Application of the most popular die cutting indent

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Application of die-cutting indentation technology in corrugated box

die cutting indentation is an indispensable process in corrugated box processing. The appearance quality and market competitiveness of the carton after die cutting and indentation have been greatly improved. The main process of die-cutting indentation is: product design → die-cutting tool processing → typesetting → loading and pad plate → die-cutting indentation → finishing → finished product

1. product design

when designing corrugated boxes, it is necessary to accurately calculate the internal dimensions of the packaging, and try to use rounded corners at the line turns to prevent sharp corners, which is conducive to knife arrangement; Multiple adjacent narrow edges shall be avoided to facilitate waste removal. After the specifications of each part of the corrugated box are determined, the method of proofing and trial forming is adopted to check the rationality of the specifications and the artistry of the appearance, and then formal plate making is carried out

2. tool selection and processing

can minimize energy input

the tool used for die cutting is called die cutting tool, also known as steel knife, beer knife, etc; The tool used for indentation is called indentation line, also known as steel line, beer line, etc. The die-cutting knife and indentation line are made by professional factories. Users only need to select them according to requirements. The height of the common die cutter is 23.8 mm and the thickness is 0.7 mm

thickness D and height h of corrugated box indentation line: D ≥ ch = H-C C - thickness of corrugated board after compaction H - height of die cutter. The cutting edge of the die-cutting indentation tool must have a certain hardness. The tool must be tough and can be bent into any complex shape to meet the needs of the complex shape of the die-cutting indentation product. The thicker the blade, the harder it is to bend; The higher the blade, the greater the force required to bend. For products with extremely precise and complex shapes, thinner blades can bring many conveniences

according to the requirements of the product, select the cutters with different hardness and shapes, and bend the cutters into the required shape with the bending machine and other equipment. Well designed bending machine die can avoid incorrect pressure on blade deformation. The blade should have a certain degree of bending plasticity. The blade can neither be like a spring nor deform under a little pressure. Good plasticity should be that the blade bends into a certain shape and rebounds slightly

when installing the blade into the slotted formwork, it should be properly tightened. The blade can be embedded by gently tapping with a plate making hammer. The thickness of the blade and the width of the sawing gap should be controlled within a certain tolerance range. The beveled blade back makes it easy for the blade to fit into the template. The die of the blade cutting machine should have precise perpendicularity to ensure that each cutting end is perpendicular to the blade. The cylinder type die cutting indentation tools are divided into assembly type and integral type. The assembly type die cutting tool and indentation line are assembled on the die cutting indentation cylinder, and the integral die cutting tool and indentation line are integrated with the cylinder. The assembled die-cutting indentation roller is easy to assemble and flexible to replace products: the manufacturing of the integral die-cutting indentation roller is complex, and the entire roller should be replaced when replacing products, but this method has high precision and fast speed of die-cutting indentation

3. holding the edition

typesetting is also called knife arrangement. Before typesetting, according to the shape of the die-cutting indentation product, bend the cutter into the required shape made of aromatic fluorinated engineering polymer, and fix the cutter in the plate frame with hollow lining material to make the die-cutting indentation plate. The lining materials include lead, wood, fiber plastic board and steel board. Lead lining materials include lead block and lead strip. Die cutting indentation plates made of lead block and lead strip have low dimensional accuracy and are easy to scatter. The wood board lining material generally adopts multi-layer plywood with a thickness of about 18mm. This material is greatly affected by the changes of ambient temperature and humidity, which is prone to deformation, unstable size and affects the precision of die-cutting indentation. Fiber reinforced plastic board is not affected by temperature and humidity changes. It has good dimensional stability. It is a good die-cutting indentation plate. It needs special equipment to process, and the cost is high. Steel die cutting indentation plate has high precision, no deformation and complex processing

