Doctor Blade Metering

The What and How in

Anilox Ink Metering.

Tony Donato
Product Development Engineer
Harper Corporation of America
tdonato@harperimage.com
 Ink Metering
FIRST 4.0
From Section 21.4 Ink Metering System:
“ The function of the ink metering system is to control the
amount of ink being transferred onto the printing plate.”
From Section 21.4.1 Doctor Blades:
“ The primary function of the doctor blade is to uniformly
remove ink from the surface of the anilox without
damaging the anilox.”
 Doctor Blade Metering
OUTLINE:
• The difference between forward and reverse doctoring.
• Ink metering terms: Set-Angle, Contact Angle, blade
deflection, sheen, back-doctoring, blade loading pressure,
blade alignment and many others.
• The importance of blade stiffness to metering.
• How blade thickness affects metering.
• Why are there different blade tips.
 Forward and Reverse Metering
Simplest Examples
Windshield Wiper Blades Windshield Ice Scraper

http://www.autogeek.net/windshield-ice-scraper.html

Forward wiping pushes Reverse metering shears off

the unwanted material. the unwanted material.
 Forward Metering
Pushes the surface ink back into the pan.

Blade points in the

direction of rotation.

Ink is pushed
back to the pan

Traditionally used in Gravure

on Chrome Rollers
 Forward Metering
Application Importance:
• Needs blade angle and location adjustability.
• Important to pick the right blade thickness, tip and
back-up blade combination.

Pluses:
• Ideal where roll diameter
changes with the jobs.
• Less wear to rollers
being metered.
• Helps to lubricate blade.
Minuses:
• Works best with low
viscosity inks.
• Potential for speed
limitations due to
hydraulic lift.
• Blade position and
stiffness dependant.
 Forward Metering Angle Relationships
Dimensions related A Distance blade tip to Cylinder Vertical Center Line
to Center line of B Distance of blade tip to Cylinder Horizontal Center line
Gravure Cylinder C Circumvential Distance Nip point to Blade Tip
D Elevator (Up & Down) adjustment for table assembly
E Slide (In and Out) adjustment blade holder
Impression F Table Tilt (Pivot) adjustment for table assembly
Roll
G Set angle for blade to Cylinder without loading deflection.
A
H Contact Angle of blade tip with deflection

ø 6.00" 0
74.92° Protractor Angle Finder

90

90

15 0

90
58.72°

0
C E

90
75
75.05°
54.11°
G Angle Finder gives angles relevant
Gravure B F D to earth.
Cylinder H Reference line (Tangent) Set angle

Typical Contact Angles are:

Packaging Gravure 40° to 65°
Publication Gravure 50° to 70°
Coating & Wall Covering 40° to 55°
 Reverse Metering
“Reverse Metering” shears the ink off the Anilox surface.

Anilox

Single Blade Enclosed Blade Chamber

Ceramic anilox rollers allow the use of reverse metering.

 Reverse Metering
Application Importance:
• Needs hard surfaces.

Pluses:
• Meters the ink surface
cleaner than forward.
• No hydraulic lift.
• Meters viscous inks.
Minuses:
• Blade holders or chambers
have fixed set angles.
• Fixed roller diameter.
• Blade wear changes angle.
• Shears large pigments
• Pearlescent
• Metallic's
 Reverse Metering
Single Blade Chamber
• Ink Pan Only • Two Blades
• Ink Pan w/ Fountain Roll • Meter & Containment
• End Seals & Pump.
Set Angle

90.00°
Anilox

Anilox

Blade Angles are fixed by holder & Chamber supplier

 Metering Terms
The “Set Angle” is the Chamber/Holder
Machined Angle without any load.

