10210ME101 - DESIGN THINKING

UNIT V

REVERSE ENGINEERING

Introduction - Reverse Engineering Leads to New understanding about Products - Reasons

for Reverse Engineering - Reverse Engineering Process - Step by Step - Case Study

INTRODUCTION

➢ Engineering is the profession involved in designing, manufacturing, and maintaining

products, systems, and structures. The whole engineering process can be broadly
classified in two groups; forward engineering and reverse engineering.
➢ Forward engineering is the traditional process of moving from high-level abstractions
and logical designs to the physical implementation of a system.

Forward Engineering

➢ The process of duplicating an existing component, subassembly, or product, without the

aid of drawings, documentation, or computer model is known as reverse engineering.

Reverse Engineering

➢ An important reason for application of reverse engineering is reduction of product

development time. In the intensely competitive global market, manufacturers are
constantly seeking new ways to shorten lead-time, to market a new product.
➢ Alexander Graham Bell’s invention of the telephone, which evolved through innovation
to become the modern cell phone.
 ➢ Product Innovation is a process of improving or modifying an existing product.
➢ Designers apply reverse engineering when they disassemble a product to learn more
about how it works and how it was made.
➢ Reverse Engineering allows the development of everyday items such as laptops,
computers, etc.
➢ Example: Other companies soon replicate a new, thin cell phone, made possibly by
newly designed internal parts and the arrangement of those parts. How do you think the
competitor learned to make a similar ultrathin cell phone? Many companies apply a
reverse engineering process to closely examine and analyze a product’s external and
internal features.
➢ The knowledge gain from this process often leads to new or improved product design.
➢ Define Reverse Engineering: A strategy used to find answers to questions about an
existing product that are later used in the design of another product.

REVERSE ENGINEERING LEADS TO NEW UNDERSTANDING ABOUT PRODUCTS

➢ What attracts us to a new product? Product function, ease of use, dependability,

appearance, and cost are all concerns of design teams when designing new products.
➢ Well-designed products are valued by customers, and are profitable to the manufacturers
who make them.
➢ Research is an important step in design process.
➢ AGRAPHIC DESIGNERwants to design a new greeting card, may go to a card store to
look at existing cards.
➢ A CIVIL ENGINEER assigned to design a new bridge may request drawings from a
previously built bridge.
➢ An ELECTRONICS ENGINEER designing a new cellular device circuit may
disassemble the circuit of an existing device.
➢ A MECHANICAL ENGINEER prepares to design a new mechanical device, will most
likely use reverse engineering to discover how a similar product functions or was
produced.
➢ Understanding how a product functions through reverse engineering is one reason to
research competitor’s product.
➢ To be competitive in the market place, companies will research the demographics,
perspectives, and preferences of potential customers.
➢ The process of reverse engineering is usually applied to consumer products, and involves
taking the object apart to discover the internal components and their operation.
➢ Unlike a traditional engineering design process that begins with a problem and works
toward a solution, reverse engineering begins with an end product, system, or process and
works toward understanding, documentation, and possibly a new idea.
➢ Reverse engineering is used to analyze a products function, mechanical features,
structural integrity, materials, and to understand the manufacturing processes used.
➢ This analysis can lead to design changes that strengthen or enhance the products features
or performance.
➢ Reverse Engineering decreases Product [Link] in the die and mold
industries have traditionally used reverse engineering to replace worn or broken parts on
old equipment. This gives new life to a product or machine that is no longer in
production.
➢ Without reverse engineering to develop replacement parts, many machines would be
scrapped.
➢ Reverse engineering is also used to improve manufacturing efficiency.
➢ When drawings for old products are no longer available, or when the existing drawings
are inaccurate, companies disassemble products to create valuable documentation and
electronic data.
➢ Designers use manual precision measurement tools, coordinate measuring machines
(CMM), and 2-D laser Scanners to collect geometry for input into Computer-Aided
Design (CAD) programs.
➢ CAD programs are then used to generate solid models and new product drawings.
➢ Solid models developed with CAD may undergo Finite Element Analysis (FEA) such as
stress analysis and mass properties calculations.
➢ Finite Element Analysis(FEA):A computerized numerical analysis technique used to
solve mechanical engineering problems, such as stress, strain and thermal distribution in
parts.
 ➢ CAD data can then be converted to Computer Numerical Control(CNC) code and sent
electronically to prototyping machines to create detailed molds for the manufacture of
parts.
➢ These precise, integrated production practices, generally referred to as Computer Aided
Manufacturing (CAM), generally reduce the amount of product waste.
➢ REVERSE ENGINEERING AND PATENTS: Patent law and professional codes of
ethics were designed to help protect inventions; however, there are no guarantees that
designs will not be copied. If a company holds a patent, which they believe competitors
has violated, it is their responsibility to sue the competitors for patent infringement.

