Parametric Optimization of Train Brake Pad Using Reverse Engineering with Digital Photogrammetry 3D Modeling Method
P. Paryanto, Muhammad Faizin, R. Rusnaldy · Eng—Advances in Engineering · 2025
Reverse engineering (RE) is essential in recreating 3D models of existing manufactured parts. It is widely used for repairing damaged components, improving used parts, and designing new items based on older models. One of the most common methods in RE is photogrammetry, which enables 3D reconstruction by capturing multiple images. Therefore, this study aimed to explore the application of mobile photogrammetry to obtain a 3D model of a train brake pad. The process started with capturing images of objects in a quick and professional manner to ensure visualization of data. This was followed by processing 2D images using Agisoft Metashape 2.2.1 software and Artificial Intelligence (AI) algorithms to create a precise 3D model. Subsequently, assessment was performed using feasibility in terms of cost, time, and accuracy. The results show that mobile photogrammetry provided an accessible and cost-effective method, alongside maximum contact stress after reducing optimization by approximately 28.42%, with maximum error value measured by the virtual model with the reference value of 0.30 mm (on Metashape) and 0.46 mm (on AI). This suggested that reverse parameterization significantly accelerated computer-aided design (CAD) model reconstruction and reduced the part redesign development cycle. By using photogrammetry and parametric modeling, engineers could accurately analyze and optimize train brake pads, ensuring safety as well as sustainability in railway operations. Additionally, RE and parametric modeling could assist in creating durable, cost-effective alternatives, and predicting appropriate replacements.