Product Design Innovation Reverse Engineering and Leadership
Dr Om Prakash SinghAsst Prof School of Engineering IIT Mandi
wwwomprakashsinghcom
Our Vision
To become a world class institution toproduce manpower with skills creativity andpassion dedicated to innovation andexcellence with quest for continuousimprovement
Jawaharlal Nehru GovernmentEngineering College Sundernagar
What is an Engineer
bull Engineering is the profession in which knowledge ofthe mathematical and natural sciences gained bystudy experience and practice is applied withjudgement to develop ways to utilize economicallythe materials and forces of nature for the benefit ofmankind
bull Eg Trouble shooting Energy conversion healthsciences aerospace transportation manufacturing
bull In fact almost every type of industry employsmechanical engineers
Engineers make design and productsInterdisciplinary nature
Think out of box
The complex interconnectionbull System level thinking is expected from engineersbull Component level design may not work in productbull Engineers should know how to work together in team
bull Human race survived as it hascontinuously inventedinnovated
bull Species those who have notinnovated became extinct
bull Only innovative companies survive
bull Lost top spot MicrosoftBlackBerry and Nokia
Invention key for survival
bull Invention is absolutely a good thing but even without inventionsa country or company or an individual can still come out ahead
bull After all Japan didnrsquot invent the car or the TV but it certainlyinnovated on them and built world-leading companies andeconomies
A movie on how technology determines who rules whom
bull Movie Planet of the Apes (2001)bull Entire movie is edited to 5 minutesbull Message from the movie
1 A technologically advanced society are the rulers over other species (here Apes rule Human being)
2 Technology changes with time3 Innovation is the key for survival4 After the movie question will be asked
What you study as an engg student
bull Forces motion structures statics dynamics kinematics mechanics of solids and fluids
bull Energy thermodynamics heat transfer
bull Materials materials engineering amp processing manufacturing
bull Machines graphics design machine elements controls
bull Economics engineering economic analysis cost engineering
bull Human and Social Studies arts humanities social sciences history government ethics law
bull Overall foundation math physics chemistry biology analysis skills communication skills computation skills
Modern method of production
1 Design2 Prototypes3 Testing4 Mass production
Convectional method of production
1 Design2 CAE3 Prototypes4 Testing5 Mass production
Optimization loop
Optimization loop
Material saving weight reduction
CAE Computer Aided Engineering
More prototypes
Less prototypes
Design Changes and costbull Initial design changes incurs less costbull As the product reaches deployment phase change in design proves very
costlybull Numerical tools such as FEM CFD etc helps in improving designs during
concept stagebull Such tools also helps in investigating failures after the product launched in
the market
Design Changes Process
Combustion
External Aerodynamics of car
External Aerodynamics of bike
Tool cutting process Dragonfly CFD simulation
CFD applications
CFD applications in buildings design
Solar collectors on roofs of industrial buildings
Two time steps in an oxygen uptake simulation of a breathing cycle
Contours and path lines at aninhalation time step
CFD in Biomedical application Predicting breathingcycle
ldquoProgress Towards a Medical Image through CFD Analysis Toolkit forRespiratory Function Assessment on a Clinical Time Scalerdquo The Pennsylvania State University daggerApplied ResearchLaboratory daggerdaggerDepartment of Mechanical Engineering Department of Aerospace Engineering Drexel UniversityDepartment of Biomedical Engineering
Finite Element Analysismedical implants
Processes involved in FEMCFD analysis
bull Geometry pre-processingbull Clean upbull Remove unwanted features
bull Mesh generationbull Boundary conditionsbull Materials element type etc
bull Solutionbull Post processing result visualization bull Reports and decision making
Extracting geometry from medical images
Stack of images from MRI (1mm)
Contour extraction by segmentation (using B-
Splines)
Sample points on extracted geometry
GEOMETRIC PRE-PROCESSING
MR (Magnetic Resonance)
Generating a computational mesh
Constrained optimization procedures are needed to maximize a suitable measure of the grid quality (to avoid triangle distorsion) while keeping the desired accuracy of surface representation
Original grid Optimized grid
GEOMETRIC PRE-PROCESSING
Splines on sections
Design Innovation Center at IIT Mandi
bull Design Studio
bull CFD FEM software HyperWorks
Ansys StarCCM+hellip
bull Prototyping and 3D printing
machines
bull Reverse Engineering
Courses
bull Applied CFD
bull Applied FEM
bull Reverse Engineering
bull Design Practicum
bull CAE based final year projects
Projects based on FEMCFD
1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip
Engines from different automotive companies
XL Super heavy duty 95 marketshare 15 year old engine
Example
Final mass
produced design
Original design
Design changes 35 Prototype design 2
Original mass produced
design
Example of real world problem Multidisciplinary natureCAE driven product design
The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26
bull Rubber dampers are provided between thefins to reduce their vibration
bull High vibration of fins produces undesirablenoise
bull Undesirable noise leads to customerdissatisfaction
bull Proper design of the fins are necessary
bull Rubber dampers add extra cost to thevehicle
Rubber dampers
Two-wheeler engine head
TVS Moped Engine Rubber dampers
bull Reliable engine gt 15 years in the market
bull Holds 95 market share in moped class
bull Lakhs of satisfied customers
bull16 dampers on the cylinder head
If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head
Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz
Radiated noise with and without rubber dampers
Experimental verificationhellip
All 16
dampers
in place
Campbell diagram during gradual acceleration
Noise levels have spread and are higher in magnitude in the 2nd case
All 16
dampers
removed
2nd Stage design of Cylinder Head
Thinner part of the fins are fixed now
1st stage design
It was observed that the new head design may notbe feasible from manufacturing point of view
2nd stage cylinder head
Further design
changes and
analysis
Experimental verification Campbell diagram
Existing head with rubber dampers 3rd stage head without rubber dampers
bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head
Noise level comparison
Computational Fluid Dynamic analysis
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Our Vision
To become a world class institution toproduce manpower with skills creativity andpassion dedicated to innovation andexcellence with quest for continuousimprovement
Jawaharlal Nehru GovernmentEngineering College Sundernagar
What is an Engineer
bull Engineering is the profession in which knowledge ofthe mathematical and natural sciences gained bystudy experience and practice is applied withjudgement to develop ways to utilize economicallythe materials and forces of nature for the benefit ofmankind
bull Eg Trouble shooting Energy conversion healthsciences aerospace transportation manufacturing
bull In fact almost every type of industry employsmechanical engineers
Engineers make design and productsInterdisciplinary nature
Think out of box
The complex interconnectionbull System level thinking is expected from engineersbull Component level design may not work in productbull Engineers should know how to work together in team
bull Human race survived as it hascontinuously inventedinnovated
bull Species those who have notinnovated became extinct
bull Only innovative companies survive
bull Lost top spot MicrosoftBlackBerry and Nokia
Invention key for survival
bull Invention is absolutely a good thing but even without inventionsa country or company or an individual can still come out ahead
bull After all Japan didnrsquot invent the car or the TV but it certainlyinnovated on them and built world-leading companies andeconomies
A movie on how technology determines who rules whom
bull Movie Planet of the Apes (2001)bull Entire movie is edited to 5 minutesbull Message from the movie
1 A technologically advanced society are the rulers over other species (here Apes rule Human being)
2 Technology changes with time3 Innovation is the key for survival4 After the movie question will be asked
What you study as an engg student
bull Forces motion structures statics dynamics kinematics mechanics of solids and fluids
bull Energy thermodynamics heat transfer
bull Materials materials engineering amp processing manufacturing
bull Machines graphics design machine elements controls
bull Economics engineering economic analysis cost engineering
bull Human and Social Studies arts humanities social sciences history government ethics law
bull Overall foundation math physics chemistry biology analysis skills communication skills computation skills
Modern method of production
1 Design2 Prototypes3 Testing4 Mass production
Convectional method of production
1 Design2 CAE3 Prototypes4 Testing5 Mass production
Optimization loop
Optimization loop
Material saving weight reduction
CAE Computer Aided Engineering
More prototypes
Less prototypes
Design Changes and costbull Initial design changes incurs less costbull As the product reaches deployment phase change in design proves very
costlybull Numerical tools such as FEM CFD etc helps in improving designs during
concept stagebull Such tools also helps in investigating failures after the product launched in
the market
Design Changes Process
Combustion
External Aerodynamics of car
External Aerodynamics of bike
Tool cutting process Dragonfly CFD simulation
CFD applications
CFD applications in buildings design
Solar collectors on roofs of industrial buildings
Two time steps in an oxygen uptake simulation of a breathing cycle
Contours and path lines at aninhalation time step
CFD in Biomedical application Predicting breathingcycle
ldquoProgress Towards a Medical Image through CFD Analysis Toolkit forRespiratory Function Assessment on a Clinical Time Scalerdquo The Pennsylvania State University daggerApplied ResearchLaboratory daggerdaggerDepartment of Mechanical Engineering Department of Aerospace Engineering Drexel UniversityDepartment of Biomedical Engineering
Finite Element Analysismedical implants
Processes involved in FEMCFD analysis
bull Geometry pre-processingbull Clean upbull Remove unwanted features
bull Mesh generationbull Boundary conditionsbull Materials element type etc
bull Solutionbull Post processing result visualization bull Reports and decision making
Extracting geometry from medical images
Stack of images from MRI (1mm)
Contour extraction by segmentation (using B-
Splines)
Sample points on extracted geometry
GEOMETRIC PRE-PROCESSING
MR (Magnetic Resonance)
Generating a computational mesh
Constrained optimization procedures are needed to maximize a suitable measure of the grid quality (to avoid triangle distorsion) while keeping the desired accuracy of surface representation
Original grid Optimized grid
GEOMETRIC PRE-PROCESSING
Splines on sections
Design Innovation Center at IIT Mandi
bull Design Studio
bull CFD FEM software HyperWorks
Ansys StarCCM+hellip
bull Prototyping and 3D printing
machines
bull Reverse Engineering
Courses
bull Applied CFD
bull Applied FEM
bull Reverse Engineering
bull Design Practicum
bull CAE based final year projects
Projects based on FEMCFD
1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip
Engines from different automotive companies
XL Super heavy duty 95 marketshare 15 year old engine
Example
Final mass
produced design
Original design
Design changes 35 Prototype design 2
Original mass produced
design
Example of real world problem Multidisciplinary natureCAE driven product design
The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26
bull Rubber dampers are provided between thefins to reduce their vibration
bull High vibration of fins produces undesirablenoise
bull Undesirable noise leads to customerdissatisfaction
bull Proper design of the fins are necessary
bull Rubber dampers add extra cost to thevehicle
Rubber dampers
Two-wheeler engine head
TVS Moped Engine Rubber dampers
bull Reliable engine gt 15 years in the market
bull Holds 95 market share in moped class
bull Lakhs of satisfied customers
bull16 dampers on the cylinder head
If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head
Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz
Radiated noise with and without rubber dampers
Experimental verificationhellip
All 16
dampers
in place
Campbell diagram during gradual acceleration
Noise levels have spread and are higher in magnitude in the 2nd case
All 16
dampers
removed
2nd Stage design of Cylinder Head
Thinner part of the fins are fixed now
1st stage design
It was observed that the new head design may notbe feasible from manufacturing point of view
2nd stage cylinder head
Further design
changes and
analysis
Experimental verification Campbell diagram
Existing head with rubber dampers 3rd stage head without rubber dampers
bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head
Noise level comparison
Computational Fluid Dynamic analysis
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
What is an Engineer
bull Engineering is the profession in which knowledge ofthe mathematical and natural sciences gained bystudy experience and practice is applied withjudgement to develop ways to utilize economicallythe materials and forces of nature for the benefit ofmankind
bull Eg Trouble shooting Energy conversion healthsciences aerospace transportation manufacturing
bull In fact almost every type of industry employsmechanical engineers
Engineers make design and productsInterdisciplinary nature
Think out of box
The complex interconnectionbull System level thinking is expected from engineersbull Component level design may not work in productbull Engineers should know how to work together in team
bull Human race survived as it hascontinuously inventedinnovated
bull Species those who have notinnovated became extinct
bull Only innovative companies survive
bull Lost top spot MicrosoftBlackBerry and Nokia
Invention key for survival
bull Invention is absolutely a good thing but even without inventionsa country or company or an individual can still come out ahead
bull After all Japan didnrsquot invent the car or the TV but it certainlyinnovated on them and built world-leading companies andeconomies
