The die-cutting and creasing process is a process in which the stencils arranged by steel knives and steel wires are used to roll and cut the printed matter under the influence of pressure. The processing effect is that the surface of the printed matter has both deformation (indentation) and fission (die cutting).
The production of die-cutting plates, commonly known as row-knife, refers to the technological operation process of assembling steel knives, steel wires, lining materials, etc. into die-cutting plates according to the prescribed requirements. The general process of making a die-cut version is as follows:
Draw the outline of the die-cut version → cut the bottom version → cutting the steel knife steel line → composite imposition → open the connection point → stick the sponge rubber strip → try cutting the pad version → make the indentation bottom touch → try die cutting and signing
1. Draw the outline of the die-cut version
First, the die-cut layout should be designed according to the requirements. The layout design tasks include: (1) determine the size of the layout, which should match the specifications and working ability of the selected equipment; (2) determine the type of die-cut layout; (3) Select the materials and specifications of the die-cut version. The designed layout should meet the following requirements, that is, the grid position of the die-cutting plate should match the printing grid position; the working part should be located in the center of the die-cutting plate; the transplantation of lines and graphics should ensure the accuracy required by the product; the layout knife line To be straight, the vertical and horizontal blade lines are at right angles to each other and parallel to the side of the die-cut plate; the broken blades and broken lines should be aligned, etc.
The outline drawing of the die-cut version is an unfolded view of the full-page product, and is the first key link in the production of the die-cut version. If the printing adopts a full-page imposition system, the outline of the die-cut plate can be directly output during the printing plate-making process, which can effectively ensure the unity of the printing plate and the die-cut plate. If the printing uses manual film imposition, it is necessary to draw the outline of the die-cut version according to the actual size of the typesetting. In the drawing process, in order to ensure that the die-cut version is not scattered during the plate-making process, a number of "crossing bridges" should be left in the large-area closed graphics section. The width of the bridge can be designed to be 3 mm to 6 mm for the small version. For large blocks, 8 mm to 9 mm can be set aside. In order to make the steel knife and steel wire of the die-cutting plate have a good die-cutting suitability, the following issues should be paid attention to in product design and layout drawing:
1. The cutting line of the slotted opening should be as full as possible, and the corners of the line should be rounded to prevent the splicing of mutually perpendicular steel knives.
2. At the joint of the two lines, sharp corners should be prevented.
3. To avoid the connection of multiple adjacent narrow waste edges, the connection part should be enlarged to make it into a piece, which is convenient for cleaning.
4. To prevent continuous sharp corners, sharp corners without functional requirements can be changed to rounded corners.
5. Prevent the sharp angle line from ending in the middle of another straight line, which will make it difficult to fix the knife, easy to loosen the steel knife, and reduce the adaptability of die cutting. It should be changed to an arc or increase the angle of encounter.
2. Cutting template (slotted)
Commonly used lining materials (base plates) of die-cutting plates are metal lining materials and non-metallic materials; multi-layer plywood is the most used, and the thickness of plywood is generally 18 mm to 20 mm. The cutting of the bottom plate (lining material) mainly includes sawing machine cutting and laser cutting.
Saw cutting is currently the main method for small and medium-sized enterprises to process die-cutting plates by themselves. The work of a sawing machine is to use a special saw blade to move up and down to process a narrow slot on the base plate that can be equipped with a steel knife and a steel wire. The thickness of the saw blade is equal to the corresponding position of the steel. The thickness of the knife and steel wire. The sawing machine is equipped with an electric drill, which can drill holes on the base plate. After drilling, the saw blade is passed through the base plate and then cut. The current sawing machines have rich specifications and perfect functions according to different occasions and types of plate-making. Some sawing machines are equipped with a vacuum system, which can automatically collect the sawdust, the saw blade can be electrically clamped, and some large-format sawing machine worktables. Also equipped with air floatation system. Can make large-scale sawing light and flexible. In recent years, CAD / CAM technology has also been used in the production of die-cutting plates. The principle is to use CAD / CAM technology and computer control technology to control the sawing machine to complete the cutting, and the quality of the slot has been greatly improved.
Laser cutting is carried out on a laser cutting machine controlled by a computer. It uses the laser as an energy source to cut the master material through the high temperature generated by the laser. To perform laser cutting, you first need to input the full-page die-cutting profile into the computer, and the computer controls the movement of the base plate, and the laser is used for cutting. However, there are many parameters required in the cutting process, such as material quality parameters, sheet thickness, laser output power, type and pressure of auxiliary gas, nozzle diameter, aperture, distance between material and nozzle, focal length of lens, focal position And the cutting speed. Therefore, in actual production, it is extremely important to learn from past experience to determine the processing effect. The main disadvantage of laser cutting is that the laser cutting machine is expensive and the cutting cost is relatively high, which makes the die-cutting plate production cost higher. Therefore, this die-cutting plate is generally produced by a professional manufacturer and directly ordered by the user.
3. Forming and combined imposition of steel knives and steel wires
First of all, the steel knife and steel wire should be cut and formed, that is, the steel knife and steel wire should be cut and bent to the corresponding length and shape as required. There are generally two methods to complete this process: manual stand-alone forming and automatic bending machine forming.
