Reverse Engineering

Reverse Engineering Techniques in Design

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Reverse Engineering Techniques in Design


Reverse engineering can be defined as the process of creating a CAD model of an existing product or component by capturing the components physical dimensions and surface features through various engineering approaches. Reverse engineering is usually undertaken in order to redesign the product for better maintainability or to reproduce a copy of the product without access to original design from which that product was made.

The main goal of reverse engineering a product or component is to successfully generate a 3D CAD model of that component which can be used for future modeling of parts when there is no CAD model available as well as to generate a clean and smooth 3D model free from noise and other imperfections. Reverse engineering is accomplished in three principle steps shown below;


The first step in creating a 3D model is Data capture or Data acquisition. Data capture is the process of acquiring point coordinates from part surface which results in a cloud of data points stored as an image. Data capture can be done through wide range of available contact or non contact techniques. Data segmentation process is performed in order to extract surface features of the part from already obtained clouds of data points. The point clouds produced by 3D scanners and 3D imaging can be used directly for measurement and visualization in the architecture and construction world. The output of segmentation process consists of labeled points belonging to a particular region on part surface. Holes are filled and noise is filtered out by applying surface modeling techniques.

Component Design with Endurance


A rotating shaft is used to support a gear wheel. The shaft is supported by Ball bearings at both the ends. A lateral load is applied on the shaft through the gear wheel. Calculations for determining maximum bending stress and fatigue life will be carried out in coming sections in order to find out if the shaft meets the criteria described by manufacturer or it fails in early stages.


F = 20 kN

Operating temperature = 50 ⁰C

Machine finished shaft

Reliability = 1

Life =

Mild steel ultimate strength,  = 430 MPa


Problem Statement


  • Maximum bending stress within the shaft
  • Fatigue life of the shaft