A movie on how technology determines who rules whom
bull Movie Planet of the Apes (2001)bull Entire movie is edited to 5 minutesbull Message from the movie
1 A technologically advanced society are the rulers over other species (here Apes rule Human being)
2 Technology changes with time3 Innovation is the key for survival4 After the movie question will be asked
What you study as an engg student
bull Forces motion structures statics dynamics kinematics mechanics of solids and fluids
bull Energy thermodynamics heat transfer
bull Materials materials engineering amp processing manufacturing
bull Machines graphics design machine elements controls
bull Economics engineering economic analysis cost engineering
bull Human and Social Studies arts humanities social sciences history government ethics law
bull Overall foundation math physics chemistry biology analysis skills communication skills computation skills
Modern method of production
1 Design2 Prototypes3 Testing4 Mass production
Convectional method of production
1 Design2 CAE3 Prototypes4 Testing5 Mass production
Optimization loop
Optimization loop
Material saving weight reduction
CAE Computer Aided Engineering
More prototypes
Less prototypes
Design Changes and costbull Initial design changes incurs less costbull As the product reaches deployment phase change in design proves very
costlybull Numerical tools such as FEM CFD etc helps in improving designs during
concept stagebull Such tools also helps in investigating failures after the product launched in
the market
Design Changes Process
Combustion
External Aerodynamics of car
External Aerodynamics of bike
Tool cutting process Dragonfly CFD simulation
CFD applications
CFD applications in buildings design
Solar collectors on roofs of industrial buildings
Two time steps in an oxygen uptake simulation of a breathing cycle
Contours and path lines at aninhalation time step
CFD in Biomedical application Predicting breathingcycle
ldquoProgress Towards a Medical Image through CFD Analysis Toolkit forRespiratory Function Assessment on a Clinical Time Scalerdquo The Pennsylvania State University daggerApplied ResearchLaboratory daggerdaggerDepartment of Mechanical Engineering Department of Aerospace Engineering Drexel UniversityDepartment of Biomedical Engineering
Finite Element Analysismedical implants
Processes involved in FEMCFD analysis
bull Geometry pre-processingbull Clean upbull Remove unwanted features
bull Mesh generationbull Boundary conditionsbull Materials element type etc
bull Solutionbull Post processing result visualization bull Reports and decision making
Extracting geometry from medical images
Stack of images from MRI (1mm)
Contour extraction by segmentation (using B-
Splines)
Sample points on extracted geometry
GEOMETRIC PRE-PROCESSING
MR (Magnetic Resonance)
Generating a computational mesh
Constrained optimization procedures are needed to maximize a suitable measure of the grid quality (to avoid triangle distorsion) while keeping the desired accuracy of surface representation
Original grid Optimized grid
GEOMETRIC PRE-PROCESSING
Splines on sections
Design Innovation Center at IIT Mandi
bull Design Studio
bull CFD FEM software HyperWorks
Ansys StarCCM+hellip
bull Prototyping and 3D printing
machines
bull Reverse Engineering
Courses
bull Applied CFD
bull Applied FEM
bull Reverse Engineering
bull Design Practicum
bull CAE based final year projects
Projects based on FEMCFD
1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip
Engines from different automotive companies
XL Super heavy duty 95 marketshare 15 year old engine
Example
Final mass
produced design
Original design
Design changes 35 Prototype design 2
Original mass produced
design
Example of real world problem Multidisciplinary natureCAE driven product design
The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26
bull Rubber dampers are provided between thefins to reduce their vibration
bull High vibration of fins produces undesirablenoise
bull Undesirable noise leads to customerdissatisfaction
bull Proper design of the fins are necessary
bull Rubber dampers add extra cost to thevehicle
Rubber dampers
Two-wheeler engine head
TVS Moped Engine Rubber dampers
bull Reliable engine gt 15 years in the market
bull Holds 95 market share in moped class
bull Lakhs of satisfied customers
bull16 dampers on the cylinder head
If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head
Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz
Radiated noise with and without rubber dampers
Experimental verificationhellip
All 16
dampers
in place
Campbell diagram during gradual acceleration
Noise levels have spread and are higher in magnitude in the 2nd case
All 16
dampers
removed
2nd Stage design of Cylinder Head
Thinner part of the fins are fixed now
1st stage design
It was observed that the new head design may notbe feasible from manufacturing point of view
2nd stage cylinder head
Further design
changes and
analysis
Experimental verification Campbell diagram
Existing head with rubber dampers 3rd stage head without rubber dampers
bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head
Noise level comparison
Computational Fluid Dynamic analysis
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Engineers make design and productsInterdisciplinary nature
Think out of box
The complex interconnectionbull System level thinking is expected from engineersbull Component level design may not work in productbull Engineers should know how to work together in team
bull Human race survived as it hascontinuously inventedinnovated
bull Species those who have notinnovated became extinct
bull Only innovative companies survive
bull Lost top spot MicrosoftBlackBerry and Nokia
Invention key for survival
bull Invention is absolutely a good thing but even without inventionsa country or company or an individual can still come out ahead
bull After all Japan didnrsquot invent the car or the TV but it certainlyinnovated on them and built world-leading companies andeconomies
A movie on how technology determines who rules whom
bull Movie Planet of the Apes (2001)bull Entire movie is edited to 5 minutesbull Message from the movie
1 A technologically advanced society are the rulers over other species (here Apes rule Human being)
2 Technology changes with time3 Innovation is the key for survival4 After the movie question will be asked
What you study as an engg student
bull Forces motion structures statics dynamics kinematics mechanics of solids and fluids
bull Energy thermodynamics heat transfer
bull Materials materials engineering amp processing manufacturing
bull Machines graphics design machine elements controls
bull Economics engineering economic analysis cost engineering
bull Human and Social Studies arts humanities social sciences history government ethics law
bull Overall foundation math physics chemistry biology analysis skills communication skills computation skills
Modern method of production
1 Design2 Prototypes3 Testing4 Mass production
Convectional method of production
1 Design2 CAE3 Prototypes4 Testing5 Mass production
Optimization loop
Optimization loop
Material saving weight reduction
CAE Computer Aided Engineering
More prototypes
Less prototypes
Design Changes and costbull Initial design changes incurs less costbull As the product reaches deployment phase change in design proves very
costlybull Numerical tools such as FEM CFD etc helps in improving designs during
concept stagebull Such tools also helps in investigating failures after the product launched in
the market
Design Changes Process
Combustion
External Aerodynamics of car
External Aerodynamics of bike
Tool cutting process Dragonfly CFD simulation
CFD applications
CFD applications in buildings design
Solar collectors on roofs of industrial buildings
Two time steps in an oxygen uptake simulation of a breathing cycle
Contours and path lines at aninhalation time step
CFD in Biomedical application Predicting breathingcycle
ldquoProgress Towards a Medical Image through CFD Analysis Toolkit forRespiratory Function Assessment on a Clinical Time Scalerdquo The Pennsylvania State University daggerApplied ResearchLaboratory daggerdaggerDepartment of Mechanical Engineering Department of Aerospace Engineering Drexel UniversityDepartment of Biomedical Engineering
Finite Element Analysismedical implants
Processes involved in FEMCFD analysis
bull Geometry pre-processingbull Clean upbull Remove unwanted features
bull Mesh generationbull Boundary conditionsbull Materials element type etc
bull Solutionbull Post processing result visualization bull Reports and decision making
Extracting geometry from medical images
Stack of images from MRI (1mm)
Contour extraction by segmentation (using B-
Splines)
Sample points on extracted geometry
GEOMETRIC PRE-PROCESSING
MR (Magnetic Resonance)
Generating a computational mesh
Constrained optimization procedures are needed to maximize a suitable measure of the grid quality (to avoid triangle distorsion) while keeping the desired accuracy of surface representation
Original grid Optimized grid
GEOMETRIC PRE-PROCESSING
Splines on sections
Design Innovation Center at IIT Mandi
bull Design Studio
bull CFD FEM software HyperWorks
Ansys StarCCM+hellip
bull Prototyping and 3D printing
machines
bull Reverse Engineering
Courses
bull Applied CFD
bull Applied FEM
bull Reverse Engineering
bull Design Practicum
bull CAE based final year projects
Projects based on FEMCFD
1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip
Engines from different automotive companies
XL Super heavy duty 95 marketshare 15 year old engine
Example
Final mass
produced design
Original design
Design changes 35 Prototype design 2
Original mass produced
design
Example of real world problem Multidisciplinary natureCAE driven product design
The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26
bull Rubber dampers are provided between thefins to reduce their vibration
bull High vibration of fins produces undesirablenoise
bull Undesirable noise leads to customerdissatisfaction
bull Proper design of the fins are necessary
bull Rubber dampers add extra cost to thevehicle
Rubber dampers
Two-wheeler engine head
TVS Moped Engine Rubber dampers
bull Reliable engine gt 15 years in the market
bull Holds 95 market share in moped class
bull Lakhs of satisfied customers
bull16 dampers on the cylinder head
If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head
Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz
Radiated noise with and without rubber dampers
Experimental verificationhellip
All 16
dampers
in place
Campbell diagram during gradual acceleration
Noise levels have spread and are higher in magnitude in the 2nd case
All 16
dampers
removed
2nd Stage design of Cylinder Head
Thinner part of the fins are fixed now
1st stage design
It was observed that the new head design may notbe feasible from manufacturing point of view
2nd stage cylinder head
Further design
changes and
analysis
Experimental verification Campbell diagram
Existing head with rubber dampers 3rd stage head without rubber dampers
bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head
Noise level comparison
Computational Fluid Dynamic analysis
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Think out of box
The complex interconnectionbull System level thinking is expected from engineersbull Component level design may not work in productbull Engineers should know how to work together in team
bull Human race survived as it hascontinuously inventedinnovated
bull Species those who have notinnovated became extinct
bull Only innovative companies survive
bull Lost top spot MicrosoftBlackBerry and Nokia
Invention key for survival
bull Invention is absolutely a good thing but even without inventionsa country or company or an individual can still come out ahead
bull After all Japan didnrsquot invent the car or the TV but it certainlyinnovated on them and built world-leading companies andeconomies
A movie on how technology determines who rules whom
bull Movie Planet of the Apes (2001)bull Entire movie is edited to 5 minutesbull Message from the movie
1 A technologically advanced society are the rulers over other species (here Apes rule Human being)
2 Technology changes with time3 Innovation is the key for survival4 After the movie question will be asked
What you study as an engg student
bull Forces motion structures statics dynamics kinematics mechanics of solids and fluids
bull Energy thermodynamics heat transfer
bull Materials materials engineering amp processing manufacturing
bull Machines graphics design machine elements controls
bull Economics engineering economic analysis cost engineering
bull Human and Social Studies arts humanities social sciences history government ethics law
bull Overall foundation math physics chemistry biology analysis skills communication skills computation skills
Modern method of production
1 Design2 Prototypes3 Testing4 Mass production
Convectional method of production
1 Design2 CAE3 Prototypes4 Testing5 Mass production
Optimization loop
Optimization loop
Material saving weight reduction
CAE Computer Aided Engineering
More prototypes
Less prototypes
Design Changes and costbull Initial design changes incurs less costbull As the product reaches deployment phase change in design proves very
costlybull Numerical tools such as FEM CFD etc helps in improving designs during
concept stagebull Such tools also helps in investigating failures after the product launched in
the market
Design Changes Process
Combustion
External Aerodynamics of car
External Aerodynamics of bike
Tool cutting process Dragonfly CFD simulation
CFD applications
CFD applications in buildings design
Solar collectors on roofs of industrial buildings
Two time steps in an oxygen uptake simulation of a breathing cycle
Contours and path lines at aninhalation time step
CFD in Biomedical application Predicting breathingcycle
ldquoProgress Towards a Medical Image through CFD Analysis Toolkit forRespiratory Function Assessment on a Clinical Time Scalerdquo The Pennsylvania State University daggerApplied ResearchLaboratory daggerdaggerDepartment of Mechanical Engineering Department of Aerospace Engineering Drexel UniversityDepartment of Biomedical Engineering
Finite Element Analysismedical implants
Processes involved in FEMCFD analysis
bull Geometry pre-processingbull Clean upbull Remove unwanted features
bull Mesh generationbull Boundary conditionsbull Materials element type etc
bull Solutionbull Post processing result visualization bull Reports and decision making
Extracting geometry from medical images
Stack of images from MRI (1mm)
Contour extraction by segmentation (using B-
Splines)
