slitting practical matters useful ideas useful tools...slitting practical matters useful ideas...
TRANSCRIPT
Slitting Practical Matters
Useful Ideas
Useful Tools
D
R
SLITTING EDUCATOR/CONSULTANT
R D
DAVE RUMSON drumson.wordpress.com
Converting Quarterly Columnist LinkedIn Slitting Community Group
AIMCAL 2 Day Slitting Technology Converting School
Shear, Crush/Score and Razor Slitting Evaluations ICE 2017 USA Expert Team Member In-House & Public Slitting Education
Slitting Laboratory Trials [email protected]
860-256-5658
My Paper & Converting Industry Background
DR Consulting - Independent Educator/Consultant - 7 years
Southworth Systems - Roll and Shaft Handling Equipment - 4 years
Parkinson Technologies - Un-winders & Re-winders – 7 years
Dienes Corp. - Slitting Knives, Holders & Positioning Systems - 9+ years
Sigmala, U.K. - Electronic Knife Holders – 6 months
28 Years Total Paper and Converting Experience
USEFUL IDEAS Slitting Process Log Book
SLITTER NUMBER 12
INDIVIDUAL TOTAL GRAMAGE FPM
WEB KNIFE TOTAL DUST PER WEB
DATE TIME BASIS WGT PROCESS CHANGE MADE NUMBERS KNIVES GRAMAGE KNIFE SET SPEED COMMENTS
Tracking the Process
Slitting, Winding Performance Data
Providing a Historical Record
Diagnosing Slitting & Roll Defects
A Place to Detail Issues & Remedies
ROLLER ALIGNMENT
M I S A L I G N E D
ROLLER ALIGNMENT
WEB WRINKLES
Gotta New Wrinkle?
OPTICAL
LASER
LASER GYRO
The Ultimate Roll & Web Defect Terminology Guide – TAPPI Press
Scheduled Alignment
Hard Wrinkle
Shear Asymmetric
Baggie Lane
CD Web Shifts*
Roll Interweaving
Roller Misalignment Leads To …
Rule: Web Travels 90⁰ to Roller Length
IDLER ROLLERS Checking Web to Roller Traction
A Little Bluing Might Help
Just a Dab
Web Slippage Scuffs Dye
Caution: Dye Transfer to Web
Web Out Shaft Hand Rotation
– Low Tension Webs
Scrap Roll Testing?
Really Good Cleaning
Always Holder Misalignments – Opposing Forces
Cut Width Accuracy
Frame Rubbing with Debris
Side Shearing Loading Concerns
More Misalignment = Quicker Failure
Knife Regrinding
Old, Worn Holders
Crush Cutting
KNIFE TO HOLDER MISALIGNMENT
Holder Bearing Failure
Pinch and Check for Looseness
Discernible Looseness = A Problem in Waiting
Suppliers Advise = < 0.002” Play
Pressure Regulator to Set Cutting Forces
Flow Control Valves to Prevent Surges
Tell tail “CLINK” … A MAJOR NO - NO
ANVIL
CLINK
Hose Removal to Disengage Knives
Crush Knife Holders
REGULATING AIR SUPPLY
AIR
IN
AIR
IN
Shear Top Knife Holders
Reduce Holder Wear
Prevent Surges
Reduce Knife Impact
Individual Flow Control
& On/Off Valves
REGULATING AIR SUPPLY
Applied Air Pressure
Mechanical Return Spring
Roll-to-Roll or 24-7…?
