US3690199A - Chemical honing of dies - Google Patents
Chemical honing of dies Download PDFInfo
- Publication number
- US3690199A US3690199A US80831A US3690199DA US3690199A US 3690199 A US3690199 A US 3690199A US 80831 A US80831 A US 80831A US 3690199D A US3690199D A US 3690199DA US 3690199 A US3690199 A US 3690199A
- Authority
- US
- United States
- Prior art keywords
- dies
- lands
- cutting
- die
- sharp
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
- B23P15/28—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass cutting tools
- B23P15/40—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass cutting tools shearing tools
- B23P15/406—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass cutting tools shearing tools rotary or plane die cutters
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23F—NON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25
- C23F1/00—Etching metallic material by chemical means
- C23F1/02—Local etching
Definitions
- This invention relates to the field of cutting and creasing dies and, more particularly, to an improved process for making such dies.
- This process provides a layer of resist on top of the areas to be produced as lands and lays bare the material between the lands so that it may be subjected to an acid etching treatment. An etching solution is then applied to remove some of the exposed material.
- This etching action often causes undercutting of the land area below the resist material thereby leaving an overhang of resist at the top edges of the land and further tending to slightly undermine the land. Because of this undercutting, the ideal cutting land is seldom produced and, instead, lands are formed which have rather sharp top edge corners.
- these corners tend to lock themselves into the cut edges of the carton until such time as the dies have been broken in sufficiently to wear off the edges.
- a typical break-in period for such dies may vary from 2 to 8 hours depending on various factors such as complexity of the layout, the type and thickness of the material being cut and the depth of etch of the dies. During this break-in period, the machine is required to run at speeds less than its nor mal operating speed thereby substantially reducing its productivity. Moreover, if any of the broke between the cartons sticks in the dies, it is necessary to shut down the machine to remove this broke.
- the cutting and creasing dies will be produced by conventional chemical milling processes but, in addition, a chemical honing step will be employed to remove the sharp corners created by the undercutting of the land area below the resist material.
- a chemical honing step will be employed to remove the sharp corners created by the undercutting of the land area below the resist material.
- FIG. 1 is a fragmentary cross-sectional view 'of cutting cylinders having a pair of dies and paperboard sheet being cut thereby;
- FIG. 2 illustrates a portion of a sheet with a carton layout as it would appear immediately after having been out between the dies mounted on the cylinder of FIG. 1;
- FIG. 3 is an enlarged cross-sectional view of an ideal pair of dies cutting sheet material therebetween, illustrating a type of preferred but not readily obtainable cutting lands;
- FIG. 4 is a view similar to FIG. 3 illustrating the type of lands frequently produced heretofore in the process of making such dies and showing what occurs to the cartons and broke prior to completion of the die breakin period;
- FIG. 5 is a view similar to FIG. 4 showing dies which have been produced in accordance with the present invention to remove their sharp land corners thus enabling them to be immediately operated at full speed when installed on a machine.
- FIG. 1 illustrated in FIG. 1 are dies of the type with which this invention is concerned which are mounted on a pair of cylinders 10 and 11.
- the dies are supported on the cylinders by conventional mounting means which are illustrated herein as bolts 12,13.
- the dies are mirror image flexible steel plates constituting a female die 14 and a male die 15.
- the female and male dies 14 and 15 respectively receive their designation from the fact that the female die 14 has a pair of spaced scoring lands 16 between which is received a male scoring land 17.
- the lands l6 and 17 form what are commonly called a crease or score, illustrated as a pair of parallel lines 18 on a sheet 19 of paperboard or the-like.
- Cutting lands 20 and 21 on the dies 14,15 perform what has come to be known as a rupture cut, which is illustrated in FIG. 2 as the cut lines 22.
- the sheet 19 is gripped between gripper fingers 23 and gripper posts 24 along its entire lead edge.
- a plurality of such posts are provided on cylinder 11, it being understood that the sheet was accurately registered to the cylinders prior to being taken by the gripper fingers and gripper posts in a conventional manner. It will be appreciated that as the cylinders 10,11 rotate, the sheet 19 is carried along by the cylinder 11 and the lands 20,21 cooperate to provide the cut lines 22 and the lands 16,17 cooperate to form the crease or score lines 18.
