Reverse Engineering Flashcards
What is design
A subset of the technical activities within the product development process
Name three major subsections of product development
- Marketing and business case
- Design process
- Manufacturing process
Define an original design
Involves elaborating original solutions for a given task
- they disrupt the market
- replace old equipment and the infrastructure around it
- often high risks involved
Define an adaptive design
Involves adapting a known system to a changed task
- can be novel but doesn’t require significant restructuring of the system within which the product operates
- reflection of the marketplace
- reasonable risk
Define variant design
Involves varying the parameters (size, geometry, material properties) of a product to develop a new or more robust design
Define redesign
Implies product already exists which falls short of some criteria - new solution required
For this new solution we can use any design approach e.g. original, adaptive etc.
Technology innovations typically manifest themselves into a market along what kind of curve
S - curve
What drives redesign
profit
What is reverse engineering
The prediction of what a product should do followed by modelling, analysis, dissection and experimentation of its actual performance
What follows reverse engineering
Redesign
First task of reverse engineering
Understand the market for current product - done by doing a customer needs analysis
Second task of reverse engineering
Make estimates of how product ought to function - dissect product, understand how it satisfies/doesn’t satisfy the customers
Customer needs: explain these terms - direct needs - latent needs - constant needs - variable needs - general needs
direct needs:
well defined that customers declare
latent needs:
customers will not express without probing
constant needs:
intrinsic to the task and always will be
variable needs:
difficult to define but important
general needs:
apply to every person in customer population
List ways of gathering customer needs
- interviews
- questionnaires
- focus groups
- be the customer yourself
Describe: function
function:
a clear statement of a reproducible relationship between input and desired output
Describe: product function
product function:
overall intent function of product
Describe: Abstraction
Abstraction:
process of ignoring what is particular and emphasizing the essential
Describe: Constraint
Constraint:
A statement of a clear criterion that must be satisfied by the product
Describe the tear down process
step1 - list the design issues
step2 - prepare for product tear down
step3 - examine the distribution and installation
step4 - disassemble, measure and analyse assemblies
step5 - form a bill of materials
During reverse engineering a product is:
- predicted
- observed
- disassembled
- analysed
- tested
- documented
In what terms is reverse engineering completed
- functionality
- form
- physical principles
- manufacturability
- assemblability
- general strengths
- general weakness
For cast aluminium alloys, what do the second 2 digits indicate.
What does Y indicate
1XX.Y
2 digits:
indicated minimum % of aluminium
i.e. 150Y - 99.5% alu
Y either (0,1)
0 - cast
1 - ingot
For wrought aluminium allows, what do final 2 digits indicate
what does second digit indicate
1XXX
Final 2 digits indicate minimum purity
e.g. 1050 is 99.50% Al
second digit indicates close relationship
e.g. 5052,5252,5325 are all very similar
Properties of non-heat treatable alloys
have low yield point, low tensile strength in the fully annealed condition. Hence easily formable
Properties of heat treatable
alloys that can be strengthened using heat treatment. The majority used for structural components
Basic temper designations: F - O - H - T -
F - As fabricated
O - Annealed and recrystallised
H - Cold worked
T - Heat treated
Example of commercially used Aluminium alloys
1060 - chemical equipment, tankers
2618 - aircraft engines
How are steel alloys classified
according to composition
e.g. first two digits indicate the type of allow additions made to iron
Example of steel alloy
4140 - pressure vessels & aircraft structural parts
How are titanium alloys classified
according to phases in the material
either: alpha, beta or alpha + beta
Properties of alpha phase in titanium alloys
- non heat treatable
- HCP
Properties of beta phase in titanium alloys
- heat treatable
- BCC
Example of titanium alloy
Ti - 6Al - 4V
How are nickel alloys designated
Designation consists of letter N, followed by 5 digit code
e.g. N02XXX - no alloying elements, impurities defined
Definition of fatigue
fatigue:
a fracture that propagates normal to the direction of maximum principle stress under cyclic loading
What materials are more likely to fail under fatigue
more likely: metals and polymers (tough)
less likely: ceramics (brittle)
What is the primary design criterion in rotating parts
cyclic loading stress limit < static stress capability
