Mold Maker End Mills

Graphite Electrode and Mold ManufacturingGraphite Electrode and Mold Manufacturing

Crystallume DCC tools are finding rapid acceptance among manufacturers of graphite electrodes for use in EDM operations because they last 10 to 30 times as long as carbide tools currently used. Increased tool life results in longer periods of unmanned machining. The machining speeds for Crystallume DCC tools can be increased 2 to 3 times over the speeds used with carbide tools to increase your productivity. These features combine to increase the utilization of your machine tools.

Crystallume's Mold Maker and Extended Shank tools offer features specifically for electrode and mold manufacturing. The Mold Maker tools have a 5 times diameter flute length with an extended shank. The big difference is the tolerance of the tools. With a cutting diameter up to 1/8" and 3mm the tolerance is +0.0000/-0.0005 and for tools larger than this, the tolerance is +0.0000/-0.0010. All shanks are held to a tolerance of -0.0001/-0.0003 to assure consistent and concentric gripping in shrink-fit holders. Mold Maker tools are available in sizes from 1/64" to 1/2" and from .5mm to 6mm in diameter. Tools below 1/4" and 6mm are available with and without extended reach. Crystallume Mold Maker tools are the most precise diamond coated tools available.

The Extended Shank tools combine a short-flute length for maximum rigidity with a long shank for extended reach into deep cavities. When the extended reach is not required, you can choke up on the tool to make it extremely rigid as a stub tool. This is a great all-around tool that will become a workhorse in your shop.

2 Flute Mold Maker End Mills (With Reach)

Cutting
Diameter

Flute
Length

Overall
Length

Reach
Length

End
Style

Shank
Diameter

Tool Number
Coated

1/64"

0.075

2-1/2"

1/8"

BN

1/8"

P820-200404-1

1/64"

0.075

2-1/2"

1/8"

SE

1/8"

P820-200403-1

 

4 Flute Mold Maker End Mills (With Reach)

Cutting
Diameter

Flute
Length

Overall
Length

Reach
Length

End
Style

Shank
Diameter

Tool Number
Coated

1/32"

5/32"

2-1/2"

1/4"

BN

1/8"

P820-200406-1

1/32"

5/32"

2-1/2"

1/4"

SE

1/8"

P820-200405-1

1/32"

5/32"

2-1/2"

1/4"

SE, .005" CR

1/8"

P820-200407-1

3/64"

15/64"

2-1/2"

1/2"

BN

1/8"

P820-200409-1

3/64"

15/64"

2-1/2"

1/2"

SE

1/8"

P820-200408-1

3/64"

15/64"

2-1/2"

1/2"

SE, .010" CR

1/8"

P820-200410-1

1/16"

5/16"

2-1/2"

1"

BN

1/8"

P820-200412-1

1/16"

5/16"

2-1/2"

1"

SE

1/8"

P820-200411-1

1/16"

5/16"

2-1/2"

1"

SE, .010" CR

1/8"

P820-200413-1

3/32"

15/32"

2-1/2"

1"

BN

1/8"

P820-200415-1

3/32"

15/32"

2-1/2"

1"

SE

1/8"

P820-200414-1

3/32"

15/32"

2-1/2"

1"

SE, .015" CR

1/8"

P820-200416-1

3/32"

15/32"

2-1/2"

1"

SE, .020" CR

1/8"

P820-200417-1

1/8"

5/8"

3"

1-1/4"

BN

1/8"

P820-200419-1

1/8"

5/8"

3"

1-1/4"

SE

1/8"

P820-200418-1

1/8"

5/8"

3"

1-1/4"

SE, .015" CR

1/8"

P820-200420-1

1/8"

5/8"

3"

1-1/4"

SE, .020" CR

1/8"

P820-200421-1

1/8"

5/8"

3"

1-1/4"

SE, .030" CR

1/8"

P820-200422-1

3/16"

15/16"

3"

1-1/2"

BN

3/16"

P820-200424-1

3/16"

15/16"

3"

1-1/2"

SE

3/16"

P820-200423-1

3/16"

15/16"

3"

1-1/2"

SE, .030" CR

3/16"

P820-200425-1

1/4"

1-1/4"

4"

2-1/2"

BN

1/4"

P820-200427-1

1/4"

1-1/4"

4"

2-1/2"

SE

1/4"

P820-200426-1

1/4"

1-1/4"

4"

2-1/2"

SE, .015" CR

1/4"

P820-200428-1

1/4"

1-1/4"

4"

2-1/2"

SE, .020" CR

1/4"

