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UNIVERSITI PUTRA MALAYSIA
ISMANIZAM BINTI ABD. MANAF
FK 2009 117
COMPARISON OF CONTACT AND NON-CONTACT REVERSE ENGINEERING TECHNIQUES FOR FREE-FORM SURFACES WITH COORDINATE MEASURING MACHINE AND 3D LASER
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COMPARISON OF CONTACT AND NON-CONTACT REVERSE ENGINEERING TECHNIQUES FOR FREE-FORM SURFACES WITH COORDINATE MEASURING MACHINE AND 3D LASER
By
ISMANIZAM BINTI ABD. MANAF
Thesis Submitted to the School of Graduate Studies, Universiti Putra Malaysia, in Fulfilment of the Requirements for the Degree of Master of
Science
July 2009
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To my dear dad, mum, brothers and sisters for believing in me.
To special one, Mohammad Faeiz Ismail, thanks for your love and staying by my side.
Special thanks to Ard who never gave up in giving me her supports and inspirations.
And to others who always pray for me.
Mama, memories of you are still fresh in my mind and close to my heart.
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Abstract of thesis presented to the Senate of Universiti Putra Malaysia in fulfilment of the requirement for the degree of Master of Science.
COMPARISON OF CONTACT AND NON-CONTACT REVERSE ENGINEERING TECHNIQUES FOR FREE-FORM SURFACES WITH COORDINATE MEASURING MACHINE AND 3D LASER
By
ISMANIZAM BINTI ABD. MANAF
July 2009
Chair: Datin Napsiah Ismail, PhD Faculty: Engineering Application of reverse engineering (RE) technology enables creation of
Computer Aided Design (CAD) models of existing product/part by capturing
the surfaces data using either contact or non-contact methods. RE process
consists of four main stages from part digitization, data editing, surface
generation to CAD model construction. Many researches in RE applications
show CAD model of an existing part was successfully reconstructed by using
CMM or 3D laser scanner, but the researches need additional task in editing
stage such as developed extra programme to reduce noises and errors.
Additional task in editing stage can be eliminated if part digitization stage is
carried out properly since surface measurement is the first priority in RE
process. In this research, a free-form (FF) surface of an automotive
component was generated using contact and non contact RE methods. Four
scanning techniques used with two types of CMM namely Global Status
Brown and Sharpe for point to point scanning and UMESS UMM550 Carl
Zeiss for line scanning and two types of 3D laser scanners such as
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Cyberware 3D Rapid Digitizer for automated scanning and Minolta 3D Laser
Scanner for manual scanning. The digitization strategies, scanned result and
CAD models generated using both methods are then analyzed and
compared. Digitization parameters for contact methods are tips radius,
minimum angle, step width and scanning speed while for non-contact
method are rotation sense, distance, laser density, rotation view angle,
scanning mode, width, pitch and scanning angles. Point to point scanning
technique with large amount of scanned data volume is most time consuming
as measured while conducting an experiment that is more than 10 hours
need to complete scanning time from CMM measurement to data
processing. In line scanning, although small data volume gathered, it takes 3
hours 25 minutes to perform complete scanned part surface. In automated
scanning required 40 minutes inclusive of processing time while manual
scanning takes 1 hour 30 minutes to perform a complete scanned. It means
in term of time taken, laser scan technique may reduce the RE processing
time compared to tactile probing. However, while comparing to editing and
modeling task, also the modeling skill required, data captured from manual
scanning technique is most demanding. Point to point scanning produced
best quality result compared to other technique since a prototype model is
successfully produced with 1% percentage error. Most unacceptable result is
manual scanning because too many missing surfaces to the surface scanned
result.
