If you're an engineer working in battery manufacturing or mold production, chances are you’ve faced the frustration of poor surface finish during graphite machining. A rough surface isn’t just about aesthetics—it directly impacts part consistency, tool life, and even downstream assembly processes.
Graphite is abrasive by nature. Standard carbide tools wear out fast—often within 30–40 minutes under heavy load. That’s why industry experts recommend polycrystalline diamond (PCD) inserts for high-precision graphite milling. According to a 2023 study by Manufacturing Engineering Journal, PCD tools can last up to 5x longer than conventional carbide when used correctly—and maintain a Ra value below 0.8 μm consistently.
| Tool Material | Avg. Tool Life (min) | Typical Surface Finish (Ra, μm) |
|---|---|---|
| High-Speed Steel | 15–20 | >3.0 |
| Carbide | 30–40 | 1.5–2.5 |
| PCD | 150–200+ | 0.5–0.8 |
Even with PCD, wrong parameters will lead to chatter and uneven finishes. For most graphite grades, we suggest starting at:
“Don’t underestimate the role of coolant flow rate—it’s not just about cooling. Proper fluid delivery reduces heat buildup and clears chips before they cause secondary damage.” — Dr. Lin Wei, Senior Machining Engineer, Siemens Digital Industries
A dry system may seem cost-effective initially—but in reality, it leads to premature tool failure and inconsistent results. Our engineers found that using a wet flushing system (like the DC6060G model) improves surface quality by up to 40% compared to dry milling. Why? Because it removes heat and debris instantly, preventing thermal cracking and chip re-cutting.
Pro tip: Use a closed-loop wet system with adjustable pressure (recommended: 3–5 bar). This setup also minimizes environmental impact—a growing concern among European OEMs and EV manufacturers.
Discover how our DC6060G wet flushing system helps engineers achieve consistent Ra values below 0.8 μm—without costly downtime or tool replacements.
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