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M A C HI N I N G MA G NE SIUM
ADVANTAGES
Relative
Power
AISI - B1112
Machinability
Index (%)
1.0
500
1.8
300
Mild steel
6.3
50
Titanium
alloys
7.6
20
Metal
Magnesium
alloys
Aluminium
alloys
TOOLING
Tool ranges used during the machining of aluminium
can also be used for magnesium. These give
satisfactory results. However, due to the freemachining characteristics, relatively low cutting
pressures and slightly lower heat capacity of
magnesium, best machining practice should take the
following points into consideration.
TOOL MATERIAL
Although HSS tooling can be used and is often
employed in twist drills, taps and broaches, carbide
is the preferred tooling material for most machining
operations on magnesium alloys. Carbide gives a
balance of economics and the ability to perform
high volume production runs. It also gives a good
surface finish, however, if a superior surface quality is
required with long series at high production volumes,
polycrystalline diamond (PCD) should be considered.
PCD tools are extremely wear resistant and their
use eliminates the occurrence of built-up edge (BUE)
on the tool.This is due to the low adhesion tendency
of PCD.
BUE is more commonly encountered while machining
magnesium-aluminium alloys or when machining is
carried out at very high speeds. The use of uncoated
carbide tools, which allows sharper cutting edges,
reduces material build up.
It is therefore recommended that uncoated carbide
tools be used for machining magnesium alloys as
these have a cost advantage over PCD. Although
where economics allow PCD should be the material
of choice.
Metal
Turning Rough
m/min
Turning Finish
m/min
Magnesium
Aluminium
Steel
Cast Iron
Up to 1200
75-750
40-200
30-90
1800-2400
120-1200
60-300
60-120
Drilling
(5-10 mm drill)
m/min
150-500
60-400
15-30
10-40
Milling 100 mm
miller 1mm cut
m/min
200-500
200-300
20-25
15-20
Tool Material
ISO 513:2004-07
Classification
Carbide
N01
N10
N20
N30
Properties
Toughness &
feed rate
Wear resistance
& cutting speed
ANSI
Classification
C3
C2
SUPPLIERS
Suitable tools and indexable inserts are available from
a wide range of well known tool manufacturers
including Ceratizit, Sandvik/Dormer, Kennametal,
SECO and Garant. Advice from the tool
manufacturer and the use of catalogues and
selection media should be used to aid in the
selection of the most appropriate tooling for the
specific job.
TOLERANCES
Similar to clamping aluminium, the component
should be firmly clamped and supported to avoid a
disfigured surface. It is preferable to clamp on heavier
sections of the part to be machined. The clamping
pressure should not be excessive to avoid deflection
or possible permanent distortion.
Metal
Elektron 21
Elektron WE43
Elektron 675
Al alloys
Steel alloys
Coefficient of
thermal expansion
(20-100 C)
26.3x10-6
26.7x10-6
27.4x10-6
24x10-6
12x10-6
DRY MACHINING
COOLING GASES
MINERAL OILS
Where there is a chance of chip jamming i.e. in
machining operations such as tapping, reaming or
deep hole drilling it is sometimes beneficial to use
a coolant.
The type of oil should always be mineral oil rather
than animal or vegetable oils. The use of animal or
vegetable oil exacerbates any potential fire risk, since
these oils can spontaneously ignite. Mineral seal oil
and kerosene have been successfully used. Using
oil rather than an emulsion type coolant has been
shown to improve both dimensional accuracy and
surface quality in certain machining operations.
Recommendations for suitable mineral oil
characteristics are given below. A low viscosity is
necessary to give adequate cooling.The free fatty acid
content should be <0.2% in order to help prevent
corrosion and inhibit the generation of hydrogen
gas. Oils with high flash point and low vaporisation
should be used so that the risk of fire and explosion
of oil mists is reduced.
The danger with using oil is the chance of creating
explosive oil mists during the machining process.