Sample points on extracted geometry
GEOMETRIC PRE-PROCESSING
MR (Magnetic Resonance)
Generating a computational mesh
Constrained optimization procedures are needed to maximize a suitable measure of the grid quality (to avoid triangle distorsion) while keeping the desired accuracy of surface representation
Original grid Optimized grid
GEOMETRIC PRE-PROCESSING
Splines on sections
Design Innovation Center at IIT Mandi
bull Design Studio
bull CFD FEM software HyperWorks
Ansys StarCCM+hellip
bull Prototyping and 3D printing
machines
bull Reverse Engineering
Courses
bull Applied CFD
bull Applied FEM
bull Reverse Engineering
bull Design Practicum
bull CAE based final year projects
Projects based on FEMCFD
1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip
Engines from different automotive companies
XL Super heavy duty 95 marketshare 15 year old engine
Example
Final mass
produced design
Original design
Design changes 35 Prototype design 2
Original mass produced
design
Example of real world problem Multidisciplinary natureCAE driven product design
The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26
bull Rubber dampers are provided between thefins to reduce their vibration
bull High vibration of fins produces undesirablenoise
bull Undesirable noise leads to customerdissatisfaction
bull Proper design of the fins are necessary
bull Rubber dampers add extra cost to thevehicle
Rubber dampers
Two-wheeler engine head
TVS Moped Engine Rubber dampers
bull Reliable engine gt 15 years in the market
bull Holds 95 market share in moped class
bull Lakhs of satisfied customers
bull16 dampers on the cylinder head
If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head
Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz
Radiated noise with and without rubber dampers
Experimental verificationhellip
All 16
dampers
in place
Campbell diagram during gradual acceleration
Noise levels have spread and are higher in magnitude in the 2nd case
All 16
dampers
removed
2nd Stage design of Cylinder Head
Thinner part of the fins are fixed now
1st stage design
It was observed that the new head design may notbe feasible from manufacturing point of view
2nd stage cylinder head
Further design
changes and
analysis
Experimental verification Campbell diagram
Existing head with rubber dampers 3rd stage head without rubber dampers
bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head
Noise level comparison
Computational Fluid Dynamic analysis
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
The complex interconnectionbull System level thinking is expected from engineersbull Component level design may not work in productbull Engineers should know how to work together in team
bull Human race survived as it hascontinuously inventedinnovated
bull Species those who have notinnovated became extinct
bull Only innovative companies survive
bull Lost top spot MicrosoftBlackBerry and Nokia
Invention key for survival
bull Invention is absolutely a good thing but even without inventionsa country or company or an individual can still come out ahead
bull After all Japan didnrsquot invent the car or the TV but it certainlyinnovated on them and built world-leading companies andeconomies
A movie on how technology determines who rules whom
bull Movie Planet of the Apes (2001)bull Entire movie is edited to 5 minutesbull Message from the movie
1 A technologically advanced society are the rulers over other species (here Apes rule Human being)
2 Technology changes with time3 Innovation is the key for survival4 After the movie question will be asked
What you study as an engg student
bull Forces motion structures statics dynamics kinematics mechanics of solids and fluids
bull Energy thermodynamics heat transfer
bull Materials materials engineering amp processing manufacturing
bull Machines graphics design machine elements controls
bull Economics engineering economic analysis cost engineering
bull Human and Social Studies arts humanities social sciences history government ethics law
bull Overall foundation math physics chemistry biology analysis skills communication skills computation skills
Modern method of production
1 Design2 Prototypes3 Testing4 Mass production
Convectional method of production
1 Design2 CAE3 Prototypes4 Testing5 Mass production
Optimization loop
Optimization loop
Material saving weight reduction
CAE Computer Aided Engineering
More prototypes
Less prototypes
Design Changes and costbull Initial design changes incurs less costbull As the product reaches deployment phase change in design proves very
costlybull Numerical tools such as FEM CFD etc helps in improving designs during
concept stagebull Such tools also helps in investigating failures after the product launched in
the market
Design Changes Process
Combustion
External Aerodynamics of car
External Aerodynamics of bike
Tool cutting process Dragonfly CFD simulation
CFD applications
CFD applications in buildings design
Solar collectors on roofs of industrial buildings
Two time steps in an oxygen uptake simulation of a breathing cycle
Contours and path lines at aninhalation time step
CFD in Biomedical application Predicting breathingcycle
ldquoProgress Towards a Medical Image through CFD Analysis Toolkit forRespiratory Function Assessment on a Clinical Time Scalerdquo The Pennsylvania State University daggerApplied ResearchLaboratory daggerdaggerDepartment of Mechanical Engineering Department of Aerospace Engineering Drexel UniversityDepartment of Biomedical Engineering
Finite Element Analysismedical implants
Processes involved in FEMCFD analysis
bull Geometry pre-processingbull Clean upbull Remove unwanted features
bull Mesh generationbull Boundary conditionsbull Materials element type etc
bull Solutionbull Post processing result visualization bull Reports and decision making
Extracting geometry from medical images
Stack of images from MRI (1mm)
Contour extraction by segmentation (using B-
Splines)
Sample points on extracted geometry
GEOMETRIC PRE-PROCESSING
MR (Magnetic Resonance)
Generating a computational mesh
Constrained optimization procedures are needed to maximize a suitable measure of the grid quality (to avoid triangle distorsion) while keeping the desired accuracy of surface representation
Original grid Optimized grid
GEOMETRIC PRE-PROCESSING
Splines on sections
Design Innovation Center at IIT Mandi
bull Design Studio
bull CFD FEM software HyperWorks
Ansys StarCCM+hellip
bull Prototyping and 3D printing
machines
bull Reverse Engineering
Courses
bull Applied CFD
bull Applied FEM
bull Reverse Engineering
bull Design Practicum
bull CAE based final year projects
Projects based on FEMCFD
1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip
Engines from different automotive companies
XL Super heavy duty 95 marketshare 15 year old engine
Example
Final mass
produced design
Original design
Design changes 35 Prototype design 2
Original mass produced
design
Example of real world problem Multidisciplinary natureCAE driven product design
The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26
bull Rubber dampers are provided between thefins to reduce their vibration
bull High vibration of fins produces undesirablenoise
bull Undesirable noise leads to customerdissatisfaction
bull Proper design of the fins are necessary
bull Rubber dampers add extra cost to thevehicle
Rubber dampers
Two-wheeler engine head
TVS Moped Engine Rubber dampers
bull Reliable engine gt 15 years in the market
bull Holds 95 market share in moped class
bull Lakhs of satisfied customers
bull16 dampers on the cylinder head
If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head
Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz
Radiated noise with and without rubber dampers
Experimental verificationhellip
All 16
dampers
in place
Campbell diagram during gradual acceleration
Noise levels have spread and are higher in magnitude in the 2nd case
All 16
dampers
removed
2nd Stage design of Cylinder Head
Thinner part of the fins are fixed now
1st stage design
It was observed that the new head design may notbe feasible from manufacturing point of view
2nd stage cylinder head
Further design
changes and
analysis
Experimental verification Campbell diagram
Existing head with rubber dampers 3rd stage head without rubber dampers
bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head
Noise level comparison
Computational Fluid Dynamic analysis
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
bull Human race survived as it hascontinuously inventedinnovated
bull Species those who have notinnovated became extinct
bull Only innovative companies survive
bull Lost top spot MicrosoftBlackBerry and Nokia
Invention key for survival
bull Invention is absolutely a good thing but even without inventionsa country or company or an individual can still come out ahead
bull After all Japan didnrsquot invent the car or the TV but it certainlyinnovated on them and built world-leading companies andeconomies
A movie on how technology determines who rules whom
bull Movie Planet of the Apes (2001)bull Entire movie is edited to 5 minutesbull Message from the movie
1 A technologically advanced society are the rulers over other species (here Apes rule Human being)
2 Technology changes with time3 Innovation is the key for survival4 After the movie question will be asked
What you study as an engg student
bull Forces motion structures statics dynamics kinematics mechanics of solids and fluids
bull Energy thermodynamics heat transfer
bull Materials materials engineering amp processing manufacturing
bull Machines graphics design machine elements controls
bull Economics engineering economic analysis cost engineering
bull Human and Social Studies arts humanities social sciences history government ethics law
bull Overall foundation math physics chemistry biology analysis skills communication skills computation skills
Modern method of production
1 Design2 Prototypes3 Testing4 Mass production
Convectional method of production
1 Design2 CAE3 Prototypes4 Testing5 Mass production
Optimization loop
Optimization loop
Material saving weight reduction
CAE Computer Aided Engineering
More prototypes
Less prototypes
Design Changes and costbull Initial design changes incurs less costbull As the product reaches deployment phase change in design proves very
costlybull Numerical tools such as FEM CFD etc helps in improving designs during
concept stagebull Such tools also helps in investigating failures after the product launched in
the market
Design Changes Process
Combustion
External Aerodynamics of car
External Aerodynamics of bike
Tool cutting process Dragonfly CFD simulation
CFD applications
CFD applications in buildings design
Solar collectors on roofs of industrial buildings
Two time steps in an oxygen uptake simulation of a breathing cycle
Contours and path lines at aninhalation time step
CFD in Biomedical application Predicting breathingcycle
ldquoProgress Towards a Medical Image through CFD Analysis Toolkit forRespiratory Function Assessment on a Clinical Time Scalerdquo The Pennsylvania State University daggerApplied ResearchLaboratory daggerdaggerDepartment of Mechanical Engineering Department of Aerospace Engineering Drexel UniversityDepartment of Biomedical Engineering
Finite Element Analysismedical implants
Processes involved in FEMCFD analysis
bull Geometry pre-processingbull Clean upbull Remove unwanted features
bull Mesh generationbull Boundary conditionsbull Materials element type etc
bull Solutionbull Post processing result visualization bull Reports and decision making
Extracting geometry from medical images
Stack of images from MRI (1mm)
Contour extraction by segmentation (using B-
Splines)
Sample points on extracted geometry
GEOMETRIC PRE-PROCESSING
MR (Magnetic Resonance)
Generating a computational mesh
Constrained optimization procedures are needed to maximize a suitable measure of the grid quality (to avoid triangle distorsion) while keeping the desired accuracy of surface representation
Original grid Optimized grid
GEOMETRIC PRE-PROCESSING
Splines on sections
Design Innovation Center at IIT Mandi
bull Design Studio
bull CFD FEM software HyperWorks
Ansys StarCCM+hellip
bull Prototyping and 3D printing
machines
bull Reverse Engineering
Courses
bull Applied CFD
bull Applied FEM
bull Reverse Engineering
bull Design Practicum
bull CAE based final year projects
Projects based on FEMCFD
1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip
Engines from different automotive companies
XL Super heavy duty 95 marketshare 15 year old engine
Example
Final mass
produced design
Original design
Design changes 35 Prototype design 2
Original mass produced
design
Example of real world problem Multidisciplinary natureCAE driven product design
The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26
bull Rubber dampers are provided between thefins to reduce their vibration
bull High vibration of fins produces undesirablenoise
bull Undesirable noise leads to customerdissatisfaction
bull Proper design of the fins are necessary
bull Rubber dampers add extra cost to thevehicle
Rubber dampers
Two-wheeler engine head
TVS Moped Engine Rubber dampers
bull Reliable engine gt 15 years in the market
bull Holds 95 market share in moped class
bull Lakhs of satisfied customers
bull16 dampers on the cylinder head
If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head
Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz
Radiated noise with and without rubber dampers
Experimental verificationhellip
All 16
dampers
in place
Campbell diagram during gradual acceleration
Noise levels have spread and are higher in magnitude in the 2nd case
All 16
dampers
removed
2nd Stage design of Cylinder Head
Thinner part of the fins are fixed now
1st stage design
It was observed that the new head design may notbe feasible from manufacturing point of view
2nd stage cylinder head
Further design
changes and
analysis
Experimental verification Campbell diagram
Existing head with rubber dampers 3rd stage head without rubber dampers
bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head
Noise level comparison
Computational Fluid Dynamic analysis
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
A movie on how technology determines who rules whom
bull Movie Planet of the Apes (2001)bull Entire movie is edited to 5 minutesbull Message from the movie
1 A technologically advanced society are the rulers over other species (here Apes rule Human being)
2 Technology changes with time3 Innovation is the key for survival4 After the movie question will be asked
What you study as an engg student
bull Forces motion structures statics dynamics kinematics mechanics of solids and fluids
bull Energy thermodynamics heat transfer
