Effect of entry material and machine parameters on drilling process on PCB.

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Effect of entry material and machine parameters on drilling process on

PCB.

Suhas Bothe, ShraddhaDeokar, AkshayCharmal.

[email protected],[email protected], [email protected]

ABSTRACT

The purpose of through-hole drilling printed circuit boards is twofold: To produce an opening through the board that will permit a subsequent process to form an electrical connection between top, bottom, and internal conductor pathways, and to permit through-the-board component mounting with structural integrity and precision of location.

The quality of a hole drilled through a printed circuit board is measured by its ability to interface with the following processes: plating, soldering, and forming a highly reliable, non-degrading electrical and mechanical connection.

In this project we are going to study the various operating parameter of machine such as spindle speed, feed, retract etc and effect of this parameter on the hole quality . This project is sponsored by M/s- Epitome Components Ltd, Supa MIDC, Ahmednagar.

1. INTRODUCTION

A printed circuit board (PCB) mechanically supports and electrically connects electronic components using conductive tracks, pads and other features etched from copper sheets laminated onto a non-conductive substrate. PCBs can be single sided (one copper layer), double sided (two copper layers) or Multi-layer (outer and inner layers). Multi-layer PCBs allow for much higher component density. Conductors on

different layers are connected with plated-through holes called vias. Advanced PCBs may contain components- capacitors, resistors or active devices - embedded in the substrate. Glass epoxy is the primary insulating substrate upon which the vast majority of rigid PCBs are produced. A thin layer of copper foil is laminated to one or both sides of panel. Circuitry interconnections are etched into copper layers to produce printed circuit boards. Complex circuits are produced in multiple layers. Printed circuit boards are used in all but the simplest electronic products. Alternatives to PCBs include wire wrap and

point-to-point construction. PCBs require the additional design effort to lay out the circuit, but manufacturing and assembly can be automated. Manufacturing circuits with PCBs is cheaper and faster than with other wiring methods as components are mounted and wired with one single part. Furthermore, operator wiring errors are eliminated.

What is Printed Circuit Board (PCB)?

A PCB is a thin board made of fiberglass, composite epoxy, or other laminate material. Conductive pathways are etched or "printed" onto board, connecting different components on the PCB, such as transistors, resistors, and integrated circuits.

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the motherboard, which is also a printed circuit board.

Types of PCB

1 Single side PCB

We are the Leading Manufacturers of Single Sided PCB in India & our products are ROHS compliant in line with European requirements .We have state of Arts manufacturing facilities spread over a land area of 16200 SQM & built up area of 8000 SQM across.

1.1.1Figure:-Single side PCB 2. Double side PCB

This state of Double Side PCB art manufacturing facility is recently been operational. & spread over a land area of 21000 SQM & built up area of 5000 SQM with approximate investment of INR 30 crore

1.1.2Fig:-Double side PCB

3 RF Antenna PCB

We recently formed a joint venture with a UK based company “Track wise Designs Ltd" for manufacturing of RF Antenna PCBs required for Cellular networks, Radar & Space industry and various high end applications.

4 Multilayer PCBThis state of Multilayer PCB art manufacturing facility is recently been operational. & spread over a land area of 21000 SQM & built up area of 5000 SQM with approximate investment of INR 30 crore.

Function

Circuit boards or printed circuit boards (PCB) are thin plates containing electronic components mostly found in electrical and communications devices. The plate allows circuit components to transfer information and signals between each other as well as information to external devices. Circuit boards can be found in computers, televisions, cell phones, and other telecommunications devices. There are also different types for circuit boards, from traditional computer motherboards to tiny flexible boards used in mobile phones.

PCBs are made of different parts and resins with circuitry on the surface to connect parts to one another. A PCB will usually have components for memory chips, processors, input/output devices, and then electrical components like resistors and capacitors. With the progression of technology circuit boards have become smaller while accommodating more components. Capacitors are now embedded into circuit boards which increase circuit performance and allow circuits to become smaller.

