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Effect of entry material and machine parameters on drilling process on

PCB.
Suhas Bothe, ShraddhaDeokar, AkshayCharmal.

suhasbothe101@gmail.com,deokarshradhha18@gmail.com, akshaycharmal98@gmail.com

different layers are connected with plated-through


ABSTRACT holes called vias. Advanced PCBs may contain
The purpose of through-hole drilling components- capacitors, resistors or active
printed circuit boards is twofold: To produce an devices - embedded in the substrate. Glass epoxy
opening through the board that will permit a is the primary insulating substrate upon which the
subsequent process to form an electrical connection vast majority of rigid PCBs are produced. A thin
between top, bottom, and internal conductor layer of copper foil is laminated to one or both
pathways, and to permit through-the-board sides of panel. Circuitry interconnections are
component mounting with structural integrity and etched into copper layers to produce printed
precision of location. circuit boards. Complex circuits are produced in
multiple layers. Printed circuit boards are used in
The quality of a hole drilled through a all but the simplest electronic products.
printed circuit board is measured by its ability to Alternatives to PCBs include wire wrap and
interface with the following processes: plating,
soldering, and forming a highly reliable, non- point-to-point construction. PCBs require the
degrading electrical and mechanical connection. additional design effort to lay out the circuit, but
manufacturing and assembly can be automated.
In this project we are going to study the Manufacturing circuits with PCBs is cheaper and
various operating parameter of machine such as faster than with other wiring methods as
spindle speed, feed, retract etc and effect of this components are mounted and wired with one single
parameter on the hole quality . This project is part. Furthermore, operator wiring errors are
sponsored by M/s- Epitome Components Ltd, Supa eliminated.
MIDC, Ahmednagar.
What is Printed Circuit Board (PCB)?

A PCB is a thin board made of fiberglass,


composite epoxy, or other laminate material.
1. INTRODUCTION
Conductive pathways are etched or "printed" onto
A printed circuit board (PCB)
board, connecting different components on the
mechanically supports and electrically connects
PCB, such as transistors, resistors, and integrated
electronic components using conductive tracks,
circuits.
pads and other features etched from copper sheets
laminated onto a non-conductive substrate. PCBs
PCBs are used in both desktop and laptop
can be single sided (one copper layer), double
computers. They serve as the foundation for many
sided (two copper layers) or Multi-layer (outer
internal computer components, such as video cards,
and inner layers). Multi-layer PCBs allow for
controller cards, network interface cards, and
much higher component density. Conductors on
expansion cards. These components all connect to

Volume 3 issue 2 April 2018 1


the motherboard, which is also a printed circuit
board.

Types of PCB

1 Single side PCB

We are the Leading Manufacturers of Single 4 Multilayer PCBThis state of Multilayer PCB art
Sided PCB in India & our products are ROHS manufacturing facility is recently been operational.
compliant in line with European requirements .We & spread over a land area of 21000 SQM & built
have state of Arts manufacturing facilities spread up area of 5000 SQM with approximate investment
over a land area of 16200 SQM & built up area of of INR 30 crore.
8000 SQM across.
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
1.1.1Figure:-Single side PCB
telecommunications devices. There are also
2. Double side PCB
different types for circuit boards, from traditional
computer motherboards to tiny flexible boards used
This state of Double Side PCB art manufacturing
in mobile phones.
facility is recently been operational. & spread over
PCBs are made of different parts and
a land area of 21000 SQM & built up area of 5000
resins with circuitry on the surface to connect parts
SQM with approximate investment of INR 30 crore
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
1.1.2Fig:-Double side PCB and allow circuits to become smaller.