Excessive Knife Overlap
SIX MAJOR SLITTING PROBLEMS
1. Web Travel Chord Increase
2. Cut Point Change
3. Knife Width Increase
MOST COMMON AND WORST ERROR MADE
4. Side Load and Knife Friction Increases
5. Top Knife Edge Cut Radial Rubbing
6. Top Knife Slowing
Web Travel Chord
WEB TRAVEL CHORD
TOP
VIEW
CUT POINT
Top Knife
Flat Side
Top Knife
Bevel Side
Winder
Pull
Tension
Excessive Knife Overlap
DAV CAD
NTS
Brake
Hold
Back
Web
Cut Point 0.030” Top Knife 6” Ф
Bottom
Knife 8” Ф
Problem 1: Web Travel Chord Increase
Shear Angle Creates
Web Misalignment
Web to Knife Contact
Aggravating
Tension Levels
Cut
Point
Excessive Knife Overlap
102% 1.580”
0.125”
At 0.125” Depth, Chord Length Increases by 102%
TRAVEL CHORD
0.781”
0.030”
0.030” – 0.040” Depth Recommended
41% 1.102”
0.060”
At 0.060” Depth, Chord Length Increases by 41%
Problem 3: Knife Width Increase
D.B. 0.030” D.B. 0.060” D.B. 0.125”
0.016” Width 0.023” Width
44% Wider
0.040” Width
148% Wider
Consider…
Web Speed
Web Tension
Cut
Point
Cut
Point t Cut
Point
148% more web displacement
Material Fragility
Excessive Knife Overlap
Web
0.030” Over Lap Cut Point
102% 1.580”
102% longer web/knife contact and …
Primary Angle
Secondary Angle
Successive 0.030” Primary Bevel
Regrinds Increase Web to Blade Contact
0.030” Overlap
0.016”
New
0.030”
0.031”
2ND
Regrind
+ 94%
0.030”
0.023”
1ST
Regrind
+ 44%
0.030”
0.039”
3RD
Regrind
+ 142%
0.030”
0.030”
0.030”
Radius
Regrinds Bottom Knife
Cut Point
Top Knife
EXCESSIVE KNIFE WIDTH
DAV CAD NTS
Increased Web Disruption*
Causes the Same Effect as Excessive Overlap
Knife Width Increases with New Overlap Setting
OVERLAP RESET
Secondary Bevel Regrind Restores Original Knife Width
DAVCAD – NTS
Bottom Knife
+94% 0.031”
2nd 0.030” Regrind
POST REGRIND OVERLAP
+94% 0.031”
0.030”
0.016”
0.016”
“Don’t Forget the Proper Surface Finish”
OVERLAP RESET
Travel Chord
Overlap
Maintaining the
same Cut Point
with smaller
diameter knives
increases Overlap
depth with no
change to the
Travel Chord
SAME CUT POINT
DAVCAD - NTS
SAME OVERLAP
Maintaining the
same Overlap
with smaller
diameter knives
moves the Cut
Point and reduces
the Travel Chord
Overlap
Travel Chord
DAVCAD - NTS
Travel Chord
Travel Chord
As long as the Cut
Point has Bottom
Knife support
maintain the same
Overlap
OVERLAP RESET
Dial Indicator Check Bottom Knife Run-Out
Run-Out Reality
Axial Run-Out Recommended
TIR 0.002”
Improves Finished Roll Edge Quality
Improves Knife Life
Older Holders & Top Knife R.O.
Radial Run-Out
Recommended
TIR 0.004”
KNIFE RUN-OUT CHECKING
Proper Run-Out…
> Than Recommended
Know What You Have
Slitting Log Book Entry
DAV/CAD NTS
Rotate 180⁰ - Mark Again
Set Dial Indicator
Lay Tape - Mark Each Knife
#3 #1 #2 #4
RADIAL RUN-OUT - Points and Plot Them
#3 #1 #2 #4 180°
Rotate 360⁰ - Mark Max - Min’s
Do All Knives
Make Necessary Corrections
Measure Shaft T.I.R.
Slitting Log Book Entry
Polar Opposite Max, Min Run-Out Can Cause Web Bounce
Max, Min Run-Out Causes Cyclic Web to Top Knife Contact
Max, Min Run-Out Causes Fluctuating Side Load Friction Forces
Measure Slitter In-Feed and Exit Roll Run-Out
Top Knife Rotation with
Web Direction
Top Knife Rotation
Opposite of Web Direction Stationary Bottom
Knife Cutting Edge
Web Direction
Photos Courtesy of Dienes USA & Tidland/Maxcess
Rotate Top Knife in One Direction Only
Web Direction
Shear
Angle
Top Knife Rotates Into the
Bottom Knife Cutting Edge
Top Knife Slides Off the
Bottom Knife Cutting Edge
CHECKING KNIFE SIDE LOAD FORCE
Check Top Knife Assembly for Looseness USEFUL IDEAS
Loose Knife Head Lessens Shear Angle
Grasp Knife Head & Tork Side-to-Side
Don’t Forget
Your Safety
Gloves
Lost Shear Angle Leads to an
Open Nip and Dust
Open Nip
Bottom Knife
Especially Older Holders
USEFUL IDEAS
Finished Roll Face Wipe
Establish Repeatable Procedure
Keep a Foto Record
Black Velvet Dust Monitoring
Courtesy of DuPont Teijin
USEFUL IDEAS
Finished Roll Face Press
Establish Repeatable Procedure
Keep Tape Press Sample
Tape Dust Monitoring
USEFUL TOOLS
Monitor High Roll Edge
Ultimate Roll & Web Defect Terminology – TAPPI Press
Flared Edge
Belled Edge
Raised Edge
Bulged Edge
Beaded Edge
Edge Curl
Wager-Meter High Edge Gauge
High Edge
Diameter Change Micrometer Adjustment
USEFUL TOOLS
Original Diameter = 6.000”
Reground Diameter = 5.970”
1 micrometer click = 0.004”
6.000 – 5.970 = 0.030” off the dia.
