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CemeCon AG

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The problem: Milling tools have to get smaller and smaller

Tools with extremely small diameters from 0.1 millimetres are increasingly being used in graphite machining in order to comply with the fine contours and ever tighter tolerances in tool and mould making. To ensure that the high accuracy of the tools persists even after coating, precision tools at Cemecon are coated to the appropriate final dimension on request - and this can be reproduced at any time, including documentation. The result is an unbeatable combination of a perfectly ground tool and high-quality smooth coating, which ensures excellent surface quality of the milled graphite electrodes.

Why graphite should be milled wet rather than dry

Another development that favours the growing use of graphite is wet machining, even though dry machining was favoured until some time ago. However, the very fine dust produced by dry milling is unsightly and prevents such electrodes from being used in hygienically sensitive industrial sectors. Cimtrode is also a pioneer in the wet machining of graphite. Early tests quickly proved that machining with cooling lubricants can actually be more efficient than without. The service life of the tools can be doubled in some cases. Dimensional accuracy was also improved. The result was finer, more homogeneous surfaces with tight tolerances, which ultimately leads to better erosion results.

Gallery

This paves the way for further precision applications, such as the production of moulds for curved mobile phone screens, as the company notes. The electrodes are also virtually washed and therefore clean thanks to the wet machining process. This also has a positive effect on quality measurements and on eroding with maximum precision. Another advantage is the more flexible machine utilisation. This is because wet machining enables graphite, copper and hard machining on one and the same milling machine. This lowers the financial hurdles for small and medium-sized companies because no additional milling machine needs to be purchased for graphite machining.

Delicate electrodes require adequate measurement technology

Especially in the case of delicate electrodes with tolerances in the micrometre range, all factors must be perfectly coordinated. Only excellent quality control can identify possible errors at an early stage and, if necessary, lead to the parameters being adjusted. Cimtrode has therefore developed a measuring and testing system specifically for mould and tool making. This brings us to the C-View system mentioned above. It allows, for example, the inspection and assessment of wear on milling or drilling tools. It also facilitates an exact assessment of electrode surfaces before they are eroded. This brings advantages for the user and significant improvements can be achieved in terms of quality and process reliability.

Cemecon, for example, uses C-View in combination with a laser measuring device to carry out input and output checks on precision tools. This is because identical tools - even sister tools - differ in diameter and length, even if only minimally, as the company explains. In order to determine the exact coating thickness for the required final dimension, it is therefore essential to measure the tools. Thanks to the attachment developed by Cimtrode with a 4K camera for the laser measuring device, Cemecon can always check the tools at the same measuring point in seconds.

To improve the CO₂ footprint during production, the major manufacturers are also conducting intensive research into the recycling of graphite. Despite the lengthy manufacturing process, this is also being done to meet the demand that the two experts expect. In addition, the potential of this grey gold is far from exhausted.

Tool and mould making

Recycled graphite dust creates sustainable tool electrodes

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