(Đồ án hcmute) applied reverse design engineering in automotive mechanical assemblies simulation

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 Project title: Applied reverse design engineering in automotive mechanical assemblies’ simulation Initial materials provided by the advisor: _ Content of the project: _ Final product: - 01 Graduation Thesis - 01 Experiment model - Upload the materials, thesis, Powerpoint on Google Drive CHAIR OF THE PROGRAM (Sign with full name) ADVISOR (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 name: Nguyen Tai Loc Student ID: 18145013 Student ID: 18145039 Major: Automotive Engineering Technology Project title: Applied reverse design engineering in automotive mechanical assemblies’ simulation Advisor: Nguyen Thien Dinh, MSc EVALUATION Content of the project: Strengths: Weaknesses: Approval for oral defense? (Approved or denied) Overall evaluation: (Excellent, Good, Fair, Poor) 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 name: Nguyen Tai Loc Student ID: 18145013 Student ID: 18145039 Major: Automotive Engineering Technology Project title: Applied reverse design engineering in automotive mechanical assemblies’ simulation Name of Reviewer: EVALUATION Content and workload of the project Strengths: Weaknesses: Approval for oral defense? (Approved or denied) Overall evaluation: (Excellent, Good, Fair, Poor) Mark:……………… (In words: ) 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: EVALUATION Content and workload of the project Strengths: Weaknesses: Overall evaluation: (Excellent, Good, Fair, Poor) Mark:……………… (In words: ) 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 Figure 71 Cylinder Top view 4.5.10 Delivery valve housing Figure 72 Delivery Valve Housing Isometric view Figure 73 Delivery Valve Housing Front view 79 Faculty for High Quality Training – HCMC University of Technology and Education Figure 74 Delivery Valve Housing Top view 4.5.11 Delivery Valve Piston Figure 75 Delivery Valve Piston Isometric view Figure 76 Delivery Valve Piston Front view 80 Faculty for High Quality Training – HCMC University of Technology and Education Figure 77 Delivery Valve Piston Top view 4.5.12 Delivery Valve Spring Figure 78 Delivery Valve Spring Isometric view Figure 79 Delivery Valve Spring Front view 4.5.13 Outlet port 81 Faculty for High Quality Training – HCMC University of Technology and Education Figure 80 Outlet Port Isometric view Figure 81 Outlet Port Front view Figure 82 Outlet Port top view 82 Faculty for High Quality Training – HCMC University of Technology and Education CHAPTER 5: ASSEMBLY AND SIMULATION 5.1 Modify parts on Solidworks After re-design solid-body of parts on Geomagic Design X, there is some geometry of model which is not have desired shape Besides, parts such as spring when designed in Geomagic DX can not simulation on assembly environment of Solidworks due to lack of flexility This is because when we export to Solidworks, we cannot bring the design features with the final model to Solidworks So that we just have the final shape of parts on the Solidworks From that, based on the parts’ requirement in the assembly, we decided which parts need to have flexibility such as spring will design on Solidworks Parts such as Control sleeve and Control rack that have gear on their geometry also need to modify on Solidworks Due to the fact that we could not scan exactly the geometry of the gear This shortage came from the complex geometry of gear, the flash from scanner not reach the root tooth of gear And when run the mesh wizard on Geomagic DX, the software auto filled these missing meshes, which is not exactly the actual shape of parts Hence, modify parts on Solidworks bring the better result before assembly and simulation Figure Compare between two gear teeth before modified (right) and after modified (left) 83 Faculty for High Quality Training – HCMC University of Technology and Education Figure The flexibility of Return Spring Figure The Control Rack's geometry before modifying Figure The Control Rack's geometry after modifying 84 Faculty for High Quality Training – HCMC University of Technology and Education 5.2 Assembly After parts have been checked for the final geometry, and tolerance, parts is going to be assembled to Pump assemblies In the Assembly environment, parts need to be placed in their position However, there are some parts which are fixed in their position while the others are moved during the operation In the pump operation, some parts move with translational motion, others have rotation motion, especially, helix plunger can have two motions in a working loop Matching part to part together, we need to understand the connection between them in geometry From that, we chose the suitable mate relationship between them Because most of parts have revolve shape, so that the most popular matching relationship is concentric from outer contour of part A and inner contour of part B Also, they can be matched by coincident between two surfaces of each other Overall, most of parts can be easily to match with others by common solutions On the other hand, there are at least two parts need different solution to make sure that they will give the simulation result as similar with reality as possible In more details, Control sleeve and Control rack have a “rack and pinion” relation In this match, we need to understand their mechanical issue Finally, we find out the best solution for this match We chose the mechanical mate, ticked on “rack and pinion” option Then at the detail, we chose option “pinion pitch diameter” with the number is “33mm” This solution offers us a similar reality simulation result Figure 5 The "Rack and pinion" mate Next, we focused on the flexible length of the Return spring Because this part has a significant role in operation of the pump assemblies Because we could not use any offered options in the assembly environment We used another solution to solve this issue At the sketch of return spring, we drawled it revolve axis without a clearly dimension of length After that, we make a new assembly which just has two 85 Faculty for High Quality Training – HCMC University of Technology and Education members, the Bottom spring seat, and the Return spring After matched them concentric between their rotation axis, we chose the 3D sketch for next step We chose