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Abstrak tesis yang dikemukakan kepada Senat Universiti Putra Malaysia sebagai memenuhi keperluan untuk ijazah Master Sains
PERBANDINGAN TEKNIK SENTUH DAN TIDAK-SENTUH BAGI KEJURUTERAAN BALIKAN UNTUK PERMUKAAN BENTUK BEBAS
MENGGUNAKAN MESIN PENGUKURAN KOORDINAT DAN LASER 3D
Oleh
ISMANIZAM BINTI ABD. MANAF
Julai 2009 Pengerusi: Datin Napsiah Ismail, PhD Fakulti: Kejuruteraan Aplikasi teknologi kejuruteraan balikan (RE) membolehkan penghasilan
model Rekabentuk Terbantu Berkomputer (CAD) bagi komponen sediaada
dengan memperolehi data permukaan sesuatu komponen menggunakan
kaedah sentuh atau tidak-sentuh. Proses RE terdiri daripada empat
peringkat utama daripada pendigitan komponen, penyuntingan data,
penghasilan permukaan dan pembinaan model CAD. Banyak penyelidikkan
dalam aplikasi RE menunjukkan model CAD dari komponen sediaada telah
berjaya dihasilkan dengan menggunakan mesin pengukuran koordinat
(CMM) dan pengimbas laser 3D, tetapi masih memerlukan kerja tambahan
dalam peringkat penyuntingan seperti membina program bagi
mengurangkan ralat. Kerja tambahan dalam peringkat penyuntingan boleh
dihapuskan atau dikurangkan jika perhatian diberikan dari peringkat
pendigitan data lagi kerana pengukuran permukaan adalah paling utama
dalam proses RE. Dalam kajian ini, permukaan bentuk bebas (FF) bagi
komponen automotif dihasilkan menggunakan kaedah sentuh dan tidak-
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sentuh. Empat teknik imbasan digunakan melalui dua jenis CMM iaitu Global
Status Brown and Sharpe bagi imbasan titik ke titik dan UMESS UMM550
Carl Zeiss bagi imbasan garisan dan dua jenis pengimbas laser 3D iaitu
Cyberware 3D Rapid Digitizer untuk imbasan berautomatik dan Minolta 3D
Laser Scanner untuk imbasan manual. Strategi pendigitan, hasil imbasan
dan model CAD yang dihasilkan melalui kedua-dua kaedah ini kemudiannya
dianalisa dan dibuat perbandingan. Beberapa parameter pendigitan dalam
kaedah sentuh ialah jejari tip, sudut minima, lebar langkah dan kelajuan
imbasan manakala untuk kaedah tidak-sentuh adalah putaran, jarak,
ketumpatan laser, putaran sudut pandangan, mod imbasan, lebar, curam
dan sudut imbasan. Teknik titik ke titik menghasilkan amaun data imbasan
yang besar dan paling memakan masa iaitu lebih dari 10 jam diperlukan bagi
melengkapkan keseluruhan kerja imbasan sehingga pemprosesan data.
Dalam teknik imbasan garisan pula, walaupun amaun data adalah kecil, ia
memerlukan 3 jam 25 minit untuk mendapatkan keseluruhan permukaan
komponen. Untuk imbasan berautomatik, 40 minit diperlukan termasuk masa
pemprosesan dan untuk imbasan manual mengambil masa 1 jam 30 minit
untuk menyempurnakan imbasan. Ini menunjukkan bahawa teknik imbasan
laser dapat mengurangkan masa pemprosesan RE jika dibandingkan
dengan prob sentuh. Walaubagaimanapun, jika dibandingkan dengan kerja
suntingan dan permodelan serta kemahiran permodelan yang diperlukan,
pemperolehan data melalui imbasan manual adalah paling rumit. Imbasan
titik ke titik telah menghasilkan keputusan yang paling berkualiti
dibandingkan dengan teknik yang lain apabila ia telah berjaya menghasilkan
sebuah model prototaip dengan 1% peratusan ralat. Keputusan yang paling
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tidak boleh diterima adalah daripada imbasan manual bilamana terlalu
banyak permukaan komponen yang tidak dapat diimbas.
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ACKNOWLEDGEMENTS I would like to thank Assoc. Prof. Datin Dr. Napsiah Binti Ismail, who has
giving me encouragement and full support from the very beginning of my
study throughout this research. Under her guidance and support, I have been
able to finish this research work. I would also like to thank Assoc. Prof. Dr.
