目的 为探究柔性版印刷过程中不同印版硬度下印刷压力对网点扩大的影响规律,并评估三维有限元仿真模型的准确性,以期为印版设计与工艺参数优化提供参考。方法 本研究采用数字及光学显微镜测量2种硬度（Dpl_x45、Dpl_x67）印版网点的几何参数;利用印刷适性仪在125、150、175 N压力下进行打样并测量网点扩大值;通过有限元仿真构建单个平顶网点三维有限元模型模拟网点变形行为。结果 实验表明,网点扩大值随网点百分比呈非线性关系,在0%~50%范围内随百分比增加而增大,在50%~100%范围内随百分比增加而减小,且在50%处扩大最显著。随着印刷压力的增加,网点扩大值呈上升趋势;而在相同压力条件下,低硬度印版的扩大值明显高于高硬度印版。以Dpl_x45印版50%网点为例,压力由125 N增至175 N,扩大值由29%升至34%。仿真结果与实测数据误差均控制在±7.5%范围内。结论 印刷压力是影响网点扩大的主要因素,印版硬度显著影响网点对压力的敏感程度;三维有限元仿真能够有效预测网点变形规律,可为工艺优化提供数据支持。
Abstract
The work aims to explore the influence of printing pressure on dot gain under different plate hardness conditions during flexographic printing, evaluate the accuracy of the three-dimensional finite element simulation model, and provide references for plate design and process parameter optimization. A digital microscope and an optical microscope were applied to accurately measure the geometric parameters of flexographic dots with two different hardness levels (Dpl_x45 and Dpl_x67). Subsequently, a printability tester was used to conduct standardized proofing for the two types of plates under three printing pressures: 125 N, 150 N, and 175 N, and a spectrophotometer was employed to measure the dot gain value of the proofs. Finally, a three-dimensional finite element model of a single flat-top dot was constructed through finite element simulation to simulate the dot deformation behavior. The experimental results showed that the dot gain value presented a nonlinear relationship with the dot percentage. The gain value increased in the range of 0%-50% and decreased in the range of 50%-100%, with the most significant effect at the 50% dot percentage. With the increase of printing pressure, the dot gain value showed an upward trend; under the same pressure conditions, the dot gain value of the low-hardness plate was significantly higher than that of the high-hardness plate. For the Dpl_x45 plate (50% dot), the gain value increased from 29% to 34% as the pressure rose from 125 N to 175 N. The errors between the simulation results and the measured data were all controlled within ±7.5%. It is concluded that printing pressure is a primary factor affecting dot gain, while plate hardness significantly influences the sensitivity of dots to pressure. Three-dimensional finite element simulation can effectively predict dot deformation trends, providing data support for process optimization.
关键词
柔性版印刷 /
网点扩大 /
有限元分析 /
印版硬度 /
印刷压力
Key words
flexographic printing /
dot gain /
finite element analysis /
plate hardness /
printing pressure
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基金
国家新闻出版署“智能与柔版印刷”重点实验室招标课题（ZBKT202304,ZBKT2502）; 2025年国家级大学生创新创业计划项目,北京市属高校基本科研业务费（Ee202511）
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