When Is Ultrasonic Polishing Equipment Justified?

Ultrasonic polishing is ideal and justifiable when work on small to very small details is required.

 

Manual polishing is a very tedious process, and in particular very small intricate detail work requires additional effort and patience. Ultrasonic lapping machines, available now for quite some time, have been improved in recent years to effectively replace certain time-consuming and costly small detail hand finishing work.

 

Ultrasonic Unit Features

By comparison to conventional die profilers, as well as air-powered lapping machines that may have a stroke length of up to ¼ inch, the reciprocating action of an ultrasonic unit ranges only from .00004 to .00012 inches. However, the extremely fast reciprocating tool motion of 21,000 and up to 25,000 strokes per second provides the extra productivity and gives the polisher complete fingertip control when finishing even the most intricate ridges, slots and details.

 

Ultrasonic systems usually consist of an electronic power module (110 or 220 volt) with a slender electric cord that powers the lightweight and easy to manipulate small, ultrasonic handpiece. Commonly, an automatic power feed system in the module adjusts the frequency required to accommodate the various individual abrasive tools that are installed for the finishing process. The systems are equipped with numerous clamps that will accommodate tools ranging from small diamond files to conventional type polishing stones and/or ceramic stones and laps.

 

As with all other power tools, great care and attention should be given when working with ultrasonic machines. Because of the ultra-fast motion, tools that are overly aggressive (especially coarse diamond files, etc.) should never be used. Surfaces that must be flawless can easily be scratched and made wavy or damaged.

 

On the other hand, dense/hard, fine grit ceramic or vitrified abrasive polishing stones or laps made of brass and cast iron when used with premium diamond compound, permit the beginner to acquire a better understanding of the fast cutting powers these ultrasonic systems offer. Note: Only the most experienced operator should use diamond files or diamond stones for ultrasonic polishing.

 

Ultrasonic Applications

We need to stay objective and remind ourselves that ultrasonic polishing is not for everyone. Frequently, ultrasonic systems are perceived to take care of all polishing problems. This is not so. Ultrasonic polishing is not a cure-all for every mold and die shop that does in-house polishing. There are many polishing professionals and/or mold shops—doing mostly mid-size to large work—that may not require an ultrasonic system. In many instances, the units are simply not practical for mid-size to large type work and ultrasonic systems are not recommended to be used on larger details and surfaces exceeding a 3/8-inch square.

 

Nevertheless, ultrasonic finishing has its place in a polishing environment and it is not overstated to say that in some instances the cost of one ultrasonic system may be recouped by polishing three to four multiple cavity/core molds. For instance, an experienced individual, when working with an ultrasonic polishing machine on very small details, may reduce finishing time by as much as 40 percent and up to 65 percent.

 

In the past, there have been several good, but very expensive ultrasonic systems on the market. The name of one system may differ from the other, yet they all practically evolved from one source. However, several new models, which have been recently developed and have proved to be highly effective, as well as very affordable for even the smallest mold shop or polishing house, are now available in the marketplace.

 

Ultrasonic Advantages

Ultrasonic units with super-fast, very short strokes, provide virtual unrestricted fingertip control. By comparison, regular reciprocating tools—such as air-driven or electric flexible shaft-operated die profilers—are more restrictive in movement and less flexible to handle.

 

Nevertheless, die profilers and/or various other filing machines are great for medium to large mold details and when used at a comfortable speed range and proper stroke lengths they will provide excellent finishing capabilities.

 

Ultrasonic polishing is ideal and justifiable when work on small to very small details is required. It is safe to say that the smaller, more intricate or precise the finishing work needs to be, and/or the harder the materials are which require finishing, the more likely it is that an ultrasonic unit will improve polishing time. Subsequently, complicated heat-treated molds and dies, carbide dies or inserts and detailed punches with fine edges and very narrow slots machined by EDM are perfect for using ultrasonic polishing systems.

 

It should be mentioned here that there are other advantages that make certain ultrasonic systems a practical purchase. Meaning, various models offer dual operating capabilities where the electronic power module not only has the ability to drive the ultrasonic handpiece, but also regulate the speed and rotational direction for a variety of rotary and/or reciprocating hand tools. Having these secondary functions presents additional cost savings over single function ultrasonic units as they permit a full range of filing/reciprocating capabilities as well as rotational grinding/polishing using mounted points, burs, polishing brushes and felt bobs. Furthermore, since the rotary or reciprocating hand tools are powered with internal DC motors, the thin electrical cord provides more freedom of movement when compared to flexible shaft powered tools.

