Turbomachinery Reverse Engineering

Reverse Engineering of Obsolete and Damaged Parts

As one of the world’s leading suppliers of comprehensive turbomachinery services, Concepts NREC has the engineering know-how, the depth of experience, the proprietary engineering software, and the complete facilities to reconstruct and often improve finished parts or assemblies.

partner-bg-img

Capabilities

Concepts NREC’s manufacturing capabilities extend far beyond simply cutting metal. Our highly skilled machinists are backed by experienced design engineers with diverse technical backgrounds and software engineers who have produced industry-leading CAE and CAM programs. This broad expertise enables us to suggest more efficient manufacturing methods, materials, processes, and designs that meet customer needs while lowering their production costs.

Quick-Turn Reverse-Engineered Parts

Requirements for reverse-engineered components come from widely diverse industries that use various types of turbomachinery, as well as unique needs that range from surgical replacement implants to automotive assemblies. Requirements are typically due to mechanical failure, performance failure, changes in policies or regulation, changes in a process, or the need for backup spares in a critical application. Concepts NREC can assist in solving both engineering and production problems by providing reverse-engineering solutions for:

  • Manufacture of critical spares
  • 3D prototype development and evaluation
  • 2D drawing and technical documentation
  • Prediction of reliability and life cycle analysis
  • Qualification and compliance testing
gallery_rerate3

High-Quality Results

Fast turnaround of a reverse-engineered part or assembly for process resumption is also a key requirement when production is waiting on the replacement. Concepts NREC can create accurate components from a variety of source information:
  • Detailed production drawings
  • Existing spare parts
  • Used, scrapped, and damaged components
  • Partial contour or dimensional data

Re-Engineered for Better Performance, Life, Reliability, and Cost

Quite often an obsolete impeller can be improved when being replaced. Engineered upgrades are typically designed for greater capacity, improved efficiency, changes in process, solving operating problems, or to avoid the replacement of expensive equipment. Examples of Concepts NREC re-engineering breakthroughs include:
  • Older chillers converted to new fluids with no loss of performance (or improved performance)
  • Clogging eliminated in petrochemical process pumps
  • Turbocharger rerating to reduce emissions
  • Compressor rerating to eliminate fatigue
gallery_rerate6-312999-edited
NewZeiss

Precision Inspection of the Existing Part

Concepts NREC reverse engineering and re-engineering services include dimensional inspection with accurate data and interpretation by experienced turbomachinery engineers (who know exactly what contributes to measurement error). Using sophisticated Zeiss technology with fourth-axis rotary table capability permits extremely tight contours with a minimum of probe changes. Other features and benefits include:
  • Fourth-axis advantage means greater accuracy in less time
  • Quality inspection data reduces project time
  • Contour tolerances to 0.0001 inch or better
  • Environmentally-controlled inspection room

Quick-Turn Reverse-Engineered Parts

Requirements for reverse-engineered components come from widely diverse industries that use various types of turbomachinery, as well as unique needs that range from surgical replacement implants to automotive assemblies. Requirements are typically due to mechanical failure, performance failure, changes in policies or regulation, changes in a process, or the need for backup spares in a critical application. Concepts NREC can assist in solving both engineering and production problems by providing reverse-engineering solutions for:

  • Manufacture of critical spares
  • 3D prototype development and evaluation
  • 2D drawing and technical documentation
  • Prediction of reliability and life cycle analysis
  • Qualification and compliance testing

High-Quality Results

Fast turnaround of a reverse-engineered part or assembly for process resumption is also a key requirement when production is waiting on the replacement. Concepts NREC can create accurate components from a variety of source information:

Reverse Engineering Obsolete Parts

  • Detailed production drawings
  • Existing spare parts
  • Used, scrapped, and damaged components
  • Partial contour or dimensional data

