When compared to copper electrodes, graphite electrodes have a smaller cutting resistance and a smaller coefficient of thermal expansion and contraction, making them more suitable for processing thin-wall structures. However, processing graphite electrodes can also be challenging and prone to edge breakage. Experienced engineers have come up with guiding principles to minimize breakage during graphite processing.
- To prevent the edge of the workpiece from collapsing when cutting to the exit, a small section is pre-milled at the processing exit end.
- Adopt a downward milling approach where the cutting direction of the cutting edge is opposite to the feed direction.
- The cutting depth should not exceed 1/3 of the diameter of the milling cutter.
- Set the vacuum cleaner wind speed as follows: processing area >150 m/min; Dust discharge outlet >600 m/min.
- Replace any failed tool promptly.
- Improve the tool line speed and reduce the feed rate for better results.
- Use high-quality, fine-grained graphite materials whenever possible.
A critical recommendation is to use the CVD pure diamond-coated integral milling cutter, which has a slight friction coefficient. The integral grinding ensures accurate geometry, making it an ideal tool for preventing edge breakage of graphite parts and processing thin-walled graphite parts.