Graphite machining is a critical process in high-precision industries like battery manufacturing and mold making—yet it’s notorious for producing burrs that compromise part quality and surface finish. In fact, studies show that up to 30% of rejected graphite parts are due to improper chip control or tool wear, not design flaws.
Unlike metals, graphite fractures unpredictably under cutting forces. This brittleness leads to micro-chipping at the edge—especially when using unoptimized tools or insufficient cooling. Common causes include:
Polycrystalline Diamond (PCD) tools outperform carbide by up to 5x longer life in graphite applications. Their extreme hardness resists abrasion while maintaining sharp edges—reducing the need for frequent tool changes and minimizing burr formation.
| Parameter | Recommended Range |
|---|---|
| Spindle Speed (RPM) | 800–1500 RPM |
| Feed Rate (mm/min) | 200–500 mm/min |
| Depth of Cut (mm) | 0.1–0.3 mm |
A properly designed wet flushing system can reduce thermal stress and dust accumulation by over 70%. By continuously removing fine particles during milling, you prevent re-cutting debris—which is a major cause of burrs. Look for systems with adjustable nozzles and full-seal enclosures to minimize maintenance and improve uptime.
Quick Check: Are You Setting Up for Success?
Many engineers overlook how small adjustments—like reducing feed rate by just 10% or adding a mist-cooling feature—can lead to measurable improvements in burr reduction. It's not about complex automation—it’s about consistent execution of best practices.
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