Micro-drilling Using Step-forward Method

Waqas CH

한국기계연구
원
Korea Institute of Machinery &
Introduction
Micro-drilling is regarded as useful process technology to make tiny holes
and widely used at electronic, semiconductor, medical, fuel injection, watch,
spinneret, dies related industry fields

Medical devices
Micro-drill
Watch component

Human hair
(D)80 µm

Spinneret & dies

Micro-drill
(D) 30 µm

Military & aerospace components Electronics & semiconductor

Fuel injection nozzle

한국기계연구
원
Korea Institute of Machinery &
Motivation

It became a common understanding that it is necessary for machining tiny holes

smaller than 100 µ m in diameter to apply the laser systems
However, it is also true that laser systems have several disadvantages compared to
conventional mechanical drilling
And the mechanical system could be competitive against the laser system, if they can
have micro drilling capabilities
Thus, many manufacturers have been making efforts to retry the traditional
mechanical precision drilling machine for machining tiny holes with high
productivity
Recently, creative precision has complete micro hole drilling capabilities for holes
down to 30 µ m in diameter

But conventional micro-drilling has also several problems such as excessive forces,
tool breakage, chatter, burr formation in metals

한국기계연구
원
Korea Institute of Machinery &
Objectives

Accomplishment of direct practice to obtain preliminary knowledge for ascertain

mechanical micro-drilling behavior through the experimental study

Examination to application capability of presented proper method to control tool damage

* Trouble-shooting to occurred tool breakage mode frequently during previous

precedent conventional micro-drilling experiment

* Presumption as the trouble is resulted in the poor chip cutting & evacuation
* Application of step-forward feeding method during micro-drilling process

한국기계연구
원
Korea Institute of Machinery &
Experimental System for Micro-drilling

Specifications of the micro drilling apparatus

Stepping motor
Pressure gauge box Drilling ability 0.05 ~ 2.0(Φ) mm
Tool speed
Air bearing spindle 50,000(Max.) rpm
(Revolution)

Micro-drill Torque 500 gr-cm

Air pressure (Bearing) 5 ~ 6 kgf/cm2
Work-piece Step feed rate 0.01 ~ 99.99 mm
Total stroke 75 mm
Tool dynamometer
Controller From table surface
Height to collets
30 ~ 200 mm
Size of machine body 300 × 350 × 680 mm
Experimental apparatus for micro drilling experiment
Weight 35 kg

한국기계연구
원
Korea Institute of Machinery &
Measuring Instrument
A/D converter
DAQ

Amplifier
Microscope with built-in monitoring system

Measuring instruments for cutting force Data acquisition system

SM45C (35 × 35 × 2.3 mm)

Work-piece C : 0.12 ~ 0.20% Micro drill
Tensile strength : 38~44kgf/mm2

Dynamometer Kistler Co Type 9257A

Amplifier Kistler Co Type 5011B
A/D converter DAQ Card-Al_16XE-50 Work-piece
Microscope with FORTEC CORPORATION
built-in monitor (sometech) Vision system
한국기계연구
원
Korea Institute of Machinery &
Micro-drill Tool
Geometric feature of micro-drill

Straight-fluted Micro-drill

Dimensions of micro-drill

Tool Undercut Diameter Body Length Tip angle

0.2(d)mm
Material Φd (mm) L1 (mm) Θ ( 0)
0.2 2.8 120
0.3(d)mm
Vanadium 0.3 5.5 120
Carbide Tool 0.4 7.0 120
0.5(d)mm 0.5 7.0 120

한국기계연구
원
Korea Institute of Machinery &
Work-piece Mounting Device

Micro drill
U. F

Work-piece
Work-piece

Work-piece
Mounting device (dummy style)

Tool dynamometer
B. F

Computer Tool Dynamometer

Y Z

A/D Board Amplifier

Data acquisition system Experimental setup components for secure clamping of work-piece

한국기계연구
원
Korea Institute of Machinery &
Experimental Conditions
Machining Conditions of Micro-drilling