Advantages

This analysis gives idea to the entrepreneur to choose the machine parameter for the PCB to avoid losses and unwanted cost.

Different type of CNC machines can be judged.

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can be implemented.

Techniques to reduce burr will be discussed.

Disadvantages

Re designing is required for the new type of circuit operation.

Very hard to get repaired if it gets damaged.

We cannot update it , once printed.

Etching of this PCB generates chemicals which are the harmful for the environment

2. LITERATURE SURVEY

2.1 Review of Book, Journal and International Paper

There were many words performed on the design of effect of machine parameters on drilling process of PCB by different investigators using various mechanisms or techniques. Present literature review gives overview of the some researchers work on effect of machine parameters on drilling process of PCB.

2.2 History

Printed circuit boards evolved from electrical connection systems that were developed in the 1850s. Metal strips or rods were originally used to connect large electric components mounted on wooden bases. In time the metal strips were replaced by wires connected to screw terminals, and wooden bases were replaced by metal chassis. But smaller and more compact designs were needed due to the increased operating needs of the products that used circuit boards. In 1925, Charles Ducas of the United States submitted a patent application for a method of creating an electrical path directly on an insulated surface by printing through a stencil with electrically conductive inks. This method gave birth to the name "printed wiring" or "printed circuit."

In the 1943, Paul Eisler of the United Kingdom patented a method of etching the conductive pattern, or circuits, on a layer of copper foil bonded to a glass-reinforced, non-conductive base. Widespread use of Eisler's technique did not come until the 1950s when the transistor was introduced for commercial use. Up to that point, the size of vacuum tubes and other components were so large that the traditional mounting and

wiring methods were all that was needed. With the advent of transistors, however, the components became very small, and manufacturers turned to printed circuit boards to reduce the overall size of the electronic package.

Through hole technology and its use in multi-layer PCBs was patented by the U.S. firm Hazeltyne in 1961. The resulting increase in component density and closely spaced electrical paths started a new era in PCB design. Integrated circuit chips were introduced in the 1970s, andthese components were quickly incorporated into printed circuit board design and manufacturing techniques.

1.Azlan Abdul Rahman, AzuddinMamat. This

paper present the effect of drilling parametersuch as spindle speed, feed rate and drilling tool size on material removal rate (MRR), surface roughness, dimensional accuracy and burr. In this work, a study on optimum drilling parameter for HSS drilling tool in micro-drilling processes in order to find the best drilling parameter for brass as a workpiece material. Micro drilling experiment with 0.5 mm to 1.0 mm drill sizes were performed by changing the spindle speed and feed at three different levels. The results were analyzed using microscope and surface roughness device. Comparatives analysis has been done between surface roughness, MRR and accuracy of drilled holes by experimentation. From the result, the surface roughness are mostly influenced by spindle speed and feed rate. As the spindle and feed rate increases, the surface roughness will decrease. The tool diameter gives less influence on the value of surface roughness. The value of MRR is decreased when the tool diameter, spindle speed and feedrate are decreases. As drilling tool diameter, feed rate and spindle speed increase the dimensional accuracy of drilled hole will decrease.

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of drilled holes was fulfilled as well as high productivity achieved. Such optimized process results in a noticeable production cost reduction.

2. PadwalGauri H1, SankayeShraddha N2,

TaralkarShweta K3, S.S. Gaonkar4, Wable

Abhay S5

A study of effect of drilling parameters like feed rates, cutting speeds and geometry of drill tool, surface roughness, cutting forces and chip formation is done in project. Machining a material removal process, is one of the most widely used manufacturing processes. At high spindle speed and lower feed rate the heat generation due to friction between cutting edges and the work material facilitate softening of the matrix which resulted in poor surface finish and lower delamination. Drilling is a type of machining operation where a cutting tool is used to create holes inside the work piece. A proper selection of tool and drilling parameters can reduce the risk of hole damages

