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Abstract The wear monitoring in the heavy and dusty industries like cement industry is a very important process and should be done perfectly and reliably. All the monitoring templates for these systems that supplied with the cement grinding and crushing machines is manual till now. It takes many times for a valuable number of records give us a reliable data about the wear occurred, but the time mean cost in the production field. We developed another portable hand held system using reverse engineering process in order to upgrading the manual wear monitoring systems to satisfy the industry needs in reducing the time and costs accurate system reports. The way to do such work is to follow the reverse engineering concepts and focusing on manual measuring methods that still used todays. [Reverse engineering definitions and steps for approach were mentioned and followed on study beginning with studying the manual measuring methods from all its side (that how it be done) and the readings per wear part, also the important results needed from the measuring process]. The next step in reverse engineering process that CAD modelling is the model for the parts need to be manufacturing, transferring to the stress analysis process that prove on the parts will work properly after manufacturing these step done by 3D CAD modelling software solidworks different versions. The next step is to make CAM modelling that converts the data cloud in the CAD model into traces, passes and lines could generate program consists of many orders guide the CNC machine to producing the needed parts. The next step is to CNC manufacturing with the available CNC machine in the college labs taking all the manufacturing and tool machining into account. Finally checking on the final product and make the necessary validation quality control tests by making trials runs and measuring surfaces could prove on . |