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Loose or sunken tooling pin bushings cause movement of the stack during drilling and result in a variety of hole defects, registration problems, and drill breakage, yet are simple to replace at a minimum cost After stacks are put in place, again wipe the surface of the top laminate material as well as the entry material Place the entry material on top of the stack and tape it in placeThe entry material size should be such that it clears the pins and does not extend beyond the stack edges Pinning the entry material to the stack is not recommended because it tends to constrict the movement of the material, causing separation between it and the stack and resulting in entry burrs and possible drill breakage..

Formal outlines follow a speci c set of rules. Example: Basic Format I. First main point. This is usually indicated by Roman numerals. A. First major subdivision. Major divisions of the main point are indented and indicated by capital letters. 1. Minor subdivisions are indicated by Arabic numerals and are further indented. 2. Continue until you ve listed all your minor subdivisions. B. Second major subdivision II. Second main point A. Second major division 1. Subdivision 1 2. Subdivision 2

This example has shown us how to carry out the rst step needed to compute curvature, getting the Christoffel symbols. Usually, we will carry our calculations further in the local frame using the Ricci rotation coef cients. The procedure used to do so is explored in the next section.

Definition of Terms The terms in Tables 24.1 and 24.2 are commonly used to describe drilled hole defects observed on copper and substrate surfaces. It is important to be able to identify these defects specifi-

TABLE 24.1 Copper Defects Defect Burr Debris Delamination Nail-heading Smearing Definition Ridge left on external surface Drilling residues Separation of the copper from the substrate Burr on internal copper layer Thermomechanically bonded resin deposit Type Mechanical Mechanical Mechanical/heat-related Mechanical/heat-related Heat-related

TABLE 24.2 Substrate Defects Defect Debris pack Delamination Loose fibers Plowing Smear Voids Definition Drilling residues packed into voids Separation of the substrate layers Unsupported fibers in the hole wall Furrows in the resin Thermomechanically bonded resin deposit Cavities due to torn-out supporting fibers Type Mechanical Mechanical/heat-related Mechanical Heat-related Heat-related Mechanical

cally rather than in general terms. Using a general term such as roughness may imply voids or plowing. While voids are a mechanical type of defect, plowing is a heat-related type of defect. Therefore, excessive voids would lead one to examine the chip load (infeed rate) used; plowing would lead one to look at surface speed (spindle speed).

Examples of Drilled Hole Defects Examples of typical drilled hole wall defects are shown in Figs. 24.9 and 24.10.

A wealth of information is available by simply examining the materials from the drilled stack and the drill bits. For instance, inspecting the drill bits will allow one to determine if wear occurs at consistent rates (for drills of same diameter) or will reveal whether hit count maximums are excessive and the type of drilled hole wall defects to expect. Bonded debris and/or extensive wear to the drill corners imply high drilling temperatures (resulting in greater extents of defects such as smearing and plowing) or materials that are not fully cured and point to a problem with the materials (laminate, entry, or backup) or may suggest an excessive surface speed. Extensive primary cutting edge wear indicates abrasive materials and may require lowering stack heights, reducing hit counts, or replacing entry or backup materials. Burrs on the surfaces within the stack mean that there is a problem with the way panels are assembled and pinned or may be the result of warped panels. Entry or exit burrs on the outer laminates should cause one to question the entry and backup materials or the infeed rate. The point of a postdrilling inspection process is that if one takes the time on a regular basis, to examine materials and drill bits after drilling, many drilling problems would be solved before they get out of hand.

Material and processing costs, as well as the resulting total drilling cost, may be determined by using an analysis matrix such as a cost model specifically designed for this purpose and generated with the use of a computer spreadsheet program. The advantage of using a spreadsheet is that it allows changes to be made in, for instance, specific material prices and processing times or parameters, and allows instantaneous viewing of the resulting effects on the total drilling costs, the cost per panel, and the average cost per hole. Knowing the cost per hole is important because it allows comparing different jobs or processing situations. Following is a step-by-step description of how to construct a drilling cost analysis matrix such as the one shown in Fig. 24.11.