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A Feasibility Study for the Hot-Air-Assisted Reflow Soldering Process Based on Computational Fluid Dynamics
(2024-10-01)
Kanjad, Natcha
;
Chanbandit, Chanapat
;
Thongsri, Jatuporn
In hard disk drive (HDD) manufacturing, a reflow soldering process (RSP) employs heat generated at the welding tip (WT) to bond tiny electrical components for assembling an HDD. Generally, the heat was generated by an electric current applied to the WT. This article reports a feasibility study of using hot air based on computational fluid dynamics (CFD), a choice to assist heat generation. First, the WT and hot air tube (HAT) prototypes were designed and created. The HAT is a device that helps to supply hot air directly to generate heat at the WT. Then, the experiment was established to measure the temperature (T) supplied by the hot air. The measure results were employed to validate the CFD results. Next, the prototype HAT was used to investigate the T generated at the WT by CFD. The comparison revealed that the T measured by the experiment was in the 106.2 °C–133.5 °C range and that the CFD was in the 107.3 °C–136.6 °C range. The maximum error of the CFD results is 2.3% compared to the experimental results, confirming the credibility of the CFD results and methodology. The CFD results revealed that the operating conditions, such as WT, HAT designs, hot air inlet velocity, and inlet temperature, influence the T. Last, examples of suitable operating conditions for using hot air were presented, which confirmed that hot air is a proper choice for a low-temperature RPS.
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Multiphysics to Investigate the Thermal and Mechanical Responses in Hard Disk Drive Components Due to the Reflow Soldering Process
(2024-09-01)
Kimaporn, Napatsorn
;
Samakkarn, Chawit
;
Thongsri, Jatuporn
In hard disk drive (HDD) manufacturing, a reflow soldering process (RSP) implements heat generated by the welding tip to melt a solder ball for bonding the following essential HDD components: a flexible printed circuit (FPC) and a printed circuit cable (PCC). Since the mentioned components are tiny and comprise many thin material layers, an experiment to study thermal and mechanical responses is complex and not worth it. Therefore, a static state multiphysics consisting of thermal analysis (TA) and structural analysis (SA) was employed to investigate both responses. First, the experiment was established to mimic the RSP, measuring the temperature generated by the actual welding tip. Then, the measured temperature was defined as the boundary conditions with the pressing force (F) for the TA and SA based on the actual operating conditions. As expected, the TA results revealed the temperature distribution in the HDD components, which was consistent with the theory and results from previous work and confirmed this work’s credibility. Significantly, the SA reported severe total deformation (δ) in FPC’s top and bottom ends. The maximum δ was 0.72–0.88 mm for the F of 0–1 N. The stronger the F, the greater the δ. This research highlights that multiphysics can investigate both responses in HDD components as slight as 0.1–100 microns thick, which can be used to develop a high-efficacy RSP.
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A Proper Lubricant for a Swage Process in a Hard Disk Drive Factory Determined by Explicit Dynamics Analysis
(2023-01-01)
Bubpatha, Watchara
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Pattanapichai, Sorathorn
;
Thongsri, Jatuporn
Since the hard disk drive industries continue to be highly competitive, many factories aim to reduce waste costs by developing their manufacturing process. This article presents the swage process (SP) development to join components: the head gimbal assembly with an actuator arm by explicit dynamics analysis (EDA). First, EDA was employed to determine the total deformation (δ) and equivalent (von Mises) stress (σ) after joining both components in the SP using a traditional lubricant currently used in the factory calculated by the friction coefficients. Then, the EDA results for the traditional lubricant were compared with the experimental results, and an agreement between both results was observed, confirming the EDA's credibility. Next, two additional different lubricants, including a non-lubricant as a control case, were investigated using the EDA. Finally, after comparing the EDA results for all four lubricants, the EDA results showed the proper type of lubricant, which can reduce the δ by 16.40% and σ by 9.40% compared to the traditional lubricant. Accordingly, the research findings were applied as important information for determining the best lubricant for other HDD generations to suit the SP, which can reduce waste costs from the trial and error method.
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A simulation of swage process for hard disk drive factory based on explicit dynamics analysis
(2022-01-01)
Bubpatha, Watchara
;
Thongsri, Jatuporn
Nowadays, the hard disk drive (HDD) industry is very competitive and focuses on enhancing the performance and capacity of HDD. To serve these purposes, HDD manufacturers prefer to increase the number of media, thus adding more head gimbal assemblies (HGAs) as well. A swage process (SP) assembles between HGAs and arm actuators into a head stack assembly (HSA). The greater the number of HGAs, the thinner it gets. Such thinness in some products, after passing the SP, there could be higher deformation and stress in arm actuators than expected values. To investigate and understand this problem. This article proposes an explicit dynamic analysis (EDA) in ANSYS software to solve the problem and simulate the SP using an actual condition from a manufacturer. The EDA provides simulation results that are consistent with the experimental results. The analytical results lead to understanding the SP's deformation, strain, and lubricant effect. Therefore, the EDS is a precise and appropriate method for developing the SP in the HDD manufacturing process.

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