Cutting fluid is a type of coolant and lubricant designed specifically for metalworking processes, such as machining and stamping. For magnesium alloys, powerful cutting can be performed at high cutting speeds and large feed rates, so that the number of machining hours can be reduced. Low power required approximately 55% of that required for al. Machining magnesium i know about the flammability, which should not be an issue since the parts are so small, oil based coolants. Alleviate aches and pains associated with arthritis, joint issues, and inflammation. Magnesium is a material commonly used in the aerospace and automotive industries because it is the lightest structural metal. Rake angles and cutting speeds influence chip formation to a high degree. In addition, the magnesium particles mixed in oil cant be recycled, and the machined parts would require extensive cleaning to remove oil residue. Difficult machining operations must be run at lower speeds and require a great deal of antiweld protection. Some experiments on drilling, turning, milling processes. In machining of magnesium alloys, waterbase cutting fluids can be effectively used to eliminate the buildup formation and minimize the possibility of chip ignition.
Sintered bronze bar stock is generally available in 612 lengths and is made to be machined. Machining of magnesium and magnesium alloys asm digital library. This fluid was specifically formulated to solve the issues of instability, short fluid life, and separation associated with machining magnesium. I want to know what precautions i should be taking when machining magnesium alloy. Magnesium alloys are readily machined and with relatively low power consumption per cubic inch of metal removed. Unless the machine construction itself is limited, the cutting fluid should always be supplied in the magnesium alloy process and the chip temperature should be reduced. However, auxiliary collection devices hamper both tool changes and machine high speed movements.
Developing a safer way to machine magnesium machining magnesium is risky business, as the chips and dust generated are flammable. A page for speeds and feeds for most cutting tools in the machining trade. Oils designed specifically for the most difficult operations, like threadcutting or broaching, are generally higher in viscosity and loaded with ep additives like active sulfur and chlorine. Magnesium must have well designed fixturing to hold tight tolerances and high finish quality. For small quantity requirements we offer oil impregnated sintered bronze bar stock. However, high pressure coolant may be helpful when cutting aluminum alloys at high speeds where a simple air blast is not enough to help break and evacuate chips. Transicut oils are nonstain, transparent cutting oils intended for highspeed automatic screw machining and simple turning. The owner of the shop not liking to have the chips setting around, took them outside and placed them bag and all on the burning camp fire.
Hydrogen gas formation in the enclosed cnc machines can be deadly. The speed of a drill is measured in terms of the rate at which the outside or periphery of the tool moves in relation to the work being drilled. Most machining of magnesium alloys is done dry,but cutting fluids sometimes are used for cooling the work. The usual practice is to employ high cutting speeds with relatively coarse feeds and deep cuts. What you should know because magnesium is lightweight, strong and resilient, it is an excellent choice for components that must be carried by personnel in the field, shot into space, or jostled repeatedly in transportation systems. In machining of magnesium alloys, waterbase cutting fluids can be effectively used to eliminate. Machining magnesium i know about the flammability, which should not be an issue since the parts are so small, magnesium is the third most commonly use structural metal after iron and aluminium and historically has been used in applications including german aircraft during world war 1. Somehow the chip or chips contacted two leads and started a fire in a small pile of chips. In machining of magnesium alloys,cutting fluids provide far smaller reductions in friction than they provide in machining of other metals and thus are of little use in improving surface finish and tool life. Furthermore, the machining of mg comes with a very limited choice of coolant, as it reacts with water as well as several oil based coolants. Magnesium is the third most commonly use structural metal after iron and aluminium and historically has been used in applications including german aircraft during world war 1. Machining stainless steels dry is a little more difficult.
Magnesium oil on skin, 50100% larger flaccid, any benefit. Cutting fluids with greater cooling ability are generally used in highspeed. The possibility of fire when machining magnesium is always a real concern. Recommended cutting fluid for various materials smithy. Highspeed tools or carbide tipped tools are preferred for the machining of magnesium. High speed machining of magnesium and its alloys request pdf. Sep 29, 2014 machining a magnesium part for a customer. In this paper the main topic on machining of magnesium is introduced. Our skilled machinists have years of experience and an extensive knowledge of various machining strategies to produce your magnesium components. This makes the machining of magnesium alloy even more challenging especially at high speeds and feed rates. Machining magnesium is risky business, as the chips and dust generated are flammable.
