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HSC processing of graphite electrodes is one of the most important procedures in tool and mold manufacturing. It is now possible to produce ultra-precision 3D profiles with dimensions up to μm, in which case precision tools for diamond coatings are essential – in fact, it is now rare to use graphite with uncoated tools. . In the production process, the increasingly high feed rate and chip evacuation, as well as the shorter and shorter machining time, must be achieved with fully optimized tools.
Let's take a look at the application case of Zecha in Konigsbach-Stein, which has a diamond-coated carbide milling tool line, so there is an opportunity to prove how important it is to have advanced tools and processing know-how. It is well known that the purpose of continuous research and development of tools is to make the surface of the workpiece smoother and more precise.
Diamond coatings extend tool life tolerances in the μm range, and the thinnest wear-resistant coatings have a negative impact on shape accuracy, diameter and actual rotational accuracy, which will also greatly affect the tool's quality. Ardat Fielen, Zecha's sales manager, said: “Our tool technicians have been working with CemeCon's coating experts for many years. They have discovered the precise conditions for building the perfect coating, and this process is perfectly suited to our precision tools. Geometric shape and material properties, as well as processing of rough and abrasive graphite."
Zecha's graphite machining and milling tool solutions include diamond-coated VHM ball-end milling cutters and R-angle milling cutters on two product lines. In large-scale production, thanks to their established diamond coatings and innovative geometries, these milling tools allow machining to be performed at optimum cost, ranging from 0.2 to 6.0 mm. Zecha's “high-end production line†is a milling tool solution that achieves extremely small tolerances and the longest tool life. The actual test has verified the following accuracy: a diameter tolerance of 10 μm, a shape accuracy of 10 mm (usually 2-5 μm), and an actual rotation accuracy of 3 μm.
With Zecha's know-how and CemeCon's technology, this diamond-coated VHM micro-milling tool is optimized to achieve the same actual rotational accuracy as can be achieved with uncoated tools.
In the tool and mold manufacturing industry, more and more filament structures and high precision are required. Many manufacturers rely on graphite electrodes because graphite is quite heat resistant and shows little tendency to distort. In the process of manufacturing graphite electrodes using modern machining centers, extremely precise and stable milling tools are required to ensure extremely tight tolerances.