Analysis Of Common Problems in Foam Die-cutting Processing!

Foam type die-cutting products are widely used in various industries nowadays, but foam die-cutting processing also encounters problems with other materials. This article mainly focuses on the problems encountered during foam die-cutting and punching processing, as well as why it is necessary to choose a knife die for foam material die-cutting processing!
Firstly, let's understand the classification of foam. Foam can be referred to as a general term for foam materials, which are generally divided into two types: foam and sponge; And there will be many different materials under the corresponding two categories.
When die-cutting, foam materials all have the same characteristic, that is, foam materials are relatively soft compared to other materials, which may cause varying degrees of deformation during foam processing. Therefore, when using foam materials for processing, adhesive backing is generally used.

The commonly used foam materials during die cutting processing include: PORON, EVA, EPDM, EPE, CR, sound-absorbing foam, PU foam, etc.
Common problems with foam die-cutting processing include:
1. Die cutting deformation: Due to the softness of foam, it is easy to flatten the foam before cutting it during punching. Generally, knife molds have inner and outer parts. When the internal pressure is greater than the external pressure, it will cause deformation of the punching cross-section, sometimes resulting in concave or inclined situations. The correct foam has a straight cross-section after punching. If the cross-section cannot be punched well, it is bent.
2. Waste discharge issue: If it is necessary to discharge waste while punching and cutting foam, water cutting or two knife cutting methods can generally be chosen; However, these two methods mainly depend on the selected cutting die and the operator's skills, and are generally achievable.
In the die cutting processing industry, most manufacturers choose die cutting molds that are mostly knife molds. Water cutting and two knife set cutting are relatively less common. There are mainly the following issues.
Problems with water cutting:
1. High cost, twice the cost of the cutting die;
2. The production capacity is low, only one tenth of that of the cutting die.
There is a problem with the two knife set cutting:
A common problem is a high defect rate, which is due to the inability to fit the two knives together during the cutting process.