Wong Shaw Voon as co-supervisor for his guidance and idea while problems
come. Also thank to Prof. Dr. Abdel Magid Salem Hamouda as co-supervisor
within this supervisory committee. Deep appreciation to all lecturers at
Department of Mechanical and Manufacturing Engineering, Faculty of
Engineering, Universiti Putra Malaysia for their help in transferring me
knowledge.
Much appreciation is also due to Mr. Azrul, Mr. Azmi and all staffs at German
Malaysian Institute for assisting me and giving opportunity to used CMM
machine in their lab. Thanks are also due to Mr. Muhammad Wildan Ilyas,
technicians and all staff of Department of Mechanical and Manufacturing
Engineering for their support and assistance. I also own deep gratitude to
Maznah, Syarliza, Rosmawati, all my colleagues at JKR, colleagues at UiTM
Penang and all my friends for their care and support.
I owe my greatest gratitude to my family, Ard and her family for
understanding me, encouraging me, advising me and supporting me by
sharing the load and love. Deep in my heart, I am also thankful to Faeiz for
his patient, support, caring and so much love.
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I certify that a Thesis Examination Committee has met on 28 July 2009 to conduct the final examination of Ismanizam Binti Abd. Manaf on her thesis entitled "Comparison of Contact and Non-Contact Reverse Engineering Techniques for Free-Form Surfaces with Coordinate Measuring Machine and 3D Laser" in accordance with the Universities and University Colleges Act 1971 and the Constitution of the Universiti Putra Malaysia [P.U.(A) 106] 15 March 1998. The Committee recommends that the candidate be awarded the Master of Science. Members of the Thesis Examination Committee were as follows: Aidy Ali, PhD Associate Professor Faculty of Engineering Universiti Putra Malaysia (Chairman) Md Yusof Ismail, PhD Professor Faculty of Engineering Universiti Putra Malaysia (Internal Examiner) Tang Sai Hong, PhD Associate Professor Faculty of Engineering Universiti Putra Malaysia (Internal Examiner) Hassan Che Haron, PhD Professor Faculty of Engineering Universiti Kebangsaan Malaysia Malaysia (External Examiner) __________________________
BUJANG BIN KIM HUAD, PhD Professor and Deputy Dean School of Graduate Studies Universiti Putra Malaysia
Date: 23 July 2010
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This thesis submitted to the Senate of Universiti Putra Malaysia and has been accepted as fulfilment of the requirement for the degree of Master of Science. The members of the Supervisory Committee were as follows: Datin Napsiah Ismail, PhD Associate Professor Faculty of Engineering Universiti Putra Malaysia (Chairperson) Wong Shaw Voon, PhD Associate Professor Faculty of Engineering Universiti Putra Malaysia (Member) Abdel Magid Salem Hamouda, PhD Professor Faculty of Engineering Universiti Putra Malaysia (Member)
____________________________
HASANAH MOHD GHAZALI, PhD Professor and Dean School of Graduate Studies
Universiti Putra Malaysia
Date: 12 August 2010
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DECLARATION I hereby declare that the thesis is based on my original work except for quotations and citations which have been duly acknowledged. I also declare that it has not been previously or concurrently submitted for any other degree at Universiti Putra Malaysia or other institutions.