 

Summary

When selecting a supplier for this type of equipment it is most prudent to purchase from a respectable company that has been around for many years, offers good customer service and has some experience in ultrasonic polishing, which can be passed on to the customer, even via the telephone.

 

I think Best Diamond Industrial Co., Ltd. will be the most excellent choice. Besdia supplies high quality ultrasonic lapping machine and much more tools for you. Learn more information about Besida, welcome to check out the website here: www.besdia.com

 

 

Article Source: https://www.moldmakingtechnology.com/careers/when-is-ultrasonic-polishing-equipment-justified

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Excetek : The Certificate of 2017 D&B TOP 1000 SMEs Elite Award

The Certificate of 2017 D&B TOP 1000 SMEs Elite Award

Congratulations! Excetek is awarded the Certificate of 2017 D&B TOP 1000 SMEs Elite Award.

The Certificate of 2017 D&B TOP 1000 SMEs Elite Award
With 11 years of experience manufacturing Wire Cutting EDM, Die Sinking EDM, and Small Hole Drilling EDM, Excetek always sticks to the principle of trustworthy and Innovative. In 2017, Excetek has received a further recognition from Dun & Bradstreet (D&B): the Certificate of 2017 D&B TOP 1000 SMEs Elite Award.

 

This award attests to Excetek’s excellence in the industry. Excetek would like to proudly attribute this honor to all of our customers around the world. Excetek could not be growing in the EDM machines industry without our customers’ supports.

 

Dun & Bradstreet

Dun & Bradstreet was founded in 1984, and is the world’s leading source of business information and insight, with a commercial database of some 230 million enterprises around the world.

 

The award was presented to Taiwan’s top 1000 small- and medium-sized enterprises (SME), in recognition of their growth and contribution to the country’s economy. And these companies will continue to drive the local economy.

 

Learn more information about Excetek or Dun & Bradstreet, try to check out below:

 

Excetek Technologies Co., Ltd.

Website: http://www.excetek.com

 

Dun & Bradstreet

Website: http://event.dnb.com.tw/

 

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Press Brakes vs. Folding Machines – Which Is Right for You?

There is a lot happening on the fabrication floor. Often time’s conflicts arise as to which machine to use for certain jobs and this can lead to confusion.

 

While at first glance it may seem like press brake machines and folding machines are the same tool made to tackle the same jobs, the truth is that they both have their niche and should have a place in your factory.

 

Let’s take a look at the two fabrication tools and see just how alike and different they really are:

 

Press Brakes

The first thing that sets a press brake machine apart from a folding machine is the most obvious: force. The punch of a press brake uses a lot of force, which means it is geared for heavier and thicker sheets of metal. It still offers precision and accuracy, but it just does so with much more substantial sheets of metal.

 

This means that press brake machines will produce stronger pieces meant for support. Also, press brakes should probably be used for applications that only require one tooling setup.

 

Folding Machines

While folding machines also bend metal, the difference between it and a press brake is how that bend is achieved. Folding machines use much less force, leading it to be used for much thinner sheets.

 

Where the force of a press brake could potentially scratch and damage a very thin sheet, a folding machine is much more delicate and produces items where look and style are paramount.

 

Folding machines will be much better and quicker with panel work of all sizes. They are also better for jobs require multiple tooling changes.

 

Can They Coexist?

Absolutely. It can be very beneficial to have both on your fabrication floor in more ways than one. While a press brake machine can handle panel work, it is going to require more time to tackle a project that a folding could knock out more accurately and with fewer operators.

 

Folding machines can free up your press brake machine by taking on smaller, more delicate tasks and allow it to be more productive – think of it as a companion instead of a replacement.

 

Reliable Hydraulic Press Brake Machine Manufacturer

Yeh Chiun Industrial Co., Ltd. is the outstanding press brake machines supplying expert in the industry. If you are interested in learning more information about hydraulic press brake machines, do not hesitate to contact with Yeh Chiun.

