Take you to know the die cutting process
The die cutting process is the most commonly used process for packaging and printing. It uses a die cutter to form a die cutting plate according to the pattern required by the product design. Under the effect of pressure, the printed product or other plate blanks are cut into the desired shape or Cutting process. The creasing process is to use a crimping knife or a crimping die to press the line marks on the sheet material through the action of pressure, or use the wire rolling wheel to roll out the line marks on the sheet material, so that the sheet material can be bent and formed at a predetermined position . Generally, the die-cutting and creasing process is a process of combining die-cutting knives and crimping knives in the same template, and simultaneously performing die-cutting and indentation processing on the die-cutting machine, referred to as die-cutting. Process introduction The main process of die-cutting indentation is: upper version → adjust pressure → determine rules → stick rubber strip → test pressure die-cutting → formal die-cutting indentation → waste removal → finished product inspection → point packaging.
Previous version
First, proofread the die-cut version that has been made, and roughly observe whether it meets the requirements of the design draft. Whether the positions of the steel wire (crimping knife) and the steel knife (die cutting knife) are accurate; whether the slotted and holed cutting line adopts the entire line, and whether the curve of the line is rounded; for the convenience of cleaning, the adjacent narrow waste edge Whether the connection increases the connecting part to make it into one; whether there is a sharp corner at the joint of the two lines; whether there is a case where the sharp line ends at the middle paragraph of another straight line. Once the above problems occur in the die-cut version, the plate-making personnel should be notified to make corrections to avoid wasting more time. Then, install the fixed die-cut plate in the frame of the die-cutting machine, and adjust the position of the plate.
Adjust the pressure, determine the rules and paste the rubber bullet
To adjust the layout pressure, first adjust the pressure of the steel knife. After padding, start the machine and press several times to make the steel knife level, and then use a cardboard that is larger than the die-cut version of the board to test the pressure. According to the cut marks cut by the steel knife on the cardboard, use some or all to gradually increase the pressure or The method of reducing the number of backing paper layers makes the pressure of each knife line on the layout uniform. In general, the steel line is 0.8mm lower than the knife line (because of the different corrugated cardboard corrugated type, the thickness of the cardboard has a large gap, it should be adjusted according to the actual situation). Adjust the pressure of the steel wire. The thickness of the backing paper is usually calculated according to the thickness of the die-cut cardboard, that is, the thickness of the backing paper = the height of the steel knife-the height of the steel wire-the thickness of the cardboard being die-cut.
Remarks: After adjusting the pressure of the plate, fix the die-cut plate. When determining the location of the rule, it is generally best to center the die-cut product. The rubber bullet plug should be placed on the two sides of the main steel knife of the die-cut version, and the good recovery of the rubber bullet strip is used to push the separated cardboard out of the blade. Generally speaking, the rubber band should be about 1.2mm higher than the die cutting blade, and the distance between the rubber band and the knife line is 1mm ~ 2mm, because if installed only by the blade body, the rubber bullet cannot expand in the direction of the blade body after being compressed. It can expand in the other direction, causing the paper to be pulled to both sides. The die cutter has not cut the paper, and it has been pulled off by the rubber bullet, which is prone to produce paper wool.
Trial die cutting, formal die cutting, waste removal, finished product inspection, point packaging
After the above work is completed, the sample sheet should be cut out first, and a comprehensive inspection should be conducted to see if the indicators meet the requirements. After the full-time inspector signs and confirms, mass production can be carried out. During the production process, the operator should conduct self-inspection from time to time. It is mainly compared with the proofs to see if there is a problem to solve in time. The die-cut product should be stripped of excess edging, and then the burr edge should be polished to make it smooth and free of burrs. Afterwards, the finished products are selected and inspected to remove the defective products, and the final points, packaging, acceptance and storage. The characteristics and development trend of the equipment The equipment used for die cutting and indentation processing is called a die cutting machine. According to the shape of the main working parts of the die cutting plate and the die cutting structure, there are three types of common die cutting machines on the market: flat pressure flat type Die-cutting machine, flat-press round die-cutting machine and round-press round die-cutting machine. But no matter what type of die-cutting machine, its structure is composed of two parts: die-cutting plate and press-cutting mechanism. The following briefly discusses their working principles, advantages and disadvantages:
Flat die cutting machine
Working principle: The shape of the die-cutting plate and die-cutting mechanism of the flat-press die-cutting machine are flat. The die-cut plate is fixed on a flat plate table, and the processed sheet is placed on the platen (lower platen). During work, the die-cutting plate is fixed, and the pressure plate reciprocates through the action of the crankshaft connecting rod, so that the plate and the pressure plate are continuously clutched and pressed, and die-cutting is realized every time the pressure is closed. Common flat die cutting machines include vertical die cutting machines and horizontal die cutting machines. At present, the vertical die-cutting machine is mainly converted from a flat-press printing machine; while the structure of the horizontal die-cutting machine is similar to that of a monochrome offset press, it consists of a feeding part, a molding part, and a discharging part, and some have Automatic waste removal device and other components.
