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24.3.4.4 Pressure Foot. The pressure foot insert lead distance to the point of the drill bit is set at approximately 0.050 in to give the pressure foot sufficient time to hold the stack flat before the drill bit contacts and enters the stack. If the lead distance is significantly less than the specified distance or if the drill bit point protrudes from the pressure foot, drill bits will break. To ensure the pressure foot assemblies function properly, check pressure foot inserts for wear or damage daily and verify that the pistons and guide rods are not bent and move smoothly. 24.3.4.5 Adjustment. When adjusting the physical z-axis height of the spindle, for instance to accommodate a thicker subtooling plate, care must be taken to also adjust the pressure foot so its height remains identical relative to the spindle. The pressure foot adjustment is independent from the spindle and, if not performed correctly, may result in a gap between the bottom of the spindle casing and the top of the pressure foot window.This gap is noticed only while the spindle is engaged and will draw most of the vacuum air, effectively cutting off the vacuum from the pressure foot insert, resulting in a great variety of hole defects and drill bit breakage. If a gap is present, it is usually accompanied by great amounts of drilling debris spewed across the stacks and drilling machine.

Mechanical Factors 24351 Heat (Coolant) Exchanger Drill motor temperatures are reduced by exchanging a fluid through the spindles The fluid is processed through a heat exchanger that works much like a car radiatorAs with a car, it is important to maintain the recommended coolant mixture, proper fill level, and flow rate indicated by the flowmeter Check the operation of the fan and minimize coolant flow restriction (due to algae buildup) by cleaning filters regularly Algae growth is promoted through exposure to ultraviolet light and may be controlled by using black hoses instead of clear ones in addition to adding growth inhibitors to the coolant mixture 24352 Hardware Although simple to perform, checking mechanical connections for loose or worn parts (ie, causing travel slop of pressure foot assembly movement) is often neglected.

People remember things in groups of three. Use three main points, talk about the three most important conclusions, or share three things the audience can do to make a difference.

It may be accomplished by observing the machine while it is running or checking by hand while the machine is idle 24353 Lead Screws and Servos The environment and cleanliness of the drill room determine how often lead screws need to be cleaned and lubricated to ensure smooth operation and minimize wear Most machine manufacturers recommend performing this type of maintenance every 6 months When lubricating the lead screws, only a light coat of the appropriate grease needs to be applied Excessive amounts of grease on the lead screws defeat the purpose, as this causes more dirt to be attracted, resulting in faster wear Constant searching for programmed x-y locations indicates problems with the servo motors or lead screws If this occurs, the displayed x or y (actual) location displayed on the controller will change continuously while the machine is stopped 24354 z-Axis Stroke.

Because machines may have as many as six mechanical connections in the z axis, travel slop during the drill stroke or retraction may occur, causing chip loads to vary during the stroke, which results in burrs and other hole defects and drill breakage Check connections by hand for slop while the machine is idle and observe and listen for improper operation while the machine is running..

Surfaces A clean drilling room decreases repair costs and the possibility of improper operation of the drilling machines. Wipe surfaces clean using a lint-free cloth or use a vacuum to remove debris.

Never use compressed air to clean the drilling machine because debris will be blown into areas that need to be kept clean (e.g., lead screws). 24.3.6.1 Granite. Granite provides a stable platform that absorbs unwanted vibration. It also offers a smooth and level surface to support the movement of the table. Keep granite surfaces clean to prevent tool table air shoes from becoming clogged and to minimize collection of dirt on the lead screws. 24.3.6.2 Working Surfaces. Maintain clean working surfaces, such as the tool table, to minimize the possibility of dirt particles getting trapped between the stacked laminate, entry, and backup panels, causing stack separation that may result in burrs and possible drill bit breakage.

Drilling parameter variables that affect the drilling process are as follows and as shown in the fishbone diagram of Fig. 24.7.