P820-200429-1

1/4"

1-1/4"

4"

2-1/2"

SE, .030" CR

1/4"

P820-200430-1

1/4"

1-1/4"

4"

2-1/2"

SE, .060" CR

1/4"

P820-200431-1

 

2 Flute Mold Maker End Mills (With Reach) Metric

Cutting
Diameter

Flute
Length

Overall
Length

Reach
Length

End
Style

Shank
Diameter

Tool Number
Coated

0.5 mm

2.5 mm

62 mm

3 mm

BN

3 mm

P820-200338-1

0.5 mm

2.5 mm

62 mm

3 mm

SE

3 mm

P820-200337-1

 

4 Flute Mold Maker End Mills (With Reach) Metric

Cutting
Diameter

Flute
Length

Overall
Length

Reach
Length

End
Style

Shank
Diameter

Tool Number
Coated

1 mm

5 mm

62 mm

12 mm

BN

3 mm

P820-200340-1

1 mm

5 mm

62 mm

12 mm

SE

3 mm

P820-200339-1

1.5 mm

7.5 mm

62 mm

25 mm

BN

3 mm

P820-200342-1

1.5 mm

7.5 mm

62 mm

25 mm

SE

3 mm

P820-200341-1

2 mm

10 mm

62 mm

25 mm

BN

3 mm

P820-200344-1

2 mm

10 mm

62 mm

25 mm

SE

3 mm

P820-200343-1

3 mm

15 mm

62 mm

30 mm

BN

3 mm

P820-200346-1

3 mm

15 mm

62 mm

30 mm

SE

3 mm

P820-200345-1

4 mm

20 mm

75 mm

40 mm

BN

4 mm

P820-200348-1

4 mm

20 mm

75 mm

40 mm

SE

4 mm

P820-200347-1

6 mm

24 mm

75 mm

50 mm

BN

6 mm

P820-200350-1

6 mm

24 mm

75 mm

50 mm

SE

6 mm

P820-200349-1

 

2 Flute Mold Maker End Mills (Without Reach)

Cutting
Diameter

Flute
Length

Overall
Length

End
Style

Shank
Diameter

Tool Number
Coated

1/64"

0.075

2-1/2"

BN

1/8"

P820-200684-1

1/64"

0.075

2-1/2"

SE

1/8"

P820-200683-1

 

4 Flute Mold Maker End Mills (Without Reach)

Cutting
Diameter

Flute
Length

Overall
Length

End
Style

Shank
Diameter

Tool Number
Coated

1/32"

5/32"

2-1/2"

BN

1/8"

P820-200686-1

1/32"

5/32"

2-1/2"

SE

1/8"

P820-200685-1

1/32"

5/32"

2-1/2"

SE, .005" CR

1/8"

P820-200687-1

3/64"

15/64"

2-1/2"

BN

1/8"

P820-200689-1

3/64"

15/64"

2-1/2"

SE

1/8"

P820-200688-1

3/64"

15/64"

2-1/2"

SE, .010" CR

1/8"

P820-200690-1

1/16"

5/16"

2-1/2"

BN

1/8"

P820-200692-1

1/16"

5/16"

2-1/2"

SE

1/8"

P820-200691-1

1/16"

5/16"

2-1/2"

SE, .010" CR

1/8"

P820-200693-1

3/32"

15/32"

2-1/2"

BN

1/8"

P820-200695-1

3/32"

15/32"

2-1/2"

SE

1/8"

P820-200694-1

3/32"

15/32"

2-1/2"

SE, .015" CR

1/8"

P820-200696-1

3/32"

15/32"

2-1/2"

SE, .020" CR

1/8"

P820-200697-1

1/8"

5/8"

3"

BN

1/8"

P820-200699-1

1/8"

5/8"

3"

SE

1/8"

P820-200698-1

1/8"

5/8"

3"

SE, .015" CR

1/8"

P820-200700-1

1/8"

5/8"

3"

SE, .020" CR

1/8"

P820-200701-1

1/8"

5/8"

3"

SE, .030" CR

1/8"

P820-200702-1

3/16"

15/16"

3"

BN

3/16"

P820-200704-1

3/16"

15/16"

3"

SE

3/16"

P820-200703-1

3/16"

15/16"

3"

SE, .030" CR

3/16"

P820-200705-1

1/4"

1-1/4"

4"

BN

1/4"

P820-200707-1

1/4"

1-1/4"

4"

SE

1/4"

P820-200706-1

1/4"

1-1/4"

4"

SE, .015" CR

1/4"