0.030” ÷ 2 = 0.015” off the
radius 0.015” ÷ 0.004” = 3.75 clicks
SETTING OVERLAP
Operator Training
Ask Sharpening Service to Provide Re-Sharpened Diameter
Courtesy of Dienes USA
Chord Gauges; Distance Over Pins
USEFUL TOOLS
SETTING OVERLAP
Instructions:
1) If you know the knife diameters in inches, enter the size in cells B11 and C11.
2) If you know the knife diameters in millimeters, enter the size in cells B13 and C13.
3) Enter the desired knife overlap in the next column - D.
4) The needed setting distance measured over the chord gage pins is shown in the results column - F.
B C D E F
VARIABLE VARIABLE Results
Bottom Knife Dia Top Knife Dia Knife overlap Pin Dia on Cord Gage Measurement over Pins
ENTER inches > 10.000 8.000 0.040 0.1875 2.207
ENTER mm > 250 203 1.01 4.76 56.058
Calculations Available
Fixed spacer
Courtesy of Dienes USA & Valmet Slitter Management Program
Off-Line Set Up Fixtures
USEFUL TOOLS
SETTING OVERLAP
Delrin Like Stop Simulates Required Overlap
Laser Beam Fixture Likewise
Courtesy of Dienes USA
SETTING ENGAGEMENT STROKE – Manual Set-Up
Slide Top Knife to Contact Spacer
Lock Top Knife Location
Courtesy of Valmet Slitter Management Program
Make a Spacer 85% to 90% of Holder Full Stroke
Confirm Knife Contact Force and Disengagement
0.200”
1/2 lb. to 9 lb. side load
Paper Mill Duty Holder
Find Your Holder’s Full Engagement Stroke
WHAT NOT TO DO!
Storage Handling
KNIFE CARE
Peg mounting - a queue system
WHAT TO DO!
Storage Cabinets
Wooden Benches
Rubber Flooring
KNIFE CARE
WHAT NOT TO DO!
Instead of 1 regrind it took
the time to do 8 regrinds to
restore a useable cutting
edge. 8 times the cost plus
the loss of 7 slitting
cycles.
Shipping Damage
KNIFE CARE
Package Properly for Shipping
WHAT TO DO!
KNIFE CARE
Edge Covering
Safety Gloves
WHAT TO DO!
KNIFE CARE
Magnetic Knife Removal
Digital Knife Locating
USEFUL TOOLS
USEFUL IDEAS Slitting Process Log Book
SLITTER NUMBER 12
INDIVIDUAL TOTAL GRAMAGE FPM
WEB KNIFE TOTAL DUST PER WEB
DATE TIME BASIS WGT PROCESS CHANGE MADE NUMBERS KNIVES GRAMAGE KNIFE SET SPEED COMMENTS
4/12/16 0900 Annual Idler Roll Alignment Idler’s 3,5 & 7 out of spec. Adjustments made
Wrinkling issue eliminated
6/10/16 1300 Bi-Annual roller traction test All spin freely
7/22/16 0800 Installed top knife secondary bevel
set All 12 Fuzzy roll face reduced
7/31/2016 1600 Knife Axial & Radial Run-Out Check All 12 Run-Outs measured in spec. < 0.008” T.I.R.
1/5/17 1630 Slitter dust up. sec. bevel face grind ALL 12 3rd re-sharpening – dust levels down
8/3/16 Winder Drives checked & tuned Loose Roll winding corrected
Slitting Practical Matters
Useful Ideas
Useful Tools
D
R
SLITTING EDUCATOR/CONSULTANT
R D
DAVE RUMSON drumson.wordpress.com
Converting Quarterly Columnist LinkedIn Slitting Community Group
AIMCAL 2 Day Slitting Technology Converting School
Shear, Crush/Score and Razor Slitting Evaluations ICE 2017 USA Expert Team Member In-House & Public Slitting Education
Slitting Laboratory Trials [email protected]
860-256-5658