2011 International Conference on Electronic & Mechanical Engineering and Information Technology
Approach of Aircraft Configuration with Complex Free-Form Surface Design
Based on Reverse Engineering
Junhui Xiong, Shengjing Tang, Jie Guo
School of Aerospace Engineering
Beijing Institute of Technology
Beijing, China
xjhwhy@126.com
Abstract— As a complex engineering technique, reverse
engineering is dependent on the high precision measuring
equipment. As to special aircraft configuration with complex
free-form surfaces, traditional direct CAD constructing
method is inefficient. By analyzing the technical characteristics
of reverse engineering, a new design approach for special
aircraft shape with complex free-form surface is proposed.
Finally, the comparison between the traditional method and
the new approach is made, and the feasibility of the new design
approach is discussed.
Keywords-reverse engineering; aircraft configuration design;
clay Model; free-form surface
I. INTRODUCTION
Reverse engineering, originated from the thought of clay
model making process, was first used in the automotive and
aerospace field [1]. As geometric model reconstruction
technology and manufacturing technology in general, reverse
engineering is a technology to put physical model into a
CAD model. Three-dimensional point cloud information of
the physical model shape captured by measuring equipment
is passed to the reverse engineering software, followed by
subsequent processing worked by reverse engineering
software and CAD / CAM system. The satisfaction of the
product and working efficiency largely depend on the
accuracy of measuring equipment, and the main measuring
equipments currently used include coordinate measuring
machine and three-dimensional laser scanners. Reverse
engineering application is also influenced by the maturity of
reverse engineering software and CAD / CAE / CAM system
development. Reverse engineering software is mainly used
for point cloud data collected pretreatment to obtain high
accuracy surface, and then followed up by the CAD software
to construct three-dimensional model.
Overall in aircraft design, the configuration design is an
important part. For regular and simple aircraft shape, the
traditional design method is qualified; for special aircraft
configuration with complex free-form surface, such as the
lifting body shape and the wing-body shape, traditional
design method is often time-consuming and inefficient.
Therefore, the characteristics and advantages of reverse
engineering technology are considered, then, with reverse
engineering technology as an assistant, a new design
approach composed by the traditional design method and
978-l-61284-088-8/ll/$26.00 ©2011 IEEE 2757
reverse engineering for the special aircraft configuration
design is proposed.
II. APPLICATION OF REVERSE ENGINEERING IN
AEROSPASE
In recent years, much research work and application have
been carried out abroad, mainly be concentrated in the
replication of aircraft parts, avionics system, data acquisition
and internal structure of the aircraft aided design and so on.
LI W, and J Swetits researched aircraft process modeling and
optimization issues related to reverse engineering[2]; G M
Lecrivain and others estimated the error on the reverse
remodeling process and proposed error control method of
reverse engineering by reconstructing the simple geometric
parts[3]; Georgia Institute of Technology posed a study
approach to teach aircraft performance by Reverse
engineering the SR-71 Blackbird aircraft[4]; T S Patel, and C
S Dixit selected optimal parameters for reverse design of a
supersonic fighter, and compared it with the existing fighter
aircraft of the same type and power plant[5]. To lower
financial cost, C-130 transport aircraft, B-52 bombers and
other aircraft were extended in service. Advanced Research
and Applications Corporation proposed reverse engineering
technology to acquire the database of aircraft parts, with
which aircraft maintenance supplies can not only quickly
manufacture parts and components but also greatly reduce
the cost [6-8]. DIRECT DIMENSIONS Corporation offered
a number of data services for u.s. military (as in Figure 1),
where most of the applications used reverse engineering
technology, involves the measurement, testing, design and
other technical fields [9].
China also carried out reverse engineering application in
aerospace research [10], a department developed several
high-precision measuring equipments with independent
intellectual property rights [11]. Nanjing University of
Aeronautics and Astronautics paid much attention to reverse
engineering research, as Jun Wang studied the key
technologies of the aircraft structure reverse modeling[12];
Changbai Tan and others researched the method of the
aircraft contour and structure reverse engineering modeling
[13]; Ruogang Pan designed the fuel tank of an aircraft
characteristics using reverse engineering technology [14];
Yongsheng Wu studied aircraft inlet pipe and surface
optimization with reverse engineering technology [15];
Jiangchao Xiao proposed surface reverse reconstruction
method with CATIA VBA [16].
