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
Korea Institute of Machinery & M a t e r i a l s
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
Korea Institute of Machinery & M a t e r i a l s
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 *
Korea Institute of Machinery & M a t e r i a l s
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
Korea Institute of Machinery & M a t e r i a l s
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
Korea Institute of Machinery & M a t e r i a l s
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
Korea Institute of Machinery & M a t e r i a l s
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
Korea Institute of Machinery & M a t e r i a l s
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
Korea Institute of Machinery & M a t e r i a l s
- 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
Korea Institute of Machinery & M a t e r i a l s
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
Korea Institute of Machinery & M a t e r i a l s
('
('
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
Korea Institute of Machinery & M a t e r i a l s
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
Korea Institute of Machinery & M a t e r i a l s
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
Korea Institute of Machinery & M a t e r i a l s
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 )
Korea Institute of Machinery & M a t e r i a l s
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
Korea Institute of Machinery & M a t e r i a l s
for your attention
Korea Institute of Machinery & M a t e r i a l s