MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION GRADUATION THESIS AUTOMOTIVE ENGINEERING TECHNOLOGY APPLIED REVERSE DESIGN ENGINEERING IN AUTOMOTIVE MECHANICAL ASSEMBLIES'SIMULATION LECTURER: MSc. NGUYEN THIEN DINH STUDENT: LAM THIEN DUC NGUYEN TAI LOC SKL 010319 Ho Chi Minh City, December 2022 HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION THESIS APPLIED REVERSE DESIGN ENGINEERING IN AUTOMOTIVE MECHANICAL ASSEMBLIES’ SIMULATION Student: NGUYEN TAI LOC Student ID: 18145039 Student: LAM THIEN DUC Student ID: 18145013 Major: AUTOMOTIVE ENGINEERING Advisor: NGUYEN THIEN DINH, MSc. Ho Chi Minh City, December 2022 HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION THESIS APPLIED REVERSE DESIGN ENGINEERING IN AUTOMOTIVE MECHANICAL ASSEMBLIES’ SIMULATION Student: NGUYEN TAI LOC Student ID: 18145039 Student: LAM THIEN DUC Student ID: 18145013 Major: AUTOMOTIVE ENGINEERING Advisor: NGUYEN THIEN DINH, MSc. Ho Chi Minh City, December 2022 THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -------- Ho Chi Minh City, December 24, 2022 GRADUATION PROJECT ASSIGNMENT Student name: Lam Thien Duc Student ID: 18145013 Student name: Nguyen Tai Loc Student ID: 18145039 Major: Automotive Engineering Technology Class: 18145CLA1 Advisor: Nguyen Thien Dinh, MSc.
Phone number: 0353 040 909 Date of assignment: September 7th, 2022 Date of submission: December 24th, 2022 1. Project title: Applied reverse design engineering in automotive mechanical assemblies’ simulation 2. Initial materials provided by the advisor: ___________________________________ 3. Content of the project: _________________________________________________ 4.
Final product: - 01 Graduation Thesis. - Upload the materials, thesis, Powerpoint on Google Drive. CHAIR OF THE PROGRAM ADVISOR (Sign with full name) (Sign with full name) THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -------- Ho Chi Minh City, Demcember 24, 2022 ADVISOR’S EVALUATION SHEET Student name: Lam Thien Duc Student ID: 18145013 Student name: Nguyen Tai Loc Student ID: 18145039 Major: Automotive Engineering Technology Project title: Applied reverse design engineering in automotive mechanical assemblies’ simulation Advisor: Nguyen Thien Dinh, MSc. Content of the project:.
Approval for oral defense? (Approved or denied). Mark:……………… (In words: .) Ho Chi Minh City, month day, year ADVISOR (Sign with full name) THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -------- Ho Chi Minh City, December 24, 2022 PRE-DEFENSE EVALUATION SHEET Student name: Lam Thien Duc Student ID: 18145013 Student name: Nguyen Tai Loc Student ID: 18145039 Major: Automotive Engineering Technology Project title: Applied reverse design engineering in automotive mechanical assemblies’ simulation Name of Reviewer:. Content and workload of the project. Approval for oral defense? (Approved or denied) .) Ho Chi Minh City, month day, year REVIEWER (Sign with full name) THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -------- EVALUATION SHEET OF DEFENSE COMMITTEE MEMBER Student name: Lam Thien Duc Student ID: 18145013 Student name: Nguyen Tai Loc Student ID: 18145039 Major: Automotive Engineering Technology Project title: Applied reverse design engineering in automotive mechanical assemblies’ simulation Name of Defense Committee Member:.
Content and workload of the project .) Ho Chi Minh City, month day, year COMMITTEE MEMBER (Sign with full name) Faculty for High Quality Training – HCMC University of Technology and Education DISCLAIMER The authors, Lam Thien Duc, and Nguyen Tai Loc confirm that the work presented in this thesis is my own. All the data and statistics in the thesis are reliable and are not published in any previous studies or research. Where information has been derived from other sources, I confirm that this has been indicated in the thesis. i Faculty for High Quality Training – HCMC University of Technology and Education ACKNOWLEDGEMENTS Throughout our studies and graduation process, my team was always cared for, guided, and assisted by our family, teachers from the Faculty of High-Quality Training, as well as the support and assistance from friends and colleagues.
