1. Abrasion & resulting tool wear: Because the graphite materials used for EDM work are extremely abrasive, tools wear out faster than usual. For best results machining graphite, use specialty coated carbide tooling.

For graphite machining, a CVD diamond coating is recommended to improve tool life and tool performance. This coating is grown directly onto carbide tools, increasing the hardness and creating a coating layer that is five times thicker than a PVD Diamond Coating. Even if these tools don’t offer the sharpest edge, the CVD diamond coating offers much longer tool life than other diamond coatings because of the thicker diamond layer.

2. Dry machining: Machining without coolant and at high speeds creates a lot of dust. Compressed air can be used to lessen tool wear and help prevent premature tool failure. A strong vacuum system within the machine tool is mandatory to remove the dust from the work envelope.

InovaTool and The Leading Edge offer a comprehensive range of Diamond coated Carbide tools that resist tool wear, making them ideal for tackling this challenge.

It is imperative to have a good surface finish on electrodes before die sinking to minimize bench time on the tool afterwards.

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Electrodes can have small ribs and features that require small diameter tools, and graphite is typically machined without coolant and at high speeds. This makes the ideal machining center one with high spindle speeds and optimal dust extraction systems.

4. Work holding. One of the most important aspects of electrode machining is rigid clamping. Be sure to use a good, solid clamping system to minimize vibration and the challenges that come with it.

3. Workpiece geometry: EDM electrodes can be complicated parts with elements that are not easily created with customary tools and regular milling machines. These electrodes can have small, deep, and fragile features that are very challenging to create. The proper cutting tools, running at the correct cutting data with specialized geometry and coatings, can help tackle the challenge.

Graphite is commonly used in the electrical discharge machining (EDM) industry. However, graphite has particular characteristics that make machining it a challenge. It is strong, but also soft and brittle, and is prone to chip if not handled correctly. Additionally, graphite is abrasive, causing unusually high tool wear.

We are proud to represent many supplier partners to support graphite machining and the mold and die industry overall, including Inova Tools, The Leading Edge, Blaser-Swisslube, botek, MST and Piranha Clamp.