Carbon drills are approximately 200 to 300% than high speed steel drills. Magnaloycouplingcompany technicalproductinformation couplings thepossibilityoffirewhenmachiningmagnesiumisalwaysarealconcern. I am personally tired of looking up 14 different sources for carbide drills, end mills, and other tools so i decided to put everything i find here on this page. The influence of tool coatings in machining of magnesium. Exceptionally fine finishes can be obtained so that grinding to improve the finish usually is unnecessary. He was blowing off his machine and somehow manged to blow a chip into an uncovered wall socket. Machining guides titanium machining guides machinability of titanium alloys machining of titanium alloys is as demanding as the cutting of other hightemperature materials.
Despite the fire hazards, as competition from overseas lowcost production bases intensifies, and magnesium becomes increasingly used in electronics products, most machining job shops could very well find machining of magnesium a niche worth pursuing. When applying oil manually as in the lab, scale the feed and speed back to 60 %, so n 450 rpm and f 3. Oil impregnated bronze bar stock has stock on the id and od to permit machining to the nominal dimension desired. The range of cutting speed for magnesium alloys is from 600 to 5000 mmin, which is higher than any other alloy in the absence of coolant. I want to know what precautions i should be taking when machining magnesium alloy bar, with particular regard to fire risk. Some of the advantages of machining magnesium compared to other commonly used metals include. Kuhlmann, safe machining of magnesium parts by cutting and burnishing operations, paper presented at the magnesium. Since 1968, specmaster has been an industry leader in machining a variety of complex parts from magnesium. Where many shops run into trouble, however, is in integrating dry machining into their existing operations.
Machining speeds and feeds calculator engineers edge. Magnesium has also been used in electronic devices such as covers of mobile phones, cameras, mini disc players etc. This calculator will determine speeds and feed rates for machining operations on mill or lathes. Fall asleep faster at night and sleep more soundly. Exceptionally fine finishes can be obtained so that. At this stage, a tradeoff of productivity to machinability is estimated. The use of oilbased coolants reduces, but doesnt eliminate, the fire risk. Jul, 2004 in machining of magnesium alloys,cutting fluids provide far smaller reductions in friction than they provide in machining of other metals and thus are of little use in improving surface finish and tool life. Oil impregnated bronze bearings are manufactured through the powdered metallurgy process. The emulsifier used must be nonionic and very hard water stable. Edm machining capabilities of magnesium mg alloy we43 for.
The 10 commandments of dry highspeed machining american. Technology applications group 810 48th street south grand forks, nd 58201 701 7461818 800 tagnite. Any way, the 50 pound dog food bag got full before we finished. High speed machining of magnesium and its alloys sciencedirect. Never use water based coolant because of the risk of any reaction with the chips during storage. This process, combined with our investments in the latest machines and.
This process is particularly beneficial for large lot sizes. Technology applications group magnesium machine shops. Sep 17, 20 this bar stock is a pm product and is already impregnated with oil. Speeds and feeds for carbide endmills internal tool. It has a broad range of applications, but some of the most common benefits of magnesium oil include. Therefore, a safe cutting speed can be estimated by cutting the color of the oxide film by the magnesium alloy at different cutting speeds. The automotive industry in particular has an upcoming interest in the use of magnesium alloys.
A research consortium has developed a novel way to extract magnesium particles out of the machine by vacuuming them through a. Conclusion wire electro discharge machining is capable of machining magnesium alloys efficiently and with good surface integrity. The common unit and term for this velocity is surface feet per minute, abbreviated sfm. In our machining department, we offer cnc machining of prototypes and small series. While we were machining some magnesium angle plates, 7 by 8 by 14, about 1 and 34 thick, we were cleaning up the shop quite regular. Machining magnesium is risky business, as the chips and dust generated. Machining magnesium paperback january 1, 1954 by dow chemical author see all formats and editions hide other formats and editions. Influence of cutting speed of magnesium alloys on the performance of machined parts is substantial, and that is why it has gained the importance of peers in research. Titanium components are machined in the forged condition and often require removal of up to 90% of the weight of the workpiece. It is becoming much more common that cast and fabricated magnesium alloy parts will undergo cnc machining. Machining magnesium one extra post regarding the ability of mg to burn.
