Dust and loose fibers are terms used in flat plate and die cutting to describe damage to the die-cut edge of a carton. In practice, this term means the production of loose particles and fragments, as well as the accumulation of fiber filaments, which adhere to the die-cut edges of the paperboard. 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 perform the flattening die-cutting process? In order to accurately describe the flattening die-cutting process using a steel die-cutting die, this process is defined as a moving process consisting of two progressive steps. The first step is called "blasting penetration" and the second step is called "blast separation."
In the simultaneous die-cutting process, the full length of the die cutting edge is in contact with the surface of the die cut material. When die-cutting, the die-cutting blade exerts pressure on the cardboard material. Although we describe die-cutting as a cutting process, it is more accurate to say that this is the process of breaking a cardboard under pressure. When the tool is drilled into the cardboard to the anvil pad, the cardboard surface is squeezed, stretched, and compressed. Finally, the surface of the cardboard cannot withstand the effects of these pressures, and it bursts in a "blast-penetration" manner.
The use of the term "blasting" to describe the breakage of the cardboard surface is most accurate, however, because the sharp edges of the paperboard cause a strong stretching and compressive force on the paperboard, thus causing the surface of the paperboard along the die cutting edge to collapse. After the cardboard surface is broken, the sharpness of the cutting edge is not as great as that of the previous step, because the double bevel of the tool/wedge translates the pressure in the vertical direction into the lateral movement force. When the tool penetrates into the board, the beveled surface of the tool pushes the board vertically.
Under strong fracture pressure, the cardboard was completely torn before the tool and anvil pad contacted. This "blast separation" process is divided into surface cracking, tool wedging, and paperboard breakage. Even under backward production conditions, the cardboard will still break under strong burst pressure as long as it is equipped with sharp steel cutters, smooth liners, and an optional die-cutting setup system.
What causes dust and loose fibers? Dust and loose fibers are caused by damaged die-cutting blades. The excess force causes the blade to impact the surface of the liner. As a result, the blade edge is widened so that the pressing force and the 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 to produce debris and "dust" molecules.
As the pressure on the tool increases, further compressive forces dull the blade. The cardboard is compressed and stretched beyond the normal range and its surface is broken into three pieces. From the description of this process, we can conclude that dust and loose fibers come from the cardboard surface, which is caused by the progressive damage of the die cutting edge.
How to avoid the generation of dust and loose fibers? The way to avoid this problem is to maintain the good condition of the steel blade. There are several ways to choose from, and one of them can be used alone in practice, and multiple methods can be used at the same time.
These methods are: using soft or "small thickness" die-cut liners; calibrating flat-plate die cutters to prevent excessive force; calibrating and balancing die-cutting tool pressures to ensure accurate "Z-axis control" of the cutting edge ; Use the "floating knife" method to operate the important tools in the production plan; accurately integrate the double paperboard and area repair technology into the joint repair process, so that the pressure is evenly cut.
How to perform the flattening die-cutting process? In order to accurately describe the flattening die-cutting process using a steel die-cutting die, this process is defined as a moving process consisting of two progressive steps. The first step is called "blasting penetration" and the second step is called "blast separation."
In the simultaneous die-cutting process, the full length of the die cutting edge is in contact with the surface of the die cut material. When die-cutting, the die-cutting blade exerts pressure on the cardboard material. Although we describe die-cutting as a cutting process, it is more accurate to say that this is the process of breaking a cardboard under pressure. When the tool is drilled into the cardboard to the anvil pad, the cardboard surface is squeezed, stretched, and compressed. Finally, the surface of the cardboard cannot withstand the effects of these pressures, and it bursts in a "blast-penetration" manner.
The use of the term "blasting" to describe the breakage of the cardboard surface is most accurate, however, because the sharp edges of the paperboard cause a strong stretching and compressive force on the paperboard, thus causing the surface of the paperboard along the die cutting edge to collapse. After the cardboard surface is broken, the sharpness of the cutting edge is not as great as that of the previous step, because the double bevel of the tool/wedge translates the pressure in the vertical direction into the lateral movement force. When the tool penetrates into the board, the beveled surface of the tool pushes the board vertically.
Under strong fracture pressure, the cardboard was completely torn before the tool and anvil pad contacted. This "blast separation" process is divided into surface cracking, tool wedging, and paperboard breakage. Even under backward production conditions, the cardboard will still break under strong burst pressure as long as it is equipped with sharp steel cutters, smooth liners, and an optional die-cutting setup system.
What causes dust and loose fibers? Dust and loose fibers are caused by damaged die-cutting blades. The excess force causes the blade to impact the surface of the liner. As a result, the blade edge is widened so that the pressing force and the 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 to produce debris and "dust" molecules.
As the pressure on the tool increases, further compressive forces dull the blade. The cardboard is compressed and stretched beyond the normal range and its surface is broken into three pieces. From the description of this process, we can conclude that dust and loose fibers come from the cardboard surface, which is caused by the progressive damage of the die cutting edge.
How to avoid the generation of dust and loose fibers? The way to avoid this problem is to maintain the good condition of the steel blade. There are several ways to choose from, and one of them can be used alone in practice, and multiple methods can be used at the same time.
These methods are: using soft or "small thickness" die-cut liners; calibrating flat-plate die cutters to prevent excessive force; calibrating and balancing die-cutting tool pressures to ensure accurate "Z-axis control" of the cutting edge ; Use the "floating knife" method to operate the important tools in the production plan; accurately integrate the double paperboard and area repair technology into the joint repair process, so that the pressure is evenly cut.
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