Simulation in reverse engineering

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

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
• How to achieve the final product

Most of the time, this process ends only with:

• 3D modeling in CAD software
• Using point cloud devices
• Measuring equipment (such as calipers, 3D scanners, etc.), material analysis

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.

When is reverse engineering simulation approaching its ideal?

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 as the boundary of the development

Is it possible that the reverse engineering product is better than the original?

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
• Information obtained is codified

Design engineers will gain knowledge that allows for optimizing the design and providing better products in later stages.

2- Preventing human errors

Copying ignores human error in the final product when measuring and taking data, analyzing materials, and producing parts.

How does reverse engineering prevent human errors?

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.

Recommendations and requirements in reverse engineering simulation

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.