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

Bradley C. and Chan V. 2001. “A Complementary Sensor Approach to Reverse Engineering”, ASME Journal of Manufacturing Science and Engineering Vol. 123, 74-82.

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