Hufschmied Zerspanungssysteme has expanded its graphite machining portfolio with the introduction of the Hexator, a new six-edged finishing tool designed to deliver high surface quality, extended tool life and increased productivity when manufacturing graphite electrodes.
The German tooling specialist says the new tool combines a lollipop geometry with a specially developed diamond coating, enabling high feed rates at comparatively low spindle speeds. This approach helps reduce spindle load while maintaining machining performance and component quality.
The Hexator has been developed in response to customer demand for a dedicated high-performance finishing solution to complement Hufschmied’s established Graftor roughing and finishing tools, which are already widely used in graphite electrode production.
According to the company, the new tool offers consistent machining results because the contact point between the cutter and the workpiece remains unchanged throughout the process. This characteristic is particularly advantageous when machining 90° wall surfaces, where maintaining dimensional accuracy and surface finish can present challenges.
A key benefit of the lollipop design is that it eliminates the recutting effect often associated with tools featuring straight cutting edges. Even minor recutting can affect surface quality and process stability, but Hufschmied says the Hexator’s geometry avoids this issue entirely, delivering a uniform milling pattern and reliably stable dimensional and geometric accuracy.
The company reports that development of the tool was influenced by a customer project in which improvements in both machining efficiency and operating costs were required. By combining Hufschmied’s graphite machining tools, including the new Hexator finishing cutter, the customer was able to reduce production costs by more than 60% while cutting manufacturing time to around one-third of its previous level.
The extended service life of the Hexator also contributes to lower operating costs by reducing the frequency of tool changes, machine set-ups and production downtime. This can be particularly valuable for electrode manufacturers seeking to maximise machine utilisation and improve overall process efficiency.
A further distinguishing feature is the tool’s specialised diamond coating, which has been developed in-house by Hufschmied. The company says its ability to design and manufacture both tooling and coatings internally gives it greater flexibility when developing products tailored to specific machining applications.
“Our specialists have once again proven that every aspect of a tool can be optimised for a specific process, from the shape to the cutting-edge distribution and geometry, right down to the coating,” said Christel Hufschmied, Managing Director of Hufschmied Zerspanungssysteme GmbH.
“We are in the fortunate position of having not only the technical expertise and experience but also all the necessary technical facilities in-house. This gives us the freedom to develop exceptional tools and significantly improve our customers’ processes.”
The Hexator is available as a standard product in diameters from 2.0 to 12.0mm, with additional sizes available on request.
Visitors to AMB 2026 in Stuttgart will have an opportunity to see the new tool first-hand. Hufschmied will be exhibiting the Hexator on Booth 3D64 in Hall 3 during the exhibition, which takes place from 15 to 19 September.