MicroMicro-drilling Using Step-forward Method Step-

2004. 9. 9. Jae-hoon, KANG * Jong-kweon, PARK Jun-yeop, SONG

Intelligent Precision Machine Dept.

Korea Institute of Machinery & Materials

Korea Institute of Machinery & M a t e r i a l s

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 Qm

Spinneret & dies

Micro-drill (D) 30 Qm

Military & aerospace components Fuel injection nozzle

Electronics & semiconductor

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Motivation
It became a common understanding that it is necessary for machining tiny holes smaller than 100 Qm 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 Qm in diameter But conventional micro-drilling has also several problems such as excessive forces, tool breakage, chatter, burr formation in metals

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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 *

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Experimental System for Micro-drilling Micro-

Specifications of the micro drilling apparatus

Stepping motor Pressure gauge box Air bearing spindle Micro-drill Work-piece Tool dynamometer Controller Drilling ability Tool speed (Revolution) Torque Air pressure (Bearing) Step feed rate Total stroke Height to collets Size of machine body 0.05 ~ 2.0( ) mm 50,000(Max.) rpm 500 gr-cm 5 ~ 6 kgf/cm2 0.01 ~ 99.99 mm 75 mm From table surface 30 ~ 200 mm 300 350 680 mm 35 kg

Experimental apparatus for micro drilling experiment

Weight

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Measuring Instrument
A/D converter DAQ

Amplifier

Microscope with built-in monitoring system Measuring instruments for cutting force
SM45C (35 35 2.3 mm) Work-piece Dynamometer Amplifier A/D converter Microscope with built-in monitor
C : 0.12 ~ 0.20% Tensile strength : 38~44kgf/mm2

Data acquisition system

Micro drill

Kistler Co Kistler Co

Type Type

9257A 5011B Work-piece

DAQ Card-Al_16XE-50 FORTEC CORPORATION (sometech)

Vision system
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MicroMicro-drill Tool
Geometric feature of micro-drill

Straight-fluted Micro-drill

Dimensions of micro-drill
Undercut Diameter d (mm) 0.2 0.3(d)mm Vanadium Carbide Tool 0.3 0.4 0.5 Body Length L1 (mm) 2.8 5.5 7.0 7.0 Tip angle ( 0) 120 120 120 120

0.2(d)mm

Tool Material

0.5(d)mm

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WorkWork-piece Mounting Device

Micro drill U. F Work-piece Work-piece Work-piece
(dummy style)

Mounting device Tool dynamometer B. F

Computer

Tool Dynamometer

Y
A/D Board

Amplifier Experimental setup components for secure clamping of work-piece

Data acquisition system

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Experimental Conditions
Machining Conditions of Micro-drilling
Tool diameter (mm) 0.2 0.3 0.4 0.5 Step number of times 4 5 5 5 Cutting depth (mm/step) 0.3 0.5 0.5 0.5 Feed-rate (mm/sec) 0.5 0.5 0.5 0.5 Tool speed (RPM) 25,000 25,000 25,000 25,000

Diagram of Step-forward Feeding Type

Start position Upper limit stop in one cycle

Non Step Micro-drilling

Trouble-shooting to Bird Nesting Problem
Total stroke Origin position of cutting Cutting origin stop in one cycle Plate thickness
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- proper chip cutting - efficient chip evacuation

Comparison of Cutting Force

Micro-drill diameter : 0.2mm, Step number of times : 4
1 .4 1 .2

N o rm a l fo rce T a n g e n tia l fo rce

1 .4 1 .2

N o rm a l fo rce T a n g e n tia l fo rce

Cutting oil supplied drilling

C u ttin g fo rce (N ) C u ttin g fo rce (N )
1 .0 0 .8 0 .6 0 .4 0 .2 0 .0 0 2 4 6 8 10 12 14 16 1 .0 0 .8 0 .6 0 .4 0 .2 0 .0 0

Dry drilling

T im e (se c)

10

12

14

16

T im e (se c)

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


25

T
1 .2

1 .2

Cutting oil supplied drilling

C u ttin g fo r c e ( N )

Dry drilling
( )
1 .0 0. 0.

f rc

0 .8 0 .6

tti

0 .2 0 .0 0 5 10 15 20 25

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T im e ( s e c )

0 .4

0.

0 .2 0 .0 0 5 10 15 20

1 .0

Ti

 

      

1 .4

N o r m a l fo r c e T a n g e n tia l fo r c e

1.

l f rc ti l f rc

(s c )

Comparison of Cutting Force

Micro-drill diameter : 0.4mm, Step number of times : 5
( 0 ( 1 2( 21 3 0 1' 0)
20 1.

T
1.2

1.2

Cutting oil supplied drilling

( ) f rc
f rc
0. 0.

Dry drilling
( )
1.0

tti

tti

0.

0.

0.2

0.2

0.0 0 5 10 15 25

0.0 0 5 10 15 20 25

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

1.2 1 .2 1 .0 0. 0.

( )

( )

f rc

f rc

0.

tti

tti

0.

0.

0.2

0 .2 0 .0 0 5 10 15 20 25 0 5 10 15 20 25

0.0

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('

('

Ti

(s c )

"

0.

&

1.0

Cutting oil supplied drilling

Dry drilling

Ti

(s c )

0 1 2( 21 3 ( 0 1' 0)

0 (

1 2( 21 3 0 1' 0)

1.

l f rc ti l f rc

1.

('

Ti

(s c )

Ti

(s c)

l f rc ti l f rc

BA

0.

0.

1.0

l f rc ti l f rc

1.

l f rc ti l f rc

D B

E FBGFE D EA DC

   

"

% $ # "

&

&

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

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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 di

t r 0.2mm

drill di

t r 0.3mm

Burr

Cutting oil supplied drilling

Dry drilling

Cutting oil supplied drilling

Dry drilling

drill di

t r 0.4mm

drill di

t r 0.5mm

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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 di

t r 0.2mm

drill di

t r 0.3mm

Cutting oil supplied drilling

Dry drilling

Cutting oil supplied drilling

Dry drilling

drill di

t r 0.4mm

drill di

t r 0.5mm

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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 micro( 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

StepStep-forward type micro-drilling micro( Example 1 : Normal mode maintained after 3rd hole machining completed )
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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

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 for your attention

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