3DWORX (www.3dworx.co.za) is the sub-Saharan distributor for eviXscan 3D scanners. A company from South Africa offers services in the field of high-precision 3D scanning, CAD design, reverse engineering, and 3D printing.
Reverse Engineering a 900kg Rotor for a Rubber Mixing Machine Using an eviXscan 3D Scanner and Oqton Geomagic Design X
Metal Fatigue Failure of Rubber Mixing Machine Rotor
3DWORX in South Africa was engaged by a truck tyre manufacturer to advise on ways to manufacture one of a mirrored pair of 900kg hardened steel rotors for a rubber mixing machine, as the rotor had snapped like a toothpick from very high torque and metal fatigue.
The machine had been imported many decades previously, so replacement parts were not available, and even if they could be sourced it could easily take a year to two for parts to land in South Africa.
The broken rotor showed signs of welding repairs and machining, and nobody knew what the original bearing and keyway sizes were, so again it was realised that if a part could be sourced it may not even match due to repairs and modifications done over decades.
Decision to 3D Scan, Design 3D CAD Models and Manufacture New Parts
A solution had to be found quickly to manufacture a replacement rotor in South Africa, but no schematics or CAD models existed.
The rotor had precision-machined bearing surfaces and keyways on each end, but the central section consisted of two organic-shaped “wings” that mixed tons of rubber as it passed through the mixer. These central sections could not be sketched in CAD easily, so generating a 3D model was not as easy as simply sketching in a conventional CAD program.
The hardened surfaces on the “wings” were severely worn, with significant abrasion and pitting, so 3DWORX proposed to their client that the unbroken rotor in the pair should be 3D scanned so that 3D CAD models could be built from the 3D scan data.
The rotors in the pair had some mirrored features, but the two rotors weren’t simply complete mirrors of one another. This was going to be tricky reverse-engineering project, requiring some state-of-the art hardware, software and techniques.
3D Scanning
The project was approved and 3D scanning was done on-site with an eviXscan HD Optima 3D scanner – a metrology-grade, professional 3D scanner that uses structured blue light to measure parts to an accuracy of 20 microns, for which the scanner has a VDI/VDE calibration certificate. The eviXscan HD Optima is portable and yet extremely stable as it is mounted on a very sturdy Manfrotto tripod, with which it ships.
A white contrast spray was applied and eviXscan’s unique-code magnetic markers were used to make alignment of the many 3D scans almost completely automated – a huge time-saver.
eviXscan unique-code magnetic markers to automate scan alignment.
The eviXscan Suite software was used to reconstruct the many 3D scans into a mesh model that could be exported so that a 3D CAD model could then be created, from which two new rotors could be manufactured.
Analysis with Geomagic Design X
Initial analysis with Geomagic Design X after 3D scanning revealed that the unbroken rotor was bent along its longitudinal axis, so it was likely that it would also fail if put back into use, so two CAD models would be needed.
Hybrid CAD Modelling using Geomagic Design X
A hybrid 3D CAD modelling technique using typical geometric CAD features combined with splines would have to be used to create the 3D models.
3DWORX knew that Geomagic Design X Pro was the only solution, with its ability to quickly generate a surface model of the organic-shaped “wings” from a massive amount of 3D scan data and also sketch the more conventional shaft end detail. Geomagic Design X was able to effortlessly manipulate the huge mesh model while the 3D CAD model was sketched and constructed around the scan data.
Geomagic Design X Pro “Auto Sketch” used to accelerate sketching the core shaft.
Modelling the organic-shaped “wings” was always going to be tricky and at first a manual “feature following” technique was used, but it was quickly discovered that Geomagic Design X Pro could do this automatically using “Auto Surfacing”, saving days of modelling time!
Geomagic Design X Pro “Auto Surfacing”
This is where Geomagic Design X Pro shines, as the reverse-engineering task and improvements to the component designs would have been almost impossibly slow and costly using traditional CAD software.
Completed 3D CAD models in Geomagic Design X Pro.
Comparing 3D CAD Model with 3D Scan
After the first 3D CAD model was completed, it was compared with the eviXscan 3D scan data using the “Accuracy Analyzer” in Geomagic Design X. The result was simply outstanding, illustrating how the best possible 3D CAD model fit was obtained, considering the significant state of damage of the rotor that was 3D scanned.
Accuracy Analyzer in Geomagic Design X Pro
Some Reflections on the Project and Tools
The above real-world example illustrates how engineers can rapidly create solutions to complex manufacturing and production problems when they access to the best toolset and skills.
The 3D scanning would have been even quicker using eviXscan’s newest 3D scanners, specifically the eviXscan WideRange 65 with its very large field-of-view, or the eviXscan 3D Quadro with its four cameras and dual field-of-view for both small and large objects.
Both of these new eviXscan models can 3D scan larger areas with their significantly faster, higher-resolution cameras for even faster, high-precision results at an affordable cost for robust and reliable, professional metrology equipment.
The combination of eviXscan’s various 3D scanners, the eviXscan Suite of software (included with scanners) and Oqton Geomagic Design X offer great value for money for the professional engineer, for reverse engineering and optical inspection for quality control.
