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عدد المساهمات : 18984 التقييم : 35458 تاريخ التسجيل : 01/07/2009 الدولة : مصر العمل : مدير منتدى هندسة الإنتاج والتصميم الميكانيكى
| موضوع: كتاب Reverse Engineering - Mechanisms, Structures, Systems, and Materials الأحد 13 أكتوبر 2024, 1:56 am | |
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أخواني في الله أحضرت لكم كتاب Reverse Engineering - Mechanisms, Structures, Systems, and Materials Robert W. Messier, Jr.
و المحتوى كما يلي :
Contents Preface CHAPTER 1 Introduction 1–1 Human Beings Are a Naturally Curious Species 1–2 Taking Things Apart to Learn 1–3 Learning from Experience 1–4 The Fundamental Approaches of Engineering 1–5 The Critical Role of Dissection 1–6 Summary 1–7 Cited References 1–8 Thought Questions and Problems CHAPTER 2 The Status and Role of Reverse Engineering 2–1 The Status of Reverse Engineering in References 2–2 Reverse Engineering Defined 2–3 Motivations for Reverse Engineering 2–4 Engineering Design and the Engineering Design Process 2–5 Types of Design 2–6 Uses for and Benefits and Risks of Reverse Engineering. 2–7 Summary 2–8 Cited References 2–9 Thought Questions and Problems CHAPTER 3 History of Reverse Engineering 3–1 The Likely Emergence of Reverse Engineering3–2 Reverse Engineering in the Middle Ages 3–3 Reverse Engineering during the Industrial Revolution 3–4 Reverse Engineering during World War II 3–5 Reverse Engineering in the Cold War and Beyond… 3–6 Summary 3–7 Cited References 3–8 Recommended Readings 3–9 Thought Questions and Problems CHAPTER 4 The Teardown Process 4–1 The Purpose of Teardown 4–2 Observation 4–3 Measurement 4–4 Experimentation 4–5 Other Specific Forms of Teardown 4–6 Summary 4–7 Cited References 4–8 Thought Questions and Problems. CHAPTER 5 Methods of Product Teardown 5–1 The Product Teardown Process Revisited 5–2 The General Procedure for the Teardown Process 5–3 Teardown Analysis or Value Analysis Teardown 5–4 The Subtract-and-Operate Procedure 5–5 Force Flow Diagrams (or Energy Flow Field Design) 5–6 Functional Models 5–7 Illustrative Example of a Product Teardown 5–8 Summary 5–9 Cited References 5–10 Thought Questions and ProblemsCHAPTER 6 Failure Analysis and Forensic Engineering 6–1 Introduction to Failure Analysis 6–2 Sources of Failures in Mechanical Systems 6–3 Mechanisms of Failure in Materials 6–4 The General Procedure for Conducting a Failure Analysis. 6–5 Two Exemplary Failure Analysis Cases 6–6 Forensic Engineering 6–7 An Exemplary Forensic Engineering Case 6–8 Summary 6–9 Cited References 6–10 Thought Questions and Problems CHAPTER 7 Deducing or Inferring Role, Purpose, and Functionality during Reverse Engineering 7–1 The Procedure for Reverse Engineering 7–2 Knowing versus Identifying versus Deducing versus Deferring 7–3 The Value of Experience 7–4 Using Available Evidence, Clues, and Cues 7–5 Using Geometry 7–6 Using Flows of Force, Energy, and/or Fluids 7–7 Using Functional Units or Subsystems from a Functional Model 7-8 Summary 7–9 Cited References 7–10 Thought Questions and Problems CHAPTER 8 The Antikythera Mechanism 8–1 The Discovery 8–2 The Recovery8–3 The Suspected Device 8–4 Operation of the Mechanism 8–5 Reverse-Engineering Investigations and Reconstructed Models 8–6 Proposed Planet Indicator Schemes 8–7 Similar Devices, Possible Predecessors, and the Possible Creator 8–8 Speculation on Role, Purpose, and Functionality 8–9 Summary 8–10 Cited References 8–11 Thought Questions and Problems CHAPTER 9 Identifying Materials-of-Construction 9–1 The Role of Materials in Engineering 9–2 The Structure-Property-Processing-Performance Interrelationship 