 

 

Article Source: http://www.fab-line.com/press-brake-vs-folding-machine-which-is-right-for-you/

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The Utilization of Vertical Injection Molding Machines

When it comes to making items that combine light weight, durability, and pleasing shape, look and feel, there’s nothing that quite matches modern plastics. And this is especially true of hand-held items, such as small electronic appliances, where providing ergonomic shape and a grippy, easy-to-hold surface are particularly important.

 

Whether they’re GPS receivers, medical devices, toys, or even kitchen utensils, the best way to produce such items is through the process of over molding. It involves the molding of two different plastics, one on top of, or around, the other, so as to produce what amounts to a single, unified structure that’s strong on the inside yet flexible, colorful, and easy to hold on the outside.

 

Benefits of over molded plastics devices include:

 

  • More Resistant To Shock
  • More Resistant To Water
  • More Resistant To Dust And Vapor
  • More Resistant To Vibration
  • Make Devices More Comfortable To Use
  • Make Devices Just Plain Prettier

 

By now, over molding is a standard process in the injection molding industry, but some methods of executing the process is superior to others. The challenge is to make sure the two pieces, rigid substrate and outer elastomer, to fit together just so, with no gaps, no slack, no possibility of slippage and with no chance of one part pulling on and distorting the shape or integrity of the other. Getting these two molded parts to match up just right takes a good deal of skill and experience. No adhesives can be used, and there should be no manual assembly steps involved, either – it’s mainly a matter of making molds that create a perfect fit and then performing the actual molding process with extreme precision.

 

And it’s here that the right machinery also helps a great deal. Indeed, the best way to produce over-molded parts is with a vertical injection molding machine. It relies on the gentle force of gravity to clamp the inner and outer parts together.

 

That’s different from a horizontal injection molding machine, which relies on mechanical clamping, a method that requires more time and effort and raises the risk of improper fit: Gravity’s pull is always there, always trying to dislocate parts in a horizontal mold. The vertical mold simply takes advantage of gravity instead of trying to fight it.

 

Vertical injection molding equipment is designed with open clamps and rotary tables, which gives them the advantage of being able to work with multiple molds and simultaneous operations such as pre-molding, injection-, and post-molding. The result: less need for manual intervention, greater efficiency, greater productivity, and less cost. What’s more, vertical molding machines often save significant space on the factory floor.

 

In short, vertical injection molding is the method of choice when it comes to producing high-strength, high-touch parts for the electronics, medical, military, and similarly demanding industries.

 

More information about vertical injection molding machine, try to visit the website of Multiplas Enginery Co., Ltd... Multiplas is a leading industrial solutions provider that offers versatile moulding solutions, innovative design and manufactures for the production systems, and provides comprehensive technical support services to the customers committed in 3C electronics, electrical, automotive, medical / optical, and other technical moulding sectors. If you have any interest, please feel free to send inquiry or contact them directly.

 

 

Article Source: http://info.crescentind.com/blog/bid/40004/Over-molding-and-the-utilization-of-vertical-vertical-injection-molding-machines

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The Ultimate Guide to Plastic Recycling

Plastic is among the most popular and important materials used in the modern world. However, its popularity is part of the huge problem and reason why plastics should be recycled. Instead of throwing them away polluting the land and our water bodies, we can optimize the lifespan of plastics by recycling and reusing them.

 

Plastic recycling refers to the process of recovering waste or scrap plastic and reprocessing it into useful product. Due to the fact that plastic is non-biodegradable, it is essential that it is recycled as part of the global efforts to reducing plastic and other solid waste in the environment.

 

Process of Plastic Recycling

 

The following is a step by step process of plastic recycling:

 

  • Collection

 

Plastics are available in a number of forms for example plastic containers, jars, bottles, plastic bags, packaging plastic, big industrial plastics just to mention but a few. Due to their nature and availability, there are plastic collection centers and some business people have ventured into plastic collecting business as a source of income. Tons and tons of scrap plastic are collected and sent to a collecting yard where they are then packed and transported to plastic processing plants. Unfortunately, not all countries have the capacity to recycle plastic. Very few developing countries can actually recycle plastic. This means that, plastic waste is still a major problem to some countries in the world.