3 RF Antenna PCB Advantages


This analysis gives idea to the
We recently formed a joint venture with a UK entrepreneur to choose the machine
based company “Track wise Designs Ltd" for parameter for the PCB to avoid losses and
manufacturing of RF Antenna PCBs required for unwanted cost.
Cellular networks, Radar & Space industry and Different type of CNC machines can be
various high end applications. judged.
Drilling procedures & tools improvement

Volume 3 issue 2 April 2018 2


can be implemented. wiring methods were all that was needed. With the
Techniques to reduce burr will be advent of transistors, however, the components
discussed. became very small, and manufacturers turned to
printed circuit boards to reduce the overall size of
the electronic package.
Disadvantages Through hole technology and its use in
Re designing is required for the new type multi-layer PCBs was patented by the U.S. firm
of circuit operation. Hazeltyne in 1961. The resulting increase in
Very hard to get repaired if it gets component density and closely spaced electrical
damaged. paths started a new era in PCB design. Integrated
We cannot update it , once printed. circuit chips were introduced in the 1970s,
andthese components were quickly incorporated
into printed circuit board design and manufacturing
Etching of this PCB generates chemicals which are techniques.
the harmful for the environment
1.Azlan Abdul Rahman, AzuddinMamat. This
2. LITERATURE SURVEY paper present the effect of drilling parametersuch
2.1 Review of Book, Journal and International as spindle speed, feed rate and drilling tool size on
Paper material removal rate (MRR), surface roughness,
There were many words performed on the dimensional accuracy and burr. In this work, a
design of effect of machine parameters on drilling study on optimum drilling parameter for HSS
process of PCB by different investigators using drilling tool in micro-drilling processes in order to
various mechanisms or techniques. Present find the best drilling parameter for brass as a
literature review gives overview of the some workpiece material. Micro drilling experiment with
researchers work on effect of machine parameters 0.5 mm to 1.0 mm drill sizes were performed by
on drilling process of PCB. changing the spindle speed and feed at three
different levels. The results were analyzed using
2.2 History microscope and surface roughness device.
Printed circuit boards evolved from Comparatives analysis has been done between
electrical connection systems that were developed surface roughness, MRR and accuracy of drilled
in the 1850s. Metal strips or rods were originally holes by experimentation. From the result, the
used to connect large electric components mounted surface roughness are mostly influenced by spindle
on wooden bases. In time the metal strips were speed and feed rate. As the spindle and feed rate
replaced by wires connected to screw terminals, increases, the surface roughness will decrease. The
and wooden bases were replaced by metal chassis. tool diameter gives less influence on the value of
But smaller and more compact designs were surface roughness. The value of MRR is decreased
needed due to the increased operating needs of the when the tool diameter, spindle speed and feedrate
products that used circuit boards. In 1925, Charles are decreases. As drilling tool diameter, feed rate
Ducas of the United States submitted a patent and spindle speed increase the dimensional
application for a method of creating an electrical accuracy of drilled hole will decrease.
path directly on an insulated surface by printing Lukas Pilny, Leonardo De Chiffre, MiroslavPiska,
through a stencil with electrically conductive inks. Morten F. Villumsen. Optimization of the metal
This method gave birth to the name "printed drilling process requires creation of minimum
wiring" or "printed circuit." amount of burrs and uniform appearance of the
drilled holes. In this paper, an experimental
In the 1943, Paul Eisler of the United investigation was performed on 2 mm sheets of
Kingdom patented a method of etching the wrought aluminium alloy Al99.7Mg0.5Cu-H24,
conductive pattern, or circuits, on a layer of copper using 1.6 and 2 mm diameter drills. Cutting data,
foil bonded to a glass-reinforced, non-conductive clamping conditions, and drill geometry were
base. Widespread use of Eisler's technique did not varied in order to optimize the process and reach
come until the 1950s when the transistor was the desired quality. The results revealed possible
introduced for commercial use. Up to that point, reduction of burr occurrence on both the entry and
the size of vacuum tubes and other components exit side of the sheet, requiring no additional
were so large that the traditional mounting and deburring. The demand on the uniform appearance