___________________________ ISMANIZAM BINTI ABD. MANAF
Date:
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TABLE OF CONTENTS
Page DEDICATION ii ABSTRACT iii ABSTRAK v ACKNOWLEDGEMENT viii APPROVAL SHEETS ix DECLARATION FORM xi TABLE OF CONTENTS xii LIST OF TABLES xiv LIST OF FIGURES xv LIST OF ABBREVIATIONS xviii CHAPTER
1 INTRODUCTION 1.1 Introduction 1 1.2 Problem Statement 4 1.3 Research Objectives 7 1.4 Scope of Research 7 1.5 Thesis Layout 7
2 LITERATURE REVIEW 2.1 Introduction 9 2.2 Reverse Engineering Definition 9 2.3 Application of Reverse Engineering 11 2.4 Reverse Engineering State of The Art 13 2.5 Review of Digitization Equipment 28 2.6 Design of Experiment (DOE) 34
3 METHODOLOGY 3.1 Introduction to Reverse Engineering Methodology 37 3.2 Digitization Methods 39
3.2.1 Contact Method using Coordinate Measuring
Machine (CMM) 41
3.2.2 Non-contact Method using Laser Scanner 45 3.3 CAD/CAM System 47 3.3.1 Unigraphics NX Version 2: 2004 (UGNX2) 48 3.4 Reverse Engineering Techniques Approach 50 3.4.1 Point to point scanning with Brown & Sharpe
CMM 55
3.4.2 Line scanning with UMM 550 UMESS Carl Zeiss CMM
58
3.4.3 Automated Scanning with Cyberware 3D Rapid Digitizer
60
3.4.4 Manual Scanning with Minolta 3D Scanner 66 3.5 Experimental Design 68 3.5.1 Point to Point Scanning 70
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3.5.2 Line Scanning 75 3.5.3 Automated Scanning 80 3.5.4 Manual Scanning 84 3.6 Prototyping of Reverse Engineered Model 87 3.6.1 FDM Vantage SE Rapid Prototyping Machine 88 3.6.2 Rapid Prototyping Steps 90
4 RESULTS AND DISCUSSIONS 4.1 Introduction 91 4.2 Results Analysis 91 4.2.1 Point to Point Scanning 91 4.2.2 Line Scanning 99 4.2.3 Automated Scanning 103 4.2.4 Manual Scanning 106 4.3 Discussions 107 4.3.1 Point to Point Scanning 107 4.3.2 Line Scanning 110 4.3.3 Automated Scanning 113 4.3.4 Manual Scanning 115 4.4 Comparison of Four Techniques 118
5 CONCLUSION AND RECOMMENDATIONS 5.1 Conclusion 123 5.1.1 Point to Point Scanning 123 5.1.2 Line Scanning 124 5.1.3 Automated Scanning 125 5.1.4 Manual Scanning 126 5.2 General Conclusion 128 5.3 Recommendations of Future Research 130
REFERENCES 131 APPENDICES BIODATA OF STUDENT LIST OF PUBLICATIONS
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LIST OF TABLES
Table
Page
3.1 Accuracy, repeatability and resolution of Brown and Sharpe CMM
56
3.2 Trial run result of input parameters for point to point scanning
73
3.3 Actual experimental input parameters of point to point scanning
74
3.4 Trial run input parameters for line scanning 77
3.5 Actual input parameters of digitization process for line scanning
78
3.6 Working range for automated scanning 81
3.7 Input parameters for automated scanning 82
3.8 Actual input parameters of manual scanning 86
4.1 Total number of points obtained for point to point scanning
93
4.2 Measurement and verification data for Diameter A and Diameter B
98
4.3 Measurement and verification data of distance for circle to circle
98
4.4 Total points and lines obtained for line scanning 100
4.5 Result of digitization process for automated scanning 103
4.6 Digitization data result for manual scanning 106
4.7 Pre-scanning considerations for different type of scanning technique
119
4.8 Comparisons of overall scanning techniques 121
4.9 Overall view of RE result for four techniques 122
5.1 Strengths and weaknesses of CMM and laser scanning 129
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LIST OF FIGURES
Figure Page
1.1 Stages in the reverse engineering process 2
3.1 General reverse engineering techniques for free form surface
38
3.2 Digitization methods 41
3.3 Moving bridge type coordinate measuring machine 42
3.4 Contact probe configurations: (a) single tip and (b) multiple tips
44
3.5 Dividing the image into a matrix of picture elements, where each element has a light intensity value corresponding to that portion of the image
46
3.6 Principle of optical triangulation sensing 47
3.7 Flow of surface/sheet body model construction 50
3.8 Selected part 53
3.9 The flowchart of experimental reverse engineering 54
3.10 Brown and Sharpe Global Status 5.7.5 CMM 56
3.11 Renishaw PH10M Probe 57
3.12 The way of collecting data for point-to-point polygon scanning technique in cross section of the part’s surface
58
3.13 UMM550 UMESS Carl Zeiss CMM 59
3.14 The Mini Model Shop Color 3D Scanner - Cyberware 3D Rapid Digitizer
61
3.15 View of scanning process 63
3.16 Division of scanning level of the part 64
3.17 Flow of all measurement processes in CyDir module (Scan, Paste and Merge)
65
3.18 Flows of measurement techniques for Cyberware 3D Rapid Digitizer
