Anilox roll size tolerance (bottom)
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The handling, installation and disassembly rules for the gears on the anilox roller are the same as for the bearings. As with bearings, when the gears are not properly installed, it can cause the drum to jump, make noise, or coordinate changes throughout the machine, which can damage the bushings, keyways, and gears.
When a keyway is subjected to transient damage, it is best to roll a new keyway on the original bushing, 180 degrees from the old keyway. The most notable area in rolling a new keyway is the center of the keyway: it must be exactly centered on the roll axis. Otherwise the key will not be fixed. To achieve a tight fit, it is also important that the keyway has the proper length and width, just as a suitable grinder is as important to the correct keyway shape. Changing the width of the keyway requires the use of a more precise gauge instead of a caliper.
Another trouble with gear stepping is that people don't pay enough attention to stepper TIR. Any stepping of the anilox sleeve can cause many problems if there is a transitional deviation. If the bottom of the gear is at the lowest point or the surface of the gear is not uniform, the gear is shaken and audible. In the case of severe conditions, this jitter will also affect the mode of transmission, seriously affecting the quality of printed matter. This condition also prematurely damages the gear.
From the numerous scratches and grooving steps in the stepping or adjacent steps of the gears, it can be seen that people often handle them incorrectly. Scratches and hook grooves are cosmetic damage and do not necessarily require extensive repairs. These shortcomings may only make it more difficult to move or install, just by licking the raw edges or the replaced metal. The problem with anilox roll suppliers is that when these machines are damaged (perhaps only on the surface), they will affect the determination of the change in parameters.
The TIR reading of a typical gear step is approximately 0.005 inches, at which point the performance of the drum is not affected. However, this reading also varies with the printer manufacturer and gear tolerances. Some machine designs are sensitive to roll deflection, so their OEMs (original equipment manufacturers) have stringent requirements for gear stepping. In this way, the deflection of the machine should be taken into account in the tolerance so that it does not affect the performance of the drum. At the beginning and end of the process, all anilox roll suppliers should check all rolls for bending or damage and record the results. Especially in the initial inspection stage of the old drum, paying attention to whether the journal is bent or damaged will help solve the problem, and it is hoped that the damage and subsequent repair costs can be reduced by modifying the operation and procedures.
In most cases, the person who orders the anilox roller is not the person who moves or installs the anilox roller, so it is necessary to have clear communication between the parties. Bad communication can lead to accused meetings, which is why good communication/recording between the anilox roller supplier and the customer is so important.
Third, the balance process
The balance of the anilox roll is a critical factor, depending on the tolerance of the press and the quality of the print. There are two balancing processes: static and dynamic. A similar example is the balance of car tires. The old bubble balance method is a static process, and the spinning balance method is a dynamic process.
An unbalanced roller can cause coordinated changes in the machine at different speeds, causing various problems on the press. The anilox roll supplier must check the balance of the drum during the initial inspection of the anilox roll repair and report the results to the customer. In the manufacturing process of the drum, it is often found that there is a welded balance weight (weight) inside the pipe. In some cases, the balance blocks are loose and you can hear them creaking in the drum duct, which should alert you enough.
Sometimes during the manufacturing process, the loose weight may be absorbed by other pieces in the drum pipe and thus silenced. At this point, a better balancing technique is required to extract a large amount of material from both ends of the finished drum, making the area empty to reduce the quality, or inserting iron bars as needed to increase the weight, and then positioning the welds in the correct position. If the original drum line is far from equilibrium, you may need to use an internal welded weight. Dynamic balancing is typically used for a special roller RPM or FPM (surface size / minute).
Generally, narrow drums no longer require balance adjustment because they are mostly made of solid materials rather than metal pipes. The drum size, construction, and dynamics of a narrow roll press are different from those of a press with a large roll.
When manufacturing new rolls for any wide format or corrugated press, high quality tubular materials must be used to minimize the need for mechanical balance.
More popular is the advanced "roller heat seal" tubular material, because even the strict parameters require this material to ensure uniform wall thickness of the pipe, thus reducing the need for excess balance.
As with many things in life, your contribution is directly proportional to the harvest, so advanced piping materials are accompanied by expensive prices. The price difference between advanced pipe materials and low-grade pipe materials is very obvious. The anilox roll supplier has a parameter standard for evaluating all advanced web materials for all new anilox rolls.
To reduce downtime, save costs, and maintain high print quality, it is important to understand the spatial parameters of the anilox rolls and how they affect the press, press performance, and maintenance of the anilox roll.