Asian Symposium for Precision Engineering and Nanotechnology 2011

Development of micro drilling burr control chart based on Taguchi methods for PCB drilling
Binayak Bhandari1, Young-Sun Hong1,Hae-Sung Yoon1, Jong-Cheon Lee1, Jong-Seol Moon1, David A. Dornfeld2, Barbara S. Linke2,Yu-Chu Huang2, Gyu-Bong Lee3 and Sung-Hoon Ahn1#
1

School of Mechanical & Aerospace Engineering, Seoul National University, Seoul 151-742, Korea 2 Laboratory for manufacturing and Sustainability, University of California, Berkeley, USA 3 Korea Institute of Industrial Technology (KITECH), Cheonan-si 330-825, Korea 1# S-H Ahn / E-mail: ahnsh@snu.ac.kr, TEL: +82-2-880-7110, FAX: +82-2-883-0179

KEYWORDS : burr

micro drilling burr control chart, drill bit, green manufacturing, printed circuit board (PCB), Taguchi method, Bakelite,

Development of drilling burr control charts for Bakelite Printed Circuit Board (PCB) based on the detailed experimental studies is presented. Based on the geometry of drill bit and burr characteristics the Micro Drill Burr Control Chart (MDBCC) based on Taguchi experimental design method has been developed. This approach facilitated the study of interaction of a large number of variables spanned by factors and their settings with fewer numbers of experiments leading to considerable economy in time and cost for the process optimization. While several other factors play role in formation of the drilling burr, in this study three factors viz. infeed (mm/sec), spindle-speed (N) and drill diameter (m) each at three levels were selected and an orthogonal array of L9 (33) performed. Three sizes of micro drill diameter ranging from 400m~800m were used for the experiment. MDBCC chart can be useful in predicting the burr type for the given drilling conditions hence selection of parameters for the most preferred burr type can be easily and comfortable done. Multiple regression used in Taguchi approach indicated that drill bit diameter plays most important role in the production of burr for micro size PCB drilling. The paper also describes several processes of burr measuring types with focus on the strength and weakness of each type. Manuscript received: July 15, 2009 / Accepted: August 15, 2009

NOMENCLATURE
Fn = non-dimensionalized feed parameter S = second nomenclature N = Spindle Speed d = drill bit diameter f =feed (mm/rev) = constant p = P-value (checking statistically significance)

has several substrate printed circuit layers separated by layers of insulation. The electronic components on the surface connect through plated holes drilled down to the appropriate circuit layer which simplifies the circuit. The most common substrate used for the PCB is made of glass fiber reinforced epoxy resin with a copper foil bonded on the surface of plate (single or double sides) knows as CCL1. A typical Copper Clad Laminated (CCL) double sided PCB is shown in figure 1.

Cu GFRP Cu
Fig. 1: Copper Clad laminated double sided PCB with GFRP su bstrate Drilling operation is done to make hole on the PCBs. Almost all machining processes produce burrs. The term burr is used to indicate the presence at an edge of material which was not there prior to the machining operation. A multitude of ideas has been tried by researchers and engineers for more efficient manufacturing in terms of energy consumption and volume produced. Process planning and other methods are used to

1. Introduction
A printed circuit board (PCB) is a thin plate made of one or more layers of insulating board also known as substrate which supports electronic components and electrically connects it using conductive pathways, tracks or signal traces. PCBs are found in wide range of applications ranging from toys to the computer and sophisticated radar systems. There are three major types of printed circuit board construction: single-sided, double-sided, and multi-layered. In single-sided board the components are on one side of the board, double sided PCBs are used when number of components to be placed on the board becomes too many and the space too less. The last type, multi-layered board,

