Client: Tajrobeh Noor Co.
Role: Lead Design Engineer
Duration: ~8 months
Software: CATIA V5
Project Overview
Reverse engineering and reindustrialization of blades No. 4 & 5 of the BBC-D13 gas turbine. The goal was to enable domestic manufacturing of spare blades under international sanctions, using only worn physical samples as input data.
Responsibilities
- Led the modeling and design team in the reconstruction of blade geometry using manual cross-sectioning and point cloud analysis
- Developed surface models with precise tangent continuity (G1/G2) using low-degree conic functions instead of high-degree splines to ensure manufacturing feasibility
- Designed the complete tooling package:
- Pre-form and final forge molds (multi-stage forging)
- Machining fixtures and gauges for all production phases
- Functional control jigs for dimensional inspection (CMM verified)
- Delivered 2D manufacturing drawings with tolerances and machining allowances
Technical Challenges & Solutions
- No CAD reference or drawings: Surface creation relied on conic-based curve fitting from imperfect point clouds to minimize deviation without introducing ripple artifacts
- Reverse Engineering Strategy: Reconstructed each blade section using four curves (2 quadratic + 2 cubic), ensuring tangent continuity and curvature smoothness
- Tooling Accuracy: Forging dies designed with consideration for material flow, shrinkage, and grain direction
Results
- Functional prototypes successfully produced and validated via CMM
- Enabled local forging and machining of turbine blades
- Paved the way for domestic production of critical aero components in the absence of OEM support
Standards & Methodologies
- ASME Y14.5 – GD&T for dimensioning
- ISO 13715 – Undefined edge control
- Forging simulation and drafting aligned with OEM-grade practice
- Industrial experience in use of CATIA V5 GSD (Generative Shape Design) and RE modules for aerodynamic surface modeling