3.R.M. Kulkarni, H. N. Narasimha Murthy, G.B. Rudrakshi, Sushilendra. This paperfocused on investigating the effects of drilling parameters like spindle speed (600rpm, 1860 rpm and 2700 rpm), Feed rate (0.1mm/rev, 0.2mm/rev and 0.3mm/rev), drill point angle (1180, 1100 and 900), drill material (HSS, Co-HSS and Tungsten Carbide) and carbon black (0, 4 and 8 wt %) on the responses: thrust force and delamination factor (entry and exit) in drilling of carbon black dispersed vinyl ester GFRP, by Design of Experiments approach. Drilling experiments were designed to control the drilling parameters based on L27Orthogonal Array. The experimental results were analyzed using MINITAB V16. Signal-to-Noise (S/N) ratio, ANOVA and Grey Relation Analysis (GRA) were employed to analyze the effect of drilling parameters on the quality of the drilled holes. Minimum value of thrust force was obtained for 4 wt% carbon black, 2700 rpm, 0.1 mm/rev, 1100 drill point angle and HSS drill. Delamination was minimum for 4 wt% carbon black, 2700rpm, 0.1mm/rev, 4mm diameter with Tungsten Carbide (WC) drill. SEM confirmed that delamination at the exit is greater than delamination at the entry

4.Vu Nguyen-Anh Lea, Yung-Jen Chenb,

Hsi-CherngChangc, Jau-Wen

Lind,∗Polymericmaterials designed with macromolecular structures present different levels of absorbance against different laser wavelengths.

CO2 laser is often applied during the drilling blind

via of printed circuit boards (PCB) and substrates used for semiconductor packaging since it features speedy processing time, but its high thermal energy easily causes serious substrate warpage and deformation after drilling is completed. Therefore, Nd:YVO4 laser is selected to create low thermal

energy as the tool used in this study. Factors including laser head movement speed, laser beam diameter, laser shot count, laser current and laser frequency control set at three design levels versus 12 sets of experimental parameters, comprise a total of 36 data sets to be taken into consideration. With the assistance of JMP software, a cross analysis is made in order to obtain the optimal set of parameters applicable to drill blind via on epoxy compound wafers.Finally, observations are made to explore the feasibility of applying the optimal set of parameters todrilling blind via on a macromolecular-structured polymeric material.

5.Yun-Chia Liang n, Yu-Ming Hsiao, Chia-Yun

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computational time.

6.Minh-Quan Phama, Gyu-Bong Leeb,

YuchuHuangc, Barbara S. Linkec, D.A. Dornfeldc,A

drilling burr-control chart (DBCC), based on experimental results, is a tool for the prediction and control of drilling burrs for a large range of drilling parameters. A micro-drilling burr-control chart (M-DBCC) was developed for a standard double-sided copper-clad laminated (CCL) printed circuit board (PCB) with laminated fiber-reinforced plastic (FRP) substrate. This chart will assist in the selection of favorable drilling parameters for predicting and achieving preferred types of burrs. Burr classification was carried out according to the burr geometric characteristics, burr formation mechanisms, burr height, and drill bit breakage while drilling. The design of experiment (DOE) technique based on the Taguchi method was used to find the most significant drilling parameter affecting burr height. The results show that the drill diameter makes a statistically significant contribution to burr-height variation.

7.L.M.P. Duraoa, A.G. Magalhaesa, A. T. Marquesb, Joao Manuel R. S. Tavaresb.

Composites are more and more increasing their importance as one of the most interesting group of materials, because of their unique properties. Hole drilling operations are common in composite parts to facilitate fastener assembly. As composites are non-homogeneous this operation causes some damages like delamination and others that reduce bearing and fatigue strength of the composite part. A proper selection of tool and drilling parameters can reduce the risk of delamination. In this paper three cutting speeds, three feed rates and three tool geometries are compared. Conclusions show the influence of an adequate selection of tool and cutting parameters in delamination reduction.