Asian Symposium for Precision Engineering and Nanotechnology 2011 optimize the manufacturing processes and thus energy efficient. In PCB manufacturing industry, most of operations are automatically controlled by computer programs except the drilling operation station because it is usually the bottleneck station2. The task of deburring in the PCB industry is one of the important areas where proper understanding is needed to make burrless PCBs. In drilling process burrs are produced on both entrance and exit surfaces of the workpiece, the formation mechanisms are however different3. In the entrance burr, the burrs are formed by undergoing plastic flow while in the exit burr, the burr are formed as the material extending off the exit surface of the workpiece 4. Generally exit burr are larger than the entrance burr and are not desirable because it causes most burr-related problems. Drilling burrs causes various problems by interfering with assembled parts, jamming and misalignment. It is likely that they reduce the fatigue life as hardned and brittle burr material can act as a crack initiation point. A drilling burr control chart is a tool for the prediction and control of drilling burrs5. The two parameters of DBCC are S and Fn. Where Fn is a non-dimensionalized feed parameter and S is a cutting speed parameter, is a constant. Several materials have distinctively different DBCC chart leading to the need of large scale research. S = dN Fn=f/d (1) (2)

Entry board
PCB 3 stacks

Backup board

Figure 3: Experimental setup of the micro drilling experiment for the development of MDBCC. The jig has sufficient slots for several drilling experiments. In this research, Taguchi experimental design approach was used for finding out contribution of drilling parameter in minimizing drill burr height. Altogether three factors viz., infeed (mm/sec), spindle speed (N), and drill diameter (m) each at three levels were selected and an orthogonal array layout of L9 (33) were performed. Table 2 shows the experimental parameters and their level while table 3 has Taguchi Orthogonal array for L9 (33). Table 2: Experimental parameters and Factors Level 1 Infeed (mm/sec) 30 Spindle speed (N) 90000 Drill dia (m) 400 their levels Level 2 Level 3 40 50 60000 30000 600 800

2. Background
2.1 Micro drill bit
High-speed steel split-point twist drills of diameter ranging from 400 m to 800 m were used for the experiments. The micro drill bits used in the experiment were manufactured by Neotis Korea Inc. The specification of the micro drill bits are shown in table 1.

Orthogonal arrays (OA) are a special set of Latin squares, constructed by Taguchi to lay out the product design experiments. By using this table, an orthogonal array of standard procedure can be used for a number of experiment situations. Table 3: Taguchi Orthogonal array L9 (33) Experiment Infeed Spindle Drill dia No. (mm/sec) Speed (N) (mm) 1 1 1 1 2 1 2 2 3 1 3 3 4 2 1 2 5 2 2 3 6 2 3 1 7 3 1 3 8 3 2 1 9 3 3 2

Figure 2: A typical micro drill bit used for PCB manufacturing Table 1: Specification of the drill bit (400m, 600m and 800 m) Helix angle 35 Point angle 130 1st relief angle 15 2nd relief angle 30

Burr Height (m) 2 2 0.5 2 0.5 4 1 3 1

2.2 Experimental setup

Three stack of both-side CCL plated PCBs were used for the experiment. The lower part of the stack was supported by the backup board made of wood and an aluminum entry board was placed on the top for heat dissipation, which is also a standard procedure for PCB drilling. All of which were clamped together as shown in the figure 3. A 3-axis stage (Justek Inc., Korea), high-speed spindle (D1733, Westwind Air Bearings, United Kingdom), and cooling devices were used for the drilling experiments.

In Taguchi approach, multiple regression tests were used to analyze the result of OA experiments and to determine the variance in the burr height contributed by each parameter. SPSS 18 was used for the analysis. Table 4: Standardized beta values and p values showing statistically significant parameter Model Parameters Beta p value 1 Infeed (mm/s) 0.061 0.87 2 Infeed (mm/s) 0.061 0.88 Spindle speed (N) -0.061 0.88 3 Infeed (mm/s) 0.061 0.79 Spindle speed (N) -0.061 0.79 Drill dia (m) -0.859 0.01* In the final model, drill diameter made a statistically significant contribution (85.9%) to the variance in burr height..