 

  • Sorting

 

The actual plastic recycling process starts with sorting of the different plastic items by their resin content and color. This process is also done to ensure all contaminates are eliminated. There are specially designed machines that help in sorting of the plastics according to their resin content. Then the recycling mill sorts the scrap plastic by symbols at the bottom of the plastics.

 

  • Shredding

 

After sorting the plastics, the next step is to cut the plastics into tiny chunks or pieces. The plastic bottles and containers are then ground and cut into tiny pieces or flakes. The heavier and lighter plastic flakes are separated using a specially designed machine. The separation process helps in ensuring that the different plastics are not put together or mixed up in the final product. Remember that different plastics are used to make different items.

 

  • Cleaning

 

After a complete separation, the flakes or chunks are then washed with detergents to remove the remaining contamination. Once the cleaning process is complete, the clean flakes are passed through specialized equipment that further separates the plastic resin types. The plastic flakes are then subjected to moderate heat to dry.

 

  • Melting

 

The dry flakes are melted down. They can be melted down and molded into a new shape or they are melted down and processed into granules. The melting process is done under regulated temperatures. There is specialized equipment designed to melt down plastic without destroying them.

 

  • Making of pellets

 

After the melting process, the plastic pieces are then compressed into tiny pellets known as nurdles. In this state, the plastic pellets are ready for reuse or be redesigned into new plastic products. It is important to point out that recycled plastic is hardly used to make identical plastic item or its previous form. It is in this pellet form that plastics are transported to plastic manufacturing companies to be redesigned and be used in making other useful plastic products.

 

Advantages of Recycling Plastics

 

Plastics should be recycled because of a number of reasons as can be seen below:

 

  • Provision of a Sustainable Source of Raw Materials
  • Reduces Environmental Problems
  • Reduces Landfill Problems
  • Consumes Less Energy
  • Encourages a Sustainable Lifestyle among People

 

In summary, any sort of effort aimed at saving the environment is very important and matters a lot. Since its inception during the environmental revolution in the late 1960s, plastic recycling is one of the most encouraged solid waste management programs in the world. Prior to the push to use of plastic containers by manufacturers, products were packaged in glass, metal and paper. Therefore, in order to keep our environment clean, reduce landfills, provide a sustainable supply of plastics to manufacturers, it is important to recycle plastics.

 

Song Ming Machinery Industries Co., Ltd. is a professional manufacturer of PVC pelletizing plants. They are not only reputable for its pelletizing extruders, it also has the best credentials in the plastic recycling peripherals such as granulators, mixers, ribbon blenders, and knife grinders. “Contributing to the World through Recycling plants”, it is their goal. Learn more information about waste plastic recycling plant, welcome to contact with Song Ming.

 

 

Article Source: https://www.conserve-energy-future.com/recyclingplastic.php

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No Machines Are Called Shoe Manufacturing Machines?!

Someone will need to buy shoe-manufacturing machines to make sandals, heels, and boots. However, they don’t know what they are called because running a “shoe making machine” query on Google simply isn’t working. In this article, I will tell you something about “shoe manufacturing machines”.

 

First and foremost, there is no “shoe making machine” as such.

 

Shoes are made on several machines including gluers, injection molders, sole makers, toe binders, riveters, upper stretchers, lasts, heat curing ovens, sewing machines, and more. There’s no one machine where you dump in plastic pellets, a square of leather and a buckle and a perfectly finished sandal is spit out the other end. There are lots of steps-each step requires a different machine and there’s some hand work too. Rivets are set by a worker using a riveter. Uppers are sewn by a skilled operator on a special sewing machine designed for sewing uppers. Soles are glued down and cured in a heat treater. So the machines you see are used for making shoes -even if they aren’t called “shoe manufacturing machines

 

Integral Parts of The Process in Footwear Manufacturing

 

You might want to become a bit more familiar with the tools, words and terminology and machines used in making shoes. Several fashion colleges have programs for shoe and footwear design starting with design and moving into making shoes and manufacturing processes. You will learn the way they are made and the correct words for each step in manufacturing. Speaking of words -change your search terms: you will have better luck searching for footwear manufacturing equipment and supplies. Again you will find injection molders, sewing machines, heat treaters, cement lasters, leather cutters, skivers, lasting equipment, belt solers, sanders, and band saws, welt stitchers, and more. While none are called “shoe making machines” all are integral parts of the process in footwear manufacturing.

