Micro Drill Remanufacturing for Restored Cutting and Chip Removal
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Solution Overview
Problem
The frequent replacement of worn-out micro drills in printed circuit board fabrication leads to increased costs and waste, as well as unqualified products due to high precision requirements, necessitating a method to restore the cutting and debris discharging abilities of drills.
Innovation Solution
A remanufacturing method for drills with worn-out areas involves aligning a grinding wheel to specific areas of the drill, performing cutting operations along helical cutting edges and debris-discharging grooves to restore the drill's cutting ability, using a process that includes precise alignment and depth, angle, and length calculations to optimize the grinding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If worn-out micro drills are replaced frequently to maintain cutting ability, then drilling precision is improved, but fabrication cost increases and waste is generated
Solution Approach 1:
The patent applies the discarding and recovering principle by collecting worn-out drills and restoring them to functional condition through a systematic remanufacturing process. Instead of discarding worn drills, the method recovers them by removing worn portions and regenerating cutting edges, thereby reducing waste while maintaining drilling precision requirements
2Manufacturing precision
If worn-out micro drills are replaced frequently to maintain cutting ability, then drilling precision is improved, but fabrication cost increases
Solution Approach 1:
The patent recovers value from worn-out drills by restoring them to functional condition, directly reducing the need for continuous purchase of new drills and thereby lowering fabrication costs while maintaining drilling precision
Solution Approach 2:
The patent performs preliminary classification and assessment of worn-out drills to identify which ones can be successfully remanufactured. This preliminary action prevents unnecessary processing of irrecoverable drills and optimizes resource allocation, reducing overall fabrication costs
3Loss of substance
If drills with worn-out areas are remanufactured, then waste is reduced and cost decreases, but drill performance may not meet original specifications
Solution Approach 1:
The patent applies parameter changes by systematically adjusting critical drill parameters during remanufacturing, including core thickness, blade angles, and helical groove dimensions. These parameter adjustments ensure that remanufactured drills meet original performance specifications while reducing waste
Solution Approach 2:
The patent replaces manual or conventional grinding methods with a computer-controlled grinding system that can precisely reproduce original drill geometry. This mechanical substitution ensures consistent dimensional accuracy and surface finish, maintaining drill performance at original specification levels
4Duration of action of moving object
If a comprehensive remanufacturing process is implemented to restore drill performance, then drill service life is extended, but process complexity increases
Solution Approach 1:
The patent segments the remanufacturing process into distinct operational stages: classification, mounting, grinding, and quality inspection. This segmentation allows each stage to be optimized independently and simplifies process control, extending drill service life without proportionally increasing overall complexity
Solution Approach 2:
The patent introduces a computer-controlled system as an intermediary that coordinates and automates multiple remanufacturing operations. This intermediary integrates various processes, reduces manual intervention requirements, and maintains consistent quality standards, extending drill service life while managing process complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method effectively extends the service life of drills by restoring their cutting ability, reducing waste and fabrication costs, while ensuring the remanufactured drills meet the necessary specifications for drilling operations.
Implementation Method 1
using the aligned grinding wheel to perform a cutting operation along the helical cutting edge or the first debris-discharging groove to grind and repair the worn-out area of the drill
Data Source
AI summary
A remanufacturing method of a drill includes providing a drill with a worn-out area. The drill comprises: a shank part; and a flute part arranged on one end of the shank part. A chisel edge is formed on the front end of the flute part, and the radius of any one of the cross section of the chisel edge is defined as a core thickness; a first blade and a second blade with tilt directions toward the shank part are formed on the two sides of the chisel edge. The first circumferential surface of the first blade and the second circumferential surface of the second blade are respectively extended and spiraled toward the shank part along a periphery of the flute part and form two helical cutting edges, a first debris-discharging groove and a second debris-discharging groove. The first blade comprises a first cutting edge. The first cutting edge and the first circumferential surface define the worn-out area. The method also includes a step of aligning a grinding wheel to the worn-out area; and a step of using the aligned grinding wheel to perform a cutting operation along the helical cutting edge or the first debris-discharging groove to grind and repair the worn-out area of the drill.