Figure 1
The flowchart illustrates the workflow for reverse engineering and additive manufacturing of a gear component. The process begins with Reverse Engineering, including Legacy Cast Part, 3-dimensional scanning using Artec Space Spider, Mesh Generation using Artec Studio, and C A D Reconstruction. The next stage, Design Optimization and Verification, includes Generative Design using Autodesk Fusion 360 followed by Static Structural F E A using A N S Y S Workbench. Process Planning, Pre-build, and A M Distortion, includes L P B F process simulation using A N S Y S Additive Print 2024 R 1. The Additive Manufacturing stage branches into L P B F using cobalt chromium and B M D using 4140 steel, followed by Post Processing, including Support Removal and Shot Blasting. The Evaluation stage includes Mechanical Testing for tensile and microhardness properties and Dimensional Verification through deviation analysis. The final stage is Field Validation through gear contact-pattern check according to A P I 677.Conceptual framework linking reverse engineering, design optimization and verification, process planning, additive manufacturing, evaluation and field validation for replacement of legacy components using additive manufacturing
Source: Authors’ own work