9–3 Material Properties and Performance 9–1 A Primer on Materials 9–5 A Primer on Material Properties 9–6 Relationships for Material Properties in Material Selection Charts 9–7 Identifying Materials by Observation Only 9–8 Laboratory Identification Methods 9–9 Summary 9–10 Cited References 9–11 Recommended Readings 9–12 Thought Questions and Problems CHAPTER 10 Inferring Methods-of-Manufacture or -Construction 10–1 Interaction among Function, Material, Shape, and Process10–2 The Role of Manufacturing or Construction 10–3 The Taxonomy of Manufacturing Processes 10–4 Process Attributes 10–5 Inferring Method-of-Manufacture or -Construction from Observations 10–6 A Word on Heat Treatment 10–7 Summary 10–8 Cited References 10–9 Recommended Readings 10–10 Thought Questions and Problems CHAPTER 11 Construction of Khufu’s Pyramid: Humankind’s Greatest Engineering Creation 11–1 Herodotus Reveals the Pyramids to the World 11–2 The Great Pyramid of Khufu 11–3 Theories on the Purpose of the Pyramids 11–4 Theories on the Location of the Great Pyramid 11–5 Theories on the Construction of the Great Pyramid 11–6 Deducing the Likely Reality of Construction by Reverse Engineering 11–7 Summary 11–8 Cited References 11–9 Recommended Readings 11–10 Thought Questions and Problems CHAPTER 12 Assessing Design Suitability 12–1 Different Designs, Different Role, Purpose, and Functionality 12–2 Form, Fit, and Function 12–3 Using Observable Evidence and Clues to Assess Form, Fit, and Function12–4 Summary 12–5 Thought Questions and Problems CHAPTER 13 Bringing It All Together with Illustrative Examples …. 13–1 Proverbs Make the Point; Pictures Fix the Lesson 13–2 Conair Electric Hair Blow-Dryer 13–3 An Automatic Electric Coffeemaker 13–4 Toro Electric Leaf Blower 13–5 Skil Handheld Electric Circular Saw 13–6 Lessons Learned 13–7 Summary 13–8 Cited References 13–9 Thought Questions and Problems CHAPTER 14 Value and Production Engineering 14–1 Manufacturability 14–2 Design for Manufacturability 14–3 Value Engineering 14–4 Production Engineering 14–5 Summary 14–6 Cited References 14–7 Recommended Readings 14–8 Thought Questions and Problems CHAPTER 15 Reverse Engineering Materials and Substances 15–1 Flattery or Forgery 15–2 Motivations for Reverse Engineering Materials and Substances 15–3 Finding Substitute and Replacement Substances and Materials15–4 Creating Generic Materials (Generics) 15–5 Synthesizing Natural Materials and Substances: Biomimicry 15–6 Imitating Natural Materials 15–7 Summary 15–8 Cited References 15–9 Thought Questions and Problems CHAPTER 16 Reverse Engineering Broken, Worn, or Obsolete Parts for Remanufacture 16–1 Necessity Is the Mother of Invention 16–2 The Motivation for Reverse Engineering for Remanufacture 16–3 Reverse Engineering Broken Parts for Remanufacture 16–4 Reverse Engineering Deformed or Worn Parts for Remanufacture 16–5 Reverse Engineering Obsolete Parts for Remanufacture 16–6 Summary 16–7 Cited References 16–8 Thought Questions and Problems CHAPTER 17 The Law and the Ethics of Reverse Engineering 17–1 Without Morals and Ethics, Laws Mean Nothing. 