- a sheet which has been cut in the nip between the cylinders and 11, normally comprises cartons 25 which have common" cut lines 26 and 27 for minimization of waste.
- Small pieces of internal broke or scrap 28 together with external lead edge broke 29 and side edge broke 30 are produced by the cutting and creasing operation.
- This broke 28, 29 and 30 may be removed down stream from the cutting nip in any known manner, one such method being shown in U. S. Pat. No. 3,410,183 issued to A. J. Sarka on Nov. 12, 1968.
- this broke frequently causes a problem by being compressed into a small area between sharp edges of the cutting lands as will be discussed hereinafter.
- FIG. 3 illustrates the preferred or ideal shape of two cooperating pairs of cutting lands as a small section of broke 28a is cut between a pair of adjacent cartons 25. Lands having the illustrated configuration minimize the potential for sticking of the broke 28a in the etched recess 14a between the cutting lands. Moreover, there would be a minimum amount of sticking of cartons 25a to the lands 1150, thus, facilitating removal of the sheet as it is released by the grippers 23 upon exit of the sheet from the cutting nip. It will be noted in FIG. 3 that the cut lines between the broke 28a and cartons 25a are at an angle relative to the surface of the sheet. This is typical of the rupture cutting process in which there is a slight overlap of 0.002 to 0.004 inch between cooperating pairs of cutting lands. This overlap or negative clearance is illustrated by the letter x in FIG. 3.
- the dies 14 and are made of steel and are produced by a chemical milling process.
- This process involves the removal of portions of a thin metal plate by chemical means to form the background or depressed areas of the plate leaving the scoring and cutting edges standing above the background areas. These cutting and creasing edges or lands are small in cross-section, often rising above the plate only about 0.020 inch.
- An etching solution of an appropriate acid is used to remove the portions of the metal plate.
- the steel plate Prior to the etching, the steel plate is provided with a pattern of the lands by coating the plate with a resist material which is hardened in selected areas by exposure to an image of the desired land layout. This may be done in accordance, for example, with U. S. Pat. No. 3,341,329 issued to T. H.
- the photographic process and developing prior to the etching provides a layer of resist material on top of the areas to be produced as lands and lays bare the material between the lands so that the exposed material may be subjected to an acid treatment for the chemical milling action.
- the spraying action on hitting the die, tends to move some of the etching acid parallel to the surface of the dies thus enhancing the tendency toward undercutting of the lands.
- the result of this undercutting action is to leave an overhang of resist material at the top edges of the land and further tends to slightly undermine the land, the magnitude of which depends on factors such as the depth of the etch, the type of acid used and the fluid pressure with which the acid may impinge on the steel material.
- the resist material be removed from the lands after the die has been completely etched.
- This can be accomplished by the use of a suitable stripping solution applied in a manner known in the chemical milling art. As is well known, the particular solution used depends on many factors including the thickness of the coating and whether the coating has been post baked.
- a quick pass of the etching spray to provide what may be termed a chemical honing of the die. This pass of the etching spray will have little or no effect on the flat surfaces of the die but it will be effective to remove the sharp undercut corners illustrated at 32b and 33b in FIG. 4. Thus, the etching solution will etch" the corners to round them off as shown at 32c and 330 in FIG. 5.
- a die produced with this additional chemical honing step now has a land profile which more nearly approaches that of one which has been broken-in by several hours of machine operation on sheet material.
- chemically honed dies have been proven to be effective in enabling the immediate operation of the machinery on which the dies are installed at normal operating speeds rather than having to run them in for several hours at lower speeds.
- a method for producing a cutting and creasing die having cutting and creasing lands thereon by a chemical milling process which includes exposing a resist coated surface of the die to a photographic image of the desired land layout, developing the exposed resist to harden the resist in the areas of the lands and to expose other areas of the die and applying an etching solution to the exposed areas of the die thereby to remove some of the metal, said method comprising the steps of:
- step of removing the sharp edges comprises the step of chemically removing said edges.
- step of removing the sharp undercut edges of the lands comprises the step of passing a spray of the etching solution across the surface of the die.
- a method of removing the sharp edges from undercut areas of a resist pattern on a chemically milled article comprising the steps of:
- step of applying the etching solution comprises the step of passing a spray across the surface.
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Perforating, Stamping-Out Or Severing By Means Other Than Cutting (AREA)
Abstract
Description
Claims (4)
- 2. The method of claim 1 wherein said step of removing the sharp edges comprises the step of chemically removing said edges.
