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How to Prevent Edge Chipping in Graphite Machining

如何避免石墨加工边缘崩缺

graphite machining

When machining graphite electrodes compared to copper electrodes, the cutting resistance is lower, and the coefficient of thermal expansion and contraction is smaller. Consequently, it is generally easier to machine thin-walled structures. However, machining graphite electrodes comes with its specific challenges and problems, with the most common being edge chipping. Experienced engineers have summarized the following guidelines based on their expertise to minimize the occurrence of edge chipping during the graphite machining process:
1.Pre-mill a small section at the exit end of the workpiece to prevent edge chipping when cutting near the exit.
2.Employ climb milling, meaning the cutting edge moves in the opposite direction of the feed direction.
3.Do not exceed a cutting depth greater than one-third of the milling cutter diameter.
4.Set the dust collector air velocity as follows: Processing area > 150 meters per minute; Dust exhaust > 600 meters per minute.
5.Replace worn-out cutting tools in time.
6.Increase cutting tool linear velocity and reduce feed rate.
7.Use high-quality fine-grain graphite materials whenever possible.
An especially important recommendation is to use CVD diamond-coated end mills, as they have a lower overall friction coefficient and are ground to precise geometric dimensions, making them ideal for preventing edge chipping in graphite workpieces and machining thin-walled graphite components.

        与铜电极相比,加工石墨电极时切削阻力小,热胀冷缩系数小,因此,总体而言较容易加工薄壁结构。然而,加工石墨电极也有其特有的困难和问题,其中最常见的是边缘崩缺。资深工程师根据经验总结了以下一系列指导原则,以最大程度避免石墨加工过程中的崩缺现象。
1) 在加工出口端预先铣进一小段,可避免切削到出口时工件边缘崩缺;
2) 采取顺铣,即,刃口切削方向与进给方向相反;
3) 切深不能超过铣刀直径的1/3;
4) 吸尘器风速设置:加工区域>150米/分钟;粉尘排出口>600米/分钟;
5) 及时更换已经失效的刀具;
6) 提高刀具线速度,降低进给率;
7) 尽量使用高质量细微粒石墨材料。
* 特别重要的建议是,CVD纯金刚石涂层整体铣刀摩擦系数小,整体磨制而确保精确的几何尺寸,是避免石墨件边缘崩缺和加工石墨薄壁件的理想刀具。

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