bull Materials materials engineering amp processing manufacturing
bull Machines graphics design machine elements controls
bull Economics engineering economic analysis cost engineering
bull Human and Social Studies arts humanities social sciences history government ethics law
bull Overall foundation math physics chemistry biology analysis skills communication skills computation skills
Modern method of production
1 Design2 Prototypes3 Testing4 Mass production
Convectional method of production
1 Design2 CAE3 Prototypes4 Testing5 Mass production
Optimization loop
Optimization loop
Material saving weight reduction
CAE Computer Aided Engineering
More prototypes
Less prototypes
Design Changes and costbull Initial design changes incurs less costbull As the product reaches deployment phase change in design proves very
costlybull Numerical tools such as FEM CFD etc helps in improving designs during
concept stagebull Such tools also helps in investigating failures after the product launched in
the market
Design Changes Process
Combustion
External Aerodynamics of car
External Aerodynamics of bike
Tool cutting process Dragonfly CFD simulation
CFD applications
CFD applications in buildings design
Solar collectors on roofs of industrial buildings
Two time steps in an oxygen uptake simulation of a breathing cycle
Contours and path lines at aninhalation time step
CFD in Biomedical application Predicting breathingcycle
ldquoProgress Towards a Medical Image through CFD Analysis Toolkit forRespiratory Function Assessment on a Clinical Time Scalerdquo The Pennsylvania State University daggerApplied ResearchLaboratory daggerdaggerDepartment of Mechanical Engineering Department of Aerospace Engineering Drexel UniversityDepartment of Biomedical Engineering
Finite Element Analysismedical implants
Processes involved in FEMCFD analysis
bull Geometry pre-processingbull Clean upbull Remove unwanted features
bull Mesh generationbull Boundary conditionsbull Materials element type etc
bull Solutionbull Post processing result visualization bull Reports and decision making
Extracting geometry from medical images
Stack of images from MRI (1mm)
Contour extraction by segmentation (using B-
Splines)
Sample points on extracted geometry
GEOMETRIC PRE-PROCESSING
MR (Magnetic Resonance)
Generating a computational mesh
Constrained optimization procedures are needed to maximize a suitable measure of the grid quality (to avoid triangle distorsion) while keeping the desired accuracy of surface representation
Original grid Optimized grid
GEOMETRIC PRE-PROCESSING
Splines on sections
Design Innovation Center at IIT Mandi
bull Design Studio
bull CFD FEM software HyperWorks
Ansys StarCCM+hellip
bull Prototyping and 3D printing
machines
bull Reverse Engineering
Courses
bull Applied CFD
bull Applied FEM
bull Reverse Engineering
bull Design Practicum
bull CAE based final year projects
Projects based on FEMCFD
1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip
Engines from different automotive companies
XL Super heavy duty 95 marketshare 15 year old engine
Example
Final mass
produced design
Original design
Design changes 35 Prototype design 2
Original mass produced
design
Example of real world problem Multidisciplinary natureCAE driven product design
The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26
bull Rubber dampers are provided between thefins to reduce their vibration
bull High vibration of fins produces undesirablenoise
bull Undesirable noise leads to customerdissatisfaction
bull Proper design of the fins are necessary
bull Rubber dampers add extra cost to thevehicle
Rubber dampers
Two-wheeler engine head
TVS Moped Engine Rubber dampers
bull Reliable engine gt 15 years in the market
bull Holds 95 market share in moped class
bull Lakhs of satisfied customers
bull16 dampers on the cylinder head
If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head
Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz
Radiated noise with and without rubber dampers
Experimental verificationhellip
All 16
dampers
in place
Campbell diagram during gradual acceleration
Noise levels have spread and are higher in magnitude in the 2nd case
All 16
dampers
removed
2nd Stage design of Cylinder Head
Thinner part of the fins are fixed now
1st stage design
It was observed that the new head design may notbe feasible from manufacturing point of view
2nd stage cylinder head
Further design
changes and
analysis
Experimental verification Campbell diagram
Existing head with rubber dampers 3rd stage head without rubber dampers
bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head
Noise level comparison
Computational Fluid Dynamic analysis
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
What you study as an engg student
bull Forces motion structures statics dynamics kinematics mechanics of solids and fluids
bull Energy thermodynamics heat transfer
bull Materials materials engineering amp processing manufacturing
bull Machines graphics design machine elements controls
bull Economics engineering economic analysis cost engineering
bull Human and Social Studies arts humanities social sciences history government ethics law
bull Overall foundation math physics chemistry biology analysis skills communication skills computation skills
Modern method of production
1 Design2 Prototypes3 Testing4 Mass production
Convectional method of production
1 Design2 CAE3 Prototypes4 Testing5 Mass production
Optimization loop
Optimization loop
Material saving weight reduction
CAE Computer Aided Engineering
More prototypes
Less prototypes
Design Changes and costbull Initial design changes incurs less costbull As the product reaches deployment phase change in design proves very
costlybull Numerical tools such as FEM CFD etc helps in improving designs during
concept stagebull Such tools also helps in investigating failures after the product launched in
the market
Design Changes Process
Combustion
External Aerodynamics of car
External Aerodynamics of bike
Tool cutting process Dragonfly CFD simulation
CFD applications
CFD applications in buildings design
Solar collectors on roofs of industrial buildings
Two time steps in an oxygen uptake simulation of a breathing cycle
Contours and path lines at aninhalation time step
CFD in Biomedical application Predicting breathingcycle
ldquoProgress Towards a Medical Image through CFD Analysis Toolkit forRespiratory Function Assessment on a Clinical Time Scalerdquo The Pennsylvania State University daggerApplied ResearchLaboratory daggerdaggerDepartment of Mechanical Engineering Department of Aerospace Engineering Drexel UniversityDepartment of Biomedical Engineering
Finite Element Analysismedical implants
Processes involved in FEMCFD analysis
bull Geometry pre-processingbull Clean upbull Remove unwanted features
bull Mesh generationbull Boundary conditionsbull Materials element type etc
bull Solutionbull Post processing result visualization bull Reports and decision making
Extracting geometry from medical images
Stack of images from MRI (1mm)
Contour extraction by segmentation (using B-
Splines)
Sample points on extracted geometry
GEOMETRIC PRE-PROCESSING
MR (Magnetic Resonance)
Generating a computational mesh
Constrained optimization procedures are needed to maximize a suitable measure of the grid quality (to avoid triangle distorsion) while keeping the desired accuracy of surface representation
Original grid Optimized grid
GEOMETRIC PRE-PROCESSING
Splines on sections
Design Innovation Center at IIT Mandi
bull Design Studio
bull CFD FEM software HyperWorks
Ansys StarCCM+hellip
bull Prototyping and 3D printing
machines
bull Reverse Engineering
Courses
bull Applied CFD
bull Applied FEM
bull Reverse Engineering
bull Design Practicum
bull CAE based final year projects
Projects based on FEMCFD
1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip
Engines from different automotive companies
XL Super heavy duty 95 marketshare 15 year old engine
Example
Final mass
produced design
Original design
Design changes 35 Prototype design 2
Original mass produced
design
Example of real world problem Multidisciplinary natureCAE driven product design
The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26
bull Rubber dampers are provided between thefins to reduce their vibration
bull High vibration of fins produces undesirablenoise
bull Undesirable noise leads to customerdissatisfaction
bull Proper design of the fins are necessary
bull Rubber dampers add extra cost to thevehicle
Rubber dampers
Two-wheeler engine head
TVS Moped Engine Rubber dampers
bull Reliable engine gt 15 years in the market
bull Holds 95 market share in moped class
bull Lakhs of satisfied customers
bull16 dampers on the cylinder head
If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head
Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz
Radiated noise with and without rubber dampers
Experimental verificationhellip
All 16
dampers
in place
Campbell diagram during gradual acceleration
Noise levels have spread and are higher in magnitude in the 2nd case
All 16
dampers
removed
2nd Stage design of Cylinder Head
Thinner part of the fins are fixed now
1st stage design
It was observed that the new head design may notbe feasible from manufacturing point of view
2nd stage cylinder head
Further design
changes and
analysis
Experimental verification Campbell diagram
Existing head with rubber dampers 3rd stage head without rubber dampers
bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head
Noise level comparison
Computational Fluid Dynamic analysis
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Modern method of production
1 Design2 Prototypes3 Testing4 Mass production
Convectional method of production
1 Design2 CAE3 Prototypes4 Testing5 Mass production
Optimization loop
Optimization loop
Material saving weight reduction
CAE Computer Aided Engineering
More prototypes
Less prototypes
Design Changes and costbull Initial design changes incurs less costbull As the product reaches deployment phase change in design proves very
costlybull Numerical tools such as FEM CFD etc helps in improving designs during
concept stagebull Such tools also helps in investigating failures after the product launched in
the market
Design Changes Process
Combustion
External Aerodynamics of car
External Aerodynamics of bike
Tool cutting process Dragonfly CFD simulation
CFD applications
CFD applications in buildings design
Solar collectors on roofs of industrial buildings
Two time steps in an oxygen uptake simulation of a breathing cycle
Contours and path lines at aninhalation time step
CFD in Biomedical application Predicting breathingcycle
ldquoProgress Towards a Medical Image through CFD Analysis Toolkit forRespiratory Function Assessment on a Clinical Time Scalerdquo The Pennsylvania State University daggerApplied ResearchLaboratory daggerdaggerDepartment of Mechanical Engineering Department of Aerospace Engineering Drexel UniversityDepartment of Biomedical Engineering
Finite Element Analysismedical implants
Processes involved in FEMCFD analysis
bull Geometry pre-processingbull Clean upbull Remove unwanted features
bull Mesh generationbull Boundary conditionsbull Materials element type etc
bull Solutionbull Post processing result visualization bull Reports and decision making
Extracting geometry from medical images
Stack of images from MRI (1mm)
Contour extraction by segmentation (using B-
Splines)
Sample points on extracted geometry
GEOMETRIC PRE-PROCESSING
MR (Magnetic Resonance)
Generating a computational mesh
Constrained optimization procedures are needed to maximize a suitable measure of the grid quality (to avoid triangle distorsion) while keeping the desired accuracy of surface representation
Original grid Optimized grid
GEOMETRIC PRE-PROCESSING
Splines on sections
Design Innovation Center at IIT Mandi
bull Design Studio
bull CFD FEM software HyperWorks
Ansys StarCCM+hellip
bull Prototyping and 3D printing
machines
bull Reverse Engineering
Courses
bull Applied CFD
bull Applied FEM
bull Reverse Engineering
bull Design Practicum
bull CAE based final year projects
Projects based on FEMCFD
1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip
Engines from different automotive companies
XL Super heavy duty 95 marketshare 15 year old engine
Example
Final mass
produced design
Original design
Design changes 35 Prototype design 2
Original mass produced
design
Example of real world problem Multidisciplinary natureCAE driven product design
The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26
bull Rubber dampers are provided between thefins to reduce their vibration
bull High vibration of fins produces undesirablenoise
bull Undesirable noise leads to customerdissatisfaction
bull Proper design of the fins are necessary
bull Rubber dampers add extra cost to thevehicle
Rubber dampers
Two-wheeler engine head
TVS Moped Engine Rubber dampers
bull Reliable engine gt 15 years in the market
bull Holds 95 market share in moped class
bull Lakhs of satisfied customers
bull16 dampers on the cylinder head
If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head
Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz
Radiated noise with and without rubber dampers
Experimental verificationhellip
All 16
dampers
in place
Campbell diagram during gradual acceleration
Noise levels have spread and are higher in magnitude in the 2nd case
All 16
dampers
removed
2nd Stage design of Cylinder Head
Thinner part of the fins are fixed now
1st stage design
It was observed that the new head design may notbe feasible from manufacturing point of view
2nd stage cylinder head
Further design
changes and
analysis
Experimental verification Campbell diagram
Existing head with rubber dampers 3rd stage head without rubber dampers
bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head
Noise level comparison
Computational Fluid Dynamic analysis
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Design Changes and costbull Initial design changes incurs less costbull As the product reaches deployment phase change in design proves very
costlybull Numerical tools such as FEM CFD etc helps in improving designs during
concept stagebull Such tools also helps in investigating failures after the product launched in
the market
Design Changes Process
Combustion
External Aerodynamics of car
External Aerodynamics of bike
Tool cutting process Dragonfly CFD simulation
CFD applications
CFD applications in buildings design
Solar collectors on roofs of industrial buildings
Two time steps in an oxygen uptake simulation of a breathing cycle
Contours and path lines at aninhalation time step
CFD in Biomedical application Predicting breathingcycle
