Abstract
Reverse engineering is the process of creating a digital version of an existing part without any knowledge in advance about the design intent. Due to 3D printing, the reconstructed part can be rapidly fabricated for prototyping or even for practical usage. To showcase this combination, this study presents a workflow on how to restore a motorcycle braking pedal from material SS316L with the Powder Bed Fusion (PBF) technology. Firstly, the CAD model of the original braking pedal was created. Before the actual PBF printing, the braking pedal printing process was simulated to identify the possible imperfections. The printed braking pedal was then subjected to quality control in terms of the shape distortion from its CAD counterpart and strength assessments, conducted both numerically and physically. As a result, the exterior shape of the braking pedal was restored. Additionally, by means of material assessments and physical tests, it was able to prove that the restored pedal was fully functional. Finally, an approach was proposed to optimize the braking pedal with a lattice structure to utilize the advantages the PBF technology offers.
Highlights
Three-dimensional printing is an additive production technology, in which a physical part is produced layer by layer from a 3D model [1]
The braking pedals printed by the SS316L were studied from both the material and the geometry perspectives
One of the solid pedals was subjected to geometry inspection using 3D scanning, and strength inspection using both the FE and physical tests
Summary
Three-dimensional printing is an additive production technology, in which a physical part is produced layer by layer from a 3D model [1]. Due to the small-scale nature of the reverse engineering process, utilization of 3D printing technology is a better option in terms of manufacturing time, not to mention that the technology can offer design freedom, such as the integration of lattice structures into the braking pedal for lighter weight. It was subjected to both numerical and physical studies for quality control regarding the shape distortion and strength Another highlight of this paper is that the braking pedal was optimized with lattice structures without changing its exterior look. Four braking pedal samples were printed, including three solid (one was used for testing the maximum force that a driver can exert on the pedal, one was subjected to 3D scanning and ESPI measurement, one was post-processed), and one optimized version with lattice. FiiinngutthhreeBBBeeecce1ososs.iinniddWdcceellessuuo,,sssrtt,iikeeootccfnnelhhosscnn..whiiccnaaoillfcnnatoohltteeenssroeaatrsreeetsolliirassattrteeeiddolnaaisnnctddaesdddeiissasccntuuudssdsseedydd.iswwciiutthhsiisnneeedaaccwhhissteehccittniioonneaaacnnhdd ssuummmmaarriizzeedd section and summ in22.. tMMheaattceeroriinaallcssluaannsddioMMnsee.tthhooddss
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