Advantages and Disadvantages: Compared with other die-cutting equipment, the flat die-cutting die-cutting machine has a series of advantages such as simple structure, convenient maintenance, easy operation, easy replacement of die-cutting indentation plate, suitable for materials with different weights, and accurate die-cutting. So it has a wide market. But its shortcomings are also obvious, for example, it needs a lot of pressure when working, which leads to high labor intensity and low production efficiency. It has a wide range of applications and is suitable for the die-cutting and creasing treatment of folding cartons, pasting cartons, and corrugated boxes. It is currently the most commonly used die-cutting equipment in China. The continuous die-cutting automatic paper-cutting machine produced by Tangshan Yuyin is the most popular in China.
Round flat die cutting machine
Working principle: The working principle of the round flat die cutting machine is similar to that of Heidelberg's early round flat printing machine. Its die cutting plate is flat, and the die cutting plate is fixed on its upper surface. The die cutting plate can With the help of the pulley on the back, the back-and-forth movement is carried out, and the processed sheet continues to feed through the gripper teeth of the molding cylinder. When working, the platen moves forward while the molding cylinder is running, so as to achieve die cutting. Before the gripper continues to the next piece of paper, the platen moves back to the starting position (at this time The table is not in contact with the working surface of the molding roller), which is convenient for the next die cutting work.
Advantages and Disadvantages: Most of these die-cutting machines are modified from the early Heidelberg flat presses. This equipment uses a cylindrical pressure roller instead of a pressure plate, so it is not "surface contact" but "line contact" when working. , The machine needs less pressure when die cutting, so the load of the machine is relatively stable. However, due to the component force generated when the die-cutting plate and the die roller roll against each other, the knife line is easily deformed and displaced, and its application range is relatively narrow. Generally, it is only suitable for die cutting of cardboard with a grammage of less than 400g / m2. For paper die-cutting and bronzing of anodized aluminum film. In the process of paper die cutting, attention should be paid to the fiber direction of the paper, generally it should be parallel to the axis of the molding roller, otherwise it will cause serious paper expansion and contraction.
Round die cutting machine
Working principle: The shape of the working part of the die-cutting plate and the die-cutting mechanism (pressure roller) of the circular die-cutting die-cutting machine are all cylindrical, and the principle of die-pressing is similar to that of an offset printing machine. Fix one or two semicircular die-cutting plates (or metal die-cutting rollers) with the same curvature as the base of the die-cutting plate base (ie die-cutting plate cylinder) on the die-cutting plate roller, and wrap a layer on the surface of the pressure roller Polyester plastic to protect the die cutting edge. As the molding progresses, the polyester plastic on the surface layer will be destroyed. Therefore, the polyester plastic on the surface layer is usually removed at regular intervals and replaced with a new plastic layer. During the molding, the feed roller sends the processed sheet between the die-cutting plate cylinder and the pressure roller, and the two clamp it against the roll to mold, and the die-cutting plate cylinder rotates once to complete the die-cutting task.
Advantages and Disadvantages: Since the die cutting machine works continuously, the working efficiency is the highest compared to other die cutting machines, especially suitable for mass production, but it is because of its fast die cutting speed , Resulting in sometimes can not guarantee the required precision of die cutting. Like the round flat die cutting machine, it uses the line contact principle to complete the molding work, so only a small pressure is needed during die cutting, and the pressure distribution is uniform, so the load of the machine is relatively stable. However, its die cutting plate is curved into a curved surface, so it is more cumbersome in plate making and plate mounting, the technical difficulty is relatively large, and the plate making cost is relatively high. The die cutting plate required by the circular pressure round wheel rotary die cutting device is flatter than the flat pressing The cost of die-cut version is 25% ～ 100% higher.
The round die cutting machine is mainly used for the die cutting of corrugated products, and the current market share is very low. However, with the development of science and technology, the development trend of this die-cutting machine is better, because it adapts to the requirements of mechanization, linkage and automation of the post-press processing technology in the future, people can connect the molding mechanism and the printing machine into one The production line realizes online operation, which can effectively reduce the demand for labor, shorten the process flow, and reduce the loss in the process, thereby improving production efficiency, reducing labor costs, and obtaining greater profits.
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