Set Angle Tangent Line

Perpendicular to
Reference line

90.00°
Anilox Reference Line
From Anilox Center
To point of
Blade Contact
Anilox
Doctor Blade Center Line.
 Metering Terms
The “Contact Angle” is worn at the tip and is
the result of all forces acting on the blade.
Contact Angle
FIRST
Anilox recommends
“Contact Angle”
should be
Worn Area between 25-40
degrees.
Contact
Patch
Lower angles Print Dirty,
Higher Angles Chatter
Deflected Doctor Blade
 Metering Terms
Blade clamping
seat area
With Inking
Chambers the
Blade metering and
Extention
containment
blade can be on
either the top or
Anilox

Blade
Tip to Tip bottom, all
depends on
Blade chamber
Extention placement on the
anilox.
 Metering Terms

Dull Sheen Indicating Good Metering

 Metering Terms
Chamber opened up from the outside deck #7
Top of picture is bottom (6 O’clock) of chamber

Drips on doctor blade is back doctoring of ink

White drops tinting is high speed “Ink Misting.”

 Back doctoring does more than just waste ink.
• Containment Blades can trap contaminates under it.

Dried ink on the back (outside) of the blades

Plastic or Composite
Small Dried Ink Chunks
Blades with
Containing Metal Embedded Particles
Particles

• Keep Containment blades Clean.

 Metering Terms
Set Angle
Unloaded blade 45.00°
is at the highest
angle.
90.00°
Meter
Blade Chambers do
Chamber not have to
Anilox have the same
Containment angles for both
Blade blades

High speed presses

are trending at
Containment
lowering the Set Angle
containment set angle.
 Metering Terms
Contact Angles decrease with increased loading pressure!
37.47°

90.00°
Anilox
Chamber has
.031" (.79mm)
of loading These are
good angles
. Lower containment 90.00° for high
blade angles help to speeds.
reduce back doctoring.
13.20°
Containment
Contact Angle
 Metering Terms
Blade holder alignment needs to be part of press maintenance.

Metering Contact Angle 28.48°

Doctor
90.01° blades are
spring steel
and the more
Chamber has
they are
.0625” (1.6mm) Anilox loaded the
of loading
harder they
push into the
90.00° anilox roller.

5.11°

Containment “Contact Angle”

 Metering Terms
Extreme loading will result in burrs created on the blade edge.

Metering Contact Angle 18.42°

Extreme low
90.00°
containment
angles will
trap dried ink
Chamber has and
.125” (3.2mm) contaminates
of loading Anilox Ink magnets
and filters are
required for
high speed
presses
3.52°
Containment Contact Angle
Anilox rotation remains the same on CI press
Back doctoring puddles behind blade
and slings off the end of the anilox

Containment
Blade

Outside decks 6 to 10 Inside decks 1 to 5

Containment
Blade

Back doctoring drips off

chamber into pan
 Doctor Blade Mechanical
Specifications and Properties:
Mechanical Properties: Affect loading
pressure, blade life and anilox wear.
•Tensile strength (spring like quality) ,
• Hardness
• Wear resistance.
• Chemical resistance.
Physical Attributes: Affect the printing
performance.
• Thickness and width tolerances, flatness,
surface finishes and camber (curvature
Deflected doctor blade
also called edge straightness) and released it laid flat!
 Doctor Blade Mechanical Property:
Deflected a piece of steel banding stock.

Blade must deflect and re-flatten, it cannot take a set!

Banding stock unsuitable for a number of reasons!

 Doctor Blade Mechanical
Specifications and Properties:
• The initial wiping between the blade and roller are effected
by variations in blade camber, flatness and width.
• All of the mechanical and physical properties affect the
amount of loading force needed to cleanly meter the anilox.
• In addition, the blade mounting, holder/chamber physical
dimensions/condition & mounting mechanism must be kept in
good working order for the doctor blade to properly work.

A A´

Blades must be parallel to each other, & tip to tip distance the same.
 Blade Mechanics Simplified
Looking at the mathematics and
mechanics a doctor blade is a “beam”
fixed on one end and loaded on the other.

“w” is load in lbs/linear inch

t “d” is deflection at the tip (inches)
“1” is the extension of blade
1" Load “E” Modulus of elasticity 30,000,000lbs for
w steel.
d “I” Moment of inertia for the blade cross
section.
d = w x 1³ (1)
3xExI
 Blade Mechanics Simplified

Moment of Inertia I = t³ (2)

12

t = blade thickness

t We substitute equation (2) into (1)

1" Load d = ____w x 1³____ (3)

3 x E x (t³ / 12)
w
d
Set w = to 1lbs/ linear inch and assume
steel “E” for the blade material we get:

d = ____1___________ x 1³ (blade ext)__ (4)

(3 x 30,000,000/ 12) t³
 Blade Mechanics Simplified

STILL AWAKE LAST SLIDE WITH MATH!!!!

