1. Drawing
The die-cut drawing is an unfolded view of the full-page carton after the printing process, and is the first key link in the production of die-cut plates. In the printing plate-making process, if a full-page imposition system is adopted, the die-cutting diagram can be directly output in the printing plate-making process, which can effectively ensure that the printing plate and the die-cutting plate have unified standards. If you are using manual film imposition in the carton printing plate process, you need to draw the die-cutting diagram according to the actual size of the typesetting in the die-cutting plate-making process. In the process of drawing die-cutting drawings, the position of the die-cutting knife and the position of the creasing line should be clearly marked according to the national carton drawing standards. In order to ensure that the die-cutting plate is not scattered during the plate making process, the graphics part should be closed in a large area. Do not cut off more than two places. This position is usually called a bridge. The width of the bridge can be designed to be 3-6 mm for the small version and 8-9 mm for the large version.
2. Cutting template
The materials used in the formwork are wood multilayer plywood, high-density board, bakelite, etc. Currently, wood multilayer plywood is commonly used. The thickness of wood multilayer plywood is about 18 mm, and the durability of wood used plywood is high.
According to different cutting methods, there are sawing machine cutting template and laser cutting template.
Sawing machine cutting is now the main processing method for stencil thread seam processing. The work of the sawing machine is to use the up and down movement of the saw blade to process the narrow slit for the die cutter and the indentation line on the stencil with a special ultra-narrow saw blade. The thickness of the saw blade is equal to the thickness of the die cutter or indentation line at the corresponding position. The commonly used saw blade has a thickness of 0.7-2.0mm and a width of 1.5-3.0mm. The saw is equipped with an electric drill, which can be drilled on the template. After drilling, You can cut through the saw blade through the hole on the plate.
The laser cutting die-cutting plate is carried out on a laser cutting machine controlled by a computer. It is a method in which the laser is used as an energy source to cut the template material through the high temperature generated by the laser. To perform laser cutting, you first need to input the entire die cutting diagram into the computer, and the computer controls the movement of the die cutting board relative to the laser head for cutting. Because laser cutting uses computer control, the cutting precision of die cutting plate is very high. However, there are many factors that affect the cutting quality in the cutting process, so in actual production, it is extremely important to use previous experience to determine the processing effect. The main disadvantage of laser cutting is that the laser cutting machine is expensive, and it is usually customized by professional manufacturers.
3. Install die cutter and creasing line (row knife)
After the template cutting is completed, the die cutting knife and the indentation line should be installed according to the relative position of the die-cutting carton. In order to ensure the quality of die cutting, the die cutting knife and the indentation line of better quality should be selected first. We first introduce the die cutting Knife, the die-cutting knife series products listed in the table below, introduce the specific performance and application of various standard die-cutting knife and special die-cutting knife in detail.
The die cutter is divided into soft knife and hard knife according to the hardness. The soft knife does not mean that the blade is soft, but the blade body of the die cutter uses a lower hardness HRC35, and the hard knife is hardened to the edge Hardness HRC56, the entire soft knife line can be bent to a smaller arc and radius; the hard knife refers to the die hardening knife is hardened to HRC45, and the knife body has higher strength.
According to the shape of the cutting edge, die-cutting knives include standard knives and double-knife knives. When die cutting cardboard with a thickness greater than 0.5mm, it is recommended to use a bimodal knife. This knife has two inclined blades, which can effectively reduce the negative effect of the two convex surfaces. And the cutting edge is exceptionally sharp, making it easy to cut into cardboard.
When choosing a high-quality die-cutting knife, pay attention to the cross-grain treatment or straight-grain treatment of the blade peak. The cross-grained knife is better for die-cutting paper, more durable, and has higher stability and accuracy, and is not easy to crack after bending .
Indentation line series products The indentation line is used to complete the indentation at the folding position of the carton on the die-cutting plate. The thickness of the indentation line is commonly 0.7mm, 1.42mm, 2.13mm, etc. The height of the indentation line is 22-23.8mm.
The selection principle of the indentation line is: the thickness of the indentation line is greater than the paper thickness. The height of the indentation line is equal to the height of the die cutter minus the paper thickness and minus 0.05-0.1mm.
4. Open connection point
In die-cutting plate-making, opening the connection point is an indispensable process for opening the surface. The connection accounted for is that a small width of the die-cutting knife edge is cut out. During the die-cutting process of the carton, the part of the carton and the waste edge are made In the place where the die-cutting is still partially connected, the carton and the waste edge after the die-cutting are not separated, so that the next step of paper feeding and paper receiving is smooth.
Special equipment should be used for opening the connection point: a knife-line punching machine, grinding the connection point with a grinding wheel, not using a hammer and a chisel to open the connection point, otherwise it will damage the knife line and the corner, and it is easy to produce burrs at the connection point . Do not open the connection point at this position because the die cutter is crossing the bridge.
There are 0.3, 0.4, 0.5, 0.6, 0.8, 1.0mm and other specifications for the width of the connection point, and the usual common specification is 0.4mm. The connection point is usually placed in a hidden place that is not visible in the molded product. The smaller the connection point in the appearance after molding, the better, to avoid affecting the appearance of the finished box.
5. Sticky sponge tape
After the die-cutting plate is installed, in order to prevent the die-cutting knife and the indentation line from sticking to the paper during die-cutting and indentation, and to make the paper run smoothly during die-cutting, elastic die-cut rubber strips should be pasted on both sides of the knife line . The role of die cutting self-adhesive strips in die cutting is very important, it directly affects the speed and quality of die cutting. On different die-cutting machines, it is very important to select die-cut strips of different hardness, size, and shape according to the speed of die-cutting, die-cutting live parts and related conditions.
Die-cut rubber strips are divided into standard rubber strips, hard rubber strips and extra-hard rubber strips according to hardness. Die-cut rubber strips need to be selected with different hardness according to different bonding positions.
The die-cut rubber strip will be compressed and deformed when it is used for die-cutting. If the die-cut rubber strip is too close to the knife line, it will cause the lateral force of the rubber strip when it is compressed, which is easy to damage the connection point of the paper or the paper line. When die cutting, the paper edge is roughened, which affects the effect of die cutting; if it is too far away from the hair cutter, it will not have the effect of preventing the cardboard from sticking to the knife. The ideal distance between the die cutting strip and the knife line is between 1-2mm.
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. When the trial cutting is performed, the trial cut sample is partially normal, and when part of it is not cut through, the pad should be carried out in the local range . The backing plate is pasted with 0.05mm thick backing paper on the bottom of the die-cutting plate to compensate the height of the die-cutting knife. When there are still individual blades that are not die-cut after the partial pad, the position pad should be carried out. The position pad is directly glued to the bottom of the die cutter with narrow strips of pad paper to compensate for the height of the knife line.
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