the bottom point of the spring revolve axis has coincident with the geometry of the Bottom spring seat We have fixed the upper surface of the spring with the top plane to make sure that if we change the position of the Bottom spring seat, the length of the spring and its shape change, but not its position Figure Made the length of the Spring depend on the Bottom spring seat Figure The length of the Spring when compressing 86 Faculty for High Quality Training – HCMC University of Technology and Education Figure The length of the Spring when stretching 5.3 The pump assemblies After finished the assembly process, the Pump assemblies are demonstrated below: Figure The Isometric view of the Pump assemblies and list of components For clearly observation, we change the Housing and some components’ view transparency to be more invisible From that, we could study more about working operation of the Helix plunger while simulation 87 Faculty for High Quality Training – HCMC University of Technology and Education Figure 10 The mechanism inside without the Housing Figure 11 The mechanism inside with the Helix plunger and the Delivery valve Figure 12 The “Rack and pinion” mechanism 88 Faculty for High Quality Training – HCMC University of Technology and Education Figure 13 Position between two components: “Control sleeve” and “Control rack” Figure 14 Two different working states of the Helix plunger In our work, there are about thirteen components, which are assembled in their order to make sure that they are clearly to follow There are sub-assemblies in the final assemblies, which include the Return spring and the Bottom spring seat This solution offers the better way to manage the geometry of the assemblies 6.4 Simulation This is the final work of the thesis The purpose is showing that the Pump assemblies on the 3D CAD could simulate the operation of the reality pump By following the relationship among components, we build a simulation of operation for the assemblies We can show the different working state of helix plunger due to the operate condition such as variable engine load requirement or cut off the fuel supply in order to turn the engine off by modify the parameter 89 Faculty for High Quality Training – HCMC University of Technology and Education Figure 15 The motion study scene Figure 16 Exporting the motion study to video We also can have an explore view to have an observation in detail Moreover, we can also change the different view to have an overall vision By applying different method, we can easily study in detail the operation of the pump assemblies 90 Faculty for High Quality Training – HCMC University of Technology and Education CHAPTER 6: CONCLUSION Overall, this graduation thesis is about applying a part of reverse engineering to build a mechanical assembly in a 3D CAD environment We have built a common process for a reverse design project at the University Each step in the process has played an important role in building a final product The scanning process is the base of the project The more detail of the data scan, the easier work is when re-design The mesh detail causes the exact drawing This is because the sketch is based on the geometry of the mesh We need to handle the direction of scan objects to make sure that we collect data with the most detail possible However, there exist some physical barriers For objects that have deep holes in the geometry, the laser from the scanner cannot reach the inside view Moreover, objects with shining surfaces, made from metal materials, or dark color surfaces cannot be scanned exactly This is because they reflect or absorb too much light from the scanner laser We could use the crack detection spray as a supporter for the scanner The reverse design is a combination solution between two software Geomagic DX and Solidworks Each program has its strong ability in processing which easily serve the different requirement of design Based on the provided mesh data, and flexible combination with the measurement method, we could build the best solution for each of the components due to their requirement in the assemblies The goal is to make sure that the final assemblies can have an operation as reality as possible The final step, assembly, and simulation is the best way to show the result of redesign This result will be used as a study tutorial for students Furthermore, this result can be a base for the next project We can build a library of machines that are available in our faculty workshop This library will play an important role in digital’s innovation in training and study at the university From this library, students can download assemblies to their storage, and self-study at home And by the strong ability of the CAD program to change the observation, the lecturer can easily show students the operation of the hiding mechanism From that, the adaptability of students could be improved With the development of technology, we can apply the VR solution as a remote study Students from distance can join the class and have a similar reality experience of assembling these machines 91 Faculty for High Quality Training – HCMC University of Technology and Education REFERENCE [1] [2] [3] [4] [5] [6] [7] [8] [9] Muhammad Yasir Anwar, Shahid Ikramullah Butt, Farrukh Mazhar_ REVERSE ENGINEERING IN MODELING OF AIRCRAFT PROPELLER BLADE - FIRST STEP TO PRODUCT OPTIMIZATION (November 2014) Documentation of 3D measurement technology, 3D scanning technology of GOM - http://www.gom.com/ Toh Yen Pang, Mohammad Fard (RMIT University) _ Reverse Engineering and Topology Optimization for Weight-Reduction of a Bell-Crank (November 2020) R Dhipakumar (Dept of MECHANICAL-PITS), Dr R Ganesh (Dept of MECHANICAL-PITS) _ Reverse Engineering in Mechanical Component Benefits of Using Geomagic Design X in Reverse Engineering | Reverse Engineering Service (reverse-engineering-service.de) Eldad Eilam (2005), Reversing: Secrets of Reverse Engineering, Published simultaneously in Canada Nguyễn Văn Long Giang, Phạm Sơn Minh, Trần Minh Thế Uyên, Nguyễn Văn Sơn_GIÁO TRÌNH THIẾT KẾNGƯỢC, xuất lần I, 2019 Võ Trường Vinh, Trình Huỳnh Đức, Đồ án tốt nghiệp_ỨNG DỤNG THIẾT KẾ NGƯỢC TRONG THIẾT KẾ VÀ TÍNH BỀN CẢN XE Ô TÔ, Khoa Cơ Khí Động Lực, 2019 Đồ án “Công nghệ thiết kế ngược ứng dụng vào trình tạo mẫu nhanh” – Trường Đại Học Giao Thơng Vận Tải 92