First and foremost, we want to thank our parents for their unwavering support during our tenure at the university. I would like to express my heartfelt appreciation to the instructor, MSc. Nguyen Thien Dinh for personally assisting and leading us in completing this study. Besides, we would love sending PhD.
Nguyen Van Long Giang a huge appreciation for supporting us in using laboratory facilities. We would like to thank the Board of Directors of Ho Chi Minh University of Technology and Education, as well as the Deans of the Faculty of High-Quality Training for their assistance and guidance during our studies. We learned a lot of new stuff that will support us in our future jobs as in our graduation thesis. At the bottom of heart, in the best respectful memories, we would love to give this work as gratitude to MSc.
Le Khanh Tan, the respectful teacher who inspired us a strong passion for our study path, and this graduation thesis is our last milestone of us before graduation. Because of the team’s limited experience, this study will have errors when practicing and finishing the graduation thesis. We are looking forward to hearing feedback and advice from professors to help us complete our report. I would also like to thank my friends, and colleagues for their assistance and encouragement in helping us finish this graduation thesis.
Thank you very much! Ho Chi Minh City, December 24th, 2022 ii Faculty for High Quality Training – HCMC University of Technology and Education ABSTRACT Reverse Engineering becomes more and more popular in the manufacturing industry, especially in the automotive area. The topic “APPLIED REVERSE DESIGN ENGINEERING IN AUTOMOTIVE MECHANICAL ASSEMBLIES’ SIMULATION” is under researched in order to build an overall process of reverse design, including scan and re-design an assembly using in a diesel vehicle. The process of the reverse design is highly focused in this research. Besides, the products and data after collected will be organized to a CAD library, which is using in university training purpose.
By using Scanner Gom Inspect Impact 5m, ATOS Professional software, Geomagic Design X software, and Solidworks software, we scanned, re-designed, assemble simulated a high-pressure PF pump assembly. Keywords: reverse design, automotive, PF pump, Geomagic Design X, Solidworks, scanner, scan iii Faculty for High Quality Training – HCMC University of Technology and Education LIST OF ACRONYMS AND SYMBOLS + CAPP (Computer-Aided Process Planning): Computer supports the planning process. + CAD (Computer Aided Design): computer-aided design. + CAE (Computer Aided Engineering): Engineering with computer support.
+ CAM (Computer Aided Manufacturing): Computer-aided manufacturing. + CFD (Computational Fluid Dynamics): Simulation of fluid dynamics. + CCD (Charge Coupled Device): CCD sensor. + CMM (Coordinate Measuring Machine): CMM coordinate measuring machine.
+ CNC (Computer Numerical Control): Lathe machine controlled by computer. + CT/MRI (Die Computertomographie/ Magnetic Resonance Imaging): Computed tomography/ Resonance Imaging. + DCC (Direct Computer Control): Direct computer control + FEA (Finite Element Analysis): Finite Element Analysis. + FDM (Fused Deposition Modeling): Made by molten profile.
+ GD&T (Geometric Dimensioning and Tolerance): Geometric dimensions and tolerances. + IGES (Initial Graphics Exchange Specification): The original graphics exchange specification. + LOM (Laminated Object Manufacture): Production of multi-layer objects. + LED (Light Emitting Diode): Light Emitting Diode + RE (Reverse Engineering): Design technology + RFID (Radio Frequency Identification): Identification via radio frequencies.
+ STL (Standard Triangle Language or Stereolithography): File format. + SGC (Solid Ground Curing): Solid surface curing. iv Faculty for High Quality Training – HCMC University of Technology and Education TABLE OF CONTENT Introduction. Reason for choosing topic.
