Theses and Dissertations Collection

Reverse-engineering (R-E) mechanical equipment and systems is less discussed than other disciplines such as computer software. There is often a reliance on simply reproducing the net-shape of a part. Replicating the net-shape of a completed part will often produce a functioning facsimile, but is not the most economical to R-E the functions of a part. A goal-based methodology should be applied parallel to established design processes to produce functioning recreations of parts. The R-E methodology developed for this study consists of three parts and is intentionally similar to new-product design: Identify functional purpose and goals of the part/system, quantify the precision and accuracy of the original part’s dimensions and tolerances, and isolate the original method of manufacturing from the proposed recreation. For this research, case studies spanning over 2000 years were used at different levels of depth: a scale model of a 1950’s hydroelectric turbine, a 1900’s desktop sterling engine, and a 2100 year old orrery (the Antikythera Mechanism). The hydro-turbine model contrasted the modern goal of the recreation against the original project. Experience with the sterling engine showed that features necessary to its function were not clearly distinguished in its drawings. Finally, the successfully recreated Antikythera mechanism was evidence that perfect knowledge of the original is unnecessary. Overall, the successful application of a common R-E methodology to these diverse cases endorses the process established in this study.