How to more accurately determine the die-cutting pressure of a new product

As the market gradually recognizes the individualization of product packaging, various box-types with corporate symbolism have also become a symbol and culture of the company. Die-cutting is an indispensable processing method in the box-type mass production process. For the entire die-cutting process, the control of die-cutting pressure is a core part of product quality control. The die-cutting pressure is too large to cause die-cutting damage. Too little pressure will cause the separation of the cartridges.

Because the die-cutting pressure of the die-cutting machine is greatly influenced by the physical properties of the pressure-bearing material and the performance of different die-cutting plates, the initial pressure is difficult to determine. There are mainly three types of pressure transmission methods of flat-pressing and horizontal die-cutting machines, namely four groups of crank connecting rod mechanisms, a chevron block cam mechanism and a worm gear worm eccentric mechanism. No matter what kind of transmission mode is used to provide die-cutting pressure, the final pressure is transmitted and realized through the steel knife and steel wire on the die-cutting plate, that is, the die-cutting pressure is converted into the linear pressure of the steel blade and steel wire. In the operation of the die-cutting machine, the most important one is to control the die-cutting pressure. However, for different processing materials and box types, how can the die-cutting pressure be set quickly and accurately?

1 Theoretical calculation

After the die-cutting pressure is converted to line pressure, the pressure value is related to the total length of the steel blade and steel wire, the effective line pressure, and the characteristics of the pressure-bearing material. The current general formula is:

P=K×L×F

P-die cutting pressure (N)

K-correction factor (usually 1.3)

Total length of steel knife or steel wire on L-die plate (mm)

F-steel knife or steel wire effective line pressure (N/mm)

However, in actual production, the physical parameters such as the tightness, thickness, and fiber direction of the material are different due to the difference in material and environment, and the die-cutting pressure will change; in addition, due to changes in processing conditions, steel knives and steel wire will be caused. The wear causes a change in the effective line pressure of the steel blade and the steel wire. In the calculation, the default steel blade and steel wire work under the condition of the best effective line pressure, which results in the error of the theoretical calculation value. In addition, due to the imperfect level of the die-cutting plate resulting from the die-cutting plate manufacturing process, the installation heights of the steel blade and the steel wire caused by the error in the bridge height machining accuracy have reduced the practical use performance of the formula. Therefore, this formula cannot be used for the determination of all die-cut pressures.

However, this formula still has important guiding significance for the production process of new production tasks, and plays a role in saving printed sheets and protecting die-cut sheets. The greatest practical value of this formula is the determination of the reasonable range of initial pressure. Before the new die-cut version is used, the reasonable theoretical pressure value for the first use of the die-cutting plate can be calculated based on the parameter values ​​required by the formula. Die-cut version of the reasonable actual pressure value. From this formula, it can be seen that the measurement of the die-cutting pressure and the pressure-bearing objects are mainly balanced by the correction coefficient, but the use of the same correction factor each time can lead to the difference caused by the change of the pressure-bearing material.

2 Trial cut method

In addition to the calculation method, the trial cut method is also a simple method for determining the die cutting pressure. It actually uses an experimental process to determine a box-shaped die-cutting pressure. This method is very helpful in determining the pressure of the first processed product. The trial-cutting method uses the operator's experience to estimate the die-cutting pressure of a new processed product. After finding a reference, it gradually increases the die-cutting pressure until 2/3 of the die-cut lines of the die-cut proofs are cut. It is called initial pressure. After the initial pressure value is determined, 3~5t pressure increment can be made according to the characteristics of the pressure-bearing material. After the normal die-cut of more than 90% of steel cutters and steel wires, the pressure is increased by 0.1~0.3t until die-cutting. The box type can be normally separated. This process is called priming.

This method is time-consuming, labor-intensive, and requires high operator demand. If the initial pressure is too high, it is easy to cause damage to the die-cutting plate. If the pressure is too low, repeated tests are required to achieve the rated value, thereby reducing the production efficiency. . However, once a reasonable pressure value is obtained, this value has very important reference value for future reprocessing. It should be recorded one by one for the next use. However, as the degree of wear of the die-cutting plate is different, the effective line pressure has changed, resulting in a change in the actual die-cutting pressure value, and the actual die-cutting pressure marked is often corrected to meet the subsequent application.

Some people think that the calculation method cannot be brought close to production at all, and it has almost become a pity that food is no longer a waste. Now the factory also generally adopts the trial cut method to obtain the reasonable pressure value of new products. If these two are used together, it will bring certain economic benefits to the actual production.

3 synthesis method

The calculation method can obtain the theoretical pressure value of the first pressure. The test cutting method can obtain the actual pressure value. If the reasonable actual value obtained by the test cutting method can be used to reverse the correction coefficient in the calculation method, then such a die cut version can be obtained. The correction factor for this type of material. The correction factor is a variable value, which is mainly used to compensate for the difference between the difference between different materials and the precision of the die-cutting plate. The correction coefficient of the material can be determined more accurately by the actual production data of the same material. In this way, we can know how much pressure should be used when the new product is die-cut for the first time and can be closer to a reasonable actual pressure value.

The test method is as follows: Assume that the initial die cut gram weight is 300g/m2 white cardboard. It is known that the total length of the steel cutter on this diecut is 1600cm, the total length of the steel wire is 1810cm, and the effective linear pressure of the used steel knife is 45N/ Mm, the effective line pressure of the steel wire is 40N/mm.

How to determine the die-cutting pressure required for a white cardboard die-cut product with a grammage of 300g/m2?

Firstly, the theoretical reasonable pressure value of die-cutting product is 187.72t through calculation method, and then die-cutting is carried out by test cutting method. The initial pressure is set at 60% of the theoretical value, and the actual pressure value is finally obtained by continuously pressurizing to 174.8t. , The pressure value is again brought into the formula to get a K value of 1.2. Therefore, in the die-cutting of this kind of material, the corresponding accurate pressure value can be calculated using K=1.2 substitution formula, which avoids the risk of the trial cutting method and saves the production cost. It is possible to obtain the closest correction factor by creating a test sheet of the same material and different products in order to obtain the ideal actual die-cutting pressure for the next new product.

Of course, this method cannot provide the same standard for all devices, because the correction factor also includes the processing error of the device, and the wear conditions of different devices are different. Therefore, the above test can only be performed on the same machine. It is better to take the average of multiple sets of actual data to find the correction factor of the material. The establishment of correction factors for different processing materials is of great help to the processing of new products. It can accurately determine the pressure required for die cutting and save a lot of materials and time. In addition, due to the wear of the equipment, the correction coefficient changes, and the effective service life of the die cutting equipment is long, and its wear is also slow. In the case of normal use, it is generally possible to perform a re-measurement of the correction coefficient in a cycle of two years. If the intensity of use of the device is large, the measurement cycle can be shortened.

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