Printing technology: How to adjust the upper knife and lower knife of the paper cutter?

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When using a paper cutter, it's common to encounter issues such as the upper knife and lower knife phenomenon, also known as the convex and concave knife problem. This can lead to misalignment during the printing process, making registration difficult. Below is a detailed analysis of the possible causes and solutions for this issue. 1. **Insufficient Pressure** There are two main reasons for this: - The spring force from the mechanical pressure springs may be too weak. In such cases, increasing the pressure is necessary. If the maximum pressure cannot be achieved, the spring should be replaced. It's important to note that if one of several springs is damaged, all of them should be replaced at once to avoid uneven pressure, which can cause the knife-up or knife-down issue. - Hydraulic pressure might also be insufficient due to low oil levels in the system or a faulty pump. In this case, identifying and fixing the root cause is essential. 2. **Excessive Gap Between Tool Holder and Slider** If the gap between the tool holder and the slider becomes too large (typically more than 0.1mm) due to wear or improper adjustment, the tool holder may become unstable, leading to the upper and lower knife problem. Adjusting the gap back to the correct specification is necessary. 3. **Blunt Blade** A dull blade can significantly affect both the cutting quality and the machine’s performance. It's crucial to monitor the cutting amount, replace the blade regularly, and ensure it remains sharp. A blunt blade not only reduces cutting efficiency but can also damage the machine and even cause accidents in severe cases. 4. **Incorrect Blade Angle** The blade angle should be adjusted based on the type of paper being cut. For thin, soft, or loose papers, a smaller angle (around 25–30 degrees) is recommended. For thicker, harder, or denser materials, a larger angle (30–35 degrees) is more appropriate. Incorrect angles can lead to the knife-up and knife-down issue and accelerate blade wear. 5. **Improper Blade Positioning** Ideally, the blade should be parallel to the platform surface. If the blade is too high or too low, it can result in an uneven cut. Adjusting the blade to ensure it aligns properly with the platform plane is key to preventing this problem. 6. **Misaligned Feeder Plane** If the feeder (or backer) is not perpendicular to the platform, it can cause the upper and lower knife issue. Using a square ruler, the angle between the two planes should be adjusted to exactly 90 degrees. 7. **Incorrect Knife Holder Movement** Even if the gap between the knife holder and the slider is correct, the movement direction of the knife holder must be perpendicular to the platform. Adjusting the height of the supporting rods at the back of the platform can help achieve this alignment. 8. **Paper Quality Issues** New paper that hasn't fully dried or has trapped air inside can be softer and less stable, increasing the likelihood of the knife-up and knife-down problem during cutting. 9. **Operator Errors** Two common mistakes include: - Failing to press the paper before cutting, which can lead to misalignment. Always ensure the paper is compacted before cutting. - Applying inconsistent pressure when pushing the paper stack forward, causing it to bounce back. Proper control and consistent pressure are essential for accurate cuts. By addressing these factors, operators can significantly reduce the occurrence of the upper and lower knife phenomenon, ensuring smoother and more precise paper cutting operations.

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