Technical Seminar @ MME UET Lahore
|
February ‘23
REV RSE ENGINEERING
E
A Metallurgical Perspective
1
Reverse Engineering:
What? Why?
How?
Metallurgical Procedure
and Outputs
Contents
Case Studies
Limitations and Challenges
2
3
Shenyang J-16
Sukhoi Su-30
Chengdu J-10
US F-16
4
US X-29
Sukhoi Su-47
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J-31
F-35
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7
Reverse Engineering
The process of determining the
design concepts by disassembling a
similar or competitive product
with or without the intent of
reproducing it
Source: Materials Selection and Design, ASM Metals HandBook Vol. 20, ASM Intl’
8
Bottom Up vs. Top Down
Forward Engineering
Product
Assembly
Design
Concept
Material &
Processing
Reverse Engineering
9
Deciphering the Nature!
SONAR Concepts derived from
Bat’s Echo-location
10
Deciphering the Nature!
Super-hydrophobicity in Lotus Leaf
used in self-cleaning glasses
11
Why to Reverse Engineer?





Competitive benchmarking
The OEM no longer produces a product
Original design needs modifications
To update obsolete materials or
antiquated manufacturing processes
Military Advantage over the enemy
Stages of
Reverse Engineering
Things to Do
Before Dismantling
During Dismantling
After Dismantling
14
Things to Do
Before Dismantling
During Dismantling
After Dismantling
Collection of the Design Information Documents
 Visual Inspection / Photography / Radiography / CT
 Functional Analysis
 Dimensional Analysis, Modeling, CAD

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Radiography and Tomography
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Radiography and Tomography
Radiography and Tomography
Things to Do
Before Dismantling
During Dismantling
After Dismantling
Functional Analysis and Design requirements
 Assembly Drawings (Assign names to each part)
 Fits & Clearances, Lateral movement, Backlash etc.
 Video Log of events

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Video Log of Events
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Assembly Details
22
Things to Do
Before Dismantling
During Dismantling
After Dismantling
Photography
 Physical Properties
 Visual Analysis (Sampling Locations)
 Destructive Testing

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Steps for Reverse Engineering
Functional Analysis
Visual Examination /
RT / CT / Photography
Engineering Drawing
& Assembly Drawing
Physical Properties
Material Analysis
Metallography &
Microscopy
Mechanical Testing
Design Documents
and Literature Survey
24
The Metallurgical Outputs of
Reverse Engineering
25
The Metallurgical Outputs of
Reverse Engineering
Material Identity /
Grade
Heat Treatment
Condition
The Outputs
Surface Treatment
Manufacturing Route
26
The Metallurgical Outputs of
Reverse Engineering
Material Identity /
Grade
AISI 1045 / AA 2024 / C37100
etc.
Heat Treatment
Condition
The Outputs
Surface Treatment
Manufacturing Route
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Standard Alloy Designation
Systems
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Nearest Standard
Element
Observed wt.%
Si
0.3
≤ 1.0
C
0.40
0.15 min
Cr
13.0
12.0 – 14.0
Mn
0.3
≤ 1.0
S
0.01
≤ 0.03
Fe
Balance
Balance
AISI 420
Method of Measurement: OES and C/S Rapid Analyzer
29
The Metallurgical Outputs of
Reverse Engineering
Material Identity /
Grade
Heat Treatment
Condition
AISI-1045 / AA2024 / C37100
etc.
Quenched & Tempered /
Annealed etc.
The Outputs
Surface Treatment
Manufacturing Route
30
Assessment of Heat Treatment Condition
Material Analysis
Mechanical Testing
Metallography &
Microscopy
Design Documents
and Literature Survey
31
Determination of Heat Treatment
Steps of Reverse
Engineering
Condition
925 ˚C
AISI
420
Engineering Drawing
350 ± 7
HB
Visual Examination
550-600
T ˚C
Functional Analysis
Physical Properties
Time
Material Analysis
Metallography &
Microscopy
Mechanical Testing
Literature Survey
˚C
Determination of Heat Treatment
Condition
Material
Microstructure
Hardness
225 ± 6
HV
Manufacturing Route
Die
Forged
Heat Treatment Cycle
Temperature
AISI
1045
Ferrite & Pearlite
(Etched in Nital)
850 ˚C
Furnace
Cool
Time
ASM Hand Book Vol: IV
The Metallurgical Outputs of
Reverse Engineering
Material Identity /
Grade
Heat Treatment
Condition
AISI-1045 / AA2024 / C37100
etc.
Annealed / Quenched &
Tempered etc.
The Outputs
Surface Treatment
Carburizing / Nitriding /
Zn-Plating etc.
Manufacturing Route
34
Assessment of Surface
Treatment

