3D CAD model reconstruction and fast prototyping of rotational parts: a reverse engineering approach

Purpose This paper aims to present a reverse engineering (RE) approach for three-dimensional (3D) model reconstruction and fast prototyping (FP) of broken chess pieces. Design/methodology/approach A case study involving a broken chess piece was selected to demonstrate the effectiveness of the proposed unconventional RE approach. Initially, a laser 3D scanner was used to acquire a (non-uniform rational B-spline) surface model of the object, which was then processed to develop a parametric computer aided design (CAD) model combined with geometric design and tolerancing (GD&T) technique for evaluation and then for FP of the part using a computer numerical controlled (CNC) machine. Findings The effectiveness of the proposed approach for reconstruction and FP of rotational parts was ascertained through a sample part. The study demonstrates non-contact data acquisition technologies such as 3D laser scanners together with RE systems can support to capture the entire part geometry that was broken/worn and developed quickly through the application of computer aided manufacturing principles and a CNC machine. The results indicate that design communication, customer involvement and FP can be efficiently accomplished by means of an integrated RE workflow combined with rapid product development tools and techniques. Originality/value This research established a RE approach for the acquisition of broken/worn part data and the development of parametric CAD models. Then, the developed 3D CAD model was inspected for accuracy by means of the GD&T approach and rapidly developed using a CNC machine. Further, the proposed RE led FP approach can provide solutions to similar industrial situations wherein agility in the product design and development process is necessary to produce physical samples and functional replacement parts for aging systems in a short turnaround time.

IPPS_R : a generative process planning system for rotational parts

An automated machining process planning system for rotational parts is designed, developed and implemented. The system is called IPPS_R for Intelligent Process Planning System for Rotational parts. The IPPS_R system is designed for generating process plans for manufacturing rotational parts using metal cutting operations. A generative approach is employed to determine process operations and sequences automatically. For each machining feature, based on the accuracy and surface quality requirements, a fuzzy logic approach is developed to generate machining operations. A method of ranking the machining priorities of the features according to the feature relationship matrix is developed for sequencing operations. Moreover, the heuristic search of process plans is achieved by minimizing the number of setups in a plan. Finally, the IPPS_R system with a user-friendly interface is implemented in Microsoft Visual C++ on a personal computer, utilizing Microsoft Foundation Class (MFC). Two sample parts are used to demonstrate applications of the IPPS_R system.

IPPS_R : a generative process planning system for rotational parts

An automated machining process planning system for rotational parts is designed, developed and implemented. The system is called IPPS_R for Intelligent Process Planning System for Rotational parts. The IPPS_R system is designed for generating process plans for manufacturing rotational parts using metal cutting operations. A generative approach is employed to determine process operations and sequences automatically. For each machining feature, based on the accuracy and surface quality requirements, a fuzzy logic approach is developed to generate machining operations. A method of ranking the machining priorities of the features according to the feature relationship matrix is developed for sequencing operations. Moreover, the heuristic search of process plans is achieved by minimizing the number of setups in a plan. Finally, the IPPS_R system with a user-friendly interface is implemented in Microsoft Visual C++ on a personal computer, utilizing Microsoft Foundation Class (MFC). Two sample parts are used to demonstrate applications of the IPPS_R system.

RECOGNITION OF PROPELLER-DRIVEN AIRCRAFT IN A PASSIVE BISTATIC RADAR

Nowadays passive bistatic radars (PBR) allow for detection, determination of coordinates and tracking of moving objects. In order to enable PBR integration into air traffic control systems, it is necessary to solve the problem of recognizing airborne objects, in particular, propeller-driven aircraft (AC). This will increase the degree of aviation safety. To solve the recognition problem, the analysis of propeller-driven aircraft echo signals, such as helicopter and propeller airplane, is performed. The in-formative features that can be used for recognition of propeller-driven aircraft in PBRs are defined. The method for propeller-driven aircraft recognition is proposed, that is based on extraction of modulation components originated from the rotational parts of the aircraft and estimation of their rotation parameters. The algorithm for echo signal processing is developed, which makes it possible to apply the proposed recognition method for PBRs. The experimental results of the processing algorithm are presented on the example of real signals reflected from the Mi- 8 helicopter and the Cessna 172 propeller aircraft. The experimental data are recorded by two different PBRs using DVB-T2 digital terrestrial television signals standard for airspace illumination. The estimated rotation parameters of the aircraft propeller blades correspond to the actual values. Such a correspondence allows not only to recognize the aircraft group, but in some cases to identify its type.