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TABLE 35.2 Tolerances for Punching or Blanking Paper-Base Laminate Tolerances, in, on distance between holes and slots, 90 F Up to 2 in. 0.003 0.005 0.006 2 to 3 in. 0.004 0.006 0.007 3 to 4 in. 0.005 0.007 0.008 4 to 5 in. 0.006 0.008 0.009 Tolerances for blanked parts, overall dimension, in. 0.003 0.005 0.008
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Material thickness To and including 1.16 in Over 1.16 in to and including 3.32 in. Over 3.32 in to and including 1.8 in.
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Tolerance on hole size, in. 0.0015 0.003 0.005
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holes is too small, cracks between holes may result even with the best of tools. If cracks between holes prove troublesome, plan the process so that the piercing is done before any copper is etched away. The reinforcing effect of the copper foil will help eliminate cracks. Most glass-epoxy laminates may be pierced, but the finish on the inside of the holes is sometimes not suitable for through-hole plating. 35.2.5 Warming Paper-Based Material The process of punching paper-based laminates will often be much more trouble-free if the parts are warmed to 90 or 100 F. That is true even of the so-called cold-punch or PC grades. Do not overheat the material to the point at which it crumbles and the residue is not ejected as a discrete slug. Overheated material will often plug the holes in the die and cause rejects. Opening the taper on the takeaway holes will reduce plugging, but the most direct approach is to pierce at a lower temperature. Glass-epoxy is never heated for piercing or blanking. 35.2.6 Press Size The size of the press is determined by the amount of work the press must do on each stroke. The supplier of copper-clad sheets can specify a value for the shear strength of the material being used.Typically, the value will be about 12,000 lb./in.2 for paper-based laminate and 20,000 lb./in.2 for glass-epoxy laminate. The total circumference of the parts being punched out multiplied by the thickness of the sheet gives the area being sheared by the die. If all dimensions are in inches, the value will be in square inches. For example, a die piercing 50 round holes, each 0.100 in. in diameter, in 0.062 in. thick laminate will be shearing, in square inches: 50 0.100 in. 3.1416 0.062 in. = 0.974 in.2 If the paper-based laminate has 12,000 lb./in.2 shear strength, 11,688 lb. of pressure, or about 6 tons, is required just to drive the punches through the laminate. Bear in mind that, if a spring loaded stripper is used, the press will also have to overcome the spring pressure, which ought to be at least as great as the shear strength.Therefore, a 12 ton press would be the minimum that could be considered. A 15 or 20 ton press would be considerably safer.
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35.3 BLANKING, SHEARING, AND CUTTING OF COPPER-CLAD LAMINATES
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35.3.1 Blanking Paper-Base Laminates When parts are designed to have shapes other than rectangular and the volume is great enough to justify the expense of building a die, the parts are frequently punched from sheets
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by using a blanking die. A blanking operation is well adapted to paper-based materials and is sometimes used on glass-based ones. In the design of a blanking die for paper-based laminates, the resilience, or yield, of the material previously discussed under Piercing applies. The blanked part will be slightly larger than the die that produced it, and dies are therefore made just a little under print size depending on the material thickness. Sometimes a combination pierce and blank die is used. The die pierces holes and also blanks out the finished part. When the configuration is very complex, the designer may recommend a multiple-stage die: The strip of material progresses from one stage to the next with each stroke of the die. Usually in the first one or two stages, holes are pierced, and in the final stage, the completed part is blanked out. The quality of a part produced from paper-based laminates by shearing, piercing, or blanking can be improved by performing the operation on material which has been warmed. Caution should be exercised in heating over 100 F because the coefficient of thermal expansion may be high enough to cause the part to shrink out of tolerance on cooling. Paper-base laminates are particularly anisotropic with respect to thermal expansion; that is, they expand differently in the x and y dimensions. The manufacturer s data on coefficient of expansion should be consulted before a die for close-tolerance parts is designed. Keep in mind that the precision of the manufacturer s data is probably no better than 25 percent. 35.3.2 Blanking Glass-Based Laminates Odd shapes that cannot be feasibly produced by shearing or sawing are either blanked or routed. Glass blanking is always done at room temperature. Assuming a close fit between punch and die, the part will be about 0.001 in. larger than the die which produced it. The tools are always so constructed that a part is removed from the die as it is made. It cannot be pushed out by a following part, as is often true when the material has a paper base. If material thicker than 0.062 in. is blanked, the parts may have a rough edge. The life of a punch, pierce, or blank die should be evaluated with reference to the various copper-clad materials that may be used. One way to evaluate die wear caused by various materials is to weigh the perforators, or punches, very accurately, punch 5,000 pieces, and then reweigh the punches. Approximately 5,000 hits are necessary for evaluation, because the initial break-in period of the die will show a higher rate of wear. Also, of course, the quality of the holes at the beginning and end of each test must be evaluated. Greatly enlarged microphotos of the perforator can be used for visual evaluation of changes in the die. 35.3.3 Shearing When copper-clad laminates are to be sheared, the shear should be set with only 0.001 to 0.002 in. clearance between the square-ground blades (Fig. 35.3). The thicker the material to
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