2.2.1 Taguchi method

DOE provides a cost-effective means for solving problems and developing new processes. One of the most powerful DOE tool was developed by Genichi Taguchi to improve the quality of manufactured goods known as Taguchi Method which is also successfully applied in engineering for the experimental designs. This approach facilitated the study of interaction of a large number of variables spanned by factors and their settings with a small number of experimental runs leading to considerable economy in time and cost for the process optimization.

2.3 Experiment Result

Three set of experiments were conducted for each size of drill bit (400 m, 600 m and 800 m). The first set of experiment were performed by keeping the infeed constant, the second set of experiment were done by keeping the spindle speed constant while

Asian Symposium for Precision Engineering and Nanotechnology 2011 the third and the last set of the experiments were done by varying both spindle speed and infeed (decreasing spindle speed and increasing the infeed). The experimental results for all the three sets of experiment for three different diameter drilling experiments are listed in table 5 through 7. The experiments were performed in room temperature (22C). All the experiments were conducted by varying the parameter as shown in the tables below until the drill bit breakage.

Table 5: An experimental result of 400 m drill bit showing various process parameters for constant infeed of (30mm/min), also shown are the drill bit condition after the drilling experiment and the S and Fn values Spindle Speed Feed Drill bit condition Burr chart functions S. No Drill Dia (m) (N,min-1) Hz mm/sec mm/rev OK Broken S Fn 1 400 90000 1500.00 30 0.020 0.36 0.050 2 400 80000 1333.33 30 0.022 0.32 0.056 3 400 70000 1166.67 30 0.025 0.28 0.064 4 400 60000 1000.00 30 0.030 0.24 0.075 5 400 50000 833.33 30 0.036 0.20 0.090 6 400 40000 666.66 30 0.045 0.16 0.112 7 400 30000 500.00 30 0.060 0.12 0.150 8 400 20000 333.33 30 0.090 0.08 0.225 9 400 10000 166.66 30 0.180 0.04 0.450 Table 6: An experimental result of 600 m drill bit showing various parameters for constant spindle speed of 90,000, also shown are the drill bit condition after the drilling experiment and the corresponding S and Fn values. Spindle Speed Feed Drill bit condition Burr chart functions S. No Drill Dia (m) (N,min-1) Hz mm/sec mm/rev OK Broken S Fn 1 600 90000 1500 30 0.020 0.54 0.033 2 600 90000 1500 40 0.026 0.54 0.044 3 600 90000 1500 50 0.033 0.54 0.055 4 600 90000 1500 60 0.040 0.54 0.066 5 600 90000 1500 70 0.046 0.54 0.077 6 600 90000 1500 80 0.053 0.54 0.088 7 600 90000 1500 90 0.060 0.54 0.100 Table 7: An experimental result of 800 m drill bit showing various parameters for constantly varying spindle speed and infeed, also shown are the drill bit condition after the drilling experiment and the corresponding S and Fn values. Spindle Speed Feed Drill bit condition Burr chart functions S. No Drill Dia (m) (N,min-1) Hz mm/sec mm/rev OK Broken S Fn 1 800 90000 1500.00 30 0.020 0.72 0.025 2 800 80000 1333.33 40 0.030 0.64 0.037 3 800 70000 1166.67 50 0.042 0.56 0.053 4 800 60000 1000.00 60 0.060 0.48 0.075 5 800 50000 833.33 70 0.084 0.40 0.105 6 800 40000 666.67 80 0.120 0.32 0.150 7 800 30000 500.00 90 0.180 0.24 0.225 8 800 20000 333.33 100 0.300 0.16 0.375 9 800 10000 166.67 110 0.660 0.08 0.825