- 3. The method of claim 1 wherein said step of removing the sharp undercut edges of the lands comprises the step of passing a spray of the etching solution across the surface of the die.
- 4. A method of removing the sharp edges from undercut areas of a resist pattern on a chemically milled article comprising the steps of: removing the resist material from the undercut areas to expose the surface therebeneath, and applying an etching solution to the exposed surface of the undercut areas thereby to remove the sharp edges.
- 5. The method of claim 4 wherein the step of applying the etching solution comprises the step of passing a spray across the surface.
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US8083170A | 1970-10-15 | 1970-10-15 |
Publications (1)
Publication Number | Publication Date |
---|---|
US3690199A true US3690199A (en) | 1972-09-12 |
Family
ID=22159890
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US80831A Expired - Lifetime US3690199A (en) | 1970-10-15 | 1970-10-15 | Chemical honing of dies |
Country Status (1)
Country | Link |
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US (1) | US3690199A (en) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4294649A (en) * | 1979-11-05 | 1981-10-13 | Sarka Albert J | Method of making die plates |
US20040020328A1 (en) * | 2002-07-30 | 2004-02-05 | Chin-Tu Wang | Method for manufacturing cutter mold |
DE102010014430A1 (en) * | 2010-04-03 | 2011-10-06 | Smurfit Kappa Rapidcorr Euskirchen Gmbh | Process for the continuous production of a corrugated cardboard web and of corrugated board formats cut to it in the course of their production, and corrugated board production plant for carrying out the process |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3170342A (en) * | 1962-08-13 | 1965-02-23 | American Can Co | Method of making cutting dies |
US3214309A (en) * | 1962-06-22 | 1965-10-26 | Modern Engraving And Machine C | Engraving embossing rolls accurately with a repeated design |
US3421865A (en) * | 1966-01-03 | 1969-01-14 | Sperry Rand Corp | Core nest |
-
1970
- 1970-10-15 US US80831A patent/US3690199A/en not_active Expired - Lifetime
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3214309A (en) * | 1962-06-22 | 1965-10-26 | Modern Engraving And Machine C | Engraving embossing rolls accurately with a repeated design |
US3170342A (en) * | 1962-08-13 | 1965-02-23 | American Can Co | Method of making cutting dies |
US3421865A (en) * | 1966-01-03 | 1969-01-14 | Sperry Rand Corp | Core nest |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4294649A (en) * | 1979-11-05 | 1981-10-13 | Sarka Albert J | Method of making die plates |
US20040020328A1 (en) * | 2002-07-30 | 2004-02-05 | Chin-Tu Wang | Method for manufacturing cutter mold |
DE102010014430A1 (en) * | 2010-04-03 | 2011-10-06 | Smurfit Kappa Rapidcorr Euskirchen Gmbh | Process for the continuous production of a corrugated cardboard web and of corrugated board formats cut to it in the course of their production, and corrugated board production plant for carrying out the process |
WO2011121131A1 (en) | 2010-04-03 | 2011-10-06 | Smurfit Kappa Rapidcorr Euskirchen Gmbh | Method for continuously producing a rigid corrugated-board web, and corrugated-board formats cut to size from this web during the production thereof, and corrugated-board making installation for implementing the method |
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Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: AMERICAN CAN COMPANY Free format text: MERGER;ASSIGNOR:CHEMPAR CORPORATION;REEL/FRAME:003901/0927 Effective date: 19810818 Owner name: AMERICAN CAN COMPANY, A CORP. OF NJ. Free format text: MERGER;ASSIGNOR:CHEMPAR CORPORATION;REEL/FRAME:003901/0927 Effective date: 19810818 |
|
AS | Assignment |
Owner name: ATLAS STEEL RULE DIE, INC., INDIANA Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:AMERICAN CAN COMPANY, A NJ CORP.;REEL/FRAME:003913/0075 Effective date: 19810901 Owner name: ATLAS STEEL RULE DIE, INC., 2000 MIDDLEBURY, ELKHA Free format text: ASSIGNMENT OF ASSIGNORS INTEREST.;ASSIGNOR:AMERICAN CAN COMPANY, A NJ CORP.;REEL/FRAME:003913/0075 Effective date: 19810901 |