P820-200708-1

1/4"

1-1/4"

4"

SE, .020" CR

1/4"

P820-200709-1

1/4"

1-1/4"

4"

SE, .030" CR

1/4"

P820-200710-1

1/4"

1-1/4"

4"

SE, .060" CR

1/4"

P820-200711-1

3/8"

1-1/2"

6"

BN

3/8"

P820-200713-1

3/8"

1-1/2"

6"

SE

3/8"

P820-200712-1

3/8"

1-1/2"

6"

SE, .015" CR

3/8"

P820-200714-1

3/8"

1-1/2"

6"

SE, .030" CR

3/8"

P820-200715-1

3/8"

1-1/2"

6"

SE, .060" CR

3/8"

P820-200716-1

1/2"

1-1/2"

6"

BN

1/2"

P820-200718-1

1/2"

1-1/2"

6"

SE

1/2"

P820-200717-1

1/2"

1-1/2"

6"

SE, .015" CR

1/2"

P820-200719-1

1/2"

1-1/2"

6"

SE, .030" CR

1/2"

P820-200720-1

1/2"

1-1/2"

6"

SE, .060" CR

1/2"

P820-200721-1

 

2 Flute Mold Maker End Mills (Without Reach) Metric

Cutting
Diameter

Flute
Length

Overall
Length

End
Style

Shank
Diameter

Tool Number
Coated

0.5 mm

2.5 mm

62 mm

BN

3 mm

P820-200670-1

0.5 mm

2.5 mm

62 mm

SE

3 mm

P820-200669-1

 

4 Flute Mold Maker End Mills (Without Reach) Metric

Cutting
Diameter

Flute
Length

Overall
Length

End
Style

Shank
Diameter

Tool Number
Coated

1 mm

5 mm

62 mm

BN

3 mm

P820-200672-1

1 mm

5 mm

62 mm

SE

3 mm

P820-200671-1

1.5 mm

7.5 mm

62 mm

BN

3 mm

P820-200674-1

1.5 mm

7.5 mm

62 mm

SE

3 mm

P820-200673-1

2 mm

10 mm

62 mm

BN

3 mm

P820-200676-1

2 mm

10 mm

62 mm

SE

3 mm

P820-200675-1

3 mm

15 mm

62 mm

BN

3 mm

P820-200678-1

3 mm

15 mm

62 mm

SE

3 mm

P820-200677-1

4 mm

20 mm

75 mm

BN

4 mm

P820-200680-1

4 mm

20 mm

75 mm

SE

4 mm

P820-200679-1

6 mm

24 mm

75 mm

BN

6 mm

P820-200682-1

6 mm

24 mm

75 mm

SE

6 mm

P820-200681-1

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toolMoldMaker

Mold Maker End
Mills Come in
Eight Varieties:

WITH REACH:

2 Flute

4 Flute

2 Flute Metric

4 Flute Metric

 

WITHOUT REACH:

2 Flute

4 Flute

2 Flute Metric

4 Flute Metric

 

MOLD MAKER
Standard
Tolerances:

Cutting Diameter (up to 0.1250") =
+0.0000/ 0.0005"

(0.1875 to 0.5000") =
+0.0000/ 0.0010"

Shank Diameter =  0.0001/ 0.0002"

Flute Length = ±0.060"

Overall Length = ±0.060"

 

MOLD MAKER
Metric
Tolerances:

Cutting Diameter (up to 3.000 mm) =
+0.000/ 0.013 mm

(3 mm to 6 mm)  =
+0.000/ 0.025 mm

Shank Diameter =  0.002/ 0.005 mm

Flute Length = ±1.000  mm

Overall Length = +0.500/ 1.500 mm

 

Machining
Case Study 1

Mold company using POCO 200 to build graphite electrodes.

Electrode was machined at 1400 sfm and 315 ipm – 2 times faster than the carbide tool. The Crystallume DCC end mill lasted 15 times longer than the TiN coated carbide tool used previously.

 

Machining
Case Study 2

Metal casting mold company using POCO 3 to build molds.

The machine was run at 940 sfm and 200 ipm. The Crystallume DCC end mill lasted 21 times longer than the TiN coated carbide tool used previously. Due to the extended tool life this customer now runs unmanned overnight operations.

 

Machining
Case Study 3

Tool and die company using POCO 200 to build electrodes.

Electrode was finish machined with a 1/4" ball end mill. The TiN coated carbide end mill lasted 7 hours (7 trodes) and the Crystallume DCC end mill lasted 97 hours (97 trodes).

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