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depending on drill diameter and is determined by calculating the drill bit point length (see Fig. 24.8) and adding approximately 0.010 in. As a rule of thumb, backup penetration depth may be set to a distance equal to the drill diameter or 0.040 in, whichever is less.
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FIGURE 24.8 Point length calculation.
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24.4.4.2 Effects. Excessive backup penetration depth increases drill wear and the occurrence of breakage of small-diameter drill bits, adversely affects hole quality, and increases process time per load. Insufficient backup penetration depth results in incompletely drilled holes. This implies that thickness variations of the backup material are very important, meaning that minimal variations are a much desired characteristic of the backup and need to be considered when choosing a material suitable for your application.
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Hits Per Tool 24.4.5.1 Definition. The maximum hits per tool specified for any given drill size implies the number of drill strokes a drill bit is used for until its expected effective life is expired. Maximum hit count per tool is product and process specific and is affected by laminate material construction, panel thickness, drilled stack height, surface speed, and the type of entry and backup material used. Therefore, no specific number of hits per tool can be arbitrarily specified. 24.4.5.2 Effects. Excessive drill wear caused by excessive maximum hit count increases drilled hole defects and may prevent proper repointing. Conservative maximum hit counts greatly impact drilling cost per hole and increase time per load because of increased numbers of tool changes.
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Stack Clearance Height 24.4.6.1 Definition. Stack clearance height is the distance between the point of the drill and the surface of the stack at the top of the drill stroke. Maintain a minimum stack clearance distance of 1/8 in (0.125 in), which implies a space between the bottom of the pressure foot and the top of the stack of 0.075 in, assuming the pressure foot lead distance to the point of the drill is correctly set at 0.050 in. Stack clearance may be adjusted for each load by simply sliding a 0.075-in shim between the pressure foot and the stack and adjusting the upper limit ( UP# ) until the pressure foot touches the shim. 24.4.6.2 Effects. The less the stack clearance distance between the drill point and the top of the stack, the shorter the drill stroke and therefore the shorter the processing time per load. Increasing the stack clearance distance allows more time between drill strokes and gives the tool table more time to settle, which may improve hole registration accuracy and prevent small-diameter drill bit breakage. In addition, the greater the time between drill strokes, the
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more likely drilling debris will be removed from the drill flutes and, consequently, the lower the drilling temperatures, which results in reduced occurrences of drill breakage and lower extents of drilled hole quality defects. 24.4.7 Drilled Stack Height Material construction (panel thickness, number of copper layers, laminate type, etc.), drill bit diameter, and flute length, as well as hole quality and registration accuracy requirements, all are factors that need to be considered when deciding on appropriate drilled stack heights. A greater number of panels in the drilled stack means higher drilling temperatures, accelerated drill wear, and greater drill deflection, affecting the resulting hole quality and registration accuracy. When using smaller-diameter drill bits, stack heights need to be reduced to prevent drill breakage and to accommodate the shorter flute lengths. As a rule of thumb, the maximum total drilled depth (number of panels panel thickness + entry thickness + backup penetration depth) that can safely be handled by the drill bit without breakage is approximately 17 times its diameter. 24.4.8 Stacking and Pinning 24.4.8.1 Building the Stack. Inspect all laminate panels and the entry and backup materials for surface damage and remove burrs from the panel edges as well as from the pinning holes. Even though the registration tooling holes on the laminate material may not be used to pin the stacked panels together, it is important to remove any resin buildup remaining around these holes after lamination (a common occurrence). Burrs and raised surface areas do not permit the panels to lay flat, causing gaps resulting in drilled hole registration problems, burrs, hole quality defects, and drill breakage. Reject entry and backup materials with excessive nicks, scratches, and other surface defects as well as those that are warped or twisted. 24.4.8.2 Pinning Procedures. Wipe the surfaces of all laminate panels and the backup material using a lint-free cloth to remove any debris before stacking the panels (allowing intimate contact between the stacked panels). Verify that the pinning holes and pin insertion are perpendicular to the stack and avoid using pins that are damaged or deformed. 24.4.8.3 Installation. Before placing the pinned stacks onto the drilling machine tool table, inspect the surface for burrs or broken drill bits protruding from the table that may prevent the stacks from lying flat. Do not continue if the pin bushings of the tool table are sunken or worn to the point that they do not hold the stack firmly in place. Loose or sunken tooling pin bushings cause movement of the stack during drilling and result in a variety of hole defects, registration problems, and drill breakage, yet are simple to replace at a minimum cost. After stacks are put in place, again wipe the surface of the top laminate material as well as the entry material. Place the entry material on top of the stack and tape it in place.The entry material size should be such that it clears the pins and does not extend beyond the stack edges. Pinning the entry material to the stack is not recommended because it tends to constrict the movement of the material, causing separation between it and the stack and resulting in entry burrs and possible drill breakage.
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