Analysis of methods for preventing dust during die-cutting processing

Dust and loose fibers are the terms used in flat die-cutting. In practical operation, this term refers to the generation of loose particles and fragments, as well as the accumulation of fiber filaments, which adhere to the die-cut edges of cardboard. It should be noted that most of these particles and fibers come from the surface of the die-cut cardboard. This raises three questions:
1, How to carry out the flat pressing die cutting process? In order to accurately describe the flat pressing die cutting process using steel die cutting molds, this process will be defined as a moving process consisting of two progressive steps. The first step is called "blasting penetration", and the second step is called "blasting separation".
In synchronous die-cutting technology, the complete length of the die-cutting blade contacts the surface of the die-cutting material. During die-cutting, the die-cutting blade applies pressure to the cardboard material. Although we describe die-cutting as a cutting process, more precisely, it is the process of cardboard breaking under pressure. When the cutting tool drills into the cardboard and approaches the anvil pad, the surface of the cardboard is compressed, stretched, and compressed. Afterwards, the surface of the cardboard could not withstand the effects of these pressures, so it ruptured in a "burst through" manner.
The term "explosion" is more accurate in describing the surface rupture of cardboard, as the blade exerts strong tensile and compressive forces on the cardboard, causing the cardboard surface to collapse along the die cutting blade. After the surface of the cardboard ruptures, the sharpness of the die-cutting blade is not as great as the previous step, because the double bevel angle of the tool/wedge converts the pressure in the vertical direction into lateral movement force. When the cutting tool penetrates into the cardboard, the slanted surface of the tool pushes the cardboard vertically towards both sides.
Under strong fracture pressure, the cardboard is completely torn before the cutting tool and anvil pad come into contact. This "explosive separation" process is divided into surface fracture, tool wedging, and cardboard fracture. Even under backward production conditions, as long as equipped with sharp steel cutting tools, smooth backing plates, and optional die cutting setting systems, cardboard can still fracture under strong blasting pressure.
2, What causes dust and loose fibers? Dust and loose fibers are caused by damaged die cutting blades, and excess force causes the blades to impact the surface of the backing plate. This widens the blade, greatly increasing the squeezing and stretching forces applied to the surface of the cardboard. The cardboard is further compressed, and the tension gradually increases until the cardboard breaks. This process applies too much force, producing fragments and "dust" molecules.
As the pressure on the tool increases, further compression force causes the blade to become blunt. The compression and stretching of the cardboard exceeded the normal range, and its surface broke into three pieces. From the description of this process, we can conclude that dust and loose fibers come from the surface of the cardboard, and their cause is the progressive damage of the die-cutting blade.
3, How to avoid the generation of dust and loose fibers? The way to avoid this problem is to keep the steel blade in good condition. There are several methods to choose from, and in practical operation, one can be used alone or multiple methods can be used simultaneously.
These methods use soft or "small thickness" die cut backing plates; Calibrate the flat die-cutting machine to prevent excessive force; Calibrate and balance the pressure on the die-cutting tool to ensure blade precision