. Therefore, here numerical simulation can control and double-check the design and production of the product.
Engineering simulation is practically applicable at every stage of product production. This is stated in many standards. Therefore, both as a contractor and as an employer, it must be considered that the documentation related to the simulation and mechanical analysis of the desired part or equipment must be available. Its absence indicates many errors in the product.
Have you had any experience in this?
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