12-14 August, 2011
 III. TRADITIONAL AIRCRAFT CONFIGURATION DESIGN
Overall layout of the aircraft is not only closely related to
the best aerodynamic shape, but also to the aerodynamic
properties and flight performances. The actual design process
in form, with the power plant selection, frame arrangement,
load-bearing structure layout and other key parameters to
affect, is a task to go through the analysis of tactical and
technical index, aerodynamics calculation, trajectory
planning, maneuverability and stability [17]. Traditional
aircraft configuration design is shown in Figure 2.
IV. AIRCRAFT CONFIGURATION DESIGN APPROACH
BASED ON REVERSE ENGINEERING
The traditional method of direct CAD modeling lacks for
efficiency of complex free-form surface configuration design
[18]. Considering the performance in the form intuitive, ease
of operation and characteristics of reverse engineering,
reverse engineering as an assistant of aircraft configuration
design method is employed. Thus, a new aircraft
configuration design approach composed by traditional
design method and reverse engineering technology is
proposed. The design process is shown in Figure 3.
Compared with traditional design method, reverse
engineering with clay model (clay model is not necessary, if
prototype model or accurate model is available) is the main
difference. Although the approach combines reverse
engineering, traditional configuration design accounts for
most work, with the analysis of tactical and technical
indicators, aircraft CAD modeling, CFD calculations /
engineering estimates, target verification and so on. Reverse
engineering as an assistant process, which contributes
through the whole design process, plays an important role in
the design program. With great convenience of repeatedly
modification of clay model, satisfied aircraft configuration is
obtained.
V. T H E TRADITIONAL M E T H O D AND N E W APPROACH
Lacking for accurate model or prototype model, clay
model is commonly used as physical model. If the accurate
model or prototype model is available, the role of reverse
engineering in the design is even more significant. In
TABLE 1, the traditional design method and the approach
based on reverse engineering are compared. The role of
reverse engineering in aircraft configuration design is as
follows:
• The ease to modify the clay model provides quick
access to expressing the designer's idea; with
positive design parameters the shape will be more
reliable and innovative .
• The traditional design process begins from scratch,
and designers can easily stick to design experience,
making it difficult to design the new concept of
shape such as the lifting body and wing-body aircraft.
The integration of reverse engineering is to fill that
gap-
• Reverse engineering can speed up the process and
reduce design cycles. Without physical model, there
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is certain blindness in direct CAD construction of
three-dimensional mathematical model.
VI. FEASIBILITY
Physical model of reverse engineering in aircraft design
applications can be divided into an accurate model and clay
model, and the feasibility is stringent for reverse engineering
based on clay model. Figure 4 shows a profile case of aircraft
reverse engineering by DIRECT DIMENSIONS based on
accurate model, which to provide an ideal CAD model to do
CFD numerical experiments [19].
The feasibility of aircraft configuration design based on
clay model mainly depends on three parts, the error of clay
model, clay model processing cycle and the rationality of
clay model.
A. The error of clay model
Considering the design process, the main sources of error
include smoothness of clay model surface, the data
acquisition system and process of making clay model to
CAD model. As technical limitations, it's difficult to provide
accurate data of the surface smoothness of the Clay model.
Putting automobile clay model as example, with the
coordinate measuring machine or ATOS data collection
systems, automobile clay model can generate the ideal CAD
model in CAD software. Compared with the aircraft clay
model making, the error of data acquisition is quite small. As
the clay model is not the final CAD model, clay model can
meet the requirements as a physical model.
B. Processing cycle of clay model
In the absence of accurate model, the clay model is an
ideal physical model. The Processing cycle of clay model
largely depends on the processor's craft, for example, it takes
about 5 days for a skilled engineer to make a 1:5 car clay
model [20]. The requirements of aircraft clay model surface
accuracy and surface parameter sensitivity are more stringent
than car clay models, and model making is an iterative
process, which helps throughout the conceptual design phase.
C. The rationality of clay mode
Clay model is handwork of the designer, so the quality
and the rationality of the clay model depend on the
designer's clay modeling technology and experience. Thus,
the rationality of the clay model can be improved through
model making skills training, what is more, the fault
tolerance of the clay model can also make up for this
deficiency.
