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Precision Graphite Solutions

Tooling Types – Milling Basics

Types of Milling

Different Types of Milling

There are many different types of tooling, the most common being work holding tools.  Work holding tools include jigs and fixtures; cutting tools for milling and grinding machines; dies for cold forming,  forging and extrusion machines; and welding and inspection fixtures. In this month’s blog, we are going to look at the basics of milling.

Milling is the machining process of using rotary cutters to remove material from a workpiece by advancing the cutter into the workpiece at a certain direction. The cutter may also be held at an angle relative to the axis of the tool.  Milling covers a wide variety of different operations and machines and is one of...Read more

Tooling Types – Grinding Basics




There are many different types of tooling, the most common being work holding tools. Work holding tools include jigs and fixtures; cutting tools for milling and grinding machines; dies for cold forming, forging and extrusion machines; and welding and inspection fixtures. In this month’s blog, we are going to look at the basics of grinding.

Grinding, or abrasive machining, is the process of removing metal in the form of minute chips by the action of irregularly shaped abrasive particles. These particles may be in bonded wheels, coated belts, or simply loose. Grinding wheels are composed of thousands of small abrasive grains held together by a bonding material. Each abrasive grain is a...Read more

Taking Quality to the Floor

Quality on the Floor

Quality Control in manufacturing is a needed process that ensures customers receive products that are free from defects and meet their needs.

Our customers expect us to deliver quality products in a timely manner. Quality is critical to satisfying our customers and retaining their trust and loyalty. It influences our reputation and helps to control our overall costs.

Recently, Graphel Carbon Products held a Kaizen event to help improve our quality and our on-time performance. One of the main pillars of LEAN methodology, a Kaizen is a specific tool to improve quality. The objective of a Kaizen is to improve productivity, reduce waste, eliminate unnecessary work and...Read more

Tooling Types – Turning



There are many different types of tooling, the most common being work holding tools. Work holding tools include jigs and fixtures; cutting tools for milling and grinding machines; dies for cold forming, forging and extrusion machines; and welding and inspection fixtures. In this month’s blog, we are going to look at turning.

Turning is a machining process in which a cutting tool, typically a non-rotary tool bit, describes a helix toolpath by moving more or less linearly while the workpiece rotates. Turning is a form of machining, a material removal process, which is used to create rotational parts by cutting away unwanted material. The turning process requires a turning machine or...Read more

Sinker EDM – Inside the Cavity

]EDM Cavity

EDM Cavity

As the cut progresses through the work metal a cavity starts to form. The deeper this cavity becomes, the harder it is for fresh dielectric fluid to get into the cavity to remove debris and quench the work piece and electrode. In order to get smooth, even flow of dielectric through the gap, flushing becomes an essential part of the EDM process.

Good flushing allows the work piece particles and eroded electrode particles to be removed from the gap. Flushing also allows fresh dielectric into the gap. Both are necessary to maintain stable cutting and to prevent arcing.

It is the volume of oil moving through the gap that performs particle removal. Turbulence in the tank would...Read more

Sinker EDM – The Spark Gap Thermoelectric Model

Spark Gap

EDM machining is considered by most to be a thermal removal process. The most convincing support for this claim is the removal of material from the electrodes by melting and/or vaporization by a thermal process, along with pressure dynamics established in the spark-gap. The spark gap generates an electrical force on the surface of the electrode that removes material.

Electric discharge machining (EDM), sometimes referred to as spark machining, spark eroding, burning, die sinking or wire erosion is a manufacturing process whereby a desired shape is obtained using electrical discharges (sparks). Material is removed from the workpiece by a series of rapidly recurring current discharges...Read more

Sinker EDM – Dielectric Fluids




Choosing Dielectric Fluid for Sinker EDM Applications
April 2018



Choosing the correct dielectric fluid for your EDM application is not always as straightforward as it might seem. Many criteria need to be taken into account. Some are obvious, such as degree of metal removal and electrode wear, while others are much more subtle.

Dielectric fluid is a material whose main purpose is to prevent or rapidly quench electric discharges. Dielectric liquids are used as electrical insulators in high voltage applications to provide electrical insulation, suppress corona and arcing, and to serve as a coolant.

A good liquid dielectric should have high dielectric strength, high thermal stability and chemical inertness against...Read more

Sinker EDM Basic Terminology Part II – Flushing

Flushing

SINKER EDM BASIC TERMINOLOGY – PART II - FLUSHING
MAR 2018 Blog


It’s been said the 3 most critical things about a good sinker EDM burn condition are flushing, flushing, and flushing. This is still true today but modern machines have built in technologies that assist with flushing even when the operator doesn’t think about flushing. More on these in a bit.

Flushing is a critical part of the EDM process, as it removes contaminated fluid and eroded particles, and replaces them with clean, temperature controlled fluid. This removes contamination from the spark gap that could develop into undesirable conditions like slow, unstable burns, pitting of the work piece, and...Read more

Sinker EDM Basic Terminology – Part I



RAM EDM, otherwise known as “Sinker EDM” or “Plunge EDM” has been around for over fifty years. Though widely used, there are some who are unfamiliar with certain EDM terminology.

KEY FACTORS OF SINKER EDM

Since Sinker EDM uses electrical energy to remove material, it stands to reason that the make-up of the material will have a direct impact on the rate of removal. This being the case there are three critical things to keep in mind.

• Since machining with Sinker EDM or Plunge EDM occurs by using electrical energy the electrical conductivity plays a key role in how fast the Spark Gap can ionize allowing a spark to...Read more

A Little History of the Sinker EDM




Electrical Discharge Machining or EDM Machining makes it possible to work with hard metals for which traditional machining techniques are inadequate.

The EDM machining process came into being during the 1770s when it was discovered by an English Physicist name Joseph Priestly, who discovered the effect of electrical discharges on various metals. However, the process was not widely used until 1943 when Russian scientists B.R. and N.I. Lazarenko discovered how to exploit the destructive effects of an electrical discharge technique that could be controlled and used for machining work.

Any conductive material can be machined using Sinker EDM such as aluminum, brass, carbide, copper, stainless steel, tool steels, titanium etc. Sinker EDM is a...Read more
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