66
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3.19 Minolta VIVID 900 Non-Contact 3D Scanner measuring
principle
68
3.20 Flow chart for DOE methodology 70
3.21 Parameters to be considered for polygon scanning 71
3.22 Affect factors for point to point scanning 72
3.23 Illustration of touch-trigger and continuous probe scanning
77
3.24 Flow of surface model construction for line scanning 80
3.25 Scanning angle in Guee Scans module 82
3.26 Illustration of manual scanning of an object 85
3.27 Smoothing task in Polygon Editing Tool
87
3.28 Rapid prototype machine 89
4.1 Points cloud scanned result 93
4.2 Number of points versus minimum angle for 1 mm and 2 mm of tip radius
94
4.3 Digitization and surface reconstruction result of the part 95
4.4 Surface CAD model 96
4.5 Prototype model 96
4.6 Dimensions measured for diameter A, B and distance between circle to circle
97
4.7 Digitization result of line scanning 101
4.8 Boundary division of surface modeling application: (a) Swept, (b) Through Curve and (c) Swept
102
4.9 Surface model of line scanning technique 102
4.10 Scanned result after merging and reposition 104
4.11 Complete scanned result 105
4.12 Measured data view in different system: (a) Cyberware CyDir; (b) UGNX2 CAD/CAM System
105
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4.13 Result after imported into UGNX2 107
4.14 Non smooth surface boundary 110
4.15 Error in generating surface modeling 110
4.16 Insufficient data of scanned surface 112
4.17 Two causes of insufficient data collection for surface digitization
113
4.18 Limitation of measurement data for object digitization 115
4.19 Noise from missing surface scanned data 116
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LIST OF ABBREVIATIONS
2-D 2-Dimensional
3-D 3-Dimensional
ABS Acrylonitrile, Butadiene, and Styrene
ABSi Methylmethacrylate Acrylonitrile Butadiene Styrene Copolymer
C/C++ C or C++ Programming Language
CAD Computer Aided Design
CAD/CAM Computer Aided Design and Computer Aided Manufacturing
CAE Computer Aided Engineering
CARE Computer Aided Reverse Engineering
CATIA Computer Aided Three-dimensional Interactive Application
CCD Charge-Coupled Device
CMM Coordinate Measuring Machine
CNC Computer Numerical Control
DEA Data Envelopment Analysis
DOE Design of Experiment
DOF Depth of Field
DXF Data Exchange Format
FDM Fused Deposition Modeling
FEA Finite Element Analysis
FEM Finite Element Method
FFF Free Form Features
FOV Field of View
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FTP File Transfer Protocol
IDEF0 Integration Definition for Function Modeling
IGES Initial Graphics Exchange Specification
ISO International Standard of Organization
LAN Local Area Network
LDM Laser Displacement Meter
LOM Laminated Object Manufacturing
MM Mini Model
NC Numerical Control
NURBS Non-Uniform Rational B-Spline
PC Personal Computer
PC-DMIS Dimensional Measuring Interface Standard Software
PC-ABS Polycarbonate - Acrylonitrile, Butadiene, and Styrene
PC-ISO Polycarbonate-ISO
PDM Product Data Management
PET Polygon Editing Tool
Pro-E Pro-Engineer
PU Polyurethane
QC Quality Control
RE Reverse Engineering
RGB Red Green Blue
RP Rapid Prototyping
SDRC I-DEAS Structural Dynamics Research Corporation Integrated Design and Engineering Analysis Software
STL Stereolitography
UGNX2 Unigraphics NX2
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VDA Verband der Automobilindustrie (CAD data exchange format)
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CHAPTER 1
INTRODUCTION
1.1 Introduction
Reverse Engineering (RE) refers to the process of creating engineering
design data or product technical data from existing parts (Huang and Tai,
2000 and Yuan et al., 2001). It recreates or clones existing parts by acquiring
the surface data of an existing part using a scanning or measurement device
(Lee and Woo, 2000). The reasons why RE are necessary because for
example old products for which there are no prints, or product technical data
are needed for the purpose of equipment maintenance, upgrading, or ISO
9000 documentation. Another example is where molds or dies were originally
out-sourced due to lack of internal manufacturing capability and where
neither blue prints nor electronic data are available in-house. With increased
in-house capability in Computer Numerically Controlled (CNC) machining,
there is a need to duplicate the existing molds or dies for the purpose of
replacement due to wear or other damages. Products designed before
computer aided design/computer aided manufacturing (CAD/CAM) existed is
one typical example.