ldquoProgress Towards a Medical Image through CFD Analysis Toolkit forRespiratory Function Assessment on a Clinical Time Scalerdquo The Pennsylvania State University daggerApplied ResearchLaboratory daggerdaggerDepartment of Mechanical Engineering Department of Aerospace Engineering Drexel UniversityDepartment of Biomedical Engineering
Finite Element Analysismedical implants
Processes involved in FEMCFD analysis
bull Geometry pre-processingbull Clean upbull Remove unwanted features
bull Mesh generationbull Boundary conditionsbull Materials element type etc
bull Solutionbull Post processing result visualization bull Reports and decision making
Extracting geometry from medical images
Stack of images from MRI (1mm)
Contour extraction by segmentation (using B-
Splines)
Sample points on extracted geometry
GEOMETRIC PRE-PROCESSING
MR (Magnetic Resonance)
Generating a computational mesh
Constrained optimization procedures are needed to maximize a suitable measure of the grid quality (to avoid triangle distorsion) while keeping the desired accuracy of surface representation
Original grid Optimized grid
GEOMETRIC PRE-PROCESSING
Splines on sections
Design Innovation Center at IIT Mandi
bull Design Studio
bull CFD FEM software HyperWorks
Ansys StarCCM+hellip
bull Prototyping and 3D printing
machines
bull Reverse Engineering
Courses
bull Applied CFD
bull Applied FEM
bull Reverse Engineering
bull Design Practicum
bull CAE based final year projects
Projects based on FEMCFD
1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip
Engines from different automotive companies
XL Super heavy duty 95 marketshare 15 year old engine
Example
Final mass
produced design
Original design
Design changes 35 Prototype design 2
Original mass produced
design
Example of real world problem Multidisciplinary natureCAE driven product design
The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26
bull Rubber dampers are provided between thefins to reduce their vibration
bull High vibration of fins produces undesirablenoise
bull Undesirable noise leads to customerdissatisfaction
bull Proper design of the fins are necessary
bull Rubber dampers add extra cost to thevehicle
Rubber dampers
Two-wheeler engine head
TVS Moped Engine Rubber dampers
bull Reliable engine gt 15 years in the market
bull Holds 95 market share in moped class
bull Lakhs of satisfied customers
bull16 dampers on the cylinder head
If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head
Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz
Radiated noise with and without rubber dampers
Experimental verificationhellip
All 16
dampers
in place
Campbell diagram during gradual acceleration
Noise levels have spread and are higher in magnitude in the 2nd case
All 16
dampers
removed
2nd Stage design of Cylinder Head
Thinner part of the fins are fixed now
1st stage design
It was observed that the new head design may notbe feasible from manufacturing point of view
2nd stage cylinder head
Further design
changes and
analysis
Experimental verification Campbell diagram
Existing head with rubber dampers 3rd stage head without rubber dampers
bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head
Noise level comparison
Computational Fluid Dynamic analysis
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Design Changes Process
Combustion
External Aerodynamics of car
External Aerodynamics of bike
Tool cutting process Dragonfly CFD simulation
CFD applications
CFD applications in buildings design
Solar collectors on roofs of industrial buildings
Two time steps in an oxygen uptake simulation of a breathing cycle
Contours and path lines at aninhalation time step
CFD in Biomedical application Predicting breathingcycle
ldquoProgress Towards a Medical Image through CFD Analysis Toolkit forRespiratory Function Assessment on a Clinical Time Scalerdquo The Pennsylvania State University daggerApplied ResearchLaboratory daggerdaggerDepartment of Mechanical Engineering Department of Aerospace Engineering Drexel UniversityDepartment of Biomedical Engineering
Finite Element Analysismedical implants
Processes involved in FEMCFD analysis
bull Geometry pre-processingbull Clean upbull Remove unwanted features
bull Mesh generationbull Boundary conditionsbull Materials element type etc
bull Solutionbull Post processing result visualization bull Reports and decision making
Extracting geometry from medical images
Stack of images from MRI (1mm)
Contour extraction by segmentation (using B-
Splines)
Sample points on extracted geometry
GEOMETRIC PRE-PROCESSING
MR (Magnetic Resonance)
Generating a computational mesh
Constrained optimization procedures are needed to maximize a suitable measure of the grid quality (to avoid triangle distorsion) while keeping the desired accuracy of surface representation
Original grid Optimized grid
GEOMETRIC PRE-PROCESSING
Splines on sections
Design Innovation Center at IIT Mandi
bull Design Studio
bull CFD FEM software HyperWorks
Ansys StarCCM+hellip
bull Prototyping and 3D printing
machines
bull Reverse Engineering
Courses
bull Applied CFD
bull Applied FEM
bull Reverse Engineering
bull Design Practicum
bull CAE based final year projects
Projects based on FEMCFD
1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip
Engines from different automotive companies
XL Super heavy duty 95 marketshare 15 year old engine
Example
Final mass
produced design
Original design
Design changes 35 Prototype design 2
Original mass produced
design
Example of real world problem Multidisciplinary natureCAE driven product design
The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26
bull Rubber dampers are provided between thefins to reduce their vibration
bull High vibration of fins produces undesirablenoise
bull Undesirable noise leads to customerdissatisfaction
bull Proper design of the fins are necessary
bull Rubber dampers add extra cost to thevehicle
Rubber dampers
Two-wheeler engine head
TVS Moped Engine Rubber dampers
bull Reliable engine gt 15 years in the market
bull Holds 95 market share in moped class
bull Lakhs of satisfied customers
bull16 dampers on the cylinder head
If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head
Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz
Radiated noise with and without rubber dampers
Experimental verificationhellip
All 16
dampers
in place
Campbell diagram during gradual acceleration
Noise levels have spread and are higher in magnitude in the 2nd case
All 16
dampers
removed
2nd Stage design of Cylinder Head
Thinner part of the fins are fixed now
1st stage design
It was observed that the new head design may notbe feasible from manufacturing point of view
2nd stage cylinder head
Further design
changes and
analysis
Experimental verification Campbell diagram
Existing head with rubber dampers 3rd stage head without rubber dampers
bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head
Noise level comparison
Computational Fluid Dynamic analysis
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Combustion
External Aerodynamics of car
External Aerodynamics of bike
Tool cutting process Dragonfly CFD simulation
CFD applications
CFD applications in buildings design
Solar collectors on roofs of industrial buildings
Two time steps in an oxygen uptake simulation of a breathing cycle
Contours and path lines at aninhalation time step
CFD in Biomedical application Predicting breathingcycle
ldquoProgress Towards a Medical Image through CFD Analysis Toolkit forRespiratory Function Assessment on a Clinical Time Scalerdquo The Pennsylvania State University daggerApplied ResearchLaboratory daggerdaggerDepartment of Mechanical Engineering Department of Aerospace Engineering Drexel UniversityDepartment of Biomedical Engineering
Finite Element Analysismedical implants
Processes involved in FEMCFD analysis
bull Geometry pre-processingbull Clean upbull Remove unwanted features
bull Mesh generationbull Boundary conditionsbull Materials element type etc
bull Solutionbull Post processing result visualization bull Reports and decision making
Extracting geometry from medical images
Stack of images from MRI (1mm)
Contour extraction by segmentation (using B-
Splines)
Sample points on extracted geometry
GEOMETRIC PRE-PROCESSING
MR (Magnetic Resonance)
Generating a computational mesh
Constrained optimization procedures are needed to maximize a suitable measure of the grid quality (to avoid triangle distorsion) while keeping the desired accuracy of surface representation
Original grid Optimized grid
GEOMETRIC PRE-PROCESSING
Splines on sections
Design Innovation Center at IIT Mandi
bull Design Studio
bull CFD FEM software HyperWorks
Ansys StarCCM+hellip
bull Prototyping and 3D printing
machines
bull Reverse Engineering
Courses
bull Applied CFD
bull Applied FEM
bull Reverse Engineering
bull Design Practicum
bull CAE based final year projects
Projects based on FEMCFD
1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip
Engines from different automotive companies
XL Super heavy duty 95 marketshare 15 year old engine
Example
Final mass
produced design
Original design
Design changes 35 Prototype design 2
Original mass produced
design
Example of real world problem Multidisciplinary natureCAE driven product design
The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26
bull Rubber dampers are provided between thefins to reduce their vibration
bull High vibration of fins produces undesirablenoise
bull Undesirable noise leads to customerdissatisfaction
bull Proper design of the fins are necessary
bull Rubber dampers add extra cost to thevehicle
Rubber dampers
Two-wheeler engine head
TVS Moped Engine Rubber dampers
bull Reliable engine gt 15 years in the market
bull Holds 95 market share in moped class
bull Lakhs of satisfied customers
bull16 dampers on the cylinder head
If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head
Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz
Radiated noise with and without rubber dampers
Experimental verificationhellip
All 16
dampers
in place
Campbell diagram during gradual acceleration
Noise levels have spread and are higher in magnitude in the 2nd case
All 16
dampers
removed
2nd Stage design of Cylinder Head
Thinner part of the fins are fixed now
1st stage design
It was observed that the new head design may notbe feasible from manufacturing point of view
2nd stage cylinder head
Further design
changes and
analysis
Experimental verification Campbell diagram
Existing head with rubber dampers 3rd stage head without rubber dampers
bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head
Noise level comparison
Computational Fluid Dynamic analysis
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
CFD applications in buildings design
Solar collectors on roofs of industrial buildings
Two time steps in an oxygen uptake simulation of a breathing cycle
Contours and path lines at aninhalation time step
CFD in Biomedical application Predicting breathingcycle
ldquoProgress Towards a Medical Image through CFD Analysis Toolkit forRespiratory Function Assessment on a Clinical Time Scalerdquo The Pennsylvania State University daggerApplied ResearchLaboratory daggerdaggerDepartment of Mechanical Engineering Department of Aerospace Engineering Drexel UniversityDepartment of Biomedical Engineering
Finite Element Analysismedical implants
Processes involved in FEMCFD analysis
bull Geometry pre-processingbull Clean upbull Remove unwanted features
bull Mesh generationbull Boundary conditionsbull Materials element type etc
bull Solutionbull Post processing result visualization bull Reports and decision making
Extracting geometry from medical images
Stack of images from MRI (1mm)
Contour extraction by segmentation (using B-
Splines)
Sample points on extracted geometry
GEOMETRIC PRE-PROCESSING
MR (Magnetic Resonance)
Generating a computational mesh
Constrained optimization procedures are needed to maximize a suitable measure of the grid quality (to avoid triangle distorsion) while keeping the desired accuracy of surface representation
Original grid Optimized grid
GEOMETRIC PRE-PROCESSING
Splines on sections
Design Innovation Center at IIT Mandi
bull Design Studio
bull CFD FEM software HyperWorks
Ansys StarCCM+hellip
bull Prototyping and 3D printing
machines
bull Reverse Engineering
Courses
bull Applied CFD
bull Applied FEM
bull Reverse Engineering
bull Design Practicum
bull CAE based final year projects
Projects based on FEMCFD
1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip
Engines from different automotive companies
XL Super heavy duty 95 marketshare 15 year old engine
Example
Final mass
produced design
Original design
Design changes 35 Prototype design 2
Original mass produced
design
Example of real world problem Multidisciplinary natureCAE driven product design
The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26
bull Rubber dampers are provided between thefins to reduce their vibration
bull High vibration of fins produces undesirablenoise
bull Undesirable noise leads to customerdissatisfaction
bull Proper design of the fins are necessary
bull Rubber dampers add extra cost to thevehicle
Rubber dampers
Two-wheeler engine head
TVS Moped Engine Rubber dampers
bull Reliable engine gt 15 years in the market
bull Holds 95 market share in moped class
bull Lakhs of satisfied customers
bull16 dampers on the cylinder head
If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head
Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz
Radiated noise with and without rubber dampers
Experimental verificationhellip
All 16
dampers
in place
Campbell diagram during gradual acceleration
Noise levels have spread and are higher in magnitude in the 2nd case
All 16
dampers
removed
2nd Stage design of Cylinder Head
Thinner part of the fins are fixed now
1st stage design
It was observed that the new head design may notbe feasible from manufacturing point of view
2nd stage cylinder head
Further design
changes and
analysis
Experimental verification Campbell diagram
Existing head with rubber dampers 3rd stage head without rubber dampers
bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head
Noise level comparison
Computational Fluid Dynamic analysis
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Two time steps in an oxygen uptake simulation of a breathing cycle
Contours and path lines at aninhalation time step
CFD in Biomedical application Predicting breathingcycle
ldquoProgress Towards a Medical Image through CFD Analysis Toolkit forRespiratory Function Assessment on a Clinical Time Scalerdquo The Pennsylvania State University daggerApplied ResearchLaboratory daggerdaggerDepartment of Mechanical Engineering Department of Aerospace Engineering Drexel UniversityDepartment of Biomedical Engineering
Finite Element Analysismedical implants
