Corrugated cardboard box die-cutting indentation process application and analysis

3.1 Manual layout

Manual typesetting is a manual method to fix steel cutters and steel wires by lining empty materials according to the design size of the corrugated carton to form a die-cutting indentation plate.

Manual layout can use lead or wood as the lining material.

The use of lead lining empty materials is to fix the steel wire of steel knife with lead block, empty lead and lead strip. The size of the die-cut creasing plate made by this method is inaccurate, and the lining material is easily scattered.

The use of wood-lined empty materials is to saw the multi-layer plywood with a hand saw in accordance with the product specifications, and the steel knife and the steel wire are fixed in the saw joint. The size of the die-cut creasing plate made by this method is inaccurate, and the wood board is easily deformed by wetness.

The manual typesetting process is simple, but it is not strong and easily scattered. The graphic is easily deformed and inaccurate, and only simple graphics can be processed.

3.2 Mechanical typesetting

According to the specifications of the layout, the mechanical typesetting uses a sawing machine and other equipment to saw out the sawn joints of the base board, and inserts the formed die-cutting indentation tool into the saw joint to make a die-cut indentation version. The slat seam cannot be fully penetrated to ensure the integrity of the board after sawing. Before kerfing, drill holes in the starting and ending points of the steel knife and steel wire bridge (gap) of each line on the plate so that the saw blade can smoothly enter the plate. The position of the plate corresponding to the steel blade and the steel wire bridge position is not cut through. Equivalent to the bridge width.

Mechanical typesetting is semi-automatic typesetting, with low investment in equipment, high production efficiency, artificial guidance of sawing line guidance, strong technology dependence of workers, less straight saw seams, poor repeatability, and the use of multi-layer plywood subject to wet deformation .

Mechanical typesetting is currently the dominant method for making die-cut indentations in China.

3.3 Laser typesetting

Laser typesetting is the use of computer graphics to draw CAD drawings of product specifications, shapes, and other parameters that require die-cutting indentations. It can also be entered using scanners, and can be used to create die-cut indentation programs. Laser-cutting machines can be used to cut sheets and make die-cut indentations.

The laser cutting machine is controlled by a computer and uses a laser as an energy source to cut the substrate material by the high temperature generated by the laser. Laser layout can control a single graphic design, automatically add bridge position when cutting the plate, and output laser cutting graphics. The computer-controlled laser cutting machine can cut out any complications in the sheet, while maintaining the integrity of the sheet, and the computer machete machete that matches it is accurate. The laser cutting machine cuts the slits smoothly and straight into place.

Laser typesetting has high precision in plate making, but the plate base still uses multi-layer plywood, which is easily deformed by moisture.

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 of nozzle, aperture, distance between material and nozzle, focal length of lens, position of focal point, and cutting Speed ​​and so on. The main disadvantage of laser cutting is that the laser cutting machine is expensive and the cutting cost is high, so that the production cost of the die cutting plate is relatively high. Therefore, such a die cutting plate is generally produced by a professional manufacturer, and the user directly customizes it.

3.4 High Pressure Waterjet Cutting and Typesetting

High pressure water jet cutting is used for the cutting of fiber plastic plates. If a laser cutting machine is used to cut fiber plastic plates, toxic gases and smoke will be produced. The use of a sawing machine to cut fiber plastic plates will cause wear of saw blades and generate large amounts of dust, both of which pollute the environment.

High-pressure water jet cutting uses computer to draw CAD graphics. It can also use scan entry to program the die-cutting indentation program, use high-pressure water jet cutting machine to cut the sheet, and make a die-cutting indentation plate. High-pressure water jet typesetting can control a single graphic design, automatically add the bridge position when cutting the plate, and can cut out any complicated cutting slot of the plate, while maintaining the integrity of the plate, and the computer machete machine machete matched with it is accurate. The laser cutting machine cuts the slits smoothly and straight into place.

There is no pollution when high-pressure water jet cutting fiber plastic plates. The high-pressure water beam is similar to the laser beam and can be accurately controlled by a computer. The slits are smooth and straight, accurate and in place, and the cutting quality is high. The fiber plastic plate is not deformed by the wet and the dimensional accuracy is high.

4. Plate version

After the die-cutting and indentation plate is arranged, the plate is fixed and then the die-cutting indenter can be processed.

4.1 Sticking rubber strips
After the die-cutting and indentation plate is arranged, a rubber strip is applied on the two sides of the die cutting knife, and the elasticity of the rubber strip is used to push the die-cut printing material from the knife-edge to prevent the steel knife from being jammed and affecting the operation.

Die cutting rubber strips generally divided into two kinds of hard and soft, hard rubber for thicker printing materials, soft rubber for thin printing materials, produced by professional manufacturers. In general, the rubber band should be 3 to 5 mm above the cutting edge, and the distance from the rubber line to the cutting line should be 1 to 2 mm.

If the distance between the die cutters is less than 8mm, a rubber strip with a hardness of HS600 shall be selected; if the distance between the die cutters is greater than 10mm, a rubber strip with a hardness of HS250 shall be selected. If the distance between the die cutter and the steel wire is less than 10mm, an arched rubber strip with a hardness of HS700 should be selected; if it is larger than 10mm, a rubber strip with a hardness of HS350 should be selected. The cutting position of the die cutter uses an arched rubber strip with a hardness of HS700 to protect the connection point from breaking.

4.2 Pad version

The pad plate is to lay one or more layers of paper or cardboard under the die-cut indentation plate, so that the plate steel cutter or steel wire is uniform in height and the pressure is uniform.

The die-cutting indentation plate can be freely loaded and unloaded from the embossing mechanism of the die-cutting and creasing machine, and can be exchanged or installed as required. Its positioning mechanism is very precise, and the positional accuracy is not affected by each loading and unloading. In order to obtain a uniform die-cut indentation pressure at each point of the plate's steel blade or steel wire edge, the layout should be kept flat, smooth, and clean. The method of pad plate and pad line can make the pressure even and ensure the quality of die-cut indentation.

In a pad-cut die-cut indentation plate, the difference in height between the steel blade and the steel wire is generally the thickness after the compaction of the corrugated cardboard to be die-cut.

(to be continued)