Re-Engineered for Better Performance, Life, Reliability, and Cost

Quite often an obsolete impeller can be improved when being replaced. Engineered upgrades are typically designed for greater capacity, improved efficiency, changes in process, solving operating problems, or to avoid the replacement of expensive equipment. Examples of Concepts NREC re-engineering breakthroughs include: Re-engineered part for better performance

  • Older chillers converted to new fluids with no loss of performance (or improved performance)
  • Clogging eliminated in petrochemical process pumps
  • Turbocharger rerating to reduce emissions
  • Compressor rerating to eliminate fatigue

Precision Inspection of the Existing Part

Concepts NREC reverse engineering and re-engineering services include dimensional inspection with accurate data and interpretation by experienced turbomachinery engineers (who know exactly what contributes to measurement error). Using sophisticated Zeiss technology with fourth-axis rotary table capability permits extremely tight contours with a minimum of probe changes. Other features and benefits include: Precision Inspection Equipment

  • Fourth-axis advantage means greater accuracy in less time
  • Quality inspection data reduces project time
  • Contour tolerances to 0.0001 inch or better
  • Environmentally-controlled inspection room

 

gallery_mach13-747671-edited.jpg

Family_of_Parts_DSC_0473_5NB.png

 

 

Experts in Prototyping Services

Concepts NREC manufacturing services include:

  • Complex prototyping of machined wax patterns for precision investment castings
  • Rapid prototyping of parts in stereolithography
  • Geometric and manufacturing data preparation
  • CNC machining instructions
  • Process drawings and layouts
  • Fixture and tool design
  • Test-rig development
  • Material and process specifications
  • Assembly
  • Inspection data analysis

Agile Products Support (APS)

APS is Concepts NREC’s software maintenance and support program that elevates us from just a software provider to a valued partner. 

An APS subscription is included with all annual licenses and is a highly-recommended option for perpetual software licenses. Every software customer is supported for one month following purchase for any installation questions that may arise. Learn more on the Agile Products Support Membership Benefits Datasheet

  • Free software updates
  • One business day response times
  • Expert technical assistance
  • Major discounts on software workshops
  • Discounted professional development course
  • Annual balloting system for development planning
  • Annual Meetings

Manufacturing Brochure

Our specialty is manufacturing prototypes and short production runs of your most challenging turbomachinery parts on our 5-axis CNC machines.

Manufacturing

Related Blog Articles

Meet Claudio Raia
CAE Software
Meet Claudio Raia
by Kate Guerrina, Marketing Manager
Dave Schowalter, Director of Global Software Sales, introduces you to Claudio Raia, our newest team member and the Managing Director of Concepts NREC Europe. Welcome Claudio!
Continue Reading
What Are the 5 Axes in 5 Axis Machining?
CAM Software
What Are the 5 Axes in 5 Axis Machining?
by Christos Maninos, CAM Application Engineer & Peter Klein, Director, CAM Software
What is 5 axis machining? In short, it is manufacturing a component on a CNC milling machine that can travel in 5 different directions. These machines allow the cutting tool to reach around parts with a high degree of freedom. This makes them ideal for milling the complex shapes of turbo machinery components.
Continue Reading
Increased Milling Capability and Capacity for Large 5-Axis Impellers
MAX-PAC
Increased Milling Capability and Capacity for Large 5-Axis Impellers
by Sean McDermott
Concepts NREC has added two additional Hermle 5-axis mills in our shop, and we’re excited  about the increased capabilities these new machines bring! In August of 2018 we received the  first of these mills, a 2018 Hermle C52uMT.  Just recently, in May of 2019, we added a Hermle C42u.  In addition to these new, state-of-the-art 5-axis Hermle mills, our shop utilizes a Mikron HSM600U, good for parts up to ~13” in diameter; a Hermle C40, which can mill parts up to ~20” in diameter, and a Mitsui Seiki HS5A-80, which can handle larger parts, up to ~32” in diameter.  We now have a full range of  5-axis mills capable of producing the most challenging parts from >1 inch up to over 39 inches in diameter.  
Continue Reading