Inoue foam, what should we pay attention to when die-cutting processing?
Inoue foam die-cutting processing, should pay attention to the following items:
Tool selection
Avoid using double bevel edge cutting tool: Because of the high thickness and elasticity of foam on the well, it is easy to produce bevel edge when punching with double bevel edge cutting tool. A single-blade knife should be used to punch with straight inside and oblique outside, which can effectively reduce the occurrence of bevel edge.
Choose the cutter according to the product structure: for the foam die-cutting parts with simple structure, the methods of dividing strips, dividing edges and jumping cutting can be used to reduce the factors that produce bevel edges; For products with complex structure, the cutter line can be decomposed and punched without closing the cutter line, and multiple wires can be overlapped, so as to reduce the extrusion stress in the punching process and reduce the bevel problem.
Waste disposal
Small aperture waste discharge: when processing porous products and the aperture is small, it is difficult to extract waste due to the thick foam. The traditional ejector fixture waste disposal method is easy to scratch the foam, resulting in poor products; When the circular knife is die-cut, the extraction knife can be used to extract and discharge waste.
Asynchronous operation scheme is adopted: the upper material is pulled asynchronously and die-cut synchronously with the lower material, which not only saves materials, but also takes away the waste foam frame when the upper material belt is taken away during the operation. Moreover, due to the stress, the bevel edge will be greatly improved, and the basic dust problem can be effectively solved.
dust management
Spraying release agent: foam is composed of foamed materials because of its low toughness. Repeated action of cutting tools can easily make crumb foam particles float in the air. For die-cutting operations with clean requirements, release agent can be sprayed to reduce dust.
Composite protective film: In the production line, a layer of OPP protective film is often compounded on the surface of inoue foam, which can effectively solve the dust problem, but it will cause some waste of auxiliary materials.
Material characteristics and adjustment of processing parameters
Considering compression ratio: Different types of inoue foam have different compression ratios. For example, some products will not be cut until they are compressed to 95% of the overall thickness. When die cutting, the cutter pressure and stroke should be adjusted according to their compression ratio to ensure complete cutting without damaging materials.
Control the processing speed: if the processing speed is too fast, the friction and impact between the cutter and the foam will increase, which will easily lead to foam deformation, bevel edge and debris dust; If the speed is too slow, it will affect the production efficiency. It is necessary to adjust the processing speed reasonably according to the factors such as foam thickness, hardness and tool performance, so as to improve the efficiency while ensuring the quality.
Mold design and installation
Precise mold design: the size and shape of the mold should be accurately matched with the required foam die-cutting parts, and the compression deformation and springback characteristics of the foam should be considered in the design to prevent product size discrepancy or quality problems caused by mold size deviation.
Ensure the mold installation accuracy: when installing the mold, ensure that it is parallel to the workbench of the die-cutting machine and firmly fixed, so as to avoid the displacement or shaking of the mold during the punching process, which will affect the die-cutting accuracy and product quality.
Quality inspection and control
First article inspection: Before formal production, first article inspection is required to check whether the dimensional accuracy, shape, bevel edge, waste discharge and surface quality of die-cut products meet the requirements. If there is any problem, adjust the mold and processing parameters in time until the first article is qualified.
Process sampling inspection: sampling inspection should be carried out regularly in the production process to find and solve quality problems caused by factors such as tool wear, material change and equipment failure in time to ensure the stability of product quality.
Inspection of finished products: comprehensively inspect the finished products after die cutting, eliminate unqualified products, make statistical analysis on quality problems, and take corresponding improvement measures to improve the qualified rate and quality level of products.