8.AykutKentli. states that this study investigated the effect of cutting speed, pecking depth andfeed rate on drilling of glass fiber reinforced polymer composite materials. Glass fiber reinforced polymer composite parts has been started to get extensively used at the industry of space, aviation, ship, chemistry and automotive nowadays. Other than these fields of usage, at processing composite parts by machining, some problems have been revealed due to the anisotropic structure that the

composite materials have. Drilling-induced damage is a serious problem in laminated composite materials. The worldwide research and development efforts have been focused on the area, but a few numbers of studies have investigated peck drilling. In this study, the effect of the above mentioned parameters was investigated and damage factor was estimated using Artificial Neural Network. The artificial neural network topology has been adopted as a predictive tool. The feed rate, cutting speed, pecking depth and damage place have been used as the input parameters. The drilling-induced damage was the output. The experimental data for drilling of woven glass-fiber-reinforced plastic composite laminates were used for training and testing the model. The results of the predictive model have been found to be in good agreement with the test data.

9.Kiha Lee, Ingo Essel, David A. Dornfeld. This

paper describes the experimental studies onmicro-milling in aluminum 6061-T6, stainless steel 304 and copper 110 have been carried out. A range of different cutting chip loads and depths of cut using 127μm, 254μm and 635μmdiameters were considered. The influence of the cutting parameters on burr size and burr type was observed. A comparison to burr formation in different materials is presented.

10.J. Campos Rubioa, A.M. Abrao, P.E. Fariaa, A. EstevesCorreiab, J. Paulo Davimc.

High speed machining (HSM) is an outstanding technology capable of improving productivity and lowering production costs in manufacturing companies. Drilling is probably the machining process most widely applied to composite materials; nevertheless, the damage induced by this operation may reduce drastically the component performance. This work employs HSM to realize high performance drilling of glass fibre reinforced plastics (GFRP) with reduced damage. In order to establish the damage level, digital analysis is used to assess delamination. A comparison between the conventional (Fd) and adjusted (Fda) delamination factor is presented. The experimental results indicate that the use of HSM is suitable for drilling GFRP ensuring low damage levels.

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Machine Parameters

Operating Parameter (R & D optimized parameter) 35 micron:

Machine Operating Conditions: Air Pressure – 110 bar Air Filter – 110 bar Cooling System - 180 C

Environmental Temperature – 220

C Current – 227 V

Vacuum Pressure – 110 bar

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Operating Language: SIBE MAYER

%%3000 G90

M47" PCB DRILL PROGRAM F-LD () DT:17.03.15 X29.901Y12.504T1

X33.901Y12.504 X37.901Y12.504 X41.901Y12.504 X45.901Y12.504 X49.901Y12.504 X53.901Y12.504

X57.901Y12.504 X61.901Y12.504 X65.901Y12.504 X69.901Y12.504 X73.901Y12.504 X77.901Y12.504 X81.901Y12.504 X85.901Y12.504 X89.901Y12.504 X93.901Y12.504 X97.901Y12.504 X101.901Y12.504 X105.901Y12.504 X109.901Y12.504 X113.901Y12.504 X117.901Y12.504 X121.901Y12.504 X125.901Y12.504 X125.901Y17.504 X121.901Y17.504 X117.901Y17.504

X113.901Y17.504 X109.901Y17.504 X105.901Y17.504

X101.901Y17.504 X97.901Y17.504 X93.901Y17.504 X89.901Y17.504 X85.901Y17.504 X81.901Y17.504 X77.901Y17.504 X73.901Y17.504 X69.901Y17.504 X65.901Y17.504 X61.901Y17.504 X57.901Y17.504 X53.901Y17.504 X49.901Y17.504 X45.901Y17.504 X41.901Y17.504 X37.901Y17.504

