Reverse engineering can be used to derive a 3D model of an existing physical part when such a model is not readily available. For parts that will be fabricated with subtractive and formative manufacturing processes, existing reverse engineering techniques can be readily applied, but parts produced with additive manufacturing can present new challenges due to the high level of process-induced distortions and unique part attributes. This paper introduces an integrated 3D scanning and process simulation data-driven framework to minimize distortions of reverse-engineered additively manufactured components. This framework employs iterative finite element simulations to predict geometric distortions to minimize errors between the predicted and measured geometrical deviations of the key dimensional characteristics of the part. The effectiveness of this approach is then demonstrated by reverse engineering two Inconel-718 components manufactured using laser powder bed fusion additive manufacturing. This paper presents a remanufacturing process that combines reverse engineering and additive manufacturing, leveraging geometric feature-based part compensation through process simulation. Our approach can generate both compensated STL and parametric CAD models, eliminating laborious experimentation during reverse engineering. We evaluate the merits of STL-based and CAD-based approaches by quantifying the errors induced at the different steps of the proposed approach and analyzing the influence of varying part geometries. Using the proposed CAD-based method, the average absolute percent error between simulation-predicted distorted dimensions and actual measured dimensions of the manufactured parts was 0.087%, with better accuracy than the STL-based method.

翻译：逆向工程可用于在缺乏现成模型时获取现有物理零件的三维模型。对于采用减材与等材制造工艺生产的零件，现有逆向工程技术可直接应用，但增材制造零件因工艺诱发变形程度高及独特零件属性而带来新挑战。本文提出一种集成三维扫描与工艺仿真数据驱动的框架，用于最小化逆向工程增材制造零件的变形。该框架采用迭代有限元仿真预测几何变形，以最小化零件关键尺寸特性的预测偏差与实测偏差之间的误差。通过激光粉末床熔融增材制造工艺生产的两个Inconel-718零件验证了该方法的有效性。本文提出一种结合逆向工程与增材制造的再制造工艺，通过工艺仿真实现基于几何特征的零件补偿。该方法可生成补偿后的STL模型和参数化CAD模型，消除了逆向工程中的繁琐实验。我们通过量化所提方法不同步骤中引入的误差，并分析不同零件几何形状的影响，评估了基于STL与基于CAD方法的优劣。采用基于CAD的方法时，仿真预测变形尺寸与制造零件实际测量尺寸之间的平均绝对百分比误差为0.087%，精度优于基于STL的方法。