R&D Project – Shenzhen Blaze Turbine Co., Ltd

R&D Reverse Enginnering

Reverse R&D is a method of systematically disassembling, analyzing, measuring, testing and researching existing products to obtain key information on their design concepts, technical principles, manufacturing processes, material composition, functional characteristics, etc., and then improving, optimizing or innovating the original products based on a full understanding of this information, thereby developing similar or even better new products or technologies. Reverse R&D is the process of in-depth exploration and re-creation of the original product. Reverse R&D requires the comprehensive use of a variety of engineering technologies and analysis methods, such as 3D scanning, material analysis, mechanical properties testing, simulation, etc. It also requires the R&D team to have deep technical accumulation and innovation capabilities, so as to be able to dig out valuable information from the original product and transform it into competitive new products or technologies.

Investment Casting, Forging CNC Machining Reverse Development Steps

Measuring and Recording

1.Precisely measure samples using a coordinate measuring machine (CMM) or laser scanner.
2.Record the size, shape and surface characteristics of each part.

Composition analysis

Determine the chemical composition of high-temperature alloys using equipment such as spectrometers, X-ray fluorescence spectrometers (XRF) or energy dispersive X-ray spectrometers (EDS).

Microstructure analysis

Analyze the microstructure of materials using metallographic microscopes, scanning electron microscopes (SEM) and other equipment. Evaluate the grain size, phase composition and inclusions of the material

CAD modeling

Based on the measured data, use CAD software (such as SolidWorks, CATIA) to reconstruct the 3D model.Make necessary adjustments and optimizations to the model to ensure that it meets the design requirements.

Finite element analysis (FEA)

Perform finite element analysis on the model to evaluate its mechanical properties, thermal properties and stress distribution.Adjust the design based on the analysis results.

Process planning

Determine the manufacturing process, including casting, forging, heat treatment, machining, etc. Select appropriate process parameters and equipment.

Mold design

Design and manufacture the required molds or fixtures.Ensure mold accuracy and durability.

Turbine Blade and Impeller Reverse Engineering Case

The gas turbines operated by an energy company faced aging and performance degradation of blades and impellers. Due to the high price and long delivery cycle of original equipment manufacturers (OEM) parts, the company decided to use reverse engineering technology to develop alternative turbine blades and impellers in-house to reduce maintenance costs and improve equipment availability.

Application Trends of Reverse Engineering

Gradually shifting to positive R&D：In some technical fields, enterprises are paying more and more attention to the improvement of independent innovation and forward R&D capabilities, and improving their market competitiveness by increasing R&D investment and cultivating professional talents.

Combined with innovation：Even when conducting reverse R&D, it is no longer just a simple copy, but more about innovation and improvement based on understanding the original technology. The information obtained from reverse analysis is combined with new design concepts and technological trends to develop more distinctive and competitive products. Application of digital technology：With the help of advanced digital technologies, such as 3D scanning, computer simulation, and big data analysis, reverse analysis can be performed more accurately, improving R&D efficiency and quality.

Ceramic core mold

Ceramic core molds are used in the manufacturing process of complex metal components, particularly in industries like aerospace and power generation. These molds are used to create ceramic cores, which act as sacrificial patterns during the investment casting process. The ceramic cores are inserted into wax patterns, and after the wax is melted away, the ceramic cores remain in place to form intricate internal passageways within the final cast metal part. This process is critical for producing components with precise internal geometries, such as turbine blades and other high-performance parts.