In the realm of graphite machining, a notable trend has emerged: an increasing number of enterprises are transitioning from dry to wet graphite machining. This shift is not without reason. Dry graphite machining has long been the norm, but it comes with inherent limitations. For instance, in dry machining, the heat generated during the cutting process can reach up to 500°C, which often leads to thermal deformation of the graphite workpiece. Moreover, the dust produced can cause significant wear and tear on the cutting tools, reducing their lifespan by as much as 30%.
The core mechanism of wet graphite machining lies in the use of coolant. Coolant plays a dual - role in the machining process: thermal management and dust removal. When the coolant is sprayed into the cutting area, it absorbs the heat generated by the cutting operation. Research shows that with proper coolant application, the temperature in the cutting area can be maintained below 100°C. At the same time, the coolant flushes away the graphite dust, preventing it from accumulating and causing damage to the cutting tools and the workpiece. The following diagram illustrates how the coolant achieves these functions:
In the mass production of graphite products such as molds and electrodes, wet graphite machining offers significant advantages in terms of efficiency, quality, and reliability. In terms of efficiency, wet machining can increase the cutting speed by up to 20% compared to dry machining. This is because the coolant reduces the friction between the tool and the workpiece, allowing for smoother cutting. Regarding quality, the surface finish of the machined graphite products is greatly improved. The surface roughness can be reduced from Ra 3.2μm in dry machining to Ra 1.6μm in wet machining. In terms of reliability, the stability of the machining process is enhanced, resulting in a higher yield rate. In high - precision mold and electrode mass production, the yield rate can reach over 95% with wet machining, compared to around 80% with dry machining.
To achieve the best results in wet graphite machining, proper parameter matching is crucial. Here are some best - practice cases for coolant flow, pressure, and spraying methods:
| Parameter | Recommended Value | Reason |
|---|---|---|
| Coolant Flow | 20 - 30 L/min | Ensures sufficient coolant supply to the cutting area for effective heat dissipation and dust removal |
| Coolant Pressure | 2 - 3 MPa | Provides enough force to flush away the dust and reach all parts of the cutting area |
| Spraying Method | Direct spraying at the cutting edge | Maximizes the contact between the coolant and the cutting area |
Dry machining poses several risks. As mentioned earlier, thermal deformation is a major issue. The high temperature can cause the graphite workpiece to expand and contract unevenly, leading to dimensional inaccuracies. Additionally, the dust generated in dry machining is not only harmful to the cutting tools but also to the working environment and the health of the operators. Prolonged exposure to graphite dust can cause respiratory problems.
In the era of intelligent manufacturing, wet graphite machining plays a crucial role in supporting the stable operation of automated production lines. The consistent quality and high yield rate of wet machining ensure that the automated production process can run smoothly. The reduced tool wear also means less frequent tool replacement, which reduces downtime and increases overall productivity.
The DC6060G wet graphite machining center from Kaibo CNC is an ideal solution for wet graphite machining. It has a positioning accuracy of 0.01mm, which ensures high - precision machining. Its fully sealed structure prevents the leakage of coolant and dust, creating a clean and safe working environment. The wet flushing system is designed to provide optimal coolant flow and pressure, ensuring efficient heat management and dust removal. With the DC6060G, enterprises can achieve efficient and reliable wet graphite machining.
If you are interested in exploring the benefits of wet graphite machining and the capabilities of the DC6060G, visit our website or schedule a trial today!
