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First pressing

Posted by Anonymous User 
Anonymous User
First pressing
August 14, 2008 05:47PM
Just finished first test sixlayer pressing on home made press.

So far so good.

Photos to follow
Anonymous User
Re: First pressing
August 28, 2008 10:15PM

The result of registration checks on the test pattern show neglegible layer movement. I can not at the moment post any photos of the microscope view but am working on it.

In the meantime here is a photo of the router in early stage of assembly along with the hot and cold multilayer press.

The Router has a vacuum chuck powered by a vacuum pump and a working platen of 580 mm x 480 mm

There is space allocated along the right hand side of the platen for a tool changer rack.

Router runs EMC2 software.
open | download - Picture 014.jpg (1.87 MB)
Anonymous User
Re: First pressing
August 29, 2008 04:32AM
Looks like some well made equipment.
Keep us posted!
Anonymous User
Re: First pressing
August 29, 2008 04:29PM
Ok .. some more photos

These photos relate to the development of the milling machine

P1010022 shows first tentative strokes of the machine using a ballpoint pen in lieu of a cutter. What else but EMC.
P1010027 shows first attempts to see if the machine could "cut it". Laminate held in place with sticky tape on a semi finished bed. Bed needs to have vacuum suction holes drilled into it and the top surface is to be machined in situ to level it off with respect to machine frame. This has now been done. Twice. A period of about two weeks was allowed to let machine de stress itself post the first pass. A second pass of 15 micron was needed to bring the plate in.

More shortly
open | download - P1010022.JPG (1.84 MB)
open | download - P1010027.JPG (1.86 MB)
Anonymous User
Re: First pressing
August 29, 2008 04:42PM

Next step was to look at multilayer pressing. A test pattern was prepared and four inner layers machined and book pressed. Outside layers were machined post pressing. All machining done with two end mills; 3mm and 0.9mm .
Milling machine uses soft tooling based on 1/8" tooling pins and layup tooling is based on four slots.
Prepreg was trimmed a bit shorter than laminate cores so as not to foul registration pins and maintain integrity of 1.8" holes for next step of outside layer machining.
30082008 shows finished six layer panel. Note top edge of panel is not fully machined. Lack of prepreg has made that edge a bit thinner.
3008 2008(001) shows test pattern ( sorry about quality of image my mobile phone is not the best for this work )the pattern consists of a square pattern layer one followed by a series of "L" shapes on subsequent layers and a rectangle on last layer so that a well defined geometric pattern can be seen when viewed through the layers. This image also shows a tooling pin hole and a registration slot.

more to come
Anonymous User
Re: First pressing
August 29, 2008 04:51PM
Seems I forgot to attach some images.. here goes

The panel is 400 mm x 400 mm or approximately 15.75 " x 15.75" which is the size of the vacuum cassette and press anvils.

almost at the end....
open | download - 30082008.jpg (174.2 KB)
open | download - 30082008(001).jpg (128.7 KB)
Anonymous User
Re: First pressing
August 29, 2008 05:03PM
Last but not least...

30082008(002) is a view through a measuring microscope captured by the humble mobile phone camera.

Image shows one corner of the afore mentioned square pattern with the view of an L shaped piece about three layers down.

It can be seen that there is slight misregistration between the two patterns of approximately 0.003".

Not too bad considering the panel dimensions and the ammateurish environment in which this was conducted.

Well folks that's all for the time being.. Next step plating process...

And as a quick intro have a look at P1010016 a three phase 12 pulse rectifier set under construction ( tanks to follow)
open | download - 30082008(002).jpg (156.1 KB)
open | download - P1010016.JPG (1.8 MB)
Anonymous User
Re: First pressing
August 29, 2008 05:33PM
Just when you thought it was safe to open the forum...on more parting snap shot...

Image shows early output from the mill. Quality of cut is not particularly good as cam be seen by distorted shapes of pads and oblique lines.
Lines involving single axis movement are clean and straight.

This problem of coordinated motion has been cleaned up by a more thorough approach to servo amplifier tuning.

Features shown in the image are 0.006" clearances and some are down to 0.005"

I hope this little pictorial was of interest, keep faith and rout on.
open | download - SHOT001.jpg (52.1 KB)
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