Tool diameter Step number Cutting depth Feed-rate Tool speed

(mm) of times (mm/step) (mm/sec) (RPM)
0.2 4 0.3 0.5 25,000
0.3 5 0.5 0.5 25,000
0.4 5 0.5 0.5 25,000
0.5 5 0.5 0.5 25,000

Diagram of Step-forward Feeding Type

U p p e r lim it s to p
S ta rt p o s itio n in o n e c y c le

Non Step Micro-drilling

Trouble-shooting to Bird Nesting Problem

O rig in p o s itio n C u ttin g o rig in s to p
Total stroke

o f c u ttin g in o n e c y c le
- proper chip cutting

Plate thickness
- efficient chip evacuation

한국기계연구
원
Korea Institute of Machinery &
Comparison of Cutting Force
Micro-drill diameter : 0.2mm, Step number of times : 4

Cutting oil supplied drilling Dry drilling

Micro-drill diameter : 0.3mm, Step number of times : 5

Cutting oil supplied drilling Dry drilling

한국기계연구
원
Korea Institute of Machinery &
Comparison of Cutting Force
Micro-drill diameter : 0.4mm, Step number of times : 5

Cutting oil supplied drilling Dry drilling

Micro-drill diameter : 0.5mm, Step number of times : 5

Cutting oil supplied drilling Dry drilling

한국기계연구
원
Korea Institute of Machinery &
Comparison of Cutting Force

For cutting oil supplied drilling, the cutting force is lower than dry drilling distinctly
But, there is a little difference in cutting force between cutting oil supplied drilling and
dry drilling as the hole diameter is smaller
--- Caused by insufficient supply condition of cutting oil

Variation of cutting force according to tool diameter

한국기계연구
원
Korea Institute of Machinery &
Comparison of Burr Formed
For cutting oil supplied drilling, the burr formed extent is diminished than dry drilling
in a greater or less degree

Cutting oil supplied drilling Dry drilling Cutting oil supplied drilling Dry drilling
drill diameter 0.2mm drill diameter 0.3mm

Burr

Cutting oil supplied drilling Dry drilling Cutting oil supplied drilling Dry drilling
drill diameter 0.4mm drill diameter 0.5mm

한국기계연구
원
Korea Institute of Machinery &
Morphology Comparison of Chip Formed
For cutting oil supplied drilling, the continuous flow type chip can be obtained distinctly
relatively to dry drilling

Cutting oil supplied drilling Dry drilling Cutting oil supplied drilling Dry drilling
drill diameter 0.2mm drill diameter 0.3mm

Cutting oil supplied drilling Dry drilling Cutting oil supplied drilling Dry drilling
drill diameter 0.4mm drill diameter 0.5mm

한국기계연구
원
Korea Institute of Machinery &
Comparison of Tool Morphology
For step-forward drilling, the tool damage can be restrained efficiently
relatively to conventional drilling

Initial tool morphology Tool breakage mode Closed-up broken region

Conventional micro-drilling
( Example 1 : Trouble mode occurred at 5th hole machining process )

( Example 2 : Trouble mode

occurred at a moment tool
contacted to work-piece ) The other tool breakage mode

Step-forward type micro-drilling

( Example 1 : Normal mode maintained after 3 rd hole machining completed )
한국기계연구
원
Korea Institute of Machinery &
Summary & Conclusion
Preliminary experiment were performed to obtain basic knowledge for ascertain process
behavior of micro-drilling

Step-forward type feeding method was applied for micro-drilling process to cope with troubles
occurred precedent case study

Cutting force was decreased in micro-drilling using tool diameter of 0.3mm or under
For cutting oil supplied drilling, the cutting force is lower degree of 5~15% than dry
drilling distinctly
There is a little difference in cutting force between cutting oil supplied drilling and
dry drilling as the hole diameter is smaller

For cutting oil supplied drilling, the burr formed extent is diminished than dry drilling
in a greater or less degree

For cutting oil supplied drilling, the continuous flow type chip can be obtained distinctly
relatively to dry drilling

For step-forward drilling, the tool damage can be restrained efficiently relatively to
conventional drilling

한국기계연구
원
Korea Institute of Machinery &
… for your attention

한국기계연구
원
Korea Institute of Machinery &