The health and well-being of toolmakers who use graphite to make electrodes for EDM mold machining must be a high priority for management. In addition to worker health concerns, very expensive machinery such as EDM machines and milling machines must be protected from the damaging effects of graphite dust. EDM and injection molding are inseparably linked in the manufacturing process of plastic products.

Anyone who has worked with graphite in the manufacture of EDM electrodes is well aware of the need for proper dust removal during the machining process. Many poorly equipped shops have very little equipment to handle the dust generated during grinding and grinding operations.

Safety

The MSDS (material safety data sheet) for synthetic graphite used in EDM shows that there are no cancer-causing properties associated with graphite. It is a chemically inert material and does not contain volatile components. It is also used for medical purposes, such as implants and heart valves in the human body.

However, this is not to say that graphite is completely harmless. It can be very irritating to the skin, eyes and nasal passages. It may cause stinging, red, and watery eyes and itchy skin. This can be a very annoying experience when expecting a tool maker to produce a close tolerance electrode with a fine finish.

controlling the dust

The simple but very ineffective solution is to use particle masks. Experience shows that this stopgap measure is a failure. The mask soon becomes clogged with fine dust and the operator is left breathing a disgusting mix of bad breath and graphite dust!

Portable vacuum cleaners are the next best solution, but this also has many drawbacks. Often the filter on a portable shop vac is not fine enough to trap microscopic sized particles, and they are simply blown out into the air. Also, because the vacuum hose is often cumbersome to handle, operators do not properly align the hose to capture most of the dust.

Many shops use a centralized vacuum system designed for the removal of fine dust particles, such as graphite. It is important to have enough air velocity in the vacuum system for it to be effective. It is recommended to have an air speed of 500 feet. per minute and the air in the lines must travel at a velocity of 2000 feet. per minute to prevent dust from settling inside the ductwork.

With a centralized system it is much easier to efficiently manage dust from different machine tools because the system is more efficient and the hoses can be placed strategically. There are special wheel guards available for surface grinders that act like a turbo to remove dust in the vacuum system.

Newer milling machines, more or less dedicated to electrode machining, are equipped with extremely effective dust removal systems. The sealed chamber around the work area allows the vacuum to capture a high percentage of dust. This development has drastically reduced the amount of graphite dust in the shop environment.

An additional method of dust removal is the use of a coolant curtain that surrounds the cutter. This prevents dust from escaping and is very efficient. This feature is available on some routers as well as an easily installed accessory.

A clean workshop environment

Graphite powder is highly conductive and has been responsible for the damage of many expensive tools and machines. Glass scales can give false measurements due to dust buildup. Dust can also short-circuit electronic equipment. The dirty nature of graphite makes it especially annoying if it accumulates on workbenches and desks.

It is in everyone’s best interest to do everything possible to maintain a clean and pleasant environment in a mold making or EDM shop. The toolmakers will be happy, the work will be better, and the machinery will work as it should. It is also very impressive for visitors to see a clean and dust-free store.