In the context of general manufacturing methods, reverse engineering is an
important process for instances where a product initially exists as a
designer’s model in a medium, such as styling foam or modeling clay. In
modern practice, and for the scope of this thesis, reverse engineering free
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form or sculptured objects may be defined as the process of generating a
computer-aided design (CAD) model from an existing part or prototype as
shown in Figure 1.1, which has changed from a skilled manual process to
one incorporating sophisticated computer software and measuring
instruments it usually has four main stages.
Figure 1.1: Stages in the reverse engineering process.
The process starts with 3-D data collection using these two broad
methodologies to generate CAD model from digitizing or scanning data by
using coordinate measuring machine (CMM) or 3D laser scanner.
Methodologies of digitization parts can be classified into two general
categories: contact and non-contact (Li et al., 2002, and Li and Gu, 2004).
CMMs with contact probe and robot manipulators are categorized as contact
method. While the 3D laser scanner is classified into non-contact method or
a non-contact machine vision system, such as an optical triangulation range
sensor which is used a laser light and a camera to capture the surface
scanned.
Part Digitization
Data Editing
Curve and Surface Generation
CAD Model Construction
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A CMM consists of a workspace in which parts are fixed, a sensor for
detecting the part surfaces, a mechanical assembly for moving the part
sensor around the workspace, and a computer for calculating the part
dimensions based on the sensor measurements. CMMs are available in
numerous sizes and styles. Some are "desktop" mechanisms moved
manually, while others are computer driven and are large enough to measure
car bodies. CMM in reverse engineering applications become widely used
with reverse engineering software that designed to take an existing physical
part and construct a computer model of the part geometry based on a large
number of measurements of its surface. Most contact methods are usually
for more accurate measurement while non-contact methods are for faster
measuring time.
An optical system, the other major type of digitizer, projects a light or laser
beam onto the surface, and a camera or detector intercepts the reflected
beam and converts it to coordinates. An optical system often referred to as a
3D digitizer is used for automating the reverse engineering of mechanical
parts and organic shapes. Manufacturing professionals apply them to the
creation of new patterns for prototype tooling, investment casting, and CNC
machining. Medical specialists use 3D digitizers to digitize bones and other
anatomy for the development of prosthetics and implants. Video production
experts use 3D digitizers to capture hard to create shapes for TV
commercials and special effects. For non-contact methods, parts are not
destructive by the contacts scanning probe and generally provide much
faster data collection rates.
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Most RE application involved to free-form surfaces or normally known as
complex surfaces. Free form features can be defined in the same way as
regular–shaped features. Such features still correspond to generic shapes,
the only difference being that there is more modeling freedom for the shape
of the features; typically, their faces can be modeled with Non-Uniform
Rational B-Spline (NURBS). Although freeform surfaces can have very
complex shapes, their shape can also be simple or even regular (Van den
Berg et al., 2002). Modelling freeform objects was done by directly modifying
its surfaces, e.g. by selecting a point on the surface of the model and
dragging it to another position, thereby deforming the object. Modelling of
CAD model from scanned data can be made using any CAD/CAM packages
that available in the market such as Unigraphics, CATIA, Pro-Engineer and
Solidworks software. The model creates depends, of course, heavily on the
representation that is used for the freeform object.