Electroplating

PVD

CVD

Carburizing

Nitriding

Carbo-Nitriding

Anodizing

Bluing

Hardfacing
Material Analysis
Metallography &
Microscopy
Design Documents
and Literature Survey
Assessment of
Surface Treatment
Collar
A
1 mm
Collar
A’
Base
Base
Ferrite – Pearlite
Martensite
260 ± 2 Hv
740 ± 2 Hv
36
Assessment of
Surface Treatment
800
Core (base)
Surface (collar)
Micro-Hardness (HV)
700
600
500
400
300
Indents
200
100
98.56
98.76
98.96
99.16
99.36
Micro-Hardness
Profile
99.56
99.76
37
Assessment of
Surface Treatment
Carburized Layer over the Gear Surface
38
The Metallurgical Outputs of
Reverse Engineering
Material Identity /
Grade
Heat Treatment
Condition
AISI-1045 / AA2024 / C37100
etc.
Annealed / As-Quenched /
Tempered etc.
The Outputs
Surface Treatment
Manufacturing Route
Carburizing / Nitriding /
Zn-Plating etc.
Casting / Die-Forging /
Extrusion etc.
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Determination of Manufacturing Route
Casting
Die Forging
Extrusion /
Rolling
Hot Working
Cold Working
Powder Metallurgy
40
Determination of Manufacturing Route
Forging Gland
A
A’
A
A’
Flow lines indicating
metal working
Flow lines without
any welding seam
Indications of Closed Die Forged and Finish Machined Part
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Determination of Manufacturing Route
Die Forged
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Determination of Manufacturing Route
Metal-working
direction
Axial
Section
100 μm
Machined from Extruded Blank
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Determination of Manufacturing Route
X’
X
Cross-Section
Y
Y
Y’
Y’
Material flow lines and presence of forging gland indicating that the part has been die forged44
Determination of Manufacturing Route
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Brazing
Fusion
Welding
Inferring Method of Joining
• Dendrites
• HAZ
Friction
Welding
Diffusion
Bonding
• Wrought
Structure
• Intermixing
• Diffusion
46
WHAT IF
PROPER METHODOLOGY IS NOT USED
?
Mindless Mimicry!
OEM
OEM
Forged and finish
machined
Prototype
Prototype
Directly Machined
from blank
AA 2006
AA 2006
134 Hv
67 Hv
T6
O
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Mindless Mimicry!
Property
Chemical Composition
Hardness
Surface Coating
Number of effective coils
Spring Constant
Reference
Prototype
AISI 1070
540 Hv
Cd plated
6.5
0.51 N/mm
AISI 1070
535 Hv
Zn Plated
5.5
0.66 N/mm
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Mindless Mimicry!
Reference
Prototype
Property
Chemical Composition
Hardness
Microstructure
Rubber Material
Reference
Prototype
X39Cr13
AISI 431
570 Hv
438 Hv
Martensitic matrix with
carbides along the
deformation direction
Martensitic matrix with
carbides on grain
boundaries
Styrene-butadiene (SBR)
Nitrile-butadiene (NBR)
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Reference
Prototype
Axial
Direction
Grain Boundary
Precipitation of Carbides
(Temper Embrittlement
Range: 870 to 540 °C)
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THE LIMITATIONS &
CHALLENGES
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The Limitations & Challenges
 The details of intermediate processes may destroy
 Part size
 Used component
 Micro-alloying
 Tolerances in size
 Sampling errors
 Mis-interpretations
53
Key Points Discussed

Reversing Engineering is “deciphering”

Metallurgically, its about

Finding the material

Its processing and heat treatments

Manufacturing route and joining techniques

Surface Treatments
54
Above and beyond every possessor of knowledge,
there is Aleem (The All Knowing)
– Al Qur'an 12:76
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Thank You
Technical Seminar @ MME UET Lahore
|
February ‘23
56