How to prevent dust in the die cutting process

Dust and loose fibers are flat-pressed die-cutting terms used to describe damage to the die-cut edges of cartons. In actual operation, the term refers to the generation of loose particles and debris, as well as the accumulation of fiber filaments, which loose particles, debris and fiber filaments adhere to the die-cut edges of the cardboard. It should be noted that most of these particles and fibers come from the surface of die-cut cardboard. This raises three issues:

How to carry out flat pressing die cutting process

In order to accurately describe the flat die-cutting process using a steel die-cutting die, this process will be defined as a moving process and consists of two progressive steps. The first step is called "blasting penetration", and the second step is called "blasting separation".

In the simultaneous die cutting process, the full length of the die cutting blade is in contact with the surface of the die cutting material. During die cutting, the die cutting blade exerts pressure on the cardboard material (see Figure 1). Although we describe die cutting as a cutting process, to be more precise, this is a process in which the cardboard breaks under pressure. When the cutter drills into the cardboard and draws closer to the anvil, the cardboard surface is squeezed, stretched, and compressed (see Figure 2). In the end, the cardboard surface could not withstand the effects of these pressures, so it burst by "blasting through".

The word "blasting" is the most accurate way to describe the rupture of the cardboard surface, because the blade produces strong stretching and compressive forces on the cardboard, so the cardboard surface along the die cutting blade collapses.

After the cardboard surface is broken, the sharpness of the die-cutting blade is not as great as the previous step, because the double bevel of the cutter / wedge converts the vertical pressure into a lateral moving force (see Figure 4). When the cutter penetrates into the cardboard, the beveled surface of the cutter pushes the cardboard vertically to both sides (see Figure 5).

Under strong breaking pressure, the cardboard is completely torn before the cutter and the anvil are in contact. This "blasting separation" process is divided into surface rupture, cutter wedge, and cardboard breakage (see Figure 6).

Even under backward production conditions, as long as it is equipped with sharp steel knives, smooth backing plates and an optional die-cutting setting system, the cardboard will still break under strong burst pressure (see Figure 7).

What caused the dust and loose fibers

Dust and loose fibers are caused by damaged die-cutting blades, and excess force causes the blades to hit the surface of the liner board (see Figure 8). As a result, the blade edge is widened (see Figure 9), so that the squeezing force and stretching force applied to the surface of the cardboard are greatly increased. The cardboard is further compressed and the tension is slowly increased until the cardboard breaks. This process is too hard, producing debris and "dust" molecules (see Figure 10).

As the pressure on the tool increases, further compression forces dull the blade. The cardboard compresses and stretches beyond the normal range, and its surface breaks into three pieces (see Figure 11).

From the description of this process, we can conclude that the dust and loose fibers come from the surface of the cardboard, which is caused by the progressive damage of the die cutting blade.

(Figure 1-Figure 6)

(Figure 7-Figure 11)

How to avoid dust and loose fibers

The way to avoid this problem is to keep the steel blades in good condition. There are several methods to choose from. In practice, one of them can be used alone, or multiple methods can be used simultaneously.

These methods are:

Use soft or "small thickness" die-cutting liners;

Calibrate the flat die cutting machine to prevent excessive force;

Calibrate and balance the pressure on the die-cutting tool to ensure accurate "Z axis control" of the cutting edge;

Use "floating knife" to operate important tools in production planning;

The double cardboard and area repair technology are accurately integrated into the joint repair process to make the pressing and cutting even.

Foam Pillow

Foam Pillow,Foam Pillows,Latex Foam Pillow,Memory Foam Pillow For Neck Pain

Hebei siuno household supplies co.,ltd , https://www.ciaosleep.com