Processes involved in FEMCFD analysis
bull Geometry pre-processingbull Clean upbull Remove unwanted features
bull Mesh generationbull Boundary conditionsbull Materials element type etc
bull Solutionbull Post processing result visualization bull Reports and decision making
Extracting geometry from medical images
Stack of images from MRI (1mm)
Contour extraction by segmentation (using B-
Splines)
Sample points on extracted geometry
GEOMETRIC PRE-PROCESSING
MR (Magnetic Resonance)
Generating a computational mesh
Constrained optimization procedures are needed to maximize a suitable measure of the grid quality (to avoid triangle distorsion) while keeping the desired accuracy of surface representation
Original grid Optimized grid
GEOMETRIC PRE-PROCESSING
Splines on sections
Design Innovation Center at IIT Mandi
bull Design Studio
bull CFD FEM software HyperWorks
Ansys StarCCM+hellip
bull Prototyping and 3D printing
machines
bull Reverse Engineering
Courses
bull Applied CFD
bull Applied FEM
bull Reverse Engineering
bull Design Practicum
bull CAE based final year projects
Projects based on FEMCFD
1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip
Engines from different automotive companies
XL Super heavy duty 95 marketshare 15 year old engine
Example
Final mass
produced design
Original design
Design changes 35 Prototype design 2
Original mass produced
design
Example of real world problem Multidisciplinary natureCAE driven product design
The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26
bull Rubber dampers are provided between thefins to reduce their vibration
bull High vibration of fins produces undesirablenoise
bull Undesirable noise leads to customerdissatisfaction
bull Proper design of the fins are necessary
bull Rubber dampers add extra cost to thevehicle
Rubber dampers
Two-wheeler engine head
TVS Moped Engine Rubber dampers
bull Reliable engine gt 15 years in the market
bull Holds 95 market share in moped class
bull Lakhs of satisfied customers
bull16 dampers on the cylinder head
If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head
Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz
Radiated noise with and without rubber dampers
Experimental verificationhellip
All 16
dampers
in place
Campbell diagram during gradual acceleration
Noise levels have spread and are higher in magnitude in the 2nd case
All 16
dampers
removed
2nd Stage design of Cylinder Head
Thinner part of the fins are fixed now
1st stage design
It was observed that the new head design may notbe feasible from manufacturing point of view
2nd stage cylinder head
Further design
changes and
analysis
Experimental verification Campbell diagram
Existing head with rubber dampers 3rd stage head without rubber dampers
bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head
Noise level comparison
Computational Fluid Dynamic analysis
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Finite Element Analysismedical implants
Processes involved in FEMCFD analysis
bull Geometry pre-processingbull Clean upbull Remove unwanted features
bull Mesh generationbull Boundary conditionsbull Materials element type etc
bull Solutionbull Post processing result visualization bull Reports and decision making
Extracting geometry from medical images
Stack of images from MRI (1mm)
Contour extraction by segmentation (using B-
Splines)
Sample points on extracted geometry
GEOMETRIC PRE-PROCESSING
MR (Magnetic Resonance)
Generating a computational mesh
Constrained optimization procedures are needed to maximize a suitable measure of the grid quality (to avoid triangle distorsion) while keeping the desired accuracy of surface representation
Original grid Optimized grid
GEOMETRIC PRE-PROCESSING
Splines on sections
Design Innovation Center at IIT Mandi
bull Design Studio
bull CFD FEM software HyperWorks
Ansys StarCCM+hellip
bull Prototyping and 3D printing
machines
bull Reverse Engineering
Courses
bull Applied CFD
bull Applied FEM
bull Reverse Engineering
bull Design Practicum
bull CAE based final year projects
Projects based on FEMCFD
1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip
Engines from different automotive companies
XL Super heavy duty 95 marketshare 15 year old engine
Example
Final mass
produced design
Original design
Design changes 35 Prototype design 2
Original mass produced
design
Example of real world problem Multidisciplinary natureCAE driven product design
The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26
bull Rubber dampers are provided between thefins to reduce their vibration
bull High vibration of fins produces undesirablenoise
bull Undesirable noise leads to customerdissatisfaction
bull Proper design of the fins are necessary
bull Rubber dampers add extra cost to thevehicle
Rubber dampers
Two-wheeler engine head
TVS Moped Engine Rubber dampers
bull Reliable engine gt 15 years in the market
bull Holds 95 market share in moped class
bull Lakhs of satisfied customers
bull16 dampers on the cylinder head
If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head
Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz
Radiated noise with and without rubber dampers
Experimental verificationhellip
All 16
dampers
in place
Campbell diagram during gradual acceleration
Noise levels have spread and are higher in magnitude in the 2nd case
All 16
dampers
removed
2nd Stage design of Cylinder Head
Thinner part of the fins are fixed now
1st stage design
It was observed that the new head design may notbe feasible from manufacturing point of view
2nd stage cylinder head
Further design
changes and
analysis
Experimental verification Campbell diagram
Existing head with rubber dampers 3rd stage head without rubber dampers
bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head
Noise level comparison
Computational Fluid Dynamic analysis
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Processes involved in FEMCFD analysis
bull Geometry pre-processingbull Clean upbull Remove unwanted features
bull Mesh generationbull Boundary conditionsbull Materials element type etc
bull Solutionbull Post processing result visualization bull Reports and decision making
Extracting geometry from medical images
Stack of images from MRI (1mm)
Contour extraction by segmentation (using B-
Splines)
Sample points on extracted geometry
GEOMETRIC PRE-PROCESSING
MR (Magnetic Resonance)
Generating a computational mesh
Constrained optimization procedures are needed to maximize a suitable measure of the grid quality (to avoid triangle distorsion) while keeping the desired accuracy of surface representation
Original grid Optimized grid
GEOMETRIC PRE-PROCESSING
Splines on sections
Design Innovation Center at IIT Mandi
bull Design Studio
bull CFD FEM software HyperWorks
Ansys StarCCM+hellip
bull Prototyping and 3D printing
machines
bull Reverse Engineering
Courses
bull Applied CFD
bull Applied FEM
bull Reverse Engineering
bull Design Practicum
bull CAE based final year projects
Projects based on FEMCFD
1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip
Engines from different automotive companies
XL Super heavy duty 95 marketshare 15 year old engine
Example
Final mass
produced design
Original design
Design changes 35 Prototype design 2
Original mass produced
design
Example of real world problem Multidisciplinary natureCAE driven product design
The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26
bull Rubber dampers are provided between thefins to reduce their vibration
bull High vibration of fins produces undesirablenoise
bull Undesirable noise leads to customerdissatisfaction
bull Proper design of the fins are necessary
bull Rubber dampers add extra cost to thevehicle
Rubber dampers
Two-wheeler engine head
TVS Moped Engine Rubber dampers
bull Reliable engine gt 15 years in the market
bull Holds 95 market share in moped class
bull Lakhs of satisfied customers
bull16 dampers on the cylinder head
If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head
Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz
Radiated noise with and without rubber dampers
Experimental verificationhellip
All 16
dampers
in place
Campbell diagram during gradual acceleration
Noise levels have spread and are higher in magnitude in the 2nd case
All 16
dampers
removed
2nd Stage design of Cylinder Head
Thinner part of the fins are fixed now
1st stage design
It was observed that the new head design may notbe feasible from manufacturing point of view
2nd stage cylinder head
Further design
changes and
analysis
Experimental verification Campbell diagram
Existing head with rubber dampers 3rd stage head without rubber dampers
bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head
Noise level comparison
Computational Fluid Dynamic analysis
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Extracting geometry from medical images
Stack of images from MRI (1mm)
Contour extraction by segmentation (using B-
Splines)
Sample points on extracted geometry
GEOMETRIC PRE-PROCESSING
MR (Magnetic Resonance)
Generating a computational mesh
Constrained optimization procedures are needed to maximize a suitable measure of the grid quality (to avoid triangle distorsion) while keeping the desired accuracy of surface representation
Original grid Optimized grid
GEOMETRIC PRE-PROCESSING
Splines on sections
Design Innovation Center at IIT Mandi
bull Design Studio
bull CFD FEM software HyperWorks
Ansys StarCCM+hellip
bull Prototyping and 3D printing
machines
bull Reverse Engineering
Courses
bull Applied CFD
bull Applied FEM
bull Reverse Engineering
bull Design Practicum
bull CAE based final year projects
Projects based on FEMCFD
1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip
Engines from different automotive companies
XL Super heavy duty 95 marketshare 15 year old engine
Example
Final mass
produced design
Original design
Design changes 35 Prototype design 2
Original mass produced
design
Example of real world problem Multidisciplinary natureCAE driven product design
The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26
bull Rubber dampers are provided between thefins to reduce their vibration
bull High vibration of fins produces undesirablenoise
bull Undesirable noise leads to customerdissatisfaction
bull Proper design of the fins are necessary
bull Rubber dampers add extra cost to thevehicle
Rubber dampers
Two-wheeler engine head
TVS Moped Engine Rubber dampers
bull Reliable engine gt 15 years in the market
bull Holds 95 market share in moped class
bull Lakhs of satisfied customers
bull16 dampers on the cylinder head
If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head
Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz
Radiated noise with and without rubber dampers
Experimental verificationhellip
All 16
dampers
in place
Campbell diagram during gradual acceleration
Noise levels have spread and are higher in magnitude in the 2nd case
All 16
dampers
removed
2nd Stage design of Cylinder Head
Thinner part of the fins are fixed now
1st stage design
It was observed that the new head design may notbe feasible from manufacturing point of view
2nd stage cylinder head
Further design
changes and
analysis
Experimental verification Campbell diagram
Existing head with rubber dampers 3rd stage head without rubber dampers
bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head
Noise level comparison
Computational Fluid Dynamic analysis
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Generating a computational mesh
Constrained optimization procedures are needed to maximize a suitable measure of the grid quality (to avoid triangle distorsion) while keeping the desired accuracy of surface representation
Original grid Optimized grid
GEOMETRIC PRE-PROCESSING
Splines on sections
Design Innovation Center at IIT Mandi
bull Design Studio
bull CFD FEM software HyperWorks
Ansys StarCCM+hellip
bull Prototyping and 3D printing
machines
bull Reverse Engineering
Courses
bull Applied CFD
bull Applied FEM
bull Reverse Engineering
bull Design Practicum
bull CAE based final year projects
Projects based on FEMCFD
1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip
Engines from different automotive companies
XL Super heavy duty 95 marketshare 15 year old engine
Example
Final mass
produced design
Original design
Design changes 35 Prototype design 2
Original mass produced
design
Example of real world problem Multidisciplinary natureCAE driven product design
The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26
bull Rubber dampers are provided between thefins to reduce their vibration
bull High vibration of fins produces undesirablenoise
bull Undesirable noise leads to customerdissatisfaction
bull Proper design of the fins are necessary
bull Rubber dampers add extra cost to thevehicle
Rubber dampers
Two-wheeler engine head
TVS Moped Engine Rubber dampers
bull Reliable engine gt 15 years in the market
bull Holds 95 market share in moped class
bull Lakhs of satisfied customers
bull16 dampers on the cylinder head
If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head
Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz
Radiated noise with and without rubber dampers
Experimental verificationhellip
All 16
dampers
in place
Campbell diagram during gradual acceleration
Noise levels have spread and are higher in magnitude in the 2nd case
All 16
dampers
removed
2nd Stage design of Cylinder Head
Thinner part of the fins are fixed now
1st stage design
It was observed that the new head design may notbe feasible from manufacturing point of view
2nd stage cylinder head
Further design
changes and
analysis
Experimental verification Campbell diagram
Existing head with rubber dampers 3rd stage head without rubber dampers
bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head
Noise level comparison
Computational Fluid Dynamic analysis
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Design Innovation Center at IIT Mandi
bull Design Studio
bull CFD FEM software HyperWorks
Ansys StarCCM+hellip
bull Prototyping and 3D printing
machines
bull Reverse Engineering
Courses
bull Applied CFD
bull Applied FEM
bull Reverse Engineering
bull Design Practicum
bull CAE based final year projects
Projects based on FEMCFD
1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip
Engines from different automotive companies
XL Super heavy duty 95 marketshare 15 year old engine
Example
Final mass
produced design
Original design
Design changes 35 Prototype design 2
Original mass produced
design
Example of real world problem Multidisciplinary natureCAE driven product design
The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26
bull Rubber dampers are provided between thefins to reduce their vibration
bull High vibration of fins produces undesirablenoise
