How to prevent dust in die-cutting process

May 14, 2021
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As we all know, die-cutting dust is a common problem in current carton production. This paper reveals the reasons and puts forward several feasible solutions.


As flat die-cutting terms, dust and loose fibers refer to describe carton die-cutting edge damage. In practice, this term shows the production of loose particles and fragments, as well as the accumulation of filaments, which adhere to the cutting edge of the cardboard. It should be noted that these particles and fibers are mostly from the surface of the die-cut cardboard. This raises us questions from the following three aspects:


◆How does the flat die cutting process being carried out?

◆What causes the dust and loose fibers?

◆How to prevent the generation of dust and loose fiber?





How does the flat die cutting process being carried out?

In order to accurately describe the use of flatted die - cutting process which the die – cutting tools are made of steel, this process will be defined as a mobile process, consisting of two gradual steps. The first step is called "blasting penetration" and the second step is called “blasting separation”.


In the synchronous die - cutting process, the complete length of the die - cutting blade contacts the surface of die - cutting material. In die-cutting, the die-cutting blade will pressure on the cardboard material. Though this process is described as a cutting process, more specifically, this is a breaking process of a cardboard under the pressure. When the cutter goes into the cardboard where is more closed to anvil pad, the cardboard surface is squeezed, stretched and compressed, that fails to bear these pressures, finally get ruptured in the name of blasting penetration.


The word "blasting" is an accurate way to describe the rupture of the cardboard surface. Because the blade will put strong extension and compression force on cardboard, giving rise to cardboard surface collapse along the die cutting edge.

After the cardboard surface rupture, the sharpness of die - cutting blade is not the same as the previous step. Because the tool's double bevel angle will convert the pressure that in the vertical direction to the lateral force. When the cutter enters the cardboard, the bevel surface of the cutter pushes the cardboard vertically to both sides.


Under the strong breaking pressure, the cardboard was completely torn before the cutting tool and anvil pad came into contact. The “blasting separation” process consists of surface rupture, cutter wedge and cardboard breaking.




What causes the dust and loose fibers?

Dust and loose fibers are caused by damaged die - cutting blades. The extra force causes the blade to hit the surface of the pad, widening the blade, in this way the cardboard extrusion and extension force on the surface of is greatly increased. The cardboard is further compressed, and the tension is slowly increased until the cardboard breaks, which is too hard, creating scraps and dust.


As the pressure increases, further compression forces blunt the blade. Cardboard compression and extension surpass the normal range, its surface cracked into three pieces.

From this process, we can draw the conclusion: dust and loose fiber come from the cardboard surface, the reason is the progressive damage of the die cutting blade.


How to prevent the generation of dust and loose fiber?




The way to avoid this problem is to keep the steel blade in good condition. There are several methods to choose from. In practice, one can be used, or several methods can be used simultaneously.

Use soft or all thickness of die - cut pad.


Calibrate the die - cuter to prevent excessive pressure

Calibrate and balance the pressure on the die - cutting tool to ensure accurate “Z - axis control” of the blade

The important tools in production planning are operated by “floating cutter”


The double cardboard and area patching technology are precisely integrated into the joint patching process to make the die cutting uniform.



The dust particles and loose fibers are directly related to the condition of the cutting blade. At the same time, some effective prevention and remedial measures can be used to avoid and reduce this kind of problem.