2.4 Burr Shape

The exit burrs are larger than the entrance burr hence the burr on the exit side of the third layer of the stack was chosen for the burr shape and height measurement. Before taking the SEM image the drilled PCBs were sonicated in MUJIGAE Analog SD-80H (Korea) with ultrasonic frequency of 40kHz for 5~10 sec. This process made debris free on the PCB surface. Figure 4 shows some of the SEM image of 400 m drill holes. (d) 90000 rpm, 90mm/s infeed (c) 90000 rpm, 70mm/s infeed Figure 4: SEM image of the drill burrs for 400m drill for constant feed of 30mm/sec and varying spindle speed (a~b) and constant spindle speed of 90000 rpm and varying infeed (c~d) It was observed that the uniform burrs were produced when the spindle speed is over 40000 rpm and feed of 30mm/sec, above which there is increase in burr height. However increasing infeed at constant spindle speed has mixed effect. (a) 90000 rpm, 30mm/s infeed (b)60000 rpm, 30mm/s infeed

Asian Symposium for Precision Engineering and Nanotechnology 2011

76.78m

(a) 90000 rpm, 30mm/s infeed (a) 80000 rpm, 40mm/s infeed (b) 20000rpm, 100mm/s infeed Figure 5: Infeed (40mm/sec~100mm/sec) Spindle Speed (80000~20000)

(b) 80000 pm, 40mm/s infeed

10.00 m

9.715 m

3. Classification of Burr Types

In order to classify the types of burr that is produced in PCB by drilling, detail information about the shape and height of burr is necessary. Depending on drilling parameters, drilling and environmental conditions the shape and height of burr are different. In the present study, we have limited our focus in the drilling parameters like infeed, spindle speed, and drill bit diameter.

(c) 70000 rpm, 50mm/s infeed (d) 40000 rpm, 80mm/s infeed Figure 7: Burr height measuring by FE-SEM

3.1.3 Laser displacement

Laser displacement sensors can measure the distance an object moves and they can also be used to measure object height and width, how ever owing to the complex geometry of drilling burr, it is impossible to measure the entire burr profile. KEYENCE LK-9150 (Japan) laser displacement sensor was used to measure the burr height. Using laser displacement sensors to measure the burr height (at a point) is much faster than both the earlier methods mentioned. However, the setup time is higher. The measurement range of the laser displacement sensor used in the experimentation was 0.2 m ~1 mm, feed rate was 0.5mm/sec, sampling frequency was 20 kHz and low pass was 9 kHz.

3.1 MDBCC Burr Height Measurement Techniques

Optical Microscope, FE-SEM and Laser displacement sensors were used to measure the burr heights which were

3.1.1 Optical Microscope

Optical microscope CAMSCOPE model SV-32 was used for measuring the burr height. Optical microscope cannot focus on base and the bur at the same time so a reference line was drawn by focusing it on the base of the burr and another line was drawn on the tip of the burr parallel to the first line. By measuring the difference of those lines max. burr height was measured.

Laser spot

75m

82m

Laser displacement sensor

(a) (b) Figure 8: Measurement of burr height using laser displacement sensor (a) set up and (b) the laser spot and the laser moving direction 90,000 rpm, 30(mm/s) infeed 80,000 rpm, 40 (mm/s) infeed Figure 6: Burr height measurement by optical microscope

3.2 Comparison of burr heights among optical microscope, FE-SEM and laser displacement sensors
In order to verify the burr height a cross matching among all three methods were performed. Table 8 shows the comparison of bur heights between optical microscope and FE-SEM for 600m drilling burr. A close match can be seen for all the burr heights measuring more than 25m. Similarly close matches in the burr height measurement were seen between FE-SEM and laser displacement sensor. Figure 9 shows the comparison of burr height

3.1.2 FE-SEM
A fine grinding on the work pieces were done as close as 500 m from the burr base followed by sputtering. ISI ABT SX-40 scanning electron microscope was used to measure the height and shape of the burr. Vertical SEM images were taken to measure burr height as shown in figure 7.