 

To start you might want to learn custom shoemaking – this is far more doable with less investment. You can start by getting a job in a shoe repair shop and learning the equipment, how it works, what tools are essential (lasts are the most important piece of equipment and/or tool used in making shoes) what goes into making high quality shoes, and how to make and repair shoes. Or look for a custom footwear maker/seller and work there. Learning from a master is a time honored method of learning a skill. When you know what you need from seeing what the master crafts-person uses you can find the specific machinery you need.

 

Find Out The Right and Suitable Shoe Making Equipment

 

There are courses in custom footwear and shoe-making -these will help you get a handle on the tools, machinery and the process used in making higher quality footwear. Custom shoe-making can be done in an artisan workshop setting: high fashion shoes and boots made mostly by hand in small quantities can be sold for higher prices and for high profits -and with time you can start to make a name for yourself the same way people like Ferragamo and Louboutin started. Again you won’t find anything labeled “shoes making machine” but you will find lasters, stitchers and more and you will know why these machines are what you are looking for.

 

MINZ Inc. divided shoe making equipment into three parts, one is shoes cutting machine including plane type cutting machine and traveling head type cutting machine, another is cutting machine energy saving system, and the other is automation development equipment. Their average energy saving is 70~90% comparing to traditional power system. When the machine is not cutting, it generates zero noise, and the temperature of hydraulic fluid and motor are reduced half.

 

If you are interested in learning further details about related shoe making equipment, please feel free to send inquiries or contact with MINZ.

 

Article Source: https://answers.yahoo.com/question/index?qid=20130512161017AAfnama

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Recycling Baler – Why Do You Need One?

Recycling balers are one of the most useful recycling equipment designed in the recent time. As cardboard is extensively used for packaging, a large amount it comes as waste in landfills. Recycling balers help conserve the environment by crushing the cardboard and compacting large amounts into a single are Cardboard Balers which is easy to transport. Cardboard balers are basically equipment in which cardboard is fed. The press installed within the balers helps to compress the cardboard. The compressed bales are tied off before it is released. Two types of balers are largely used – horizontal cardboard baler and vertical cardboard baler.

 

Why Cardboard Balers are rising in popularity?

 

Cardboard balers are becoming hugely popular these days as it not only helps conserve environment but also help companies save a huge amount of money. Commercial establishments that are increasingly making use of recycling balers include retail outlets, restaurants, office, convenient stores, warehouses, and pharmacies. Discussed here are some of the major advantages of a cardboard baler.

 

  • Follow rules and avoid fines

    – To conserve the environment, in many countries Governments have set up rules and regulation for companies regarding waste disposal. It is suggested that the producers of cardboard’s should be responsible for the reprocessing and recycling of cardboards. A fine is imposed on companies who fail to follow such rules. In this regard, cardboard baler helps companies abide by the rules and avoid fines.

 

  • Help economize on waste disposal

    – Through the use of recycling balers, the recyclable material is compacted significantly. Companies thereby save on the cost of hauling the recyclables. Besides, if a company does not have a recycling facility of its own and decides to sell the recyclables to a recycler, it again stands to make money.

 

  • Help reduce storage needs

    – As the cardboard’s are compacted through the use of balers, they’ll occupy less space. This means companies would not need to allocate a large amount of space for keeping the baled material. This not only helps companies economize on space, which is a valuable resource but also help safeguard the life of workers through efficient material management.

 

  • Helps reduce guilt

    – Environment is everybody’s concern. Throwing a large amount of material produces guilt in the minds of sensitive human beings. However, by making use of recycling equipment such as cardboard balers, people experience a feel good factor as they get a feeling that they too are doing their small bit towards environment conservation.

 

Godswill is the professional manufacturer of recycling equipment. They can offer baling presses machine, cardboard balers, paper baler, recycling balers, and more recycling equipment with high quality and competitive price. If you need more information about recycling balers, welcome to visit their website and feel free to contact with Godswill.

