When it comes to machining graphite which is considered as one of the most brittle and demanding materials, precision is essential. Its brittle nature and complex features like corner radii and draft angles leave no room for error. And, this is where most processes stumble. However, when technology meets the right solution, every sharp corner achieves its precision. Proving this right, Prime Graphite found its match in Manleo’s advanced probing technology which acknowledged the rising demands for accuracy and speed, bringing real time and in-machine inspection to the forefront. This solution has reduced setup time, rework and material waste, all while maintaining high standards and consistent quality.
About Prime Graphite
Prime Graphite Pvt. Ltd. is India’s largest and oldest graphite machine shop, headquartered in Nasik. As the exclusive representative of Tokai Carbon Co. Ltd., Japan since 1998, the company has built a legacy of excellence in precision graphite machining across a wide range of high-performance applications. Recognized as a premium supplier in the Indian graphite industry, Prime Graphite stands apart for its consistent ability to meet Quality-Cost-Delivery (QCD) expectations, helping customers reduce waste, improve product quality, and optimize manufacturing cycles.
With over two decades of technical competence, it aims to provide value-driven solutions based on Lean, QMS, and TPM processes.
Challenge: Getting it right the first time
The real challenge while working with graphite machining is not only about shaping materials but doing it with micron-level accuracy, especially when working with tricky shapes like corner radii and draft angles on moulds. In addition, when it comes to electrode machining, the end user always expects high accuracy to be achieved with speed. This pushes manufacturers to not only meet tight tolerances but also do so within tight production deadlines. In such high-pressure environments, the ability to deliver finely detailed electrodes quickly and reliably is a genuine measure of machining excellence, tooling technology, and process expertise.
Earlier, Prime Graphite relied mostly on manual measurements and CMM (Coordinate Measuring Machine) checks to inspect critical features, but this approach had its own set of difficulties. Small dimensional errors often went unnoticed until after the machining was complete, resulting in time-consuming rework and extra setup delays. The problem was compounded by the abrasive and ultra-fine nature of graphite particles, which would easily get into machine components and sensors, while its conductive properties gradually affected the reliability of the equipment and the accuracy of inspections. Thus, this resulted as a challenge for Prime Graphite in maintaining speed while ensuring precision.
“Graphite machining differs from working with metals and alloys in that even the smallest deviation in a corner radius or draught angle can result in hours of rework and wasted material. Thus, working with graphite demands a consistent investment in novel technology. And, nowadays, quality machining is just as vital as accurate financial records for customers. So, we must cope with the machining time furnished with precision, just as with usual metal cutting. Investing in Manleo’s probing solution brought quality control straight to the machine, significantly reducing setup time and rework. This was a game changer for us at Prime Graphite,” says Ashish Singh, Operations Head at Prime Graphite Pvt Ltd.
High-Precision Probing Solution
Manleo’s Operator-Friendly Probing Solution for Accurate & Faster Datum Referencing. When working with graphite, the slightest deviation might result in rework, material loss, or failed inspection. Especially when cutting for electrodes with stringent tolerances of less than 20 microns. Prime Graphite often struggled with inspecting these fine details, relying heavily on post-process CMM inspections. But that meant feedback came only after machining was done, leading to delays, longer setup times, and a disrupted workflow and productivity on the shop floor.
Nevertheless, with the adoption of Manleo’s Datum Referencing Probe, operators were able to catch up their speed with real-time, in-machine measurement job setup and precise datum reference directly on the VMC. This removed the need for constant manual checks and significantly reduced the time spent on rework due to unnoticed errors or deviations.
The probe is built in a compact and sealed way, which makes it perfect for working with graphite which is an abrasive and conductive material. Its design keeps out fine graphite dust and helps the probe last longer without issues. It’s also gentle to use, thanks to its low trigger force, which means it doesn’t damage the delicate electrode surfaces. And with an accuracy of up to 5 microns, it gives highly precise readings, whether it’s for setting the centre, bore, base, angle, slope, along with surface finish. This level of precision fits perfectly with the high standards Prime Graphite.
By automating these metrics, Prime Graphite reduced not only operator dependency and judgement. This resulted, over 90% less rework and rejections, and more than 70% faster job setup times. With precise in-machine reference and low human error, the shop floor observed a huge improvement in quality consistency, faster delivery, and much improved productivity, showcasing a crucial improvement in high- precision graphite machining. Prime Graphite has been using this system for over a year, with approximately half a dozen units deployed across their shop floor.
The Manleo Probe Advantage
What really made Manleo’s probes stand out was how simple they were to set up and calibrate without the need of a CMM. Their user-friendly design made them perfect for everyday use on the shop floor, along with it, they provide exact component data that indirectly leads to increased tool life and consistent machining quality.
Another big plus? They’re cost-effective. So for a CNC machining shop, they’re not just a smart technical choice, they’re a solid investment.
For Prime Graphite, adopting these advanced probes has strengthened its ability to fulfil the stringent and high-precision demands of large OEMs. It has proven and helped reduce errors, avoid costly rework or penalties, and consistently deliver top-quality components. The fact that Manleo also offers local service and repair support means fewer production delays and more uptime, letting the team maintain a steady, high output without interruption.
“The probe not only simplified datum referencing and job setting for us but also provided us with real-time insights that help us prevent possible errors. Its rotatable design and operator-friendly interface made it viable for all of our shop floor workers, seamlessly adding to our workflow. Installation was straightforward, and integration into our process required minimal training. In short, it’s a smart, reliable solution that’s made a measurable difference in our graphite machining operations,” concludes Ashish.
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