Heavy Fabricated Steel Assembly
A reverse engineering project focused on recreating the PD Entry Hood, a 3.2-ton heavy fabricated steel assembly comprising 26 structural components manufactured primarily from IS 2062 E250BR steel. The assembly consists of fabricated plates (20–32 mm thick), machined blocks, welded joints, and bolted connections designed for heavy-duty industrial applications. The project involved manual dimensional measurement, accurate 3D CAD modeling, assembly development, material assignment, and preparation of manufacturing drawings with a complete Bill of Materials (BOM) to support fabrication and assembly.
The existing PD Entry Hood was available only as a physical fabricated assembly, with no complete digital engineering documentation to support manufacturing or future modifications. Due to its heavy welded construction, multiple structural components, varying plate thicknesses, and machined interfaces, accurately capturing the assembly geometry and manufacturing intent was a significant challenge. A comprehensive digital engineering package was required to document component relationships, fabrication details, material specifications, and assembly features while ensuring consistency with established fabrication and welding standards.
The assembly was reverse engineered by collecting critical dimensions from the fabricated structure and recreating each component in CAD while preserving assembly relationships and manufacturing intent. Structural steel plates, machined blocks, lifting lugs, and welded subassemblies were modeled using IS 2062 E250BR as the primary material. Manufacturing documentation included detailed fabrication drawings, weld details, machining requirements, section views, GD&T where applicable, and a complete Bill of Materials (BOM).
Successfully developed a complete digital engineering package for the 3.2-ton PD Entry Hood, including accurate 3D models, assembly documentation, fabrication drawings, material specifications, and a comprehensive Bill of Materials (BOM). The recreated assembly accurately captured all 26 structural components, welded features, and machined interfaces, providing a reliable reference for fabrication, inspection, assembly, and future engineering modifications. The project demonstrated proficiency in reverse engineering, heavy fabrication detailing, and manufacturing documentation while ensuring compliance with applicable fabrication, welding, and dimensional standards.
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