Volume 3 issue 2 April 2018 3


of drilled holes was fulfilled as well as high CO2 laser is often applied during the drilling blind
productivity achieved. Such optimized process via of printed circuit boards (PCB) and substrates
results in a noticeable production cost reduction. used for semiconductor packaging since it features
2. PadwalGauri H1, SankayeShraddha N2, speedy processing time, but its high thermal energy
TaralkarShweta K3, S.S. Gaonkar4, Wable easily causes serious substrate warpage and
Abhay S5 deformation after drilling is completed. Therefore,
A study of effect of drilling parameters like feed Nd:YVO4 laser is selected to create low thermal
rates, cutting speeds and geometry of drill tool, energy as the tool used in this study. Factors
surface roughness, cutting forces and chip including laser head movement speed, laser beam
formation is done in project. Machining a material diameter, laser shot count, laser current and laser
removal process, is one of the most widely used frequency control set at three design levels versus
manufacturing processes. At high spindle speed 12 sets of experimental parameters, comprise a
and lower feed rate the heat generation due to total of 36 data sets to be taken into consideration.
friction between cutting edges and the work With the assistance of JMP software, a cross
material facilitate softening of the matrix which analysis is made in order to obtain the optimal set
resulted in poor surface finish and lower of parameters applicable to drill blind via on epoxy
delamination. Drilling is a type of machining compound wafers.Finally, observations are made to
operation where a cutting tool is used to create explore the feasibility of applying the optimal set
holes inside the work piece. A proper selection of of parameters todrilling blind via on a
tool and drilling parameters can reduce the risk of macromolecular-structured polymeric material.
hole damages
5.Yun-Chia Liang n, Yu-Ming Hsiao, Chia-Yun
3.R.M. Kulkarni, H. N. Narasimha Murthy, TienAmong all types of productionenvironment,
G.B. Rudrakshi, Sushilendra. This paperfocused identical parallel machines are frequently used to
on investigating the effects of drilling parameters increase the manufacturing capacity of the drilling
like spindle speed (600rpm, 1860 rpm and 2700 operation in Taiwan printed circuit board (PCB)
rpm), Feed rate (0.1mm/rev, 0.2mm/rev and industries. Additionally, multiple but conflicting
0.3mm/rev), drill point angle (1180, 1100 and 900), objectives are usually considered when a manager
drill material (HSS, Co-HSS and Tungsten plans the production scheduling. Compared to the
Carbide) and carbon black (0, 4 and 8 wt %) on the single objective problem, the multiple-objective
responses: thrust force and delamination factor version no longer looks for an individual optimal
(entry and exit) in drilling of carbon black solution, but a Pareto front consisting of a set of
dispersed vinyl ester GFRP, by Design of non-dominated solutions will be needed and
Experiments approach. Drilling experiments were established. The manager then can select one of the
designed to control the drilling parameters based alternatives from the set. This research aims at
on L27Orthogonal Array. The experimental results employing a variable neighborhood search (VNS)
were analyzed using MINITAB V16. Signal-to- algorithm and a multiple ant colony optimization
Noise (S/N) ratio, ANOVA and Grey Relation (MACO) algorithm to solve the identical parallel-
Analysis (GRA) were employed to analyze the machine scheduling problem with two conflicting
effect of drilling parameters on the quality of the objectives: makespan and total tardiness. In VNS,
drilled holes. Minimum value of thrust force was two neighborhoods are defined— insert a job to a
obtained for 4 wt% carbon black, 2700 rpm, 0.1 different position or swap two jobs in the
mm/rev, 1100 drill point angle and HSS drill. sequence. To save the computational expense, one
Delamination was minimum for 4 wt% carbon of the neighborhoods is randomly selected for the
black, 2700rpm, 0.1mm/rev, 4mm diameter with target solution which is also arbitrarily chosen
Tungsten Carbide (WC) drill. SEM confirmed that from the current Pareto front. In MACO, a two-
delamination at the exit is greater than phase construction procedure where three colonies
delamination at the entry are employed in each phase is proposed. These two
algorithms are tested on a set of real data collected
4.Vu Nguyen-Anh Lea, Yung-Jen Chenb, Hsi- from a leading PCB factory in Taiwan and their
CherngChangc, Jau-Wen performances are compared. The computational
Lind,∗Polymericmaterials designed with results show that VNS outperforms all competing
macromolecular structures present different levels algorithms—SPGA, MOGA, NSGA-II, SPEA-II,
of absorbance against different laser wavelengths. and MACO in terms of solution quality and