In summary, the new approach based on reverse
engineering is theoretically feasible. Lacking for accurate
data acquisition systems, large-scale point cloud data
processing restrictions and rules that conventional aircraft
shape are the three main reasons to prevent reverse
engineering being used before, which is not impediment any
longer nowadays.
VII. CONCLUSION
Although the direct CAD construction becomes more
perfect, it remains difficult in the CAD software real-time
image display and complex free-surface construction. Thus,
for aircraft configuration with the complex free-surface, the
traditional design method is inadequate in efficiency and
reliability. Because of its intuitive shape description and the
convenience of shape modification, clay model has a great
advantage to design the aircraft configuration with complex
free-form surface, especially for conceptual aircraft
configuration. As an assistant to aircraft configuration design,
reverse engineering is combined with traditional design
process to form a new approach, which can improve design
efficiency and reduce costs.
REFERENCES
[1] Wang Xiao. Reverse engineering technology and its applications [M].
Beijing: Chemical Industry Press, 2004.
[2] Li. W, Swetits J. Automation of Reverse Engineering Process in
Aircraft Modeling and Related Optimization Problems [R]. Report:
NAS 1.26:197109; ODURF-124303, 87p, 1994
[3] G. M. Lecrivain, I. Kennedy, A. Slaouti. Evaluation and optimization
of errors in the reverse engineering process: a case study [C]. IET
International Conference on Agile Manufacturing, ICAM 2007.
[4] Daniel Guggenheim. A case study approach to teaching aircraft
performance: Reverse engineering the SR-71 Blackbird [C] .2010
ASEE Annual Conference and Exposition, 2010.
[5] T. S. Patel, C. S. Dixit. Optimum selection of main parameters for the
reverse design of a supersonic military aircraft [J]. Canadian
Aeronautics and Space Journal, v 26, n 3, p 218-229, 1980.
[6] R. N. Yancey. Creating data packages for aircraft resupply [C].
Nondestructive Characterization of Materials in Aging Systems.
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[7] Yancey, N. Robert. CT-assisted reverse engineering for aging aircraft
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Optical Engineering, v 3397, p 211-216, 1998.
[8] Ted Rifle, Battelle, Columbus, Ohio. Reverse engineering & Re-
engineering of avionics legacy components [C], 21st Digital Avionics
Figure 1. Data services based on reverse engineering by DIRECT DIMENSIONS
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Systems Conference. Proceedings (Cat. No.02CH37325), 12C3-1-9
vol.2, 2002.
[9] DIRECT DIMENTIONS.
http://www.dirdim.com/apps_militaryaerospace.htm.
[10] Wen Chen. Reverse Engineering's application in aviation[J]. Aviation
Maintenance and Engineering, 2005 / 2.
[11] Beijing Institute of Aviation Precision Machinery Technology
Division. Http://www.avic303.com/.
[12] Jun Wang. Aircraft Structure Modeling reverse of key technologies
[D], Nanjing University of Aeronautics and Astronautics, 2008.
[13] Changbai Tan, Laishui Zhou etc. Aircraft shape and structural
modeling technique of reverse engineering [J], Acta Aeronautica et
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[14] Ruogang Pan. Characteristics of an aircraft fuel tank design of
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[15] Yongsheng Wu. Inlet pipe and surface optimization of the reverse
generation [C], the general branch of China Aviation Institute of
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[16] Jiangchao Xiao. Using CATIA VBA surface reconstruction for
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[17] Shiguang Lu, Cruise Missile Design [M]. Beijing: Astronautics Press,
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[19] Aircraft OML Reverse Engineering Enables Complex CFD Analysis.
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 Tactical and technical index Tactical and technical index

Subsystem analysis Sketch drawing

Subsystem parameters design Clay model

Wing, airframe and tail design etc. Reverse engineering

Shape layout CAD model

Wing, airframe and tail design etc. CFD /engineering calculation

No No

Aircraft configuration Aircraft configuration

Figure 2. Flowchart of traditional aircraft configuration design Figure 3. Flowchart of new approach based on reverse engineering

TABLE I. THE TRADITIONAL DESIGN METHOD COMPARED WITH THE NEW DESIGN APPROACH

Design method Advantages Disadvantages Scope

Rigorous thinking, steps strict; Inefficient on shape formed

Simple and mature
Traditional method for simple shape quickly and by complex free-form
configuration
efficiently surface

Modified clay model intuitive

Clay model processing; Configuration of complex
and convenient; reliable direct
New approach access to accurate or free-form surfaces; new
reconstruction or modification
prototype model concept vehicle
on accurate model

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Figure 4. Profile cases of aircraft reverse engineering by DIRECT DIMENSIONS

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