17–2 Legal versus Ethical 17–3 The Legality of Reverse Engineering 17–4 The Ethics of Reverse Engineering 17–5 Summary 17–6 Cited References 17–7 Thought Questions and ProblemsCHAPTER 18 The End of a Book, the Beginning of a New Story: Closing Thoughts 18–1 The First Design 18–2 Imperfect Humans Need Reverse Engineering 18–3 Order from Chaos, Light from Darkness, Knowledge from Knowledge 18–4 Learning from the Old to Create Anew: Four Opportunities 18–5 Final Words 18–6 Cited References 18–7 Recommended Readings 18–8 Thought Questions and Problems Appendix A List of All Material Classes and Major Subtypes, and Major Members of Each Appendix B Comprehensive List of Specific Manufacturing Methods by Process Class Index Page numbers followed by “F” refer to figures, by “FN” refer to footnotes, and by “T” refer to tables. Academic learning, 18 Actuators, 138 Adaptive design, 22, 23T Additive processing methods, 203 Adhesives: bioadhesives, 350–351 natural adhesives, 350 synthetic adhesives, 353 Aesthetics (in design), 166 Alloys, metals and, 173, 175 Analysis, analyzing (approach to engineering), 6, 7 Anomalistic month, 150 Antikythera mechanism, 144, 145 Approaches to engineering, 6 Artificial stone, 350–351 Assembly errors (in failures), 94, 95F Astrolabe, 145 Atomic bonding: covalent, 175, 176T ionic, 175, 176T metallic, 175, 176T Backward problem-solving, 17, 17T, 105 Benchmarking, use of reverse engineering for, 24, 25T Benefits of reverse engineering, 26Bioadhesives, 350–351 Biomedical engineering, biotechnology, 400–401 Biomimetics, biomimicry, 349 Bottoms-up teardown analysis, 70 Brittle (overload) failures, 98, 99 Built-up details (for manufacturing), 202 Callippic (gear) train, 151 Castability, 170 Casting methods, 205 Castings, identifying, 307–308 Chemical spot test kits for metal ID, 192 Cheops’ Pyramid (see Khufu’s [Great] Pyramid) Clones, 339–340, 380 Clue(s), definition of, 124 Codes of ethics for engineers, 373–375 Combination failures, 98 Combination properties, 177 Commercial espionage, 18 Competitive technical intelligence gathering, 18, 338 Composite materials, 186, 203FN, 331, 353 Computer-based models, use in engineering, 7, 8 Computer simulation (use in engineering), 7, 8 Conceptual design stage, 7 Conjecture, 156 Constructing versus manufacturing, 201 Construction, use of reverse engineering for, 24, 25T Controls, controllers, 138–139 Converters (of power or motion), 138 Copies, 339 Corrosion failures, 98 Corrosion-fatigue failures, 98 Cost (in design), 166, 317FNCost teardown, 65 Cues, definition of, 124 Curiosity (in humans), 1, 2 Deduction: of fact versus fiction, 119 process of, 17 Deformation processing methods, 203, 205 Degradation, 91FN Design: definition of, 19 failures in, 93 process of (steps), 20, 21F stages of, 7, 8T types of, 22, 23T use of reverse engineering for, 24, 25T Design errors (in failures), 94, 95F Design for assembly, 318, 320–322, 321T Design for manufacture (DFM), 318–319, 319F Design for process, 319–320 Designer materials, 399 Detail design stage, 7 Developmental design, 22, 23T Differential scanning calorimetry (DSC), 193 Dimensionality, 127, 128T Discovery (of new concepts/technologies via reverse engineering), 25 Dissection, 9, 10, 11 Documentation shortcoming, 18 Ductile (overload) failures, 98, 99 Duplication, unauthorized, 18 Duty cycle, 274–275 Dynamic teardown, 65 Ease of assembly, 165Ease of fabrication, 165 Ejector pin marks, 288, 295, 301 Electronegative elements, 175 Electropositive elements, 173 Elevated-temperature failures, 98 Embodiment design stage, 7 Energy flow field design/diagram, 76, 85, 292 Energy flow/transport, 129, 129T Engineered wood/lumber, 354 Engineering composites, 353 Engineering design process (steps), 20, 21F Enigma, 152 Espionage, 17, 337–338 Ethical conduct, 373–375 Ethicality, 375 Evidence, definition of, 124 Exeligmos (gear) trains, 148, 151 Experience: for learning, 4 value of in reverse engineering, 120 Experiential learning, 4, 5 Experiential Learning Model (ELM), 4, 5F Experiments/experimentation (use in engineering), 7, 64, 65 Exploded view(s), 58, 59F, 72, 83F, 286, 287, 294, 300, 306 