Volume 3 issue 2 April 2018 4


computational time. composite materials have. Drilling-induced damage
is a serious problem in laminated composite
6.Minh-Quan Phama, Gyu-Bong Leeb, materials. The worldwide research and
YuchuHuangc, Barbara S. Linkec, D.A. development efforts have been focused on the area,
Dornfeldc,A but a few numbers of studies have investigated
drilling burr-control chart (DBCC), based on peck drilling. In this study, the effect of the above
experimental results, is a tool for the prediction mentioned parameters was investigated and
and control of drilling burrs for a large range of damage factor was estimated using Artificial
drilling parameters. A micro-drilling burr-control Neural Network. The artificial neural network
chart (M-DBCC) was developed for a standard topology has been adopted as a predictive tool. The
double-sided copper-clad laminated (CCL) printed feed rate, cutting speed, pecking depth and damage
circuit board (PCB) with laminated fiber- place have been used as the input parameters. The
reinforced plastic (FRP) substrate. This chart will drilling-induced damage was the output. The
assist in the selection of favorable drilling experimental data for drilling of woven glass-fiber-
parameters for predicting and achieving preferred reinforced plastic composite laminates were used
types of burrs. Burr classification was carried out for training and testing the model. The results of
according to the burr geometric characteristics, the predictive model have been found to be in good
burr formation mechanisms, burr height, and drill agreement with the test data.
bit breakage while drilling. The design of
experiment (DOE) technique based on the Taguchi 9.Kiha Lee, Ingo Essel, David A. Dornfeld. This
method was used to find the most significant paper describes the experimental studies onmicro-
drilling parameter affecting burr height. The milling in aluminum 6061-T6, stainless steel 304
results show that the drill diameter makes a and copper 110 have been carried out. A range of
statistically significant contribution to burr-height different cutting chip loads and depths of cut using
variation. 127μm, 254μm and 635μmdiameters were
considered. The influence of the cutting parameters
7.L.M.P. Duraoa, A.G. Magalhaesa, A. T. on burr size and burr type was observed. A
Marquesb, Joao Manuel R. S. Tavaresb. comparison to burr formation in different materials
is presented.
Composites are more and more increasing their
importance as one of the most interesting group of 10.J. Campos Rubioa, A.M. Abrao, P.E.
materials, because of their unique properties. Hole Fariaa, A. EstevesCorreiab, J. Paulo Davimc.
drilling operations are common in composite parts High speed machining (HSM) is an
to facilitate fastener assembly. As composites are outstanding technology capable of improving
non-homogeneous this operation causes some productivity and lowering production costs in
damages like delamination and others that reduce manufacturing companies. Drilling is probably the
bearing and fatigue strength of the composite part. machining process most widely applied to
A proper selection of tool and drilling parameters composite materials; nevertheless, the damage
can reduce the risk of delamination. In this paper induced by this operation may reduce drastically
three cutting speeds, three feed rates and three tool the component performance. This work employs
geometries are compared. Conclusions show the HSM to realize high performance drilling of glass
influence of an adequate selection of tool and fibre reinforced plastics (GFRP) with reduced
cutting parameters in delamination reduction. damage. In order to establish the damage level,
digital analysis is used to assess delamination. A
8.AykutKentli. states that this study investigated comparison between the conventional (Fd) and
the effect of cutting speed, pecking depth andfeed adjusted (Fda) delamination factor is presented.
rate on drilling of glass fiber reinforced polymer The experimental results indicate that the use of
composite materials. Glass fiber reinforced HSM is suitable for drilling GFRP ensuring low
polymer composite parts has been started to get damage levels.
extensively used at the industry of space, aviation, 3. PROPOSED SYSTEM
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

Volume 3 issue 2 April 2018 5


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 – 220C
Current – 227 V
Vacuum Pressure – 110 bar

