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FIGURE 24.4 Center.)
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Drill point defect illustrations. (Courtesy of LCOA Technical
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24.2.3 Drill Bit Rings Drill bit rings are set to a common distance from the point to the back of the ring, thereby allowing a controlled drilling depth. The quality of these rings is as critical as the consistency of drill bit attributes because they can equally affect drill bit performance. Rings that fit loosely on the drill shank have been known to move during tool changes, resulting in insufficient drilling depth. Rings that fit too tightly may crack. Rings that have protruding material ( flash ) on the inside diameter may cause improper seating of the drill bit in the collet (of the spindle) or may prevent the drill bit from being properly inserted into the tool pod or cassette, resulting in destructive tool change problems.
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Rings have specific color codes assigned to each size and are commonly imprinted with size, diameter, and design or series number. Rings may be either machined or mold-injected. While machined rings are superior because of their consistency and quality, their cost is prohibitive for many drill bit manufacturers. Some of the drawbacks of mold-injected rings that must be monitored are inside diameter, affecting how well the ring fits on the drill shank, and remaining flash.
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Entry Material 24.2.4.1
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Purpose. The purpose of the entry material is fivefold:
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Centers the drill Prevents drill breakage Prevents copper burrs Avoids contamination of the hole or drill bit Prevents pressure footmarks
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24.2.4.2 Types. There are many different available types (constructions) of materials used as entry material for printed circuit board drilling, although few are specifically designed and engineered for this purpose. Engineered products are designed to improve hole registration accuracy and reduce drill breakage.The performance qualifications of the most popular materials are discussed in the next section. Commonly available entry materials, listed in order of performance quality with respect to the five characteristics listed in the preceding section, are:
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Aluminum-clad cellulose core composite Solid aluminum (various alloys and thicknesses) Solid or melamine-clad phenolic Aluminum-clad phenolic
24.2.4.3 Performance. The right entry material will improve drilled hole registration and lower the risk of drill bit breakage by minimizing drill deflection upon contact with the stack. In order for the entry material to function properly, it must be flat and free of pits, dents, and scratches. Warped or twisted material will result in increased extents of entry burrs and drill bit breakage. Surface imperfections and materials that are too hard contribute to drill deflection, resulting in decreased hole registration accuracy and breakage of small-diameter drills. Phenolic materials or phenolic composites (i.e., aluminum-clad phenolic) often warp and under most drilling conditions contaminate the hole wall, which results in problems with adherence of the plating because desmearing chemicals are not designed to remove phenolic resin. Solid aluminum materials of the correct composition and hardness that are not of an excessive thickness, yet are not too thin, may work satisfactorily with larger-diameter drill bits. However, drilling with solid aluminum materials (0.008 in and thicker) may increase the risk of breakage of smaller-diameter drills.Aluminum-clad cellulose core materials provide a hard surface to prevent burrs yet minimize drill deflection and breakage associated with solid aluminum.
Backup Material 24.2.5.1 Purpose. The purpose of backup material is defined by the following criteria. An ideal backup material will:
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Provide a safe medium for drill stroke termination Prevent copper burrs Not contaminate the hole or drill bit Minimize drilling temperatures Improve hole quality
24.2.5.2 Types. Numerous materials are available that are sold as backup material. Few of the materials used as backup materials are actually specifically engineered for circuit board drilling. Many of the popular backup products are composites with a variety of surface coatings or skins bonded to several different core materials. Available backup products include the following:
Epoxy-paper-clad, wood-core composite utilizing a bonding agent with lubricating properties Aluminum-clad, wood-core composite Epoxy-paper-clad, wood-core composite Melamine-clad, wood-core composite Urethane-clad, wood-core composite Solid phenolic Aluminum-clad phenolic composite Plain wood Hardboard
24.2.5.3 Performance. Desired qualities in a backup material are minimal thickness variations, flatness (no bow, warp, or twist), no abrasives or contaminants, a smooth surface, low cutting energy (minimizing drilling temperatures), and a surface hardness that supports the laminate copper surface (to prevent burrs) yet does not cause damage or extensive wear to the drill bit. Backup materials with lubricating properties have been proven to significantly reduce drilling temperatures by as much as 50 percent or more, often resulting in temperatures below the Tg of the laminate product being drilled. This advantage greatly reduces hole wall defects such as roughness, smear, and nail-heading and often allows increased drill stack heights and/or greatly increased drill bit maximum hit counts. The importance of these benefits is significant reduction in drilling cost per hole and improved productivity and yield. Remember that drilled backup debris exits the stacks by passing through the holes in the laminate material and that therefore contamination (from the backup material) is of great concern. Materials containing phenolic, or composed of solid phenolic, are not suitable for circuit board drilling. Phenolic materials or phenolic composites (i.e., aluminum-clad phenolic) often warp and under most drilling conditions contaminate the hole wall, which results in problems with adherence of the plating because desmearing chemicals are not designed to remove phenolic resin. Hardboard types of materials cannot be maintained to thickness variation tolerances acceptable for circuit board drilling and are a source for a great variety of contaminants (e.g., oils crystallized on the surface for hardening purposes).
Tooling Pins Seldom is any due attention given to the tooling pins.They come in many shapes and sizes and their cost, with respect to how much they add to the cost of fabricating a circuit board, is insignificant. Yet, quite often, tooling pins are found to be damaged or deformed (e.g., mush-
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