1. Unclassified U.S. ARMY TANK AUTOMOTIVE RESEARCH, DEVELOPMENT AND ENGINEERING CENTER Reverse Engineering Re-defined Requirements TARDEC 25 AUG 2015 1 Presented by: Kim Hanke TARDEC SIE CSI/EST Distribution A approved for Public Release; distribution Unlimited, per AR 380-5. OPSEC Review conducted per AR 530-1 OPSEC#27140

2. Unclassified 2 What is R/E…….. Questions to Ask –What does the Customer really need? –How do I select the provider of services Assumptions –Identify and share your assumptions with the R/E Team Types of Reverse Engineering –The Current OEM is out of Business or No Longer supplies this part –We have parts and no drawings (supplied as Urgent Need) –We have drawings but no 3D CAD Data to use as reference –We need the entire Vehicle for future integration efforts Cautions –How to interpret the data I have received Validation –How do I check the R/E items –Training Agenda

3. Unclassified 3 What is Reverse Engineering Merriam-Webster :to study the parts of (something) to see how it was made and how it works so that you can make something that is like it Reverse Engineering

4. Unclassified 4 Decision of Support: TARDEC / CSI PLDM / Industry Depot Reverse Engineering Steps to Success

5. Unclassified 5 What does the Customer really need or want? What is the information going to be used for? Reference to create something new? Reference to integrate something new? To make new parts? To evaluate current systems through Modeling & Simulation, Virtual Testing To solicit a new supplier for a current part? To solicit a new supplier for a obsolete part? To solicit suppliers for competition? The Government owns the drawings but not the 3D data for evaluation, integration or manufacturing. What is available to start with? What level of detail is needed? From the questions above decisions can be made to identify Levels vary from basic 3D point cloud data to a complete 3D parametric model, with individual parametric components, containing weld information, wire routing, material type and evaluation of manufactured process and more Discussions between customer and our experienced team will help determine which level is necessary to achieve goal Questions to Ask

6. Unclassified 6 The Customer and Team need to understand the types of Reverse Engineering and what is gained from each type. Types of Reverse Engineering 3D Visual Model 3D Point Cloud Model completed for viewing Basic CAD Model Material, weight, and part information defined. CAD model has volume, but limited modification ability. (Known as a “dumb solid”) Parametric CAD Model CAD model completely modifiable – change size, shape, thickness, add or remove holes, cut sections, calculate mass. Kinematic Model Develop kinematic model Data & Information for “Blast Simulation and Analysis” Data and Information for “Technical Data Package creation” Types of Reverse Engineering

7. Unclassified 7 Reverse Engineering Decision Tree

8. Unclassified 8 How to how to interpret the data I have created or received. Use the process flow to review the data received with an experienced designer and the collector of the data. Ensure that what you needed is what you have received Ensure that what you have received can be used for what you need. You may to need to review with: Modeling & Simulation Team Manufacturing Contracting Cautions

9. Unclassified 9 Validate and Verify what you have received is what you needed and is accurate. Comparison and Test Conduct the scan process in reverse Created data to object used Test the build process if parts are going to be made Reliefs in part, spring back for parts, mold flow for plastic for example The Reverse Engineering effort is only the start what the effort will be used for will need to tested and verified then refined. Results Refinement to the validation or test results is an opportunity for process improvement Comparison studies and result differences are an opportunity for additional training. Validation

10. Unclassified 10 Disassembly, Storage, and Reassembly In order to ensure complete, accurate scan data, all significant surfaces of a part must be scanned Therefore, disassembly may be required Amount of disassembly to be determined by customer’s project requirements Vehicle can be completely disassembled, down to bare chassis, if necessary Part storage system, including space allocation, will be tailored per project requirements, then implemented and utilized throughout duration of project. All data will be backed up and stored on an external hard drive At the conclusion of project, vehicle will be reassembled back to original “as received” condition Process Overview Step 1

11. Unclassified 11 3D Point Cloud Model First step in reverse engineering Scan to gather geometric data and produce three dimensional point cloud model Useful for visual aid – basically, a three dimensional picture Cannot be modified, separated or analyzed Point cloud data can be used as a CAD model assembly template for assembling multiple components – from a small assembly up to a complete vehicle, interior and exterior Process Overview Step 2

12. Unclassified 12 3D Surface Model Data post processed and saved into customer specified CAD software (Pro E, Creo, Solidworks, etc.) CAD parameters added to CAD model per customer requirements Part information available – material, weight, part number, etc. (metadata) Also known as “dumb solid” – limited modification ability 3D Parametric Model Features of each part model rebuilt from surface data to form a solid, parametric model Part completely modifiable, enabling the ability to change size, shape, and thickness, add or remove holes, etc., quickly and easily CAD model data verified to physical part to ensure accuracy Ability to cut sections, create subassemblies, and calculate mass Process Overview Step 3 & 4

13. Unclassified 13 Assembled Cad Model Part models inserted into Vehicle Model with proper location and orientation Allows the ability to make virtual vehicle modifications: add/remove parts, interchange sub systems, upgrade armor Electrical wire harness routing or space claim can be added Ability to repurpose vehicle for new and evolving mission package needs Process Overview Step 5

14. Unclassified 14 Additional Benefits Fully processed, parametric data provides the ability to perform additional follow-on activities: FEA: Surfaces can be meshed to perform FEA calculations for finding component displacements, strains, and stresses under internal and external loads Blast simulation analysis: Welds can be located and identified, using X-ray equipment, if necessary. The welds can then be added to the CAD model indicated by callouts and annotations Kinematics can be applied to various components for motion analysis, interference checking, & troubleshooting Technical Data Package can be created from this level of data. TDP can include such items as engineering drawings, product information, process specifications, quality assurance, technical manuals, and more. Additional Benefits (Step 6)