Yes, despite being absolutely covered in glass, the iPhone 13 should be impressively durable (if it's anything like the iPhone 12). However, the front glass, while not uncrackable, is at least dingable (I've got the chewed up front glass on my iPhone 12 to prove it) and the back glass? Well, there's a reason that no one talked about ceramic coated anything during the keynote when referring to the rest of the enclosure.
Hybrid manufacturing is the process of integrating several processes in a single machine [13]. These processes can be joining, dividing, subtractive, transformative, additive, etc. [14]. The integrated hybrid process provides an ideal industrial solution for complex parts manufacturing or repair. In this way, hybrid manufacturing overcomes the drawbacks of each process by combining another process that has strong corresponding advantages, thus enhancing overall competitiveness. For example, additive manufacturing enables fabrication of freeform structures while associated with low accuracy and coarse surface finish [15]. Subtractive operation such as CNC machining, in contrast, possesses precise production capacity [16]. The combination of both processes takes advantage of each technology, enabling production of end-use products in a single hybrid machine.
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Studies have been conducted to utilize the hybrid manufacturing approach to remanufacture worn components. A thin-curved damaged aircraft engine blade was repaired in [10] by depositing material back to the worn area and followed by CNC milling for post-machining. A damaged blade tip was repaired using laser cladding to add materials in the damaged region and the blade was then machined on a CNC machine to obtain the exact dimensions [17]. A hybrid machine was developed to integrate AM with CNC machining that is capable of adding features to existing objects or repairing worn components [18].
An integrated hybrid process for component remanufacturing in this study obeys the following procedure as shown in Figure 2: (1) pre-repair inspection; (2) pre-repair processing; (3) AM; (4) subtractive manufacturing (SM); (5) repair quality inspection. In the beginning, a complete inspection was performed on worn parts to assess the feasibility of repair. Considering the excessive variety of locations and geometries of defects, the inspection is highly a case to case basis. After that, pre-repair processing was conducted to guarantee the worn parts were repairable. Previous work in component repair is concentrated on post-machining. However, pre-repair processing is also crucial in the repair chain. Pre-repair processing discussed in this paper includes pre-repair machining and pre-repair heat-treatment. Pre-repair machining is required because many defects such as cracking are not directly accessible to AM systems. Such defects cannot be repaired without machining off materials surrounding the inaccessible defects. The inclination angle of boundaries of defects should also be considered in the machining process since it is reported that too steep walls cannot form sound bonding between filler material and substrates [19]. The AM process builds materials in the damaged area to restore the missing geometry in a layer-upon-layer fashion [20]. The key is to reconstruct the exact missing geometry to provide a tool path for material deposition [21]. SM succeeds the AM process since the as-deposited geometry may have unsatisfied surface roughness. In the quality inspection step, the geometry and mechanical properties of the repaired part were inspected to validate a successful repair.
The current research proposed a general procedure for removing surface superficial defects. In general, the damaged component is 3D scanned to recreate the model. After that, the model is loaded to CAM software. The area for machining is defined and machining parameters including cut-off thickness are determined. Subsequently, machining program is generated and transferred to a CNC machine for machining.
(a) Damaged blade; (b) 3D model of the blade; (c) point cloud in damaged area; (d) convex hull of the point cloud; (e) optimized contour for machining; (f) blade after machining.
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