X33.901Y17.504 X29.901Y17.504 X29.901Y22.504 X33.901Y22.504 X37.901Y22.504

X41.901Y22.504 X45.901Y22.504 X90.158Y177.956 X96.158Y177.956 X102.158Y177.956 X108.158Y177.956 X114.158Y177.956 X120.158Y177.956 X126.158Y177.956 X132.158Y177.956

M47"DRILL TEXT X141.088Y12.940T9M98,85 X141.322Y33.261T9M98,90

X141.634Y52.236T9M98,100 X141.628Y72.742T9M98,110 X140.638Y95.623T9M98,120 X140.785Y118.630T9M98,150 X141.962Y141.304T9M98,200 X144.786Y166.065T9M98,400

X57.927Y191.681T1M97,1 M47"FOR SETTING X0.000Y0.000T10 X150.000Y0.000

X150.000Y200.000 X0.000Y200.000 M47"GUIDES X6.397Y4.521T11 X148.068Y7.018

X140.052Y197.860 X2.847Y193.925

$ T01D85

T02D90 T03D100 T04D110 T05D120 T06D150 T07D200 T08D400 T09D80 T10D40 T11D200

$

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Part name: Copper

Part weight –250kg

Part material – Copper

Part quantity – 4

Part size -150 x 200 mm

Part name: Backup

Part material –Backup(soft wood )

Part quantity – 5

Part name: Aluminium

Part weight –20kg

Part material –Aluminium

Part quantity – 1

Part name: Bakellite

Part material –Bakellite (hard wood )

Part quantity – 1

Used materials and their properties:

Following are the material details used in the project

4. Result Analysis

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.

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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 aluminium

6.1 SAMPLE

TESTING:-6.1.1 Testing Name:-Burr Analysis on top surface of the hole.

Machine Name:-Digital microscope tester

1) Burr analysis report

Comparative statement graph

6.1.2 Testing Name:-Hole allignment with respect to CNC Film

Machine Name:-CNC Film with White light

inspections table

2) Along hole and alignment with respect to

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5. CONCLUSION

From the discussion so far it has been concluded that Aluminum is better entry material than copper, Bakelite or wooden material. Al will help in reduction in burr, plain surface finishing and better hole quality than other materials like copper, Bakelite, wood etc. Burr minimization techniques can be easily implemented in Al material. The overall conclusions from the investigations are:

•Burr reduction with increased speed.

•Burr reduction with reduced feed rate.

• Conical defect at hole entry can be eliminated by using high feed, short drill length, and drill point warranting good self-centering capability.

Significant reduction of exit burr with properly constructed clamping system.

6. REFERENCES

[1]. Azlan Abdul Rahman, AzuddinMamat ,‘Effect of Machining Parameters on Hole Quality of Micro Drilling’, vol.3,No.5(2009)

[2]. PadwalGauri H1, SankayeShraddha N2,

TaralkarShweta K3, S.S. Gaonkar4, WableAbhay S5 , ‘Effect of Machine Parameters on Drilling Process of PCB ,international journal of engineering and management research,vol.6,Issue.2,March-April2016,Page No-163-167.

[3]R.M. Kulkarni, H. N. Narasimha Murthy, G.B. Rudrakshi, Sushilendra

[4]. Vu Nguyen-Anh Lea, Yung-Jen Chenb, Hsi-CherngChangc, Jau-Wen Lind ‘Investigation on drilling blind via of epoxy compound wafer by 532 nm Nd:YVO4 laser,’ Journal of

Manufacturing Processes 27 (2017) 214–220

[5]. Yun-Chia Liang n, Yu-Ming Hsiao, Chia-Yun Tien ‘Metaheuristics for drilling operation scheduling in Taiwan PCB industries’, Int. J. Production Economics 141 (2013) 189–198

[6]. Minh-QuanPhama, Gyu-Bong Leeb, YuchuHuangc, Barbara S. Linkec, D.A. Dornfeldc

‘_{Development of a micro-drilling burr-control chart for} PCB drilling’