when typesetting, first design the die cutting layout according to the product. The size of the layout shall match the specification and working capacity of the selected equipment; The position of die-cutting plate shall be consistent with that of printing; The working part shall be located in the center of the die-cutting plate; The cutting lines of the layout shall be aligned, and the vertical and horizontal cutting lines shall be at right angles to each other and parallel to the side of the die-cutting plate

the outline drawing of the die cutting plate is the unfolded drawing of the whole plate product. If the printing adopts the whole page assembly system, the outline drawing of the die cutting plate can be directly output in the printing and plate making process. In order to ensure that the die-cutting plate is not scattered during the plate making process, several "bridges" shall be reserved in the large-area closed graphic part. The bridge width can be designed as 3 ~ 6mm for the small plate and 8 ~ 9mm for the large plate. When designing the layout, the cutting line for slotting and opening shall be the whole line as far as possible, and the corner of the line shall be rounded to prevent the splicing of mutually perpendicular steel knives; Sharp corners shall be prevented at the joint of two lines; Avoid the connection of multiple adjacent narrow waste edges, and increase the connection part to make it connected into a piece for the convenience of waste removal; Prevent multiple continuous sharp corners. Sharp corners without functional requirements can be changed into rounded corners; Prevent the sharp angle line from cutting off the middle section of another straight line, which will make it difficult to fix the knife, the steel knife easy to loosen, and reduce the die cutting suitability. It should be changed to arc or increase the included angle

during plate making, the connection points should be opened. The connection point is to open a small opening with a certain width at the edge of the die-cutting blade. During the die-cutting process, the waste edge is still partially connected to the whole printing sheet after die-cutting, which is convenient for paper feeding. The connection point shall be opened with a tool line drilling machine, which shall be ground with a grinding wheel. Do not open the connection point with a hammer and chisel, otherwise the tool line will be damaged and burrs will be generated in the connection part. The connection point is usually placed in the concealed place of the formed product to avoid affecting the appearance of the finished product. Do not open the connection point at the bridge crossing position, and try to avoid opening the connection point at the gluing position. Generally speaking, the width of the connection point of the corrugated board is corrugated paper, and the actual thickness of the board plus 0.2mm is about 1 ~ 3mm

(1) manual typesetting

manual typesetting is to use manual method to fix the steel knife and steel wire with hollow lining material according to the design size of corrugated box to form a die-cutting indentation plate. For manual typesetting, lead or wood board can be used as lining material. The lead lining material is used to fix the steel wire of the steel knife with lead blocks, empty lead and lead bars. The size of the die-cutting indentation plate made by this method is not accurate, and the lining material is easy to scatter. The wood board lining material is to use a hand saw to saw the multi-layer plywood according to the product specifications, and embed the steel knife and steel wire into the SAW seam for fixation. The size of the die-cutting indentation plate made by this method is not accurate, and the wood board is easily deformed by moisture. The manual typesetting process is simple, but it is not solid, easy to scatter, and the graphics are easy to deform and inaccurate. It can only process simple graphics

(2) mechanical typesetting

mechanical typesetting is to use a sawing machine and other equipment to saw the base board out of the sawing seam according to the layout specification, and insert the formed die-cutting indentation cutter into the sawing seam to make a die-cutting indentation plate. The sawing seam of the layout cannot be completely penetrated to ensure the integrity of the plate after sawing. Before sawing, first drill holes at the starting and ending points of the steel knife and steel wire bridge position (notch) of each line on the plate, so that the saw blade can smoothly enter the plate. The plate position corresponding to the steel knife and steel wire bridge position is not sawed through, leaving an interval equivalent to the width of the bridge position

mechanical typesetting is semi-automatic typesetting, with low equipment investment and high production efficiency. The direction of sawing line is manually controlled, which is highly dependent on workers' technology. The sawing seam is not too straight and has poor repeatability. The multi-layer plywood used is prone to deformation when wet

mechanical typesetting is the leading method for making die cutting and indentation plates in China at present