1.2 Problem Statement
In engineering areas such as aerospace, automotives, shipbuilding and
medicine, it is difficult to develop a CAD model of an existing product that
has a free-form surface or a sculptured surface (Yu, 2003). Application of the
RE technology is to generate necessary CAD models of the existing
product/part by capturing the surface. RE process in getting a CAD model
consists of four main stages such as (1) part digitization – contact and non-
contact, (2) data editing, (3) curve and surface generation and (4) CAD
model construction. The successful of producing a prototype model is
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depends on all main stages and not only limited to certain stage. Most
studies of RE undertaken are not concentrated on part digitization stage
although it will influence the output of prototype. Researchers are not
focused on gathering good raw data through digitization strategies.
Kruth & Kerstens (1998), Huang & Tai (2000) and Budak et al. (2005) used
contact method (CMM) in their research and focused on second stages of
RE process, pre-processing of data points measured from an existing object
before B-spline curve fitting in improving the low quality of digitization results.
Those researchers have focused on the data editing stage for good
prototype results although they have gone through the part digitization stage.
It is due to improper handle of part digitization strategies will lead to data
uncertainties hence it is requires emphasizing on data editing stage.
In other way where much attention are to deal with redundant data
elimination, Wang et al. (1999) and Xie et al. (2007) have concentrated on
part digitization stage in order to achieved better 3D results by developed
their own digitizing system. Wang et al. (1999) had introduced a system for
design sculptured surfaces by four-axis non-contact scanning (which whole
system that integrated of a PC-based XYZ table, a laser displacement meter
(LDM), and a personal computer) while Xie et al. (2007) had proposed for a
full field of view scanning system by composing of a CCD camera, a
galvanometer and a laser projector. However, the studies in part digitizing
process is limited to configuration of hardware and no digitizing parameters
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were highlighted. As a result, the accuracy of the system is relatively low
when measuring parts with fine structures.
While another research by Feng (2005) was trying to skip data point pre-
processing to express reverse engineering time by a methodology of
internet-based reverse engineering approach to perform contact method
CMM digitization process and creating a solid model that then transmitted via
internet to rapid prototyping machine to produce a final part and also similar
research by Lee and Woo (2000) in integration of reverse engineering using
non-contact method 3D scanner that allows fabricating RP parts directly from
geometric data. Those researchers are used different approach of part
digitization which is contact and non-contact data capturing without stress on
digitizing parameters involvement and eliminates the data editing stage to
fasten RE process.
As the conclusion, even though many researches in reverse engineering
applications show CAD model of an existing parts were successfully
reconstructed by using CMM or 3D laser scanner, but the researches need
additional task in editing stage such as developed extra programme to
reduce noises and errors. However, additional task in editing stage can be
eliminated if part digitization stage is carried out properly since surface
measurement is the first priority in reverse engineering process. There are
also none of the researches have been done in focusing to digitization
methods based on contact and non-contact techniques.
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1.3 Research Objectives
The objectives of the present research can be divided as the followings:
1. To evaluate the parameters and capabilities of contact and non-
contact digitization methods.
2. To compare the quality of method used in re-engineering CAD models
by using contact and non-contact methods.
1.4 Scope of Research
The scopes of the research are focusing to:
1. Digitization stage in producing CAD model for reverse engineering by
implementation of two digitization method using contact and non-
contact.
2. Generating of CAD model to compare the quality produced.
1.5 Thesis Layout
The thesis consists of five chapters. Chapter One gives an introduction of
reverse engineering, methodology and reverse engineering process, problem
statement, objective, scope and thesis layout. Chapter Two presents state-
of-the art of RE, review of digitizing equipment using CMM and laser scanner
for the free-form surfaces and design of experiment (DOE). Chapter Three
describes the details of RE methodology, digitization methods, RE
techniques approach involved in part digitization for contact and non-contact
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such as point to point scanning, line scanning, automated scanning and
manual scanning by using CMM and 3D laser, data editing and CAD model
construction for every technique used., experimental design, CAD/CAM
system and also included about rapid prototyping machine used for model
prototyping, The analysis of the results and discussions are discussed in
Chapter Four. Finally, the thesis concluded with Chapter Five with a
summary of research findings, the conclusion and future research
recommendations.
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REFERENCES
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