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The health and welfare of toolmakers that use graphite to make electrodes for use the EDM machining of molds should be a high priority for management. In addition to the health issues for the workers, the very expensive machinery, such as the 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 manufacturing of EDM electrodes is keenly aware of the need for proper dust removal during the machining process. Many ill-equipped shops have very little equipment to handle the dust generated during milling and grinding operations.
Safety
The MSDS (material safety data sheet) for the synthetic graphite used in EDM show that there are no carcinogenic properties associated with graphite. It is a chemically inert material and contains no volatile components. It is also used for medical purposes, such as implants and heart valves in the human body.
This is not to say that graphite is totally harmless though. It can be very irritating to the skin, eyes, and nasal passages. It can cause stinging, redness and watering of the eyes, and itching of the skin. This can be a very annoying experience when a toolmaker is expected to produce a close-tolerance electrode with a fine finish.
Controlling the Dust
The simple but very ineffective solution is to wear particle masks. Experience shows that this stop-gap measure is a failure. The mask soon is clogged with the fine dust and the operator is left breathing a disgusting blend of bad-breath and graphite dust!
Portable vacuums are the next best solution, but this also has many drawbacks. Often the filter in the portable shop vacuum is not fine enough to trap the microscopic sized particles, and they are simply blown back into the air. Also, because the vacuum hose is often cumbersome to manipulate, operators fail to properly align the hose to capture the most 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 to be effective. It is recommended to have an air velocity of 500 ft. per minute and the air in the lines should travel at a rate of 2,000 ft. per minute in order to prevent the dust from settling inside the duct work.
With a centralized system it is much easier to efficiently manage the dust from the various machine tools because the system is more efficient and the hoses can be strategically placed. Special wheel guards are available for surface grinders that act as a turbo to remove the dust into the vacuum system.
Newer milling machines which are more or less dedicated to electrode machining are equipped with extremely effective dust removal systems. The sealed chamber around the work area enables the vacuum to capture a high percentage of the dust. This development has dramatically reduced the amount of graphite dust in the shop environment.
An additional method of dust removal is the use of a curtain of coolant surrounding the milling cutter. This prevents the dust from ever escaping and is very efficient. This feature is available on some milling machines as well as an accessory that is easily installed.
A Clean Shop Environment
Graphite dust is highly conductive and has been responsible for the damage of many expensive tools and machines. Glass scales can give false measurements due to the settling of dust. Electronic equipment can be short-circuited by the dust as well. The grimy nature of graphite makes it especially annoying if it accumulates on work-benches and desks.
It is in the best interest of everyone to make every effort of maintain a clean and pleasant atmosphere in a moldmaking or EDM shop. The toolmakers will be happier, the work will be better and the machinery will perform as it should. It is also very impressive to visitors to see a clean, dust-free shop.
If you haven't already done so, 5S process implementation should rank high on your list to organize your shop!
Mijas Hot Tubs - History
The Hot Tub industry would not have started but for the input from Roy Jacuzzi and his family and as an insight here is an extract from a Jacuzzi press release dealing with the History of the Jacuzzi Brand.
According to a Jacuzzi, Inc press release "The History of the Jacuzzi Brand": ...begins in the early 1900s, when the seven Jacuzzi brothers immigrated to California from Italy.
The brothers made great strides in aviation by inventing the first enclosed cabin monoplane, which carried mail for the U.S. Postal Service as well as passengers from the San Francisco Bay Area to Yosemite National Park in California.
Incorporating their hydraulic insight, Jacuzzi Brothers, as they'd come to be known in 1920, later made notable advancements in the agricultural pump industry, which led to an invention that remains an iconic fixture in American homes today.
Since then there have been many further developments and one example would be that the Jets designs have increased very considerably.
There is no doubt in my mind that that back in time just over half a century ago (1954) when the Jacuzzi brothers Invented a portable whirlpool pump (simply as I understand it because one of their relatives had arthritis) that they would not have had an inkling that this would go on to form such a large and developing industry.
Hot Tubs are now being made in most western countries to the highest standards and the development of the product continues at a pace. The original Jacuzzi pump, when coupled with jets using an air-injection system, a mixture very similar to a kind of bubbly water-and-air was created. With the natural passing of time, a variety of American manufacturers experimented with methods to propel the air/water stream into the spa with ever increasing digress of pressure and control. Initially spas used a simple idea that involved something like a vacuum cleaner motor but operating as a blower in some ways similar to blowing air into the hot tub in exactly the same way that we as children would have used a straw to blow bubbles in to a glass of lemonade or coca cola.
Again as time passed the designers soon began thinking of things like the venturi principle, in which water is pumped through a funnel-like device to create a vacuum that pulls in air. As the water flow and pressure begins to increase, the jet automatically sucks in more air, which results in a greatly increased water flow and movement not unlike the idea of an exhaust driven turbo charger in a car.
Many Hot Tubs have the ability to bleed air into so that one is able to inject air into the Jets thereby increasing the pressure and movement of the water. Not unlike perhaps a turbo charger on a car.
The pioneering spirit of the original Jacuzzi brothers was alive and well in third generation family member Roy Jacuzzi, who invented the world's first whirlpool bath in 1968. As a teenager, he started working in the family business in a variety of odd jobs, really learning how the business worked from the ground up. In 1968, his passion for design and engineering emerged when he invented and marketed the world's first fully integrated whirlpool bath, known as the Roman. Sensing that American consumers were moving toward an emphasis on health, fitness and leisure activities, the determined Jacuzzi peddled his invention one at a time at county fairs and trade shows in California.
At the same time his family members looked on with both surprise and delight, Roy slowly and more or less on his own created a brand new industry.
Quoting the chairman and president of Jacuzzi Inc Roy Jacuzzi. of California, United States of America, Roy said "A venturi system is a conventional approach," "What I did was take air and water all around that so I was getting a 300/60 air-to-water mixture. "I was actually taking the water and air combination ... and exploding that," he added.
The earliest spas, though, incorporated only enough jets to churn the water.
Quoting another Spa manufacturer Bernie Burba, founder of Baja Products Inc in Tucson, Arizona said "When we first came out with spas, they had two spa jets on them, "Now you see portable spas with 60 on them. You might say that's overkill, but it isn't," he said. "We have really learned a lot about water therapy and that lots of jets - together with plenty of warm water and air moving across your body - is a very satisfying, restful and helpful experience."
Today, the jets of a Hot tub provide pulsating and soothing massage action all over the body, from stiff necks to sore feet. Hot Tub & Jacuzzi style Spa manufacturers now offer various specific jets and massage systems to help massage the neck and shoulders, arms, wrists, hips and thighs, the knees, calves and feet etc.
Apart from the original idea of being able to mix warm water and air to create the Spa effect there is no part of a Hot Tub that has not had considerable improvements and amendments made to the technology and indeed the construction and manufacturing processes used in making a Hot Tub.
Whole industries have been spawned producing the components and raw materials that Hot Tub manufactures require. The Acrylic Sheets that form the Shell the electronic controls the pumps and motors. Each and every American Hot Tub manufacturer has tried to be at the cutting edge when introducing new ideas.
To summarize it pays to buy a product from a leading American or Western manufacturer as clearly they have been at the forefront of developments in this industry for more thsn 40 year and not a cheap import from China no matter how well it is disguised or packaged.
About the Author
The author Jacuzzi John supplies luxury American Hot Tubs on the Costa Del Sol In Spain and his web site is at Hot Tubs Spain and for a designer range go to Spain Hot Tubs
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