bull Undesirable noise leads to customerdissatisfaction
bull Proper design of the fins are necessary
bull Rubber dampers add extra cost to thevehicle
Rubber dampers
Two-wheeler engine head
TVS Moped Engine Rubber dampers
bull Reliable engine gt 15 years in the market
bull Holds 95 market share in moped class
bull Lakhs of satisfied customers
bull16 dampers on the cylinder head
If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head
Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz
Radiated noise with and without rubber dampers
Experimental verificationhellip
All 16
dampers
in place
Campbell diagram during gradual acceleration
Noise levels have spread and are higher in magnitude in the 2nd case
All 16
dampers
removed
2nd Stage design of Cylinder Head
Thinner part of the fins are fixed now
1st stage design
It was observed that the new head design may notbe feasible from manufacturing point of view
2nd stage cylinder head
Further design
changes and
analysis
Experimental verification Campbell diagram
Existing head with rubber dampers 3rd stage head without rubber dampers
bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head
Noise level comparison
Computational Fluid Dynamic analysis
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Projects based on FEMCFD
1 Earthquake resistance building designs2 Medical implants3 Vehicle aerodynamics4 Energy efficient buildings5 Solar photovoltaic analysis6 Engine design7 Crankshaft design8 Reverse engineering and 3D Printing9 hellip
Engines from different automotive companies
XL Super heavy duty 95 marketshare 15 year old engine
Example
Final mass
produced design
Original design
Design changes 35 Prototype design 2
Original mass produced
design
Example of real world problem Multidisciplinary natureCAE driven product design
The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26
bull Rubber dampers are provided between thefins to reduce their vibration
bull High vibration of fins produces undesirablenoise
bull Undesirable noise leads to customerdissatisfaction
bull Proper design of the fins are necessary
bull Rubber dampers add extra cost to thevehicle
Rubber dampers
Two-wheeler engine head
TVS Moped Engine Rubber dampers
bull Reliable engine gt 15 years in the market
bull Holds 95 market share in moped class
bull Lakhs of satisfied customers
bull16 dampers on the cylinder head
If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head
Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz
Radiated noise with and without rubber dampers
Experimental verificationhellip
All 16
dampers
in place
Campbell diagram during gradual acceleration
Noise levels have spread and are higher in magnitude in the 2nd case
All 16
dampers
removed
2nd Stage design of Cylinder Head
Thinner part of the fins are fixed now
1st stage design
It was observed that the new head design may notbe feasible from manufacturing point of view
2nd stage cylinder head
Further design
changes and
analysis
Experimental verification Campbell diagram
Existing head with rubber dampers 3rd stage head without rubber dampers
bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head
Noise level comparison
Computational Fluid Dynamic analysis
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Engines from different automotive companies
XL Super heavy duty 95 marketshare 15 year old engine
Example
Final mass
produced design
Original design
Design changes 35 Prototype design 2
Original mass produced
design
Example of real world problem Multidisciplinary natureCAE driven product design
The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26
bull Rubber dampers are provided between thefins to reduce their vibration
bull High vibration of fins produces undesirablenoise
bull Undesirable noise leads to customerdissatisfaction
bull Proper design of the fins are necessary
bull Rubber dampers add extra cost to thevehicle
Rubber dampers
Two-wheeler engine head
TVS Moped Engine Rubber dampers
bull Reliable engine gt 15 years in the market
bull Holds 95 market share in moped class
bull Lakhs of satisfied customers
bull16 dampers on the cylinder head
If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head
Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz
Radiated noise with and without rubber dampers
Experimental verificationhellip
All 16
dampers
in place
Campbell diagram during gradual acceleration
Noise levels have spread and are higher in magnitude in the 2nd case
All 16
dampers
removed
2nd Stage design of Cylinder Head
Thinner part of the fins are fixed now
1st stage design
It was observed that the new head design may notbe feasible from manufacturing point of view
2nd stage cylinder head
Further design
changes and
analysis
Experimental verification Campbell diagram
Existing head with rubber dampers 3rd stage head without rubber dampers
bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head
Noise level comparison
Computational Fluid Dynamic analysis
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Final mass
produced design
Original design
Design changes 35 Prototype design 2
Original mass produced
design
Example of real world problem Multidisciplinary natureCAE driven product design
The Effect of rubber dampers on engines NVH and thermal performance 2014 O P Singh et al Appl Acoustics (Elsevier) 75(1) pp 17-26
bull Rubber dampers are provided between thefins to reduce their vibration
bull High vibration of fins produces undesirablenoise
bull Undesirable noise leads to customerdissatisfaction
bull Proper design of the fins are necessary
bull Rubber dampers add extra cost to thevehicle
Rubber dampers
Two-wheeler engine head
TVS Moped Engine Rubber dampers
bull Reliable engine gt 15 years in the market
bull Holds 95 market share in moped class
bull Lakhs of satisfied customers
bull16 dampers on the cylinder head
If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head
Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz
Radiated noise with and without rubber dampers
Experimental verificationhellip
All 16
dampers
in place
Campbell diagram during gradual acceleration
Noise levels have spread and are higher in magnitude in the 2nd case
All 16
dampers
removed
2nd Stage design of Cylinder Head
Thinner part of the fins are fixed now
1st stage design
It was observed that the new head design may notbe feasible from manufacturing point of view
2nd stage cylinder head
Further design
changes and
analysis
Experimental verification Campbell diagram
Existing head with rubber dampers 3rd stage head without rubber dampers
bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head
Noise level comparison
Computational Fluid Dynamic analysis
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
bull Rubber dampers are provided between thefins to reduce their vibration
bull High vibration of fins produces undesirablenoise
bull Undesirable noise leads to customerdissatisfaction
bull Proper design of the fins are necessary
bull Rubber dampers add extra cost to thevehicle
Rubber dampers
Two-wheeler engine head
TVS Moped Engine Rubber dampers
bull Reliable engine gt 15 years in the market
bull Holds 95 market share in moped class
bull Lakhs of satisfied customers
bull16 dampers on the cylinder head
If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head
Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz
Radiated noise with and without rubber dampers
Experimental verificationhellip
All 16
dampers
in place
Campbell diagram during gradual acceleration
Noise levels have spread and are higher in magnitude in the 2nd case
All 16
dampers
removed
2nd Stage design of Cylinder Head
Thinner part of the fins are fixed now
1st stage design
It was observed that the new head design may notbe feasible from manufacturing point of view
2nd stage cylinder head
Further design
changes and
analysis
Experimental verification Campbell diagram
Existing head with rubber dampers 3rd stage head without rubber dampers
bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head
Noise level comparison
Computational Fluid Dynamic analysis
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Two-wheeler engine head
TVS Moped Engine Rubber dampers
bull Reliable engine gt 15 years in the market
bull Holds 95 market share in moped class
bull Lakhs of satisfied customers
bull16 dampers on the cylinder head
If dampers are removed the new cylinder head should have noise level equal to or better than the existing cylinder head
Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz
Radiated noise with and without rubber dampers
Experimental verificationhellip
All 16
dampers
in place
Campbell diagram during gradual acceleration
Noise levels have spread and are higher in magnitude in the 2nd case
All 16
dampers
removed
2nd Stage design of Cylinder Head
Thinner part of the fins are fixed now
1st stage design
It was observed that the new head design may notbe feasible from manufacturing point of view
2nd stage cylinder head
Further design
changes and
analysis
Experimental verification Campbell diagram
Existing head with rubber dampers 3rd stage head without rubber dampers
bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head
Noise level comparison
Computational Fluid Dynamic analysis
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Comparison of noise radiated from the engines with and without rubberdampers on the cylinder head at 3150 Hz
Radiated noise with and without rubber dampers
Experimental verificationhellip
All 16
dampers
in place
Campbell diagram during gradual acceleration
Noise levels have spread and are higher in magnitude in the 2nd case
All 16
dampers
removed
2nd Stage design of Cylinder Head
Thinner part of the fins are fixed now
1st stage design
It was observed that the new head design may notbe feasible from manufacturing point of view
2nd stage cylinder head
Further design
changes and
analysis
Experimental verification Campbell diagram
Existing head with rubber dampers 3rd stage head without rubber dampers
bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head
Noise level comparison
Computational Fluid Dynamic analysis
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Experimental verificationhellip
All 16
dampers
in place
Campbell diagram during gradual acceleration
Noise levels have spread and are higher in magnitude in the 2nd case
All 16
dampers
removed
2nd Stage design of Cylinder Head
Thinner part of the fins are fixed now
1st stage design
It was observed that the new head design may notbe feasible from manufacturing point of view
2nd stage cylinder head
Further design
changes and
analysis
Experimental verification Campbell diagram
Existing head with rubber dampers 3rd stage head without rubber dampers
bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head
Noise level comparison
Computational Fluid Dynamic analysis
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
2nd Stage design of Cylinder Head
Thinner part of the fins are fixed now
1st stage design
It was observed that the new head design may notbe feasible from manufacturing point of view
2nd stage cylinder head
Further design
changes and
analysis
Experimental verification Campbell diagram
Existing head with rubber dampers 3rd stage head without rubber dampers
bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head
Noise level comparison
Computational Fluid Dynamic analysis
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
It was observed that the new head design may notbe feasible from manufacturing point of view
2nd stage cylinder head
Further design
changes and
analysis
Experimental verification Campbell diagram
Existing head with rubber dampers 3rd stage head without rubber dampers
bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head
Noise level comparison
Computational Fluid Dynamic analysis
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Further design
changes and
analysis
Experimental verification Campbell diagram
Existing head with rubber dampers 3rd stage head without rubber dampers
bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head
Noise level comparison
Computational Fluid Dynamic analysis
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Experimental verification Campbell diagram
Existing head with rubber dampers 3rd stage head without rubber dampers
bull Similar Campbell diagram in both the cylinder headbull 3rd stage cylinder head can replace the existing cylinder head
Noise level comparison
Computational Fluid Dynamic analysis
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Noise level comparison
Computational Fluid Dynamic analysis
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Computational Fluid Dynamic analysis
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Temperature distribution
1st stage cylinder head 3rd stage cylinder head
bull 3rd stage cylinder head shows lower temperature on the fins and in thebull combustion chamber compared to the 1st stage design of the headbull This is experimentally verifiedbull 3rd stage design without rubber dampers is implemented on the vehicle for mass
production
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
bull Among many benefits few advantages are listed below
1 Rubber damper manufacturing process is eliminated completely rubberproduction is harmful to the environment
2 Long term benefits over a period of time typically after six months of use rubberdampers properties deteriorates and it becomes brittle due high temperature of thefins The initial grip between the dampers and fins reduces and finally these damperscome off the engine The noise radiated from the engine increase again Henceputting rubber dampers on engines does not provide long-term benefits
3 Logistics and inventory reduction logistics of dampers involves the integration ofinformation transportation inventory warehousing material handling andpackaging
4 Man power saving since rubber dampers are not an integral part of the engineadditional workman are needed to hammer down the rubbers between the fins
5 Part count reduction rubber dampers are additional parts that needs to put on theengine before integrating on the vehicle and hence increases the number of partcount of the engine
6 Improves engine cooling rubber dampers restricts the free flow of air around theengines and hence increases the overall engine temperature
Costs and environmental impact
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Life cycle cost benefit
Each rubber damper cost = Rs 1
Total cost dampers = 16 x 1 = Rs 16
Additional benefit = Rs 4
Total saving = Rs (16 + 4) = Rs 20vehicle
Sales = 70000 vehiclesmonth
Benefitmonth = Rs 20 x 70000 = 14 Lakhmonth
Benefityear = 12 x 14 lakh = 168 Croreyear
Life cycle benefit = 10 x 168 crore = 168 crore