 

Article Source: http://www.norcalcompactors.net/cardboard-baler-why-do-you-need-one/

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Coming Soon! The Grand Opening of Twenty-Sixth Asia Food Expo 2017

Asia Food Expo 2017 Is Opening Soon. KWT Is Also An Exhibitor in This Grand Event.

 

The Asia Food Expo now on its 26th year showcases the most comprehensive line of food machineries and equipment for the food and beverage industry; AFEX showcases the latest top of the line packaging & food processing technologies, food marking and labeling services, material handling equipment, food storage systems, baking accessories and equipment, food services supplies & equipment, coffee machineries, confectionary machineries, process control technology, quality control technologies and solutions among other. AFEX is held in conjunction with Bakery Asia and Food Service Asia.

 

Profile for Asia Food Expo exhibit includes Adhesive Systems, Bag making, Bakery materials, Beverage processing equipment, Bottling equipment, Canning machinery, Catering equipment, Cleaning machines, Confectionery products, Cooking equipment, Dairy products, Dispensing machines, Filtration & Separation equipment, Flavors & fragrances, Food packaging equipment, Hotel equipment, Kitchen equipment, Refrigeration equipment, Water treatment equipment, Weighing equipment.

https://10times.com/asia-food-expo

 

By the way, Taiwan local company KWT Machine Systems Co., Ltd. is also going to take participates in AFEX 2017. The company is famous for its bottle unscrambler, capping machine, filling machine, labeling machine, and induction sealing machine etc.

 

KWT also can provide high quality rinsing machine. They provide water and air cleaning systems, those are used in food filling applications to ensure food safety. The bottle rinser can utilize compressed air, wash liquid to clean dust or sanitize your containers prior to filling.

 

Don’t miss 2017’s Biggest Food Trade Show. For more information about Asia Food Expo 2017, welcome to click here: http://www.afex.com.ph

 

Details about KWT, check out here: http://www.kwt-auto.com/

 

KWT Machine Systems Co., LTD.

Booth: 41-D

Tel: +886-4-22773390

Fax: +886-4-22773412

Email: sales@kwt.com.tw

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Basic Introduction of Rotary Die Cutting

In today’s label production, die cutting in most cases is performed in a rotary process. Compared to flat-bed cutting, rotary cutting needs less pre-tension. The material web can be processed continuously and at high speeds. Flexible dies which are put on magnetic cylinders have been established as a standard tool. However, many factors need to be considered to create flawless die-cutting results. This article explains important basics of rotary die-cutting, which can help to prevent cutting problems.

 

Die-Cutting As The Interaction of Three Components

Label printers and converters need to produce quickly and trouble-free, in order to fulfill their customers’ high demands. Along with the printing quality, the die-cutting result is crucial for success. Very demanding customer needs, continuous developments in the material sector and time constraints – all of these factors make die-cutting a real challenge.

 

A high-quality die-cutting result principally depends on three components which must be optimally coordinated. These components are the material to be cut, the cutting unit (in rotary cutting in particular the cylinder gap), and the cutting tool. The following notes will introduce all three components in greater detail and explain their importance in successful die-cutting.

 

Rotary Die-Cutting of Labels – Label Material

First, let us take a look at the material to be cut. An infinite variety of self-adhesive labels are used in all walks of life and workplaces: food & drink, home and personal care products, medicine, pharmaceuticals, retail, office materials, logistics, automotive industry and industrial chemicals – to name just a few. The great variety of applications is a result of the multi-layered structure of the materials.

 

In the die-cutting process the face material is compressed by the tool’s cutting edge until it bursts. The silicone layer and the backing material should remain undamaged. This kind of cutting is referred to as “kiss-cutting”, and is the main application for self-adhesive label stock. It is also possible to completely cut through the whole material including the liner, for example in the production of perforations (also called “metal-to-metal” cutting).

 

Material Influences on The Cutting Process

The properties of the material have a considerable influence on the optimum design of the cutting tool: In rotary cutting, the thickness and properties of the liner material along with the gap determine the height of the cutting lines. Sometimes multi-layered materials are also used which require various heights in one tool. The cutting edge geometry (cutting angle, bevel etc.) is adjusted depending on the hardness and compressibility of the material.

 

Some materials (e.g. thermal papers) are very abrasive and lead to rapid wear of the cutting tool, which in such cases should be provided with a special coating or are laser hardened.