Table 8: Burr height comparison between FE-SEM and Optical microscope for 600m drilling (3rd layer, for varying spindle speed and feed rate) S. No Experiment No. Experimental Condition Hole No FE-SEM Optical Microscope (m) rpm infeed Max height (m) Min height(m) 1 1 90000 30 mm/s 1 76.78 75 2 1 90000 30 mm/s 3 76.19 34.26 3 2 80000 40 mm/s 2 83.58 82 4 3 70000 50 mm/s 1 67.44 57 5 4 60000 60 mm/s 2 25.71 6 6 40000 80 mm/s 1 42.47 19

Asian Symposium for Precision Engineering and Nanotechnology 2011

600 m
83.58m

REFERENCES
1 J-B. Park, K-H Wie, J-S Park, and S-H Ahn, "Evaluation of machinability in the micro end milling of printed circuit boards," Journal of Engineering Manufacture 223 (2009). Pei-Chann. Chang, Jin-Chang. Hsieh, and Chih-Yuan Wang, "Adaptive multi-objective genetic algorithms for scheduling of drilling operation in printed circuit board industry," Applied Soft Computing 7, 800-806 (2007). J.C. Aurich, Dornfeld. D., P.J. Arrazola, V. Franke, L. Leitz, and S. Min, "Burrs-Analysis,control and removal," CIPR AnnalsManufacturing Technology 58, 519-542 (2009). Jinsoo. Kim, Sangkee. Min, and David A. Dornfeld, "Optimization and control of drilling burr formation of AISI 304L and AISI 4118 based on drilling burr control charts," International Journal of Machine Tools & Manufacture 41, 923-936 (2001). Sangkee. Min, Jinsoo. Kim, and David A. Dornfeld, "Development of a drilling burr control chart for low alloy steel, AISI 4118," Journal of Materials Processing Technology 113, 4-9 (2001). Hidehiti. Watanabe, Hideo Tsuzaka, and Masami Masuda, "Microdrilling for printed circuit boards (PCBs)-Influence of radial run-out of microdrills on hole quality," Precision Engineering 32, 329-335 (2008).

2 (a) (b) Figure 9: Comparison of burr height between (a) FE-SEM and (b) Laser displacement

3.1.6 Comparison of burr height measurement techniques

It was seen that the measured height with FE-SEM matches well with optical microscope for the larger height ( >25 m). However, the accuracy drastically drops under 25 m using optical microscope (X 500 lens). A good match has been seen between laser displacement experiment and FE-SEM. Difference between FE-SEM and laser displacement result about 20m. The good match between all the measurement techniques validated our burr height measurement techniques. Table 9 shows a comparison of the three burr height measurement techniques. Table 9: Comparisons of three different burr height measurement Techniques Methods Pros Cons Optical Microscope Easy, Fast Not reliable FE-SEM Good resolution Slow ( for large no.) Laser Displacement Good data acq. Complicated, large noise 4

4. Micro Drilling Burr Control Chart

From all the experimental results obtained from the several tests a micro- DBCC chart has been developed. Figure 10 shows three different regions for uniform burr, transient burr and tool breakage region. It can be clearly seen in the diagram that the uniform burr is at the center of transient burr. In both cases of low spindle speed and high spindle speed there can be breakage. The breakage during high spindle speed might be because of run out of the spindle6.
0.8 0.7 400 'var Spindle speed' 400 'var infeed' 400 'var infeed & S. speed 600 'var Spindle speed' 600 'var infeed' 600 'var infeed & S. speed 800 'var Spindle speed' 800 'var infeed' 800 'var infeed & S. speed Taguchi method

Drill bit broken

0.6

0.5

Transient

0.4

Uniform

0.3

0.2

Transient

0.1

Drill bit broken

0 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8

Fn

Fig 10: The experimental result for 400 m, 600 m and 800 m drilling for (a) constant feed, (b) constant spindle speed and (c) varying feed and spindle speed and (d) Taguchi method In low infeed, the majority of the experimental data falls either on the uniform burr or transient. A higher infeed rate of the tool the breakage is common. However a more detailed experiment with other parameters included should be performed to find out the dependence and characteristics of MDBCC for PCB materials.

ACKNOWLEDGEMENT
This work was supported by the Brain Korea 21 project at Seoul National University, and KITECH funded by the Ministry of Knowledge Economy (No. 2010-TD-700203-001).