The exponents in equation (4) show the
cube factor.
Example leaving a blade in too long:
(.750/.625)³ = 1.73 times stiffer

Example replace .006” with 0.008: (.008/.006)³= 2.24 times.

If the stiffer blade was left in until it was 1/8” shorter:

Then: 1.73 (shorting) x 2.24 (thickening) = 3.87 times stiffer

CHANGES IN THICKNESS AND EXTENSION CAN EFFECT

ANILOX WEAR.
 Blade Mechanics Tested
Experiment:

Used .006” & .008” doctor blades and two different widths
to get ½” extension and a 1” extension. Applied two
separate weights first 4.75lbs and second 7.2lbs statically
and measured the deflection with a dial indicator.
Blade Mechanics Tested
Blade Mechanics Tested
Unloaded

Loaded
 Blade Mechanics Tested
Blade Blade Blade Weigh Load per Deflection
Thickness Extension Length used linear inch

.006” 0.500” 6.25” 4.75lbs 0.38lbs/in 0.029”

.008” 0.500” 6.25” 4.75lbs 0.38lbs/in 0.012”

.006” 0.500” 6.25” 7.2lbs 0.58lbs/in 0.049”

.008” 0.500” 6.25” 7.2lbs 0.58lbs/in 0.021”

.006 1.000” 6.25” 4.75lbs 0.38lbs/in 0.132”

.008” 1.000” 6.25” 4.75lbs 0.38lbs/in 0.082”

.006” 1.000” 6.25” 7.2lbs 0.58lbs/in 0.162”

.008” 1.000” 6.25” 7.2lbs 0.58lbs/in 0.146”

 Doctor Blade Loading

What to expect from what we have learned so far!

• Typically the highest angle is the set-angle.
• As the loading pressure increases the “Contact-Angle”
decreases.
• Loading pressure can lower the contact angle beyond the
point of clean metering. (Below 26°)
• As a blade wears it narrows and the contact angle increases.
• Between loading and wearing the blade contact point moves
away from the center line.
 Overloading the blades changes wear.
Anilox Roll
Do Not Lamella Tip
do this to your
Doctor Blades !!

Wear Patch Tip not

contacting roll Chamber
Is behind Tip
Over-Loaded
Blades can
Cause Scoring !! Radius Tip
Clamp Bar
Excessive pressure may result in creating wire like slivers.
Steel Slivers created from overloading.

Slivers form
break off and get
loaded between
blade and anilox
damaging
surface.

Top blade has .217” worn off came from white deck!
 Doctor BladeisLoading
Chamber engagedObservations
.125" (3.2mm)
Blade was 1-3/8” and
48.17° after the chamber is
loaded to 1/8” the blade
Chamber has
.125” (3.2mm)
18.42° can wear to a width 1-1/4”

of loading

90.00°
90.00° The contact
patch shifts
1.25 in with chamber
loading and
blade wear.
0.23 in
 Doctor BladeisLoading
Chamber engagedObservations
.125" (3.2mm)
As the blade narrows the
point of contact on the
48.17° anilox moves increasing
the set angle.