The special equipment for manual single-machine forming processing mainly includes blade cutting machine, blade forming machine (bending machine), blade punching machine (bridge cutting machine), blade angle cutting machine, etc. Among them, the blade cutting machine is used to cut the length of the steel knife and the steel wire; the blade forming machine (bending machine) is used to accurately shape the arc or angle of the steel knife and the steel wire; the blade punching machine (over-bridge cutting Power machine) is used for punching the knife and line of the bridge; the blade angle cutter is used for the cutting angle of the steel knife at the intersection of the knife and line (to ensure effective cutting). This processing method has a slow speed, low production efficiency, can not process fine and complex graphics, poor repeatability, and has a great dependence on the proficiency and technical level of labor; but the cost is relatively low, suitable for low-quality, tight schedule molds Cutting plate processing.
The forming process of automatic bending machine is a forming method of steel knife and steel wire which has gradually emerged in recent years. It is generally used in conjunction with laser cutting machine to complete the production of die-cutting plate. The fully-automatic computer numerical control bending machine integrates cutting, bending, punching, and cutting angle into one machine, which can be said to be a qualitative leap in the bending knife process. The graphics of the scimitar used in the automatic scimitar are directly taken from the graphic design of the product. When working, you only need to transfer the graphic and input the quantity to be formed, and the machine can complete the scimitar shaping. During processing, the blade is sent into a special channel, which holds the blade tightly, and it is described as running smoothly and accurately. The machine can accept straight cutting lines, but it is best to use package cutting lines, which can increase the speed and save materials.
After the steel knife and steel wire are formed, it is required to place the cut base on the plate table during installation, place the back of the processed knife line downward, align it with the corresponding base plate position, and hit the upper part with a special knife die hammer Cutting edge, insert it into the template. When hammering, you must use a special knife die hammer or wooden hammer. The head of the knife die hammer is made of high-elastic rubber. When you hit the edge of the knife line, you can ensure that the edge is not hurt. In recent years, automatic loading machines have also appeared, which has greatly improved the speed and quality of knife loading.
The forming process of automatic bending machine is a forming method of steel knife and steel wire which has gradually emerged in recent years. It is generally used in conjunction with laser cutting machine to complete the production of die-cutting plate. The fully-automatic computer numerical control bending machine integrates cutting, bending, punching, and cutting angle into one machine, which can be said to be a qualitative leap in the bending knife process. [next]
Four, open the connection point
In the process of die-cutting plate making, opening connection points is an indispensable process. The connection point is a small width of 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 entire printed sheet after die-cutting and does not spread out, so that the next paper is smoothly fed.
The special equipment that should be used to open the connection point is a knife line puncher, that is, grinding with a grinding wheel, without using a hammer and a chisel to open the connection point, otherwise it will damage the knife line and the feet, and easily produce burrs at the connection part. The width of the connecting point has different specifications such as 0.3mm, 0.4mm, 0.5mm, 0.6mm, 0.8mm, 1.0mm, etc. The commonly used specification is 0.4mm. The connection point is usually placed in a hidden place that is not visible to the molded product. The connection point of the appearance after molding should be as small as possible to avoid affecting the appearance of the finished product. In addition, care should be taken not to open the connection point at the bridge crossing position (the die cutter at the bridge crossing position is suspended).
5. Paste sponge tape
After the steel knife and steel wire are installed, in order to prevent the die cutter from sticking to the paper during die cutting and indentation, and to make the paper flow smoothly, stick elastic sponge tape on both sides of the knife line. The role of elastic sponge strips in die cutting is very important, it directly affects the speed and quality of die cutting. Generally speaking, the sponge tape should be 3mm ~ 5mm higher than the die cutter. On different die-cutting machines, sponge strips with different hardness, size and shape should be selected according to the die-cutting speed, die-cutting live parts and various related conditions. The following principles can be followed when choosing elastic sponge tape specifically:
1. Rigid sponge strips are mostly placed in the gaps at the lower edge of the die cutting blade, and soft sponge strips are mostly placed under the die cutting knife or in the gap between the die cutting knife and the die cutting knife.
2. If the distance between the die-cutting forces is less than 8mm, a sponge strip with a hardness of HS600 should be selected.
3. If the distance between the die-cutting knives is greater than 10mm, sponge rubber strips with a hardness of HS250 (corrugated cardboard) or 350 (cardboard) should be selected.
4. If the distance between the die-cutting knife and the steel wire is less than 10mm, you should choose an arched sponge rubber strip of hardness HS700; if it is greater than 10mm, you should choose a sponge rubber strip of hardness HS350.
5. The arched sponge rubber strip with hardness of HS700 is used at the punching position of the die-cutting knife to protect the connecting point from being pulled off.
6. The ideal distance between the die cutting strip and the knife line is 1mm ～ 2mm.
6. Trial cutting pad
After the die-cutting plate processing is completed, the die-cutting plate must first be installed on the die-cutting machine for trial cutting. Pressure ". The backing plate is to use 0.05mm thick backing paper to stick to the bottom of the die-cutting plate to compensate the height of the die-cutting knife. When there are still individual knife lines die-cutting after the partial backing plate, the position backing plate should be carried out. The position backing plate is directly adhered to the bottom of the die cutting knife with a narrow strip backing plate to compensate for the cutting line height. This process also has a direct impact on the quality and speed of die-cutting, and has higher requirements on the experience and technology of the operator.
Through the above several processes, the production of die-cutting plates is basically completed, and the finished die-cutting plates can be produced on the machine, but before formal production, they must also go through "making indentation roots (to facilitate the formation of indentation, commonly used Methods include manual sticking die method and indentation die method), trial die cutting, customer signing "and other processes before formal production can be carried out.
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