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Product life cycle Competitors upper hand
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
3D printing technology Innovation in manufacturing
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Recent news headlines on 3D printing technology
How 3D Printing Is Revolutionizing Surgery
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
How 3D printing works
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
3D printed parts in space
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Misuse of 3D printing technology Making gun
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
3D printing machine by IIT Mandi students
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
A movie on how technology can save our life
bull Movie Jurassic Park IIIbull Entire movie is edited to 6 minutesbull Message from the movie
1 Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs)
2 Even though a technology developed keeping in mind an specific use but it end in many other useful usages
3 Eg mobile was developed to transfer wireless voice but today is used for internet photos videos doing business etc
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Be an entrepreneur उदयमी उदयोगपति
Get a high paying jobbull Aerospace Engineerbull Agricultural Engineerbull Automotive Engineerbull Biomedical Engineerbull Chemical Engineerbull Drafting and Design Engineerbull Environmental Engineerbull Geological Engineerbull Marine Engineerbull Petroleum Engineerbull Software Engineer
You work for others
Options for an engineers
Can you work for yourself for your passion
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Definition of Entrepreneur
ldquoAn individual who rather than working as an employee runs a smallbusiness and assumes all the risk and reward of a given business ventureidea or good or service offered for sale The entrepreneur is commonly seenas a business leader and innovator of new ideas and business processesrdquo
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
News headlines
bull Sachin Bansal 32 a mere six years to buildFlipkart the countrys best-known online retailbrand
bull The IIT-Delhi alumnus started off with collegefriend Binny Bansal in a small flat in southeastBangalore in 2007 with Rs 4 lakh
bull Started from selling books now diversified manyother areas such as electronics house holdappliances etchellip
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Budget 2014 Startups amp entrepreneursget Rs 10000 crore backup
Yes we can
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
bull A student interview with APJ Abdul Kalambull APJ Kalam ask students how India can become a developed nationbull How Any Idea
How India can become a developed nation
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
bull How India can become a developed countrybull Oath for the Students
httpswwwyoutubecomwatchv=ZkBEq5dk7BI
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
When broken from INSIDE its life When broken from OUTSIDE its death
Life or death it depends on you
bull Lots of external pressure from peer group teachers employer friendshellipbull If you give in to external pressure you are finishedbull Always say from within ldquoI can do itrdquo ldquoIrsquoll winrdquo ldquoIrsquoll fightrdquohellipbull ldquoMann ke Jite Jeet Mann ke Hare Haarrdquobull If you think you will succeed you will its all in mind
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
bull A journalist interview with APJ Abdul Kalambull APJ Kalam was asked on what qualities a leader should possessbull A leader should have vision able to take risk take his time together
in success and failurebull A leadership qualities can be developed with patience practicehellip
What are the qualities of a leader
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Be a leader
APJ Abdul Kalam speaks on leadership with Arnab Goswami
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Yoursquore the future of India we look towards you to solve our society problems
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Reverse Engineering
Khul Ja Sim-Sim
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Forward Engineering
Concept Engineering
a product Product
Reverse Engineering
Product Reverse
Engineering Concept
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Reverse Engineering
ldquoExamining competitive or similar or prior products ingreat detail by dissecting them or literally taking themapartrdquo
- Dym amp Little
ldquoHow does it do thatrdquo
ldquoWhy would you want to do thatrdquo
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
ldquoSometimes the best way to advance
is in reverserdquo By Eldad Eilam
Why Reverse Engineering
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
In general the product is defined as
bull a ldquothing produced by labor or effortrdquo or
bull the ldquoresult of an act or a processrdquo
Example Fan Computers Software Pen Clock Bottle
etc
What is a Product
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Who make product
bull Entrepreneurs
bull Engineers
bull Designers
bull Students
bull hellip
Why make product
bull Earn money
bull Get recognition
bull Social service
bull Personal satisfaction
bull hellip
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Startup company by IIT studentsbull Company name IdeaForge
bull NETRA is a completely autonomous Unmanned
Aerial Vehicle ndash for Intelligence Surveillance
and Reconnaissance of moving and fixed
targets
bull NETRA streams you real time video of the
target area with spotless clarity
bull Helped Nepal during Earthquake saved many
life
bull Initially struggled lots of failure in designs
Unmanned aerial vehicles are the best way to
access risky terrain especially cracked
buildings during an earthquake Here rescue
officials are inspecting a ramshackled building
in the 2015 Nepal earthquake Image
ideaForge
Video
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
If you want to design a bird like machine
you have to study the bird first
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Reverse Engineering
Gain insight into our own design problem bylooking at how other people have addressed thesame issues
Restrictions
ndash Expensive designs
ndash Protected by copyrights and patents
ndash May be the competitorrsquos design
ndash Design may not work very well
ndash Design may be copied difficult to copy knowledge
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Reasons for reverse engineering
Interfacing
Military or
commercial
espionage
ObsolescenceBug fixing
Saving money
(Value Engineering
Competitive
technical
intelligence
Creation of
unlicensed
unapproved
duplicates
Software
modernization
Reverse Engineering
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Reasons for reverse engineering a part or product
1 The original manufacturer of a product no longer produces a product
2 There is inadequate documentation of the original design
3 The original manufacturer no longer exists but a customer needs the product
4 The original design documentation has been lost or never existed
5 Some bad features of a product need to be designed out For example
excessive wear might indicate where a product should be improved
6 To strengthen the good features of a product based on long-term usage of the
product
7 To analyze the good and bad features of competitors product
8 To explore new avenues to improve product performance and features
9 To gain competitive benchmarking methods to understand competitors
products and develop better products
10The original CAD model is not sufficient to support modifications or current
manufacturing methods
11The original supplier is unable or unwilling to provide additional parts
12The original equipment manufacturers are either unwilling or unable to supply
replacement parts or demand inflated costs for sole-source parts
13To update obsolete materials or antiquated manufacturing processes with more
current less-expensive technologies
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Reverse Engineering for military applications
World war II Jerry can
bull British and American forces noticed
that the Germans had gasoline cans
with an excellent design
bull They reverse-engineered copies of
those cans
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Reverse Engineering for military applications
World war II Panzerschreck
bull The Germans captured an American Bazooka during World War
II and reverse engineered it to create the larger Panzerschreck
bull See how the need of mask removed in improved design
Improved designOriginal design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Reverse Engineering for military applications
World war II Tupolev Tu-4
bull Three American B-29 bombers on missions over Japan were
forced to land in the USSR
bull The Soviets who did not have a similar strategic bomber decided
to copy the B-29
bull Within a few years they had developed the Tu-4 a near-perfect
copy
Tupolev Tu-4B-29 bombers
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Reverse Engineering for military applications
World war II K-13R-3S missile
K-13 Short-range infrared homing air-to-
air missile developed by the Soviet Union
An AIM-9E Sidewinder missile on
display at the National Air and
Space Museum
bull Soviet reverse-engineered copy of the AIM-9 Sidewinder was made possible
after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding The missile
became lodged within the airframe and the pilot returned to base with what
Russian scientists would describe as a university course in missile development
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Investigation Prediction and Hypothesis
Concrete Experience Function amp Form
Design Models
Design Analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
Adapted from Otto and Woodrsquos ldquoReverse Engineering and Redesign Methodologyrdquo UT Austin
Reverse
Engineering
Modeling amp
Analysis
Redesign
Product (re)design begins with Reverse
Engineering Methodology
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
1 Investigation Prediction and Hypothesis
bull Develop black box model
bull Use Experience product
bull List assumed working principles
bull Perform economic feasibility of redesign
bull State process description or activity
diagram
Reverse Engineering Methodology
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Car Crash
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Engine Oil consumption measurement
Drain capDipstick
Example
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Method Advantages Disadvantages
Drain amp
measure
Simple and economical
No complicated equipment
required
No skilled labor required
Error in measurement
Approx 25 hrs to run
Impossible to drain all oil practically
Increase in viscosity due to degradation increases
time of drain
Tracer
Radioactive
Sulfur
Measurement time ndash order of
minutes
Transient effects can be measured
Very costly equipment and special handling
procedures for radioactive material
Secondary measurements and calibration of air
and fuel flow
Oil deposited on piston valves and exhaust after
treatment devices not accounted for in final
measurement
Smart Oil
Consumption
Meter
Level sensor to gauge level of oil in
crankcase
Measurement time of the order of
hours
Accuracy of level sensor is of concern
Requires addition of new oil
Suitable for diesel engines
Transient effects cannot be measured
New Method
Cheap to build and use
Portable
Run time of the order of hours
Pump flow characteristics can be
studied
Addition of new oil not required
Accuracy of the scale
Vibrations need to be handled better
Leakages have to be monitored
Comparison of various oil consumption measurement techniques
Engine Oil consumption measurement methods
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
Glass tube
Metal stand
Metal scale
Slider
Tube
Tube
Engine
Engine stand
Crankcase
Dipstick
Drain cap
1 Investigation Prediction and Hypothesis
Example Engine oil measurement
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
75
8
85
9
95
10
105
11
1000 1060 1120 1180 1240 1300 1360 1420 1480 1540 1600
Lev
el o
f oil
(cm
)
Volume in crankcase (ml)
45
42
37 372
6
52
46
44
3
35
4
45
5
55
6
65
0 20 40 60 80 100 120
Oil
Co
ns
um
pti
on
(m
lh
)Time (hours)
New Method
Drain amp Measure
Example Engine oil measurement
Calibration and measurement
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
2 Concrete Experience Function and Form
bull Plan and execute product disassembly
bull Group defined systems and components together
bull Experiment with product components
bull Develop free body diagrams
bull Identify function sharing and compatibility
bull Transform to engineering specs and metrics
Reverse Engineering MethodologyRE
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
3 Design Modelsbull Identify actual physical principlesbull Constantly consider the customerbull Create engineering models and metric rangesbull Alternatively or concurrently build prototype to test
parametersbull Ethical issuesbull IPR issues
Reverse Engineering Methodology
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
4 Design Analysis
bull Calibrate model
bull Create engineering analysis simulation or optimization
bull Create experiment and testing procedures
Reverse Engineering Methodology
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
5 Parametric Redesign
bull Optimize design parameters
bull Perform sensitivity analysis and tolerance design
bull Build and test prototype
Reverse Engineering Methodology
Parametric design Prototypes testing
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
6 Adaptive Redesign
ndash Recommend new subsystems
ndash Search for inventive solutions
ndash Analyze force flows and component combinations
ndash Build and test prototype
Reverse Engineering Methodology
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
7 Original Redesign
ndash Develop new functional structure
ndash Choose alternatives
ndash Verify design concepts
ndash Build and test prototype
Reverse Engineering Methodology
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
System Level Design
bull Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together
bull This concept is known as System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design
System Level Design
System = Components + Connections
bull Components
ndash Physical - pick-up measure draw on CAD
ndash Functional - flowcharts difficult to define
bull Connections
ndash Fundamental - intended design
ndash Incidental - created by physical proximity of components (vibration heat transfer etc)
System Level Design