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Sunday, November 20, 2011

Reverse Modeling Versus Reverse Engineering: Comparison and Contrast

In engineering, reverse engineering and reverse modeling are often interchangeable, but contrary to popular belief, they are not the same. The former is based on the process of interpreting an existing system to analyze components and their inter-connectivity to each other. Using a different form with a higher level of abstraction, this process is used for the redesigning of the system to better maintain or produce a copy of a system without having to access the original design. In other words, reverse engineering does not rely solely on modeling, but includes fit, form and function. The latter, on the other hand, is simple: it creates a 3D CAD model in reverse, meaning from an existing component, the process has to recreate the existing geometry alone.
The purpose of reverse engineering is to reproduce a part or an object to make a new one that functions the same way, but not too similar, in order to avoid trademark issues. The process has been used by different countries to further understand, or possibly replicate, technologies from other countries. Companies use it today to attain better knowledge of the products their competition uses to get the upper hand in the business. In the software industry, reverse engineering involves the reproduction and recompilation of the instructions in a program to produce one that, while similar to the previous one in terms of behavior, will ultimately result in a similar output as the original one.
With the advancements of technology today, the most basic way to capture a model that already exists is through scanning. Using contact or non-contact 3D scanning methods like CMM, white light scanners, laser scanners or CT/MRI, may result in some parts being destroyed by cutting thin sections to capture different sections and mapping these into a 3D model.
Before technology, the traditional way of doing Reverse Modeling involved the use of calipers, rulers, and CMM to measure points and dimensions on an area. It will then manually create a line or curve using a software (e.g. Pro/E, Solidworks, Autocad), to produce a model in 2D, 3D, or in working drawings. While CMM produces accurate results, the speed of the process and the density of the gathered points prove to be two of the main disadvantages. In addition, caliper measurements also tend to be subjective, and the CMM can cause issues with soft materials (e.g. clay). Most of the software used today that reads in-point cloud data requires a dense point cloud to create an accurate geometry.
With modern technology, the above mentioned process includes the following: scanning of the object, overlaying the curves above the data, and then using these curves to create cad operations on scan data. This can usually be done through most applications, including Rapidform, Geomagic, Solidworks, and others.
Digital parts libraries are now possible because of technology. It is considered an advantage as it has become a cost-effective solution to reproduce the existing designs into a useable CAD or mesh model. Reverse Modeling, ultimately, will create more accurate models to benefit the entire engineering industry.
Reverse modeling is the process of recreating a system using the existing geometry by itself. The process begins with the laser scanning of the subject.