電子產品和半導體應用逐漸變得更加微型化，導致高效率切削刀具的需求不斷增加。PCD（聚晶鑽石）工具相比傳統的鎢鋼鑽頭，提供更好的切割質量、更高的生產效率和精度。本研究提出了一種新的PCD微鑽頭設計，其鑽頭特點是具有三個切割面。PCD作為鑽頭材料，通過真空焊接固定在鑽身上。採用超短脈衝雷射技術的EWAG LASER LINE ULTRA雷射加工機用於塑造鑽頭。測試了三組不同鑽頭角度的鑽頭，以確定最有效的切割角度，以增強工具壽命。採用田口方法分析工具磨損數據，並確定最佳的PCD鑽孔參數。確定最佳參數後，進行了最多20,000次的鑽孔實驗，評估切削工具的壽命，結果證實其耐用性。

The increasing demand for smaller electronic products and semiconductor applications has led to the development of more efficient tools. PCD (polycrystalline diamond) tools, known for their superior cutting quality, productivity, and precision compared to traditional tungsten steel drills, are at the forefront of this advancement. This study introduces a novel design for a PCD micro-drill with three cutting faces on its tip. The PCD material, crucial for drill performance, is securely attached to the drill body using vacuum welding. Utilizing the EWAG LASER LINE ULTRA laser processing machine, which employs ultra-short pulse laser technology, the drill tip is precisely shaped. Three groups with varying drill tip angles are tested to determine the most effective cutting angles, thereby improving tool longevity. The Taguchi method is employed to analyze tool wear data and pinpoint optimal PCD drilling parameters. The optimal parameters identified are then rigorously tested, demonstrating the ability of the drilling process to endure up to 20,000 drilling cycles, thereby validating the cutting tool’s durability.

English Abstract....... i
Chinese Abstract....... ii
Acknowledgements....... iii
Table of Contents....... v
List of Tables....... vii
List of Figures....... ix
Chapter 1 Introduction....... 1
1.1 Research Background....... 1
1.2 Motivation and Objectives....... 1
1.2.1 Value Chain of Advanced Machining Manufacturing Efficiency....... 1
1.2.2 Current Situation and Trends in the Global Tool Market....... 2
1.2.3 Current Status and Issues in Industry Development....... 4
1.2.4 Analysis of Problems in the Taiwanese Tool Industry....... 5
Chapter 2 Literature Review....... 7
2.1 Advancements in Polycrystalline Diamond (PCD) Micro-Drills....... 7
2.2 Wear Analysis of PCD Tools....... 10
2.3 Application of Taguchi Method in Quality Engineering....... 12
2.3.1 Parameter Design....... 13
2.3.2 Classification of Parameters....... 15
2.3.3 Quality Loss Function....... 16
2.3.4 Signal-to-Noise Ratio (SNR)....... 19
2.3.5 Analysis of Variance (ANOVA)....... 20
2.3.6 F-distribution....... 24
2.3.7 Orthogonal Arrays....... 26
2.3.8 Predicting Quality Characteristics for Optimal Design....... 27
Chapter 3 PCD Micro Drill Bit Design....... 29
3.1 The Drawbacks of Existing Micro Drills....... 29
3.2 Design of Novel PCD Micro Drill Bit....... 30
3.3 Micro Drill Machining Analysis....... 35
3.3.1 Drill and Drilling Thrust....... 35
3.3.2 Drilling Force....... 36
Chapter 4 Tool Processing and Measurement Parameters....... 38
4.1 Tool Processing Equipment....... 38
4.1.1 PMC VPM-BC140 Five-axis Machine....... 38
4.1.2 EWAG LASER LINE ULTRA....... 41
4.2 Measurement Equipment....... 44
4.2.1 PCD Tool Data Collection....... 45
4.3 Measurement Equipment....... 57
Chapter 5 Preliminary and Mid-Term Experiment....... 60
5.1 Preliminary Experiment....... 60
5.1.1 Machining Method....... 63
5.1.2 Preliminary Test Result....... 65
5.2 Mid-Term Experiment (Verification of Tool Machining Parameter)....... 68
5.2.1 Machining Method....... 68
5.2.2 Mid-Term Test Result....... 69
Chapter 6 Final Experiment....... 71
6.1 Durability Test of The Designed PCD Drill Head....... 71
6.1.1 Tool Testing for Aluminum Alloy 6061....... 71
6.1.2 Tool Testing for Aluminum Alloy 7075....... 76
6.2 Comparison of PCD Tool Data with Foreign Products....... 82
6.2.1 Tool Testing for Aluminum Alloy 6061....... 82
6.2.2 Comparative Results....... 83
Chapter 7 Conclusions....... 86
References....... 88
Extended Abstract....... 94

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