In rotary die manufacturing, the die cylinder is the primary load-bearing component and a key determinant of cutting accuracy, durability, and long-term die performance.
A high-quality cylinder must work seamlessly with die-cutting blades, padding cylinders, anvils, and various substrates such as cardboard, film, leather, and composite materials.
Its material selection, structural design, and precision machining directly influence the quality and lifespan of the rotary die.
Below is a complete breakdown of the core functions, structural design, and machining process of professional rotary die cylinders.
The cylinder holds and secures steel rules, engraved cutters, or etched blades.
It ensures accurate positioning according to the die layout and prevents cutter deformation or loosening during high-speed rotation.
Both shaft ends connect to the die-cutting machine’s drive system.
The cylinder rotates synchronously at a uniform speed, enabling continuous, high-efficiency die-cutting.
Cylinder roundness and coaxiality directly affect die-cutting precision.
Typical tolerance requirements:
Roundness: ±0.01 mm
Coaxiality: ±0.01 mm
Poor accuracy can lead to issues such as offset cutting, ghosting, uneven cuts, or premature blade wear.
The cylinder works together with padding cylinders / anvils to apply consistent cutting pressure based on material thickness.
This ensures clean cuts without burrs, crushing, or sticking and maintains stable production quality.
| Item | Specification |
|---|---|
| Outer Diameter | φ80–φ300 mm (customized per die-cutting machine) |
| Length | Material width + 5–10 mm for full-edge cutting |
| Wall Thickness | Steel: 8–15 mm / Aluminum: 15–25 mm |
Must match the padding cylinder diameter for synchronized linear speed.
Steel ensures rigidity; aluminum offers lightweight performance.
Shaft Head Material:
40Cr or other high-strength alloy steel
Forged integrally or welded to maintain precision
Bearing Type:
Deep groove ball bearings
Angular contact bearings (for high-speed operation)
Requirements:
Dustproof
Waterproof
Compatible with 100–500 r/min die-cutting speeds
Three main fastening technologies:
A groove is milled into the cylinder surface
Cutter embedded & soldered / pressure plate fixed
Pros: low cost
Cons: slower changeover
Permanent magnets embedded under the surface
Cutter easily installed and removed
Ideal for: small batches, frequent design changes
Cutter fixed via bolts through the cylinder
Best for: heavy-duty, thick, or large-format cutters
Balance holes added to both ends
Final dynamic balancing achieves G2.5 precision grade
Prevents vibration, noise, and cutting inaccuracy during high-speed rotation—extending both die and machine lifespan.
Machining of outer diameter and shaft ends
Ensures roundness ≤0.003 mm
Coaxiality ≤0.005 mm
Quenching + tempering = hardness HRC 58–62
Nitriding optional: surface hardness ≥HRC 65
Improves wear resistance and service life.
CNC milling grooves for cutter insertion
Chemical etching for fine or micro-patterns
Groove tolerance ±0.01 mm
External cylindrical grinding
Surface roughness Ra ≤ 0.8 μm
Ensures smooth contact and avoids material scratching.
Performed on a balancing machine
Ensures vibration-free high-speed rotation
Steel cylinders: galvanizing or chrome plating (corrosion resistance)
Aluminum cylinders: anodizing (increased hardness)
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