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As a rule of thumb, the maximum total drilled depth (number of panels panel thickness + entry thickness + backup penetration depth) that can safely be handled by the drill bit without breakage is approximately 17 times its diameter 2448 Stacking and Pinning 24481 Building the Stack Inspect all laminate panels and the entry and backup materials for surface damage and remove burrs from the panel edges as well as from the pinning holes Even though the registration tooling holes on the laminate material may not be used to pin the stacked panels together, it is important to remove any resin buildup remaining around these holes after lamination (a common occurrence) Burrs and raised surface areas do not permit the panels to lay flat, causing gaps resulting in drilled hole registration problems, burrs, hole quality defects, and drill breakage.

Reject entry and backup materials with excessive nicks, scratches, and other surface defects as well as those that are warped or twisted 24482 Pinning Procedures Wipe the surfaces of all laminate panels and the backup material using a lint-free cloth to remove any debris before stacking the panels (allowing intimate contact between the stacked panels) Verify that the pinning holes and pin insertion are perpendicular to the stack and avoid using pins that are damaged or deformed 24483 Installation Before placing the pinned stacks onto the drilling machine tool table, inspect the surface for burrs or broken drill bits protruding from the table that may prevent the stacks from lying flat Do not continue if the pin bushings of the tool table are sunken or worn to the point that they do not hold the stack firmly in place.

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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..

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-

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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.

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