Cutting speeds are usually given in feet or meters per minute and these speeds must be converted to spindle speeds, in revolutions per minute, to operate the machine. Primary recommended for low carbon steels, free machining steels and nonferrous alloys. Machining, magnesium, hydrogen abstract in machining of. Magnesium is the lightest structural metal with a high strengthtoweight ratio. Hazards of machining magnesium practical machinist. The usage of magnesium is also in applications of medicals because of its low weight. A research consortium has developed a novel way to extract magnesium particles out of the machine by vacuuming them through a hollow tool and spindle during machining. Following are the particulars on tool sharpening, feeds, speeds, and depthsofcut recommended for. Some use mineral oil, i cut dry, conservatively in speed, faster in feed. Some applications and properties of magnesium is also discussed to give overview of magnesium. Precision machining and knowledge of tighttoleranced magnesium components necessary for success of program.
Tapping speeds ordinarily range from 75 to 200 feet per minute, and mineral oil cutting fluid should be used. For example, pep recently machined an 8 x 11 x 3 block of magnesium into the housing for a hand held military vision system. By adapting the tool path correction of stateoftheart edm technologies for the machining of steel alloys very good results were achieved. If when necessary to use coolant, a light mineral oil will suffice. The first commandment of dry machining concerns holemaking. Recommended peck depth when drilling less than 3xd e. They have excellent lubricity and antiweld properties and assist in extending tool life and producing a quality finish on machined parts. I cant speak to your feeds and speeds question but i know of a guy that was facing some magnesium that had a fire issue. Narrow lands should be used to provide ample chip space. Various capabilities include milling, drilling, boring, turning, knurling, reaming and facing. Edm machining capabilities of magnesium mg alloy we43. Magnesium has been used in varioustransplants in humans as well as animals 19. Machining magnesium with water base coolants semantic scholar. We can process most types of metal and plastics but mainly focus on aluminium and magnesium materials.
Note that these speed and feed values are guidelines assuming adequate flooded lubrication, workpiece stiffness and drill depth less than 3 drill diameters 0. Coolants containing water should not be used because of the fire danger when magnesium chips react with water. Various mineral oil cutting fluids are used on magnesium, and mineral seal oil and. If the magnesium oil helps to counter act the cold induced shrinkage and keep my flaccid girth around 4. Cutting speeds are for high speed steel drills except as indicated. Magnesium was selected as new material for four components on final assembly.
Cutting fluid are made from petroleum distillates, animal fats, plant oils, water and air, or other raw ingredients. Reduction of machining time because of the high speeds. Machining of magnesium magnesium is the lightest structural metal and exhibits excellent machinability. Magnesium machining is normally done without any coolant. Magnesium machining practices and precautions magnaloy. Every tool manufacturer has a recommended table of sfm values for their tools. There are various kinds of cutting fluids, which include oils, oil water emulsions, pastes, gels, aerosols mists, and air or other gases. Sintered bronze bar stock is generally available in 612 lengths. Magnesium machining for low to high volume production.
We see an increasing number of requests for machined parts out of magnesium. A new customer has a few jobs to quote, machining magnesium parts. When applying oil manually as in the lab, scale the feed and speed back to 60%, so n 900 rpm and f 3. Where coolants are desired, only mineral oil based. This bar stock is a pm product and is already impregnated with oil. The influence of tool coatings in machining of magnesium abstract magnesium is the lightest metal used in construction and therefore offers the greatest potential for weight reduction. Cnc machining aluminium and magnesium 35 axis and turning. On a normal day to day i know my feeds and speeds to get the job done, but there is always room for improvement and there will always be a sp. Dry cutting of magnesium alloy thin walls was achieved using cutting speed of 440mmin for roughing and 628mmin for fine finishing. The study of machining of magnesium is very important for researchers and industries. We do what many dont that is, safely make machined magnesium parts.
Below are 8 tips to make machining sintered bronze bar stock even. This makes the machining of magnesium alloy even more. Fortunately, the following 10 commandments of dry highspeed machining can serve as a guide to make the most efficient and economical use of dry machining technology. Fast machining employing the use of high cutting speeds.
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