Machine Program:
Software: CAM 350

Volume 3 issue 2 April 2018 6


Operating Language: SIBE MAYER X33.901Y17.504
X29.901Y17.504
%%3000 X29.901Y22.504
G90 X33.901Y22.504
X37.901Y22.504
M47" PCB DRILL PROGRAM F-LD () DT:17.03.15
X29.901Y12.504T1 X41.901Y22.504
X45.901Y22.504
X33.901Y12.504 X90.158Y177.956
X37.901Y12.504 X96.158Y177.956
X41.901Y12.504 X102.158Y177.956
X45.901Y12.504 X108.158Y177.956
X49.901Y12.504 X114.158Y177.956
X53.901Y12.504 X120.158Y177.956
X126.158Y177.956
X57.901Y12.504 X132.158Y177.956
X61.901Y12.504
X65.901Y12.504 M47"DRILL TEXT X141.088Y12.940T9M98,85
X69.901Y12.504 X141.322Y33.261T9M98,90
X73.901Y12.504 X141.634Y52.236T9M98,100
X77.901Y12.504 X141.628Y72.742T9M98,110
X81.901Y12.504 X140.638Y95.623T9M98,120
X85.901Y12.504 X140.785Y118.630T9M98,150
X89.901Y12.504 X141.962Y141.304T9M98,200
X93.901Y12.504 X144.786Y166.065T9M98,400
X97.901Y12.504 X57.927Y191.681T1M97,1 M47"FOR SETTING
X101.901Y12.504 X0.000Y0.000T10 X150.000Y0.000
X105.901Y12.504 X150.000Y200.000 X0.000Y200.000 M47"GUIDES
X109.901Y12.504 X6.397Y4.521T11 X148.068Y7.018
X113.901Y12.504 X140.052Y197.860 X2.847Y193.925
X117.901Y12.504
X121.901Y12.504 $
X125.901Y12.504 T01D85
X125.901Y17.504 T02D90
X121.901Y17.504 T03D100
X117.901Y17.504 T04D110
T05D120
X113.901Y17.504 T06D150
X109.901Y17.504 T07D200
X105.901Y17.504 T08D400
T09D80
X101.901Y17.504 T10D40
X97.901Y17.504 T11D200
X93.901Y17.504
X89.901Y17.504 $
X85.901Y17.504 Stack After Drilling:
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

Volume 3 issue 2 April 2018 7


Part name: Bakellite

Part weight –150kg

Part material –Bakellite (hard wood )

Part quantity – 1

Part size -150 x 200 mm

Part name: Copper

Part weight –250kg

Part material – Copper Used materials and their properties:

Part quantity – 4 Following are the material details used in the project
Part size -150 x 200 mm

Part name: Backup

Part weight –350kg

Part material –Backup(soft wood )


4. Result Analysis
Part quantity – 5
The right entry material will improve drilled hole
Part size -150 x 200 mm 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
Part name: Aluminium contribute to drill deflection, resulting in decreased hole
registration accuracy and breakage of small-diameter
Part weight –20kg drills.
Part material –Aluminium Phenolic materials or phenolic composites (i.e.,
aluminum-clad phenolic) often warp and under most
Part quantity – 1 drilling conditions contaminate the hole wall, which
results in problems with adherence of the plating
Part size -150 x 200 mm 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

Volume 3 issue 2 April 2018 8


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

Machine Name:-CNC Film with White light


inspections table

1) Burr analysis report

2) Along hole and alignment with respect to


Master CNC Film Report

Comparative statement graph

Volume 3 issue 2 April 2018 9


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,


YuchuHuang , Barbara S. Linke , D.A. Dornfeldc
c c


Development of a micro-drilling burr-control chart for
PCB drilling’

5. CONCLUSION [7]. .L.M.P. Duraoa, A.G. Magalhaesa, A. T.


From the discussion so far it has been Marquesb, Joao Manuel R. S. Tavaresb
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 H 1, SankayeShraddha N2,

Volume 3 issue 2 April 2018 10

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