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While the maximum retract rate setting may be fine for larger-diameter drill bits, when using drill bits in the diameter range of 00250 in (size #72) to 00135 in (size #80), retract rates may have to be reduced to 500 ipm or lower to prevent drill breakage When drilling with sizes smaller than 00135 in in diameter, retract rates may have to be reduced even further The maximum retract rate that may be used with any given drill diameter without causing drill breakage greatly depends on the stability and vacuum system efficiency of the drilling machine as well as the drilled stack height, laminate construction and thickness, type of entry material, use of proper stacking and pinning procedures, and the design characteristics of the drill bit such as flute length, web thickness, and web taper 2444 Backup Penetration Depth 24441 Definition.

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Backup depth is the distance a drill bit penetrates the backup material at the bottom of the drill stroke The minimum backup penetration depth setting varies.

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.

Polishing reagent Thickness removed (1 m grit size) during polishing dT ( m) Polycrystalline diamond Monocrystalline diamond Cerium oxide 39500 3700 1623 Polishing pressure P (kPa) 5506327 3317041 1925292 Polishing time, dt (min) 45 65 30 Relative speed, ds/dt (m s 1) 282743 282743 141371 Preston coefficient, k (m2 N 1) 9397 10 13 1012 10 13 3313 10

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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.

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

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 2447 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.

Fig 443: (a) Precitech s Optimum 2800 ultra-precision turning and grinding machine and a (b) close-up of the

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