Punch-Die Geometry for Precise Creasing Plate Projections
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Solution Overview
Problem
Existing creasing machines struggle to quickly adapt to specific patterns of creases, especially when used in conjunction with digital printing, as the manufacturing time for new creasing tools is lengthy and the lifetime of these tools is often inadequate for rapid job changes.
Innovation Solution
A punching tool with a specialized die geometry that allows for the creation of creasing projections with rounded end portions, enabling precise and flexible creasing patterns. The punch has projections with varying radii to ensure smooth transitions and precise placement of creases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional etching processes are used to manufacture creasing tools, then the creasing tool has long lifetime and high precision, but the manufacturing time is very long (several hours) and cannot adapt quickly to new creasing jobs
Solution Approach 1:
The creasing tool is divided into a carrier and separate creasing projections that can be independently manufactured and then assembled. The projections are created using rapid manufacturing techniques and then attached to the carrier, allowing quick changes without re-etching the entire tool.
Solution Approach 2:
The invention changes the manufacturing parameters from traditional slow etching processes to rapid manufacturing methods such as selective laser melting or stereolithography, which can create creasing projections in minutes rather than hours, while maintaining the required precision through controlled manufacturing parameters.
2Loss of time
If plastic material is applied to form creasing projections, then the manufacturing time is shorter, but the lifetime of the creasing tool is significantly shorter than etched steel plate
Solution Approach 1:
The invention uses composite construction where creasing projections are made from materials optimized for rapid manufacturing (such as metal alloys suitable for selective laser melting) and are attached to a durable carrier. This combination allows the projections to be quickly replaced while the carrier maintains long-term durability.
Solution Approach 2:
The creasing projections are designed as replaceable components that can be manufactured quickly and economically, allowing them to be replaced when worn rather than replacing the entire tool. This approach accepts that the projections have limited lifetime but compensates through rapid, low-cost manufacturing and replacement.
3Manufacturing precision
If creasing projections are made with sharp edges, then the crease precision is high, but the transition between deformed areas is not smooth
Solution Approach 1:
The punch is designed with different geometries at different locations: the working edge maintains a sharp profile for precise crease formation, while the end portions have rounded contours with larger radii to ensure smooth transitions between deformed and undeformed areas. This local differentiation of geometric properties solves both requirements simultaneously.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables rapid manufacturing of creasing plates with precise creasing projections, allowing for quick adaptation to different creasing patterns and improving the efficiency of creasing machines, especially in digital printing environments.
Implementation Method 1
A punching tool with a specialized die geometry that allows for the creation of creasing projections with rounded end portions, enabling precise and flexible creasing patterns
Data Source
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AI summary
A punching tool comprising a punch (42) and a die (46), in particular for manufacturing a creasing plate (24), the die having a straight recess (50) for accommodating material deformed by the punch (42), characterized in that the die (46) has an outer contour which extends, adjacent the open end of the recess (50), at an angle of less than 90° with respect to the longitudinal direction of the recess (50).