Reengineering and Fast Manufacturing for Impact-Induced Fatigue and Fracture Problems in Aging Aircrafts

Abstract

The public reporting burden for this collection of information is estimated to average 1 hour per response, including the ering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regardir matio including suggestions for reducing the burden, to Department of Defense, Washington Headquarters Services, Directo fferso Davis Highway, Suite 1204, Arlington, VA 22202-4302. Respondents should be aware that notwithstanding any of ailing comply with a collection of information if it does not display a currently valid OMB control number. PLEASE DO NOT NUMBER(S)12. DISTRIBUTION/AVAILABILITY STATEMENT Distribution Statement A. Approved for public release; distribution is unlimited. SUPPLEMENTARY NOTES ABSTRACTIn this research, a systematic reverse engineering, re-engineering, and fast manufacturing (RRF) process has been developed and validated. Commercial off-the-shelf (COTS) software tools and equipment that support the RRF process have been identified, evaluated, and tested. An integration framework has also been developed and employed to create an RRF testbed. This testbed constructed using COTS software and equipment supports three major engineering tasks: the reverse engineering that supports recovering of technical data from worn sample parts, re-engineering that alters design for better performance or lower cost, and fast prototyping that incorporates advanced manufacturing technologies to produce functional or physical prototype of the part in small quantity in a short turnaround time. The primary objective of the project is to develop a systematic, accurate, and efficient re-engineering and prototyping technology for fatigue and fracture of mechanical parts and subsystems, especially due to impact loads, for both military and industrial applications. The goals are to demonstrate such a technology, to support Oklahoma City Air Logistics Center (OC-ALC) to establish similar integrated system in the near future, and to assist OC-ALC to gradually build up expertise to adequately tackle the fatigue and fracture problems. Ultimately, the system developed in the proposed research will support OC-ALC engineers to re-engineer and manufacture quality parts and subsystems that enhance reliability of the aging fleets, therefore, overcoming the new challenge and successfully accomplishing OC-ALC's missions.In this research, a systematic reverse engineering, re-engineering, and fast manufacturing (RRF) process has been developed and validated. Commercial off-the-shelf (COTS) software tools and equipment that support the RRF process have been identified, evaluated, and tested. An integration framework has also been developed and employed to create an RRF testbed. This testbed constructed using COTS software and equipment supports three major engineering tasks: the reverse engineering that supports recovering of technical data from worn sample parts, re-engineering that alters design for better performance or lower cost, and fast prototyping that incorporates advanced manufa...

A Review on Shape Engineering and Design Parameterization in Reverse Engineering

“…We did the first screening on nine leading software tools that are commercially available. This screening was carried out based on the information provided in product brochure, technical reports (for example, Siddique, 2002;Chang et al, 2006), thesis (for examle, Gibson, 2004), company web sites, on-line software demo, case study reports, etc. After the screening, we acquired four tools and conducted hands-on evaluations, using five industrial examples.…”