FAQ
Frequently Asked Questions
Insight into the world of high-performance carbon: Answers to technical specs, logistics, and sustainability.
How is graphite made?
The graphite manufacturing process is very lengthy. It can be synthesized using various processes, the oldest of which involves simply heating the mineral carborundum (silicon carbide) to very high temperatures. Below are the steps in the graphite manufacturing process. To learn more about the graphite manufacturing process, click here.
1. Raw Material Storage
2. Crushing
3. Milling
4. Vibration and Sieving
5. Storage & Pitch Binder = Kneading & Mixing
6. 2nd Stage Milling
7. ISO-Static Pressing
8. Baking
9. Graphitizing
10. Inspection
What is TCGS' standard lead time?
Tokai’s lead times vary depending on what you order. We have hundreds of items in stock available for same-day shipping! If you need machined components, the lead time will depend on the complexity of your part. In addition, our production schedule changes frequently, therefore, we recommend that you contact us for a quote.
What information is required to quote custom / machined graphite parts?
Ideally, we’d like to receive a print and a model of the part you’d like machined.
What type of dielectric oil doesTCGS offer for EDM?
We offer DC-100 which is our proprietary blend formulated specifically for EDM. In addition, we carry IONOPLUS-3000 for our customers that prefer a full synthetic fluid.
What is TCGS's standard tolerance for sawcut material?
Our standard tolerance for sawcut finish is +.125 / -.000
Does TCGS have 5-axis machining capabilities?
Yes, we have the capability to produce complex graphite components and electrodes.
Are there weight and size limitations for custom crates?
There are size limitations based on how the crate will be transported. Depending on the size of your order, we can build custom crates specifically to ship your parts. Our crates are designed to ship via LTL (Less-than-Truckload) freight carriers, to ensure they arrive in excellent condition. MWI handles your items with great care.
Does my application require extruded or isotopically pressed graphite?
- Extruded graphite characteristics include unidirectional grain orientation, large particle size, low density and relative low strength values.
- Isotropic graphite has no primary grain direction, smaller particle sizes and higher density / strength values.
How is EDM grade graphite classified?
Typical users compare graphite particle size and density as the primary indicators for this choice of materials. Larger particle size grades are less expensive and typically used for achieving the highest work piece removal rates. Smaller particle size materials with a higher density are used for the EDM of work pieces that require intricate detail and specific surface finishes.
How do I compare one grade of EDM graphite to another?
Requesting the distributor’s material specifications is a good starting point. These specifications can often be compared to the manufacturer’s. We recommend conducting actual test cuts in your EDM machine. Simple tests, such as sharp corner wear and material removal rate (MRR) at varying depths, can provide valuable insights. Using tools like a CMM, optical comparator, or microscope can offer more detailed information on material wear for comparison. For more details, check out MWI’s EDM graphite product guide here!
How does EDM work?
Electrical Discharge Machining (EDM) is a non-traditional machining process that uses electrical sparks to remove material from a conductor. It works by creating an electric spark between an electrode and a conductive workpiece immersed in a dielectric fluid. The spark repeatedly erodes the material, creating a precise cavity or cutting a desired shape. The spark is generated by passing a high-frequency electric current between the electrode and the workpiece. The dielectric fluid isolates the electrical circuit and cools the process, preventing damage to the electrode and the workpiece.
Can graphite be cut by wire EDM?
Yes, graphite can be cut by wire EDM (Electrical Discharge Machining). Wire EDM is a type of EDM that uses a thin wire as the electrode to remove material from the workpiece. The wire runs though the workpiece, and electrical discharge sparks occur between the wire and workpiece, cutting away the material. Graphite is a common material used in wire EDM operations due to its high electrical conductivity and ability to withstand high temperature.
Where does TCGS’s graphite come from?
Our graphite is made in Japan and we are the exclusive distributor for Tokai Carbon in North America. We guarantee material consistency for every grade.
EDM Wire Handling & Wire Storage
My wire is tangled. What can I do to fix it?
If your wire is snagged, then do the following: Expose the snagged wire on the spool and cut the bundle of coils with scissors. Grasp all ends by hand and pull the wire layers over the spool.
What is the best way to store Bedra spools?
It is very important to properly secure the loose end of the wire on partially used spools. This will prevent the wire from shifting on the spool and becoming tangled. Improper handling and storage techniques can cause unwinding problems and unnecessary wire breakage. Partially used spools should be stored in their original packaging material when not in use. This will minimize contamination and shifting of the wire on the spool.
What is the best way to store a used spool?
It is very important to properly secure the loose end of the wire on partially used spools. This will prevent the wire from shifting on the spool and becoming tangled. Improper handling and storage techniques can cause unwinding problems and unnecessary wire breakage. Partially used spools should be stored in their original packaging material when not in use. This will minimize contamination and shifting of the wire on the spool.
Can you reuse EDM wire?
No, EDM wire is single-use. As it passes through the machine, it erodes from electrical discharge and loses precision. Reusing it would compromise accuracy, surface finish, and risk wire breaks.
Is coated wire always better?
Not always. Coated wires (like zinc-coated or diffusion-annealed) often offer faster cutting and fewer breaks, but they cost more and aren’t ideal for every application. The right choice depends on your material, tolerance needs, and budget.
EDM Filters
What micron filter can I use when cutting aluminum or carbide?
A 20-micron filter is the recommended choice for extended filter life when cutting materials like aluminum or carbide, as it allows for greater flow and reduced maintenance. The 5-micron filter is common and better suited for general tool steel cutting applications.