Optimization of Double sided Groove TVS Cutting

Replacing the traditional three-stage process of "front shallow slotting+back shallow slotting+splitting" with a one cut cutting technique, the cutting efficiency is improved by 100%, reducing the risk of edge breakage in the double groove structure from the source.

Device type:Double channel TVS
Using equipment:AR3000
Efficiency improvement:100%

Question background

TVS stands for Transient Voltage Suppressor. Among them, groove type/double groove TVS has outstanding advantages such as bidirectional protection, ultra-low junction capacitance, high power density, small size, excellent heat dissipation performance, and fast response speed. It is widely used in high-end technology fields such as high-speed communication and data interfaces, new energy vehicles, medical, aviation, and military industries.

Due to the strict requirements for reliability, stability, and security in application scenarios, TVS chips adhere to extremely high standards in production, process, and quality control. The double groove structure is a typical difficulty in the industry: after the material is slotted on both sides, the upper and lower cutting stresses are overlapped, and the effective support on the back of the workpiece is greatly reduced. At the moment of cutting, it is prone to shaking and displacement, which can lead to fatal defects such as edge breakage and cracking. At the same time, the narrow bottom cavity space and poor chip removal conditions, combined with the brittleness and poor toughness of TVS materials themselves, further exacerbate the risk of edge breakage, which has become a core industry pain point restricting the efficient and high-precision processing of TVS devices.

Key improvement steps

Three step process optimization to systematically solve the problem of double groove TVS cutting edge breakage.

Step 1 | Adopt a one blade cutting process

Abandoning the traditional three-stage process of "shallow slotting on the front, shallow slotting on the back, and splitting" in the industry, we adopt a one blade cutting process to directly complete the cutting, simplifying the process from the source.

Function: Effectively simplifies the workflow, reduces operational difficulty, significantly improves cutting efficiency and processing stability, and increases efficiency by 100%.

Step 2 | Optimize the blade model and finely match the process parameters

Based on the material characteristics of the double groove TVS, highly adaptable specialized blades are selected, and key process parameters such as spindle speed and feed rate are finely matched according to the machine characteristics.

Function: Effectively improve cutting quality, significantly reduce edge breakage defects, and ensure stable and reliable appearance and performance of finished products.

Step 3 | Expand the film first and then invert it after cutting is completed

Optimize the post cutting process flow, first perform film expansion treatment after cutting, and then perform film pouring operation to avoid squeezing and collision between products.

Function: It can effectively avoid product squeezing and collision during transportation, reduce the risk of edge breakage from the source, and ensure the appearance and integrity of cut products.

Comparison before and after optimization

Before optimization | Edge collapse 37.61 μ m (measured)

Adopting the traditional three-stage process of "front shallow slotting+back shallow slotting+splitting", the equipment investment cost is high, the labor cost is high, the operation process is complex, and the stress superposition of the double groove structure leads to high risks of edge collapse and cracking, making it difficult to guarantee product yield.

Optimized | Broken edge 4.47 μ m (measured)

After adopting the one blade cutting process, the cutting efficiency has been improved by 100%, and equipment investment and labor costs have been significantly reduced; By selecting highly adaptable specialized blades and finely matching process parameters, stable application of one cut cutting technology has been achieved, achieving overall optimization of cutting quality while ensuring high efficiency.