Industry: 3DWORX
3DWORX (www.3dworx.co.za) is the sub-Saharan distributor for eviXscan 3D scanners. A company from South Africa offers services in the field of high-precision 3D scanning, CAD design, reverse engineering, and 3D printing.
Reverse Engineering a 900kg Rotor for a Rubber Mixing Machine Using an eviXscan 3D Scanner and Oqton Geomagic Design X
Metal Fatigue Failure of Rubber Mixing Machine Rotor
3DWORX in South Africa was engaged by a truck tyre manufacturer to advise on ways to manufacture one of a mirrored pair of 900kg hardened steel rotors for a rubber mixing machine, as the rotor had snapped like a toothpick from very high torque and metal fatigue.
The machine had been imported many decades previously, so replacement parts were not available, and even if they could be sourced it could easily take a year to two for parts to land in South Africa.
The broken rotor showed signs of welding repairs and machining, and nobody knew what the original bearing and keyway sizes were, so again it was realised that if a part could be sourced it may not even match due to repairs and modifications done over decades.
Decision to 3D Scan, Design 3D CAD Models and Manufacture New Parts
A solution had to be found quickly to manufacture a replacement rotor in South Africa, but no schematics or CAD models existed.
The rotor had precision-machined bearing surfaces and keyways on each end, but the central section consisted of two organic-shaped “wings” that mixed tons of rubber as it passed through the mixer. These central sections could not be sketched in CAD easily, so generating a 3D model was not as easy as simply sketching in a conventional CAD program.
The hardened surfaces on the “wings” were severely worn, with significant abrasion and pitting, so 3DWORX proposed to their client that the unbroken rotor in the pair should be 3D scanned so that 3D CAD models could be built from the 3D scan data.
The rotors in the pair had some mirrored features, but the two rotors weren’t simply complete mirrors of one another. This was going to be tricky reverse-engineering project, requiring some state-of-the art hardware, software and techniques.
3D Scanning
The project was approved and 3D scanning was done on-site with an eviXscan HD Optima 3D scanner – a metrology-grade, professional 3D scanner that uses structured blue light to measure parts to an accuracy of 20 microns, for which the scanner has a VDI/VDE calibration certificate. The eviXscan HD Optima is portable and yet extremely stable as it is mounted on a very sturdy Manfrotto tripod, with which it ships.
A white contrast spray was applied and eviXscan’s unique-code magnetic markers were used to make alignment of the many 3D scans almost completely automated – a huge time-saver.
eviXscan unique-code magnetic markers to automate scan alignment.
The eviXscan Suite software was used to reconstruct the many 3D scans into a mesh model that could be exported so that a 3D CAD model could then be created, from which two new rotors could be manufactured.
Analysis with Geomagic Design X
Initial analysis with Geomagic Design X after 3D scanning revealed that the unbroken rotor was bent along its longitudinal axis, so it was likely that it would also fail if put back into use, so two CAD models would be needed.
Hybrid CAD Modelling using Geomagic Design X
A hybrid 3D CAD modelling technique using typical geometric CAD features combined with splines would have to be used to create the 3D models.
3DWORX knew that Geomagic Design X Pro was the only solution, with its ability to quickly generate a surface model of the organic-shaped “wings” from a massive amount of 3D scan data and also sketch the more conventional shaft end detail. Geomagic Design X was able to effortlessly manipulate the huge mesh model while the 3D CAD model was sketched and constructed around the scan data.
Geomagic Design X Pro “Auto Sketch” used to accelerate sketching the core shaft.
Modelling the organic-shaped “wings” was always going to be tricky and at first a manual “feature following” technique was used, but it was quickly discovered that Geomagic Design X Pro could do this automatically using “Auto Surfacing”, saving days of modelling time!
Geomagic Design X Pro “Auto Surfacing”
This is where Geomagic Design X Pro shines, as the reverse-engineering task and improvements to the component designs would have been almost impossibly slow and costly using traditional CAD software.
Completed 3D CAD models in Geomagic Design X Pro.
Comparing 3D CAD Model with 3D Scan
After the first 3D CAD model was completed, it was compared with the eviXscan 3D scan data using the “Accuracy Analyzer” in Geomagic Design X. The result was simply outstanding, illustrating how the best possible 3D CAD model fit was obtained, considering the significant state of damage of the rotor that was 3D scanned.
Accuracy Analyzer in Geomagic Design X Pro
Some Reflections on the Project and Tools
The above real-world example illustrates how engineers can rapidly create solutions to complex manufacturing and production problems when they access to the best toolset and skills.
The 3D scanning would have been even quicker using eviXscan’s newest 3D scanners, specifically the eviXscan WideRange 65 with its very large field-of-view, or the eviXscan 3D Quadro with its four cameras and dual field-of-view for both small and large objects.
Both of these new eviXscan models can 3D scan larger areas with their significantly faster, higher-resolution cameras for even faster, high-precision results at an affordable cost for robust and reliable, professional metrology equipment.
The combination of eviXscan’s various 3D scanners, the eviXscan Suite of software (included with scanners) and Oqton Geomagic Design X offer great value for money for the professional engineer, for reverse engineering and optical inspection for quality control.
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Event Information
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