High-speed finishing milling of industrial graphite electrodes

The production of molds and dies in hardened steel is one of the most difficult machining tasks, mainly in cases where good dimensional precision and superficial quality are required. Normally, electrodischarge machining (EDM) and milling processes are used for mold and die manufacturing. Thus, a better understanding and analysis of the graphite electrode manufacturing process is of absolute importance for tool makers, where the machining of deep cavities and complex forms is commonly required. In this study, graphite machinability tests were carried out, followed by an analysis of tool wear and surface quality generated in down- and up-milling. Conclusions are drawn regarding the best machining strategies and parameters to use in the machining of this material. The technological information gained from this study will be of great interest to small and large tool making industries and will enable them, through a better understanding of the graphite cutting process, a greater productivity in electrode manufacturing. (c) 2006 Elsevier B.V. All rights reserved.