Our Client:
Our Client is an intercontinental provider of climate control products for the Heating,Ventilation, air conditioning (HVAC) and refrigeration markets.
Scope:
Reverse Engineering of Heat Exchanger Assembly.
- Measuring & Scanning of all parts/assemblies using CMM/3D Scanner
- Creation of 3D parametric model of Heat Exchanger from the physical part.
Why APA?
APA has a dedicated team to work on Reverse Engineering of Components with an exclusive lab set up for Probing, Scanning (3D Non-Contact), and measuring dimensions of various automotive and non-automotive components. We also have the capability to identify the chemical and mechanical properties of materials.
Reverse Engineering process:
Scanning:
- Prepare part by spraying white powder.
- Fix the part properly to scan.
- Get symmetry profile measurements before scanning the part.
PREPROCESSING:
- Cleanup of Noise in the scan data and fill gaps.
- Align to coordinate system.
- Export as .stl format.
PARAMETRIC MODELING:
- Import .stl file.
- Extracted curvature profiles,Generate outer surface as per ASTM A963/A963M97standards.
- Build parametric model from scan data.
Quality Check:
- Overlay scanned data and 3D model.
- Identify deviations and geomertry correction.
- Generate comparison report.
Challenges Involved:
- Complexity of stamped features on the Heat Exchanger
- Extracting complex curves from the scanned data
- Constructing the geometry by carefully ignoring the surface Deformations
- Capturing the exact curvature of the involute profile to be used for CFD analysis
Value delivered:
- Delivered, high accuracy model achieving 98% match, higher than the client’s 95% requirements
- Developed 3D Model considering manufacturing feasibility, tooling and flexible for future design optimization.
If you would like to know more about this topic.