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Endmilling graphite EDM electrodes A leading supplier of
molded plastic products for the microelectronics industry uses
sp3 endmills to machine the sinker EDM electrodes used to
make injection molds. The electrodes are made from various grades of graphite
which include EDM 200, Poco 2 and Poco 3. Previously, using uncoated carbide
endmills at spindle speeds from 12,000 to 14,000 rpm and feed rates between 120
and 160 ipm, tool life averaged 4 hours. With sp3 CVD diamond
endmills operated at the same parameters tool life is 60 hours—an
improvement of 15 times over carbide—achieving a major gain in unattended
machining.
 With
sp3 CVD diamond tools, one Makino SNC64 graphite machining
center is able to produce all the electrodes necessary to feed four Makino EDNC
series EDM machines. Besides increasing productivity through fewer tool
changes, the low wear of CVD diamond endmills has made it easier to obtain the
required electrode accuracy of ±0.0005 in. because the CNC machinist
doesn't have to fight tool wear. |
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Machining Kevlar-reinforced graphite epoxy wing stringers
An aircraft manufacturer has demonstrated the advantages of diamond-coated
routers for machining graphite epoxy reinforced with Kevlar fibers. The present
tool used is a cylindrical router covered with diamond grit bonded with nickel
plating. This approach requires 2 to 3 hours of hand work on each part to bring
the surface finish within specifications.
sp3 custom-ground and
diamond-coated special .375" 2-flute routers with a 10° helix. Speed was
20,000 rpm, feed was 100 ipm with coolant. The routers met the expected life
criteria with greatly improved surface finish, eliminating post-machining hand
work. The cost saving in hand work per part is over $100. |
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Endmilling graphite parts for semiconductor furnaces A
manufacturer of semiconductor furnace components is using extra-long .25"
diameter sp3 endmills to machine graphite parts. The
parameters are: speed 4100 rpm (400 sfm), feed 25 ipm (.006 ipr), and DOC
.500". No coolant is used, and a surface finish of 63 Ra is required.
The sp3
tool machines 19 complete parts (2300 linear inches) vs. 1 part for uncoated
carbide. The cost saving is approximately $28.00 per part. |
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Endmilling green aluminum oxide A ceramic parts
manufacturer uses sp3 .375" diameter 2-flute endmills to
machine parts from green aluminum oxide. Speed is 2000 to 4000 rpm, feed .004
ipr, DOC .500" to 1.000". No coolant is used.
The sp3
endmill produces 2600 pieces vs. 50 for uncoated carbide. Machining cost per
part is $.10 for sp3 vs. $.68 for uncoated carbide.
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