 

Optimal Cutting Results with Regard to Labels

In the cutting process the question is not only to detach the face material cleanly; detaching the adhesive layer is equally important so as to achieve optimum matrix stripping. The silicone layer and the liner material must remain undamaged, however. Cutting into the liner is classed as quality defects which can lead to problems in further processing of the labels (e.g. in dispensing machines). Moreover, no adhesive should leak from the sides of the labels. If the layers in the label roll stick to each other, considerable malfunctions can arise in the dispensing of the labels.

 

Apart from visual checking for obvious defects with regard to the dimensions and quality of the outer contours, what is known as an “ink test” is often used in practice to discover any damage to the silicone layer and the liner material. After stripping the matrix and detaching the labels, ink is applied to the liner and evenly rubbed in with a cloth. If the cutting has gone too deep, clear outlines will now appear. The ink test is not suitable for filmic layers, as they are not able to absorb ink. For these materials (like PET), penetration may only be discovered by light reflections from the liner.

 

Die-Cutting Unit and Gap

In rotary cutting, the material to be cut is passed through the cutting tool and the anvil cylinder in the die-cutting unit. The cylinders and the material web run at the same speed. For a high-quality cutting result, components of the cutting unit must be in perfect condition. The gap is of particular importance in rotary label cutting. To adjust the height of a flexible die perfectly to the material to be cut, the gap must be stated exactly. In Europe a standard gap of 0.480 mm (480 μm) is usual, while in North America 483 μm is common. Wear on the bearer rings and changes in the cylinders can cause the gap to vary considerably in the course of time, so that a satisfactory cutting result may no longer be achievable.

 

Deviations of ± 2 μm from the standard normally have no negative effects on the cutting result. If the gap is considerably smaller, however, the insufficient distance between the cylinders causes over-heavy cutting. Causes may be worn bearer rings or a fatigued anvil cylinder. If the gap on the other hand is considerably greater than the standard, the gap between the cylinders becomes too great and the cutting result is therefore too light. To compensate for this, a very high cutting pressure must be set; however, this puts a strain on bearer rings and bearings. If the gap varies over the width of the cylinder, the cylinders may be running out of true. There are also often combinations such as an insufficient gap on the drive side at the same time as an excessive gap on the operating side.

 

The gap and all components of the cutting unit should be checked regularly and measured to guarantee trouble-free die-cutting. Some tool manufacturers offer free gap measurements and also provide professional equipment for this task.

 

Pretension and Cutting Pressure

Along with the cylinder gap, the amount of the initial pressure (“pretension” or “preload”) in the cutting machine is critical for successful and precise cutting. The pretension needs to be greater than the resulting resistance of the material, which is mainly caused by the transversal lines. Another important factor in the cutting process is heat generation. This is caused by friction between the magnetic cylinder and the anvil cylinder during machine operation. The pressure in the cutting machine increases continuously due to this heat generation. This can lead to the cutting edges penetrating too deeply into the material and damaging the liner and wear is increased on all components involved.

 

For efficient die-cut processing, the use of a pressure control system can be very helpful. Such systems facilitate the adjustment and control of the cutting pressure. The cutting pressure can be evenly adjusted on both sides of the cylinder by means of pressure cells. If the cylinder generates too much pressure due to thermal expansion, this can be read immediately on the cell’s display.

 

Magnetic and Anvil Cylinders

The cylinders in the cutting unit are the basis for perfect die-cutting results. Magnetic and anvil cylinders must be manufactured to the highest accuracy. The manufacturing tolerances and concentricity should be only a few microns, otherwise even the most precise flexible die will not function properly. In addition, a sufficient width-circumference-ratio of the cylinder needs to be observed.

 

If rotary cylinders are sized incorrectly, there is a danger of bending. This applies especially to systems with no bridge and non-supported anvil cylinders. Dynamic forces in the cutting of transversal lines can deform cylinders. As a consequence, the cutting in the middle of the web becomes too light. A rule of thumb for magnetic and anvil cylinders is: The circumference should be at least as great as the maximum working width of the cylinder.