Chamber has 18.42°

.125” (3.2mm)
of loading
90.00°
90.00°
22.96°
18.62°
 Doctor Blade Material Selection
Work with your blade supplier.
• Carbon Steels:
• Blue Carbon, White (Bright) Carbon
• Wear (Premium) Alloy Steels:
•Tool Steel Alloys:
•Laser Hardened Tips
• Stainless Steels:
• Coated Steel or Stainless:
• Ceramic, or Plated
• Plastics:
• UHMW, Acetal, Polyester, Proprietary compounds.
• Composite:
• Fiberglass, Carbon Fiber
Each material has its best application!
 Blade Tips (Profile)
•Square

• Round Radius

• Beveled 45.00° 20.00°

• 45
• 15 to 20
• 5 or less

• Stepped (Lamella)
• Single Step
• Double Step
 Blade Tips
Typical tip applications:
• Square Tip
• Plastic Containment blades.
• Back-up Steel Blades
• Round (Radius) Tip
• Metal Metering WW w/Chamber w/Sunday Drive
• Beveled 45°
• UHMW Plastic
• Beveled 15 or 20°
• Metal on NW (seats quickly)
• Composites and stiffer plastics
• Lamella (stepped)
• Where the tip needs to thin and body stiffer.
• Double stepped
• Where a stiff blade is needed w/ narrow contact.
 Blade Thickness
Thickness considerations:
• Blade Material dependant
• Plastics & Composites thicker than metals
• Application dependant
• Corrosive ink or coating or environment.
• Ink pigmentations or material (ex. TiO² white)
• Metering or Containment
• Anilox Geometry
• 30 & 60°
• 45° Quad
• Channeled
• Trihelical
• Anilox Screen
• Process & solids
• Coatings and adhesives
Blade Optimization work with your supplier
• Periodically have a used blade analysis
– Check contact angle over 3 spots across web
– amount worn 3 spots
• The Used Blade can tell you:
– Loading degrees (pressure)
– Blade alignment to anilox
– Chamber condition
• Set shop practices.
– Blade Changing schedules.
– Loading pressures
– Mounting training
 Anilox effects wear pattern.
Anilox Engraving post intersections leave lines in doctor
blades contacting edge
Equation to calculate
the CPI of an Anilox
from a worn blade

CPI = 25,400µ/” x Cos of Engr ∟

Line to lineµ

25,400 µ/in x 0.5 = 705 CPI

60° Angle of Engraving
18 µ

Worn Doctor
Blade showing
engraving lines 18 Microns
 Metering Review
• Doctor Blade contact angle does effect blade vibration.
• Doctor blades can change the surface smoothness of the
anilox.
• Loading pressure reduces the blade angle.
• Blade wear can increase the contact angle.
• Thicker doctor blades increase the blade angle because
they deflect less.
• Thicker doctor blades increase wear area spreading load.
• Best metering contact angles between 26°to 38°.
• Above 40°contact angle can result in chatter.
• 4° to 5°of loading deflection is helpful for metering
above a 1000 fpm.
 Metering Review
• The empty anilox cells bring air back into the chamber.
• Know what your set angles are.
• Lower containment contact angles can reduce back
doctoring.
• Containment blades can wear faster on full coverage.
• Use caution when handling used doctor blades. They
are sharp.
• Your suppliers they are your best resources.
• Doctor blades should shear off the surface ink leaving
only the ink in the Anilox cells.
• The abrasiveness of the ink itself needs to be
considered.
• Change blades when changing cpi.
• Remove ink contaminants with filters and magnets.
 Be Observant of the Anilox Metering
• Anilox properly metered “Dull Sheen”
• Looks shinny excessive “surface ink”
– Excessive loading pressure.
– Chamber or holder at bottom of adjustment.
• Shinny streaks “nicks in blade”
• Sheen varies side to side:
– Mounting and or alignment issue.
• Variation in density across web:
– Uneven loading pressure.
– Mounting and or alignment issue.
 Doctor Blade Review
Work with your blade supplier.
• Specified by material, thickness and tip.
• There is a proper blade for each application.
• Blades affect print quality and Anilox life.
• Blade Mounting is very important.
• Important: Holder/Chamber alignment to Anilox
• Blade loading pressure critical.
• Record Doctor Blade Information: Create a log
and track issues and concerns
• Used blades are sharp are a razor blade.
• Have used blades analyzed periodically.
 Doctor Blade Metering
The What and How in Anilox Ink Metering.

QUESTIONS?
 Doctor Blade Metering
The What and How in Anilox Ink Metering.

THANK YOU FOR ATTENDING!

Tony Donato
Product Development Engineer
Harper Corporation of America
tdonato@harperimage.com