Fabrication errors (in failures), 94, 95F Failure analysis: definition of, 91 general procedure, 104, 105T Failures: catastrophic, 90, 91 causes of, 94, 95F clues to, 97Tdegradation, 91 FN eventual/ultimate, 89 manifestations of, 91 mechanisms of, 95, 96T premature, 90 sources of, 92, 93, 94T, 95T Fastening (in manufacturing), 202 Fatigue failures, 98, 99 high-cycle/low-stress, 98, 104 low-cycle/high-stress, 98, 104 Finishing processes, finish processing, 207 Fit, 127, 266 Flow processing methods, 203 Flows, 128, 129T Fluids: flow of, 129, 129T movers of, 138 Force flow diagram, 72, 76, 79T, 86F, 128–129, 292 Force flow/transfer, 128, 129T Form, 127, 266 Form, fit, and function (FFF, F3), 126, 265 Form, fit, and function assessment using observations, 267 design details, 275, 277 electrical and/or thermal robustness, 273 material selection, 270–273 method-of-manufacture/-construction, 270–273 precision, 273 size and robustness, 268, 270 Formability, 170 Formulations of substances, 337, 347, 348 Forensic engineering, 59, 60, 91, 111–112 Forensics, forensic science, 111–112 Forward engineering (see Forward problem-solving)Forward problem-solving, 17, 17T Fourier transform infrared spectroscopy (FTIR), 193 Fractographic analysis, fractography, 99 Fractures: brittle, 364, 366F ductile, 365, 366F Function: actual, 64 intended, 57 latent, 57 predicted, 64 Function/functionality of design/entity, 126, 127, 165, 199, 266, 317 Function-Material-Shape-Process interrelationship, 199, 200F Function units, 130 Functional analysis, 79 Functional diagram, 74 Functional measurement, 63 Functional models, 72, 79, 81F, 136T–137T, 327 Functional structure, 64, 81 Functional tree, 74, 82F Fundamental approaches to engineering, 6 Gene therapy, 400 Generics, 340, 345–348 Genetic engineering, 400 Geometric measurement, 61 Geometric model, 72 Geometric shape, 127, 128T Geometric symmetry, 127, 128T Great Pyramid (of Khufu), 229 Heat treating/treatment, 206, 218–221 High-cycle/low-stress fatigue, 98, 104 Human-caused/-based failures, 93Identification: of materials/metals by observation: characteristics, 189T–191T color, 186 coolness (from thermal conductivity), 187 density/heft, 186–187 flex (for stiffness/modulus), 187 hardness, 187 luster, 186 magnetic attraction/magnetism, 188 ring, sound, 187 of polymers by applications, 191T as true/false, 119 Imitation: definition of, 339 of natural materials, 352–353 of Nature (biomimetics), 348–349 Immunotherapy, 400 Improvements of materials, substances, items, 342 Inferring, inference, 119 Injection molding, 288 Inspiration from Nature, 348 Integral mechanical attachments, 322T Intelligence gathering, 18 Intended function, 57 Internet, growth/impact of, 383 Joining (processes), 207 adhesive bonding, 207 brazing and soldering, 207 integral mechanical attachment, 207 mechanical fastening, 207 mechanical joining, 207welding, 207 Joints, 139 Khufu’s (Great) Pyramid, 30–31, 229 Knockoffs, 341 Knowing (true/false), 119 Kolb ELM (see Experiential Learning Model) Latent function, 57 Learning: from experience, 4 from sensory input, 4 by taking things apart, 3 Learning styles, 4 Learning Styles Inventory (LSI), 6 Legality, 375 Life-cycle cost, 317FN, 318 Look-alikes, 340–341 Low-cycle/high-stress fatigue, 98, 104 Machinability, 170 Machined parts, identifying, 312 Machining (in manufacturing), 206 Maintenance errors (in failures), 94, 95F Manifestation of failures, 91 Manufacturability, 165–166, 317 cost, 166, 318 of designs, 165 ease of assembly, 165 ease of fabrication, 165, 318 Manufacturing: versus constructing, 201 failures in, 93 methods of, 199 use of reverse