REASONS FOR REVERSE ENGINEERING

Reverse engineering process starts when a design team or management team identifies a need or
concern that could be addressed through reverse engineering inquiry. Typically, designers use
reverse engineering for one or more of the following reasons

➢ The original manufacturer of a product no longer produces a product.

➢ If there is an inadequate documentation of the original design.
➢ The original manufacturer no longer exists, but the customer needs the product.
➢ The original design document has been lost or never existed.
➢ Some bad features of a product need to be designed out.
➢ To strengthen the good features of a product based on long-term usage of the product.
➢ To analyze the good and bad features of competitors product.
➢ To explore new avenues to improve product performance and features.
➢ The original CAD model is not sufficient to support modifications or current
manufacturing methods.
➢ To update obsolete materials or antiquated manufacturing processes with more current,
less-expensive technologies.
➢ To research similar products in an effort to discover possible ways to make a more
competitive product.
➢ To test a product or design to determine what is causing a failure.
➢ As part of a company’s continuous product improvement policy.
 ➢ To provide documentation for product components when original drawings are no longer
available or accurate.
➢ To educate design professionals on the topics of function, structure, manufacturing, and
aesthetics.
➢ For equipment repair, through the design of replacement parts, for products no longer in
production.
➢ To develop CAD and CNC electronic data for computer-enhanced manufacturing
process.

REVERSE ENGINEERING PROCESS - STEP BY STEP

STEP I: Identify the purpose

➢ When you are ready to reverse engineer a product, begin by recording your purpose in
your engineer’s notebook.
➢ What do you want to learn about the product?
 ➢ Think about questions to ask, areas of research, people to contact, and tests to be
completed.
➢ It is important that you keep accurate and detailed documentation throughout the entire
reverse engineering process.
➢ Your engineer’s notebook will provide evidence of your process, thoughts, and findings.
➢ ENGINEER’S NOTEBOOK:
• Also referred as an engineer’s logbook, a design note book.
• Used as a record of design ideas generated in the course of engineer’s
employment, so that others may not claim the idea as their own.
• An archival record of new ideas, product modifications, and engineering
research achievements.

STEP II: Develop a Hypothesis

➢ Reverse engineering is most appropriately used to determine how something functions

and how the components work together to achieve that function.
➢ A hypothesis is a statement that suggests a possible, unproven answer to a question.
➢ Scientists often develop hypotheses (Predictions or unproven ideas) that require thorough
research and evaluation.

STEP III: Disassembly

➢ Once you have documented the purpose of inquiry and hypothesis, you may carefully
disassemble the product to uncover the internal components and [Link]
process is often called as teardown.
➢ TEARDOWN: The process of product disassembly to expose individual parts for
analysis and enhanced understanding.
➢ When someone enters a material laboratory, he/she must wear safety gear.
➢ Safety is taken very seriously in business, industry, and education.
➢ General safety rules include wearing safety glasses, ear protection, and proper protective
clothing.
➢ It is common practice to remove all jewelry.
 ➢ If dust or other environmental contaminants are present, respiratory protection is
required.
➢ Common disassembly tools include:
• Screwdriver set
• Allen wrench set
• Needle nose and regular pliers
• Spring compressor
• Drill and index
• Utility knife and cutting mat
• Small hand saw
• Strip heater or heat gun
➢ The disassembly process is a very delicate process; you should do it slowly and with
great care.
➢ It is very important to take careful notes on the internal parts found within the product.
➢ Designers often use digital photographs to record information at several stages of
disassembly and place them in their engineer’s notebooks.
➢ Thoughtful, deliberate analysis and documentation must occur during all stages of
disassembly.