 

However, the cylinders must not only be very accurate and stable, but should at all times be in a perfectly clean condition. When cleaning magnetic cylinders the use of the right cleaning materials should be strictly adhered to. Some chemicals can attack the adhesive of the magnets, so that the cylinder starts to “bleed”, i.e. adhesive is exuded from the magnets, thus having a negative influence on the cutting result. For the prevention of “bleeding”, one should only use a cleaner which is recommended by a manufacturer, and the cylinders should be oiled with corrosion protection products after use.

 

The Die-Cutting Tool

Various die-cutting tools are used depending on the application, material and machine type or cutting unit. In order for the tool to be perfectly adapted for the desired purpose, all relevant parameters must be provided with the order.

 

Thanks to their many advantages, flexible dies in combination with magnetic cylinders have been established as standard in the label business. Flexible dies are not only relatively cost effective, but also shorten the set-up time at job changes, are easily replaced and their storing saves space. In order to guarantee manufacturing tolerances of a few microns, state-of-the-art CNC technology is used. The tool manufacturers offer flexible dies in various qualities and finishing options that are recommended for various applications, depending on the provider.

 

Often laser hardening is applied, which gives the cutting tip a particular stability and is therefore predestined for cutting through filmic materials in long runs. Special coatings (e.g., with nickel or chromium) protect the cutting lines from wear from abrasive materials and allow long lifetimes. Various non-stick coatings can be used against ink and adhesives residue, so that residues on the cutting edge and die surface are minimized.

 

On the other hand, solid dies (cutting cylinders) are still the first choice for some applications, e.g. when particularly voluminous materials are processed or punched parts need to be extracted. As a variant of the cutting cylinder, sheeting and slitting cylinders are equipped with interchangeable knives, which are used for tear-off or folding perforations, and other applications.

 

In contrast to flexible dies, solid dies offer the advantage that they can be repeatedly reworked and resharpened. However, solid dies are considerably more time and cost intensive to manufacture than flexible dies. Moreover, unlike with flexible dies it is not possible to undertake subsequent corrections by turning, shifting or under laying the tool.

 

Solutions for Cutting Problem

When cutting problems occur, the cause can usually be ascribed to one of the following three components. Therefore, it always makes sense to check the following points first:

 

  • Which material has been cut?

(Type and composition of the material, thickness of the liner, desired application: kiss-cutting and/or cutting-through)

  • Are cutting unit and cylinders in a flawless condition?

(Contaminants, wear, stability pretension / cutting pressure, size of gap, sufficient width-circumference ratio)

  • Is the cutting tool okay?

(Contaminants, wear, production errors)

 

In this context, the operator should always recheck the order details. A flexible die can only be manufactured perfectly, if all relevant material and machine specifications are delivered exactly and completely, along with the measurements of the labels.

 

If you are looking for ideal die cut machine, please don’t miss the website of Smooth Machinery Co., Ltd.. They are the professional flat-bed printing machine and semi-rotary machine supplier in Taiwan. Welcome to check out their product pages to obtain further details about die cut machine series. Feel free to send inquiry or contact with Smooth Machinery.

 

Article Source: http://narrowwebtech.com/dossiers/basics-of-rotary-die-cutting/

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EMO Hannover 2017 : Taiwan Excetek Technologies Is Going to Attend This Grand Event

More than 2037 exhibiting companies from 41 nations will be seen participating at EMO Hannover. With exchange of industrial knowhow and specialized networking events as the highlights of the show, the entire business community benefits from it.

 

The products and services demonstrated in this show are as follows, Turning machines, Drilling machines, Boring machines, Milling machines, Flexible manufacturing cells and systems, Transfer machines, Grinding machines, Tool grinding machines, Planning, shaping, slotting and broaching machines, Gear Cutting and finishing machines, Sawing and cutting off machines …etc.

 

Taiwan local company Excetek Technologies Co., Ltd. is also going to attend this grand event. Excetek is famous for its Wire Cutting Machine, Small Hole Drilling Machine, and EDM Machine. If you will enjoy this B2B event, try to visit the booth NO.D88 HALL13 of Excetek to obtain more information about their company and machinery.

 

Pack your bag and get ready to attend this exciting B2B event – EMO Hannover 2017. Related information please check out here: http://www.emo-hannover.de/
EMO Hannover 2017

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