engineering for, 24, 25TManufacturing processes taxonomy, 203, 204F additive processes, 203 flow/deformation processes, 203 processing for finish, 203 processing for geometry (shape and dimensions), 203 processing for properties, 203 subtractive processes, 203 Market pull (in design), 22 Marketing, use of reverse engineering for, 24, 25T Material errors (in failures), 94, 95F Material performance indices, 181 Material properties: definition of, 169 by specific type, 177–181, 182T Material selection charts, 181–186 Material teardown, 65 Materials, 165, 172, 187F amorphous, 336 composite, 336 crystalline, 336 for engineering, 336 identification of, 186–191 versus substances (definitions), 335–337 Materials-by-design, 399 Materials-of-construction/-manufacture, 165 Materials revolution, 397–399 Materials science, 163 Matrix teardown, 65 Measurement: of function, 63 use in engineering, 7, 60 Measurement device criteria, 62TMechanical dissection, 11, 73 Medicine, revolution in, 399–400 Meta-materials, 399 Metal (identification) test kits, 192 Metalloids (semimetals or semiconductors), 175, 177 Metals (and alloys), 173, 175 Method-of-manufacture/-construction, 199 Method-of-manufacture from observation: cast metal parts, 210, 219T cold cast ceramic parts, 214 composite material parts, 214 deformation processed metal parts, 212, 219T forged metal parts, 212–213 identification of: using batch size, 216 using cost/apparent value, 217 using geometric complexity, 214 using joining method, 217–218 using material class, 210–214 using production rate, 216 using roughness/surface finish, 215 using shape, 214 using size, 214 using surface details, 216 using tolerance/precision, 214–215 using workmanship, 217 machined parts, 219T molded polymer parts, 214 powder processed metal (or ceramic) parts, 213–214, 219T Methodizing, 24, 327–329 Methods engineering, 327 Metonic (gear) train, 151Military espionage, 18 Misuse (in failures), 94, 95F Model-centric approach to design, 21 Moldability, 170 Molding parting lines, 303, 303F Molding/pressure-molding methods, 205 Moon gear, 151 Motion converters, 138 Motivations for reverse engineering, 18, 19T Net-shape/near-net-shape processes, 204 New paradigms, 384 Nonmetals, 175 Nuclear magnetic resonance (NMR), 193 Observation, use of, 58 Occam’s (Ockham’s) razor, 242, 242 FN Olympiad (gear) train, 152 Original design, 22, 23T Overload failures, 98 Periodic Table of the Elements (Standard), 173, 174F Physical models (use in engineering), 7 Polymers, 177 identification by application, 191T laboratory techniques for identifying, 192–193 Powder processing methods, 205 Power converters, 138 Power sources, 135 Practice of engineering, 4 Primary properties, 177 Primary shaping processes, 204 Prime movers, 138 Printing press, moveable-type, impact of, 390 Problem statement/formulation, 7Process, 199 Process attributes, 207, 208T cost, 207, 208T dimensional accuracy/tolerance/precision, 207, 208T geometric complexity, 207, 208T material class, 207, 208T minimum batch size, 207, 208T production rate, 207, 208T shape, 207, 208T size range, 207, 208T speed (of processing), 207, 208T surface finish/roughness, 207, 208T Process selection charts, 208–209 Processing errors (in failures), 94, 95F Producibility, 24, 318, 330 Product form, 204 Product functional model, 85, 86F Product security analysis, 18 Product teardown, 56 benchmarking, 57 forms of, 65 procedure for, 71 process (definition), 69 purposes, 56, 69T, 70 subtract-and-operate procedure, 70, 74, 75T Production, use of reverse engineering for, 24, 25T Production engineering, 325 Properties of materials: