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If drill bits are measured to verify diameter using a contact-type measuring device (such as a contact micrometer), take the measurement away from the point to prevent chipping of the cutting corners Following diameter measurement, inspect the drill bit for damage using a microscope After use, again use care when removing drill bits from the tool pods or cassettes and remember, if they are intended for repointing, to use the same careful handling practices as when they were new 24223 Geometric Attributes The geometry of a drill bit very much affects the way it behaves during drilling (See Fig 242 for attribute nomenclatures) The land is the area remaining after fluting In order to reduce the amount of land that creates friction with the hole wall (thus generating heat), drill bits are margin relieved.

The amount of land remaining in contact with the hole wall during drilling is referred to as the margin The wider the margin, the greater the friction area and the higher the drilling temperature, resulting in higher extents of heat-related hole quality defects such as resin smear and plowing (defined as furrows in the resin)..

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values were obtained using both wheels for Si Si, however, was more difficult to polish, and a lighter pressure had to be applied to prevent the felt from coming off Thus, for the same time interval, Ge had a much better surface finish Polishing improved the form accuracy for Ge but not for Si Both ductile and fracture modes of material removal were observed in the case of both Si and Ge [55] Figure 435 shows a number of ductile streaks on silicon and Figure 436 a large number of ductile streaks on Ge A better surface roughness, form accuracy, and smoothness can be obtained with a five-axis CNC jig grinder, and also by dressing the grinding wheel for the ductile mode as suggested by Rusell [60] The same type of work has been done by Kapoor [48], which suggests that resinoid-bonded wheels give more ductile streaks than do metal-bonded wheels, the latter giving a better form accuracy The main idea to use a general purpose machine such as VMC for aspherizing arising is to reduce the cost of the final product Extensive experimental work was done by Venkatesh et al [62] [64] to establish optimum grinding parameters for economical machining A resin-bonded wheel with a smaller grit size was recommended to facilitate ductile machining with little expense in the form accuracy as compared with the metal-bonded wheel Research work that is reported shows that in addition to ductile mode grinding and conventional fracture mode grinding, the intermediate mode of grinding, microcrack grinding can also yield good results at a low cost Microcrack grinding can also be described as partial ductile grinding The curves of surface roughness versus polishing time are shown in Figure 437 Parks and Evans have reported the knee points in the polishing curves

The result of increasing the land mass and the web is a smaller flute area. Less flute space implies reduced amounts of available area to remove drilling debris, which again raises the drilling temperature. It is important to understand that some drill designs that are meant to increase strength (particularly in smaller-diameter drill bits, with the intent to reduce breakage) may include what are referred to as partial margin reliefs (see Fig. 24.3). What this means is that when the drill bit is viewed from the point, a relieved margin is seen. However, viewing

this type of design drill bit from the side reveals that the relief extends only part of the way, typically about one-fifth of the total flute length The major drawback of this particular design is that it increases drilling temperatures (documented to be as much as 25 percent or more), resulting in increased heat-related drilled hole defects (such as smear) and drill breakage due to packed margins 24224 Flute Length Minimum flute length must equal total drilled depth (total laminate thickness + entry thickness + backup penetration depth) plus at least 0050 in of unused drill flute remaining above the stack at the bottom of the drill stroke to allow debris to be removed by the vacuum system If debris cannot be removed from the drill flutes during and between drill strokes, the results are extensive hole quality defects and drill breakage 2422.

5 New Drill Bits It is not necessary to inspect incoming orders of drill bits 100 percent A procedure proved to be effective is to inspect drill bits according to an acceptable quality level (AQL) method (such as MIL-STD-105) This type of sampling plan allows the user to determine the percentage of drill bits that are inspected to judge an entire lot of drill bits to a predetermined quality level Using this method, finding a defined quantity of drill bits that do not meet the specification is cause to return all received drill bits to the vendor; if the selected quantity of inspected drill bits meets specification, the entire lot of drill bits is accepted Inspection criteria might include point geometry defects (refer to Fig 24.

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