Topic research purpose and goals. Topic research purpose .2 Topic research goals. Scope of the study. Structure of the thesis .1 Foreign scientific studies on reverse engineering methods.1 Reverse Engineering in Modeling of Aircraft Propeller Blade - First Step to Product Optimization.2 Reverse Engineering and Topology Optimization for Weight Reduction of a Bell-Crank.3 Reverse Engineering of Automotive Parts Applying Laser Scanning and Structured Light Techniques.4 Reverse Engineering in Mechanical Component.2 Domestic scientific research articles on reverse engineering methods.1 Reverse engineering and 3D printing technology in supporting craniofacial surgery.2 Reverse engineering for re-export of worn-out machine parts based on 3D scan data.3 Development of reverse engineering process of metal parts in the Aviation industry.9 Chapter 2: Basis of R&D theory .1 Overview of reverse engineering technology .1 Introduction to reverse engineering technology .12 v Faculty for High Quality Training – HCMC University of Technology and Education 2.3 Advantages and disadvantages of reverse engineering technology.2 Reverse engineering process.1 First reverse engineering process .2 Second reverse engineering process .3 Third reverse engineering process.4 Reverse design process.1 Exposure measurement method .2 Contactless measurement method .4 Common types of 3D scanners .5 Application of reverse engineering technology.6 Software that supports reverse engineering .1 Geomagic Design X software.4 Software that supports reverse engineering .31 Chapter 3: Object scanning .1 Set up scanning device.2 Interaction with the software .35 Chapter 4: Reverse design.
Import raw file (with extension. Divide the region for the model .3 Set up new alignment, new coordination for the model. Compare two methods. Reverse design based on the mesh model .5 Result after reverse design process .4 Bottom spring seat: .5 Upper spring seat .72 vi Faculty for High Quality Training – HCMC University of Technology and Education 4.10 Delivery valve housing .11 Delivery Valve Piston .12 Delivery Valve Spring .81 Chapter 5: Assembly and simulation .1 Modify parts on Solidworks .3 The pump assemblies .92 vii Faculty for High Quality Training – HCMC University of Technology and Education TABLE OF FIGURE Figure 2.
Overview of reverse engineering. Second reverse engineering. Atos Gom Inspect scanner. Atos Gom inspect compact 5M.
Reverse engineering in Art. Reverse engineering in automotive engineering. Reverse engineering in archaeology. Reverse engineering in medicine.
ATOS start screen. Set up sensor. Set up sensor. Adjust right camera aperture.
Object scanning view. Object scanning view. Change scanning angle .46 viii Faculty for High Quality Training – HCMC University of Technology and Education Figure 3. Remove unnecessary details.
Mesh Build up. Overview the object. Level of “Sensitivity”. Extruding lines for new planes.
Result with three planes. Checking observation direction. Remove old plane. Build a solid model.
Comparing section geometry. Tools to build model. Tools to build model .66 ix Faculty for High Quality Training – HCMC University of Technology and Education Figure 4. Housing's isometric view.
Housing's Front view. Housing's Right view. Housing's Top view. Housing's Section view.
Cam head Isometric view. Cam head Front view. Cam head Top view. Return Spring Isometric view.
Return Spring Front view. Return Spring Right view. Return Spring Top view. Bottom Spring Seat Isometric view.
Bottom Spring Seat Front view. Bottom Spring Seat Right view. Bottom Spring Seat Top view. Upper Spring Seat Isometric view.
Upper Spring Seat Front view. Upper Spring Seat Top view. Helix Plunger Isometric view. Helix Plunger Front view.
Helix Plunger Right view. Helix Plunger Top view. Control Sleeve Isometric view. Control Sleeve Front view.
Control Sleeve Right view. Control Sleeve Top view. Control Rack Isometric view. Control Rack Front view.
Control Rack Right view. Control Rack Top view. Cylinder Isometric view. Cylinder Front view.
Cylinder Right view. Cylinder Top view. Delivery Valve Housing Isometric view. Delivery Valve Housing Front view.
Delivery Valve Housing Top view. Delivery Valve Piston Isometric view .80 x Faculty for High Quality Training – HCMC University of Technology and Education Figure 4. Delivery Valve Piston Front view. Delivery Valve Piston Top view.
Delivery Valve Spring Isometric view. Delivery Valve Spring Front view. Outlet Port Isometric view. Outlet Port Front view.
Outlet Port top view. Compare between two gear teeth before modified (right) and after modified (left). The flexibility of Return Spring. The Control Rack's geometry before modifying.
The Control Rack's geometry after modifying. The "Rack and pinion" mate .