acoustical, 170 biological, 170 chemical, 169 combination/complex, 169, 170, 177electrical, 169 magnetic, 169 mechanical, 169 optical, 169 physical, 169 primary, 177 radiological, 170 secondary, 177 thermal, 169 Property-performance relationship, 171T–172T Proprietary materials, 342–343 Purpose of design/entity, 126 Pyramids: alignment, 241–242 casing stones, 252 construction, 244–256 design layout/measurement, 246–247 internal details, completion of, 252 location, 238–239 materials-of-construction, 247–248 orientation of Three Pyramids, 242–244 progress check/plan adherence, 247 purpose, 234–238 role of reverse engineering, 252–256 site preparation, 245–246 site selection, 245 stone transport/positioning, 248–252 Pyramids of Giza, 237 Quality assurance, using reverse engineering for, 24, 25T Raman spectroscopy, 193 Remanufacture, using reverse engineering for: broken parts, 363, 364deformed parts, 365 obsolete parts, 363, 367, 369 worn parts, 363, 365 Renewable energy, 394, 395T Replacements (for materials or substances), 338–339, 344–345 Reverse engineering: benefits of, 26 during Cold War and post–Cold War, 47–49 definition of, 13, 16, 18, 55 emergence of, 29 of Great Pyramid of Khufu, 29–32 during Industrial Revolution, 35–37, 40, 42 during Middle Ages, 33, 35 motivations for, 18, 19T procedure for, 73, 117–118, 118T for remanufacture, 362 risks of, 26 status of (in textbooks), 15, 16 uses/potential uses, 23, 25T during World War II, 42–47 Role of design/entity, 126 Root-cause for failure, 92 Rules of Engineering Practice (NSPE), 375 Saros (gear) train, 151 Scaling/variant design, 22, 23T Secondary processes/processing methods, 206 Secondary properties, 177 Security analysis of products, 18 Semiconductors, 175, 177 Sensors, 138 Sensory input for learning, 4 Service errors (in failures), 94, 95F Service failures, 93Shape, macro-/micro, 199, 200 Sidereal month, 150 Simulation, computer (use in engineering), 7, 8 Special processing methods, 206 Spider silk, artificial, 350 Stages of engineering design, 7, 8T Statement of problems (in design), 7 Static overload failures, 98 Structure(s), 138 Structure-Property-Processing-Performance interrelationship, 166, 167, 168, 168F Substances versus materials, definitions of, 335–337 Substitutes (for materials or substances), 338, 343T, 344–345 Subtract-and-operate procedure (SOP), 70, 74, 75T Subtractive processing methods, 203 Suitability of design for purpose, 265–266 Sun gear, 150 Sustainable energy, 394–396, 395T Synodic month, 151 Synthesis/synthesizing (approach to engineering), 6, 7 Synthetics: bioadhesives, 350–351 diamonds, 349 fibers, 355–356 stone, 350–351 Systems analysis, 81 Systems approach to design, 21, 22 Taking things apart (to learn), 3 Teardown process, 56 (See also Product teardown) Technical systems, 79, 80F Technology push (in design), 22 Tissue engineering, 401Top-down teardown analysis, 70, 73 Topological evidence/features, 125 Trade-off decisions stage in design, 7 Transportation, new concepts for, 396–397, 398 Troubleshooting, use of reverse engineering for, 25, 25T Unlicensed/unauthorized duplication, 18 Value, definition of, 323 Value analysis, 323 Value analysis teardown, 73 Value engineering (VE), 24, 322–324, 324T Variant/scaling design, 22, 23T Visual, auditory, kinesthetic (VAK) learning styles, 4 Vivisection, 9, 10, 74 Wear failures, 98 corrosion, 98 fatigue, 98 Weldability, 170 Welding (in manufacturing), 202 Who, What, When, Where, Why, and How (“Five Ws”), 3 Wide-angle x-ray diffraction/scattering, 193 Wood, 354, 354FN Workmanship, 58, 122, 217
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