STEP IV: Analyze the Elements

• Analysis is the most crucial part of the reverse engineering process. During the
analysis step, engineers attempt to answer all of the questions originally posed.
There are four main categories of product analysis.
1. Functional
2. Structural
3. Material
4. Manufacturing
• Analysis requires detailed research of each category.
• Research results are recorded in the Engineers note book along with sketches and
digital photos to provide clarity for detailed information.
 • During analysis, some products may require partial reassembly to observe the
interaction of functional components.
1. Functional Analysis
➢ Functional analysis involves answering questions about how a mechanical system or how
an electronic circuit works.
➢ Simply put, how does a product work?
➢ Nearly all mechanical systems contain at least one of the following elements:
• Lever or Crank
• Wheel or Gears
• Cam
• Screw
• Object that transmits tension or compression, such as pulley, belt, chain, spring.
➢ During analysis, an engineer will take measurements or perform tests on products
components.
➢ Micrometers and calipers are widely used to take precise measurements of material
thickness, internal and external diameters of shafts.
➢ Modern measurement instruments include the dial caliper and digital caliper.
➢ Tools used to obtain measurement:
• Micrometers
• Calipers
• Radius gauge
• Protractor
• Digital Scales
• 3-D Scanner
2. STRUCTURAL ANALYSIS
➢ First step in structural analysis is to determine the purpose of each part and how it
interacts with the other parts.
➢ All structures must support internal and external loads, and must hold parts in place.
➢ The way product is constructed must provide:
• Support of internal parts
• Housing
 • Container
• Protection
• Transportability
➢ Structural analysis involves principles of mechanics and material properties.
➢ Finite Element analysis (FEA) software can be used to learn more about the
structural qualities of the product being reverse engineered.
3. MATERIAL ANALYSIS
➢ The choice of material greatly affects a parts performance, and the materials properties
must be correctly matched to the parts application.
➢ Materials are usually identified by type, such as wood, metal, plastic, ceramic, or
composite.
➢ Designers need to understand material properties and how these properties contribute to
performance and durability.
➢ Analyzing materials requires understanding basic material properties. These properties
include:
• Mechanical
• Electrical
• Thermal
• Chemical
• Optical
• Acoustical
➢ Material properties are measured in various units. Example: Young’s modulus is a
mechanical property that describes dimensional change in material as it is subjected to an
applied load (pressure or weight).
➢ Systems which are helpful in testing material properties are:
• Digital force scale
• Thermometer
• Strip heater, heat gun
• Stop watch or timer
• Magnets
• Durometer hardness gauge
 ➢ When engineers analyze a product, they add careful notes in the engineer’s notebook
about the material characteristics of each part.
➢ As engineers examine the parts, they also look for signs of wear or other indicators of
potential failure.
4. MANUFACTURING ANALYSIS
➢ Manufacturing is a broad term used to describe the application of tools and
processes to the transformation of raw materials into finished goods.
➢ Designers always consider manufacturing processes during the design process.
➢ Manufacturing engineers are either part of the design team, or act as consultants
during the design process.
➢ The reverse engineering process determines how the product was manufactured.
➢ Materials are manipulated by three different methods-forming, material
removal,and joining
• Forming- Methods use heat and/ or pressure to reshape a material into a
desired form.
• Material Removal - Methods carve a desired form from an existing block
of material.
• Joining- Methods combine two or more objects together.

Common Industrial Processes

MATERIAL REMOVAL
FORMING PROCESSES JOINING PROCESSES
PROCESSES
• Casting • Drilling • Welding
• Molding • Milling • Brazing
• Forging • Turning • Soldering
• Rolling • Shaping • Sintering
• Pressing • Planning • Fastening
• Bending • Broaching • Adhesive bonding
STEP V: Prepare the Report

➢ In the report stage of the reverse engineering process, you will present your findings.
➢ Communicating the results of your reverse engineering process in a clear and concise
way require careful consideration and planning.
➢ Design team often uses a PowerPoint program to support their presentation.
➢ Sometimes teams use a poster session to graphically present information on a series of
poster panels.
➢ Other support documentation might include charts, graphs, photographs, video, or
combination of these.

STEP VI: Product Redesign

➢ Depending on the initial purpose behind the reverse engineering and the outcome of the
process, redesign may occur.
➢ If continuous improvement or part failure initiated the process, then the data you have
gathered will lead to brainstorming of ideas for redesign.
➢ The redesign may be as simple as correcting a weakness by changing the size or part or
material. However, it may be as complex as redesigning into a completely different
product.
➢ Many times a quality product inspires or leads to other developments by other companies.
You will see similar items on store shelves.

➢ EXAMPLE: Cell phone covers. They are designed to fit a product made by another
manufacturer and there are many styles and materials available.
IMPORTANT TERMS USED IN REVERSE ENGINEERING

CAD - Computer Aided Design

CAM - Computer Aided Manufacturing

CAE – Computer Aided Engineering

FEA - Finite Element Analysis

CNC – Computer Numerical Control

CMM – Coordinate Measuring Machine

CASE STUDY FOR REVERSE ENGINEERING (Do and study by Own)

1. Video game Player

2. Mobile Phones

3. Laptops

4. Watches

5. Hybrid Vehicle Engines

Prepared by DIVYA SADHANA.A

Asst. Prof /Mech Engg.