(3) laser typesetting

laser typesetting is to use the computer to draw CAD graphics for the product specifications, shapes and other parameters that need die-cutting indentation, or use the scanner to input, compile the die-cutting indentation program, and use the laser cutting machine to cut the plate to make the die-cutting indentation plate

the laser cutting machine is controlled by a computer and uses the laser as the energy source to cut the substrate material through the high temperature generated by the laser. Laser typesetting can control a single graphic design, automatically add bridge position when cutting plates, and output laser cutting graphics. The computer-controlled laser cutting machine can cut any complex cutting seam of the plate, while maintaining the integrity of the plate. The matched computer scissor machine is accurate. The cutting seam cut by the laser cutting machine is smooth, straight and accurate

the accuracy of laser typesetting and plate making is high, but the plate base still uses multilayer plywood, which is easy to deform when wet

there are many parameters needed in the cutting process, such as material quality parameters, plate thickness, laser output power, type and pressure of auxiliary gas, diameter and caliber of nozzle, distance gap between material and nozzle, focal length of lens, position of focal point, cutting speed, etc. The main disadvantage of laser cutting is that the laser cutting machine is expensive and the cutting cost is high, which makes the production cost of die-cutting plate higher. Therefore, this kind of die-cutting plate is generally produced by professional manufacturers. For example, the sampling position and direction, the shape and size of the sample, the force adding characteristics during the experiment, including the loading speed, the composition and temperature of the environmental medium, etc., will affect the results of the experiment. Users can directly customize it

(4) high pressure water jet cutting typesetting

high pressure water jet cutting is used for cutting fiber plastic boards. If a laser cutting machine is used to cut the fiber plastic board, it will produce toxic gas and smoke. Cutting the fiber plastic board with a saw machine is easy to wear the saw blade and produce a large amount of dust, both of which will pollute the environment

high pressure water jet cutting uses computer to draw CAD graphics, or can use scanning input to compile die cutting indentation program, and uses high pressure water jet cutting machine to cut plates to make die cutting indentation plates. High pressure water jet typesetting can control a single graphic design, and automatically add a bridge position when cutting the plate. It can cut any complex cutting seam of the plate, while maintaining the integrity of the plate. The matched computer cutter is accurate. The cutting seam cut by the laser cutting machine is smooth, straight and accurate

high pressure water jet cutting fiber plastic board, no pollution. High pressure water beam is similar to laser beam, which can be accurately controlled by computer. The cutting seam is smooth, straight, accurate and high-quality. Fiber plastic board does not deform when wet, with high dimensional accuracy. The equipment cost is high

4. plate mounting and pad plate

after the die cutting and indentation plate is arranged, it is installed into the plate frame for fixation, and then installed into the die cutting and indentation machine for processing

(1) stick a rubber strip

after the die-cutting indentation plates are arranged, stick a rubber strip on the plate bases on both sides of the die-cutting knife, and use the elastic effect of the rubber strip to push the die-cutting printing materials out from the knife edges, so as to prevent the steel knife from being embedded firmly and affecting the operation

rubber strips for die cutting are generally divided into hard and soft ones. Hard rubber is used for thicker printing materials and soft rubber is used for thinner printing materials. They are produced by professional manufacturers. Generally speaking, the rubber strip shall be 3 ~ 5mm higher than the die cutting blade, and the distance between the rubber strip and the knife line shall be 1 ~ 2mm

if the distance between die cutters is less than 8mm, the rubber strip with hardness of hs600 shall be selected; If the distance between the die-cutting knives is greater than 10mm, the rubber strip with hardness of hs250 shall be selected. If the distance between the die cutter and the steel wire is less than 10mm, the arch rubber strip with hardness of hs700 shall be selected; If it is greater than 10mm, the rubber strip with hardness of hs350 shall be selected. The punching position of the die-cutting knife uses an arch rubber strip with a hardness of hs700 to protect the connection point from being broken

(2) backing plate

backing plate is to pad one or more layers of paper or paperboard under the die-cutting indentation plate to make the height of the plate steel knife or steel wire consistent,

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