Parametric Optimization of Train Brake Pad Using Reverse Engineering with Digital Photogrammetry 3D Modeling Method
Abstract
:1. Introduction
2. Materials and Methods
2.1. Creating 3D Models Using Photogrammetry
2.2. Specifications and Setting Camera
2.3. Data Acquisition
2.4. Object Photogrammetry
2.5. Data Processing
- Triangulation Algorithm
- b.
- Mesh TypesTwo principal mesh types were considered during the reconstruction workflow:
- Surface Mesh: Comprising triangles or quadrilaterals, this mesh type captures only the external geometry of the object. It is primarily used for visualization, CAD modeling, and rendering purposes. In this project, software like Agisoft Metashape and Geomagic generated surface meshes suitable for high-resolution visualization and dimension analysis.
- Tetrahedral Mesh (Volume Mesh): This mesh divides the internal volume of the model into tetrahedral elements and is essential for structural simulations, such as Finite Element Analysis (FEA). While surface meshes were adequate for model reconstruction and accuracy validation, tetrahedral meshes were later generated for structural analysis and optimization simulations.
Selection Guidance:- Surface mesh: best for geometric modeling and visualization.
- Tetrahedral mesh: required for physical simulations and performance evaluation.
- c.
- Mesh Parameter Settings
- Mesh Density: This setting controls the number of mesh elements, directly influencing detail and computational load. A higher density allows for more accurate geometry representation but increases processing time. In this study, a high-density configuration was chosen during meshing to capture fine details of the brake pad geometry.
- Decimation Factor: To improve performance during post-processing and analysis, polygon count reduction (decimation) was applied. This technique reduces the number of faces in the mesh while preserving the overall geometry, enhancing efficiency for CAD export and real-time rendering. For example, the initial dense mesh containing over one million triangles was decimated to below 300,000 for simulation readiness.
- Surface Smoothing: Algorithms such as Laplacian smoothing were employed to refine the mesh by eliminating noise and irregularities, especially around the curved and transition regions. Care was taken to preserve key geometrical features and avoid distortion of critical surfaces.
2.6. Process 3D Model with AI
2.7. Photogrammetry Studio
3. Result
3.1. Data Acquisition and Processing
3.2. Parametric Surface Analysis and Model Reconstruction
3.3. 3D Model Evaluation
3.4. Optimization of Brake Pad Structure
3.5. Boundary Conditions and Simulation Setup
3.5.1. Boundary Conditions
3.5.2. Loading Conditions
3.5.3. Mesh Characteristics
3.5.4. Computational Cost
3.5.5. Stress Concentration
3.6. Result Accuracy of Brake Pad
4. Conclusions
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Camera Settings | |||
---|---|---|---|
No | Aperture | Shutter Speed | ISO |
1 | F1.8 | 1/160 s | 200 |
2 | F1.8 | 1/160 s | 400 |
3 | F1.8 | 1/160 s | 600 |
SfM Software | Arrange Images | Dense Cloud (Number of Points) | Mesh Model (Number of Triangles) | Export Model |
---|---|---|---|---|
Agisoft Metashape (Version 2.2.1) | 206 | 8,768,647 | 456,688 | .obj |
AI Google Colab | 206 | 9,346,687 | 907,434 | .obj |
Parameter | Before Optimization | After Optimization | Improvement |
---|---|---|---|
Maximum Contact Stress | 950 MPa | ≤680 MPa | 28% reduction in contact stress |
Maximum Equivalent Stress (von Mises) | 1.214 GPa (1214 MPa) | ≤800 MPa | 34% reduction in equivalent stress |
Stress Distribution | Localized at sharp edges and transitions | More uniform across surface | Reduced stress concentrations |
Material Safety Margin | Exceeds yield strength (250 MPa) | Stays within safe limit | Eliminates risk of plastic deformation |
Structural Durability | High risk of fatigue failure | Improved lifespan and reliability | Increased durability |
Measurement Brake Pad | [C.M] CMM Measurements (mm) | [AM] Metashape (mm) | [AI] .AI (mm) | Error [AM] | Error [AI] | %Error [AM] | %Error [AI] |
---|---|---|---|---|---|---|---|
C1 | 8.00 | 8.15 | 5.22 | 0.30 | 0.46 | 1.15 | 1.77 |
C2 | 26.00 | 26.30 | 26.46 | 0.07 | 0.16 | 0.09 | 0.20 |
C3 | 78.20 | 78.27 | 78.36 | 0.12 | 0.23 | 2.40 | 4.60 |
C4 | 5.00 | 5.12 | 5.23 | 0.07 | 0.16 | 0.88 | 2.00 |
C5 | 8.00 | 8.07 | 8.16 | 0.09 | 0.18 | 0.29 | 0.58 |
C6 | 31.00 | 31.09 | 31.18 | 0.08 | 0.14 | 0.32 | 0.56 |
C7 | 25.00 | 25.08 | 25.14 | 0.30 | 0.46 | 1.15 | 1.77 |
Min | 0.09% | 0.20% | |||||
Max | 1.5% | 4.60% |
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Paryanto, P.; Faizin, M.; Rusnaldy, R. Parametric Optimization of Train Brake Pad Using Reverse Engineering with Digital Photogrammetry 3D Modeling Method. Eng 2025, 6, 96. https://doi.org/10.3390/eng6050096
Paryanto P, Faizin M, Rusnaldy R. Parametric Optimization of Train Brake Pad Using Reverse Engineering with Digital Photogrammetry 3D Modeling Method. Eng. 2025; 6(5):96. https://doi.org/10.3390/eng6050096
Chicago/Turabian StyleParyanto, P, Muhammad Faizin, and R Rusnaldy. 2025. "Parametric Optimization of Train Brake Pad Using Reverse Engineering with Digital Photogrammetry 3D Modeling Method" Eng 6, no. 5: 96. https://doi.org/10.3390/eng6050096
APA StyleParyanto, P., Faizin, M., & Rusnaldy, R. (2025). Parametric Optimization of Train Brake Pad Using Reverse Engineering with Digital Photogrammetry 3D Modeling Method. Eng, 6(5), 96. https://doi.org/10.3390/eng6050096