0.79-0.86
Viscosity at 50C
1.75 E
135 C (Min)
Saponification No.
16 (Max)
0.2% (Max)
Use water with a low salt content i.e. Deionised, Reverse osmosis or Ultra filtration distilled water although the coolant should
still be designed to deal with extreme water
hardness.
2)
3)
4)
5)
6)
7)
8)
9)
FIRE PRECAUTIONS
1.5.6. Fire
Recommended
Type D fire
extinguisher
e.g. Met-L-X / G-1
powder
DRY Sand
Cast Iron Chips
(Dry)
Do not use
MACHINING OPERATIONS
Water
Foam
A, B, C fire
extinguishers
Carbon dioxide,
Nitrogen
Argon Gas
Operation
Speed m/min
Feed m/min
Roughing
90-180
180-300
300-500
500-600
600-1500
0.75-2.50
0.50-2.00
0.25-1.50
0.25-1.00
0.25-0.75
12.5
10.0
7.5
5.0
3.75
Finishing
90-180
180-300
300-500
500-600
600-1500
0.125-0.625
0.125-0.500
0.075-0.375
0.075-0.375
0.075-0.375
2.5
2.0
1.25
1.25
1.25
MILLING
Extremely high speeds and large feed rates are
possible and are encouraged during the milling
of magnesium alloys; these still produce excellent
surface finishes. Using coarse feed rates and high
cutting speeds enables the full advantage of machining
magnesium to be realised.As with turning and boring,
HSS tools can be used at normal speeds, but, carbide
is the tool material of choice for high speed milling
operations. Indexable carbide inserts are particularly
suitable for use in milling operations.
Milling cutters should have one-half to one-third the
cutting edges found on conventional milling tools
used on other metals such as steel. Having fewer
teeth assists with chip clearance due to the increase
in chip space and also reduces the frictional heat
associated with a greater number of teeth rubbing
on the work piece. Simple types of two and fourcutter side and face mills are illustrated in figure 2.
It is possible to successfully use slot drills instead of
end mills and 2 blade fly cutters for high speed milling
operations. Front and side relief angles of 7-10 and
secondary clearance angles of 20 are recommended.
Operation
Speed m/min
Feed m/min
Roughing
Up to 275
275-450
450-900
250-1250
250-1500
375-1900
Up to 12
Up to 10
Up to 5
Finishing
Up to 275
300-900
900-1500
1500-2750
250-1250
250-1750
250-2250
250-3000
Up to 275
0.13-1.3
0.07-0.7
0.07-0.7
DEEP HOLES
SHEET DRILLING
Drill Diameter
(mm)
Speed m/min
Feed Sheet
mm/rev
100-600
0.12-0.75
0.12-0.75
0.12-0.20
13
100-600
0.25-0.75
0.40-1.00
0.30-0.50
25
100-600
0.25-0.75
0.50-1.25
0.40-0.75
REAMING
Carbide inserts are the preferred tooling choice
especially for high production runs, although steel
reamers can be used, if carburised and case-hardened.
In order to increase chip space, reamers for
magnesium alloys should have fewer flutes than
those used for the machining of most other metals.
Reamers under 25mm diameter should have 4 or 6
flutes. Flutes can be either straight or have a negative
helix. The use of negative spiral will prevent the
reamer from drawing itself into the hole.
The chamfer on the reamer should be approximately
45, with a rake angle of 7, a primary relief of 5-8
and a secondary clearance angle of about 15-20.The
helix should be between 0 to -10.The cutting edges
should be polished and have as little land as possible
see figure 5. For fine finishes the opposing cutting
edges should be spaced at 180, however, to minimise
chatter it is often beneficial to have the opposing
cutting edges unequally spaced by a small amount.
It is recommended that high speeds and medium
feeds are used in order to obtain the best surface
finish with the greatest dimensional accuracy of the
holes.
The feed rate should be as high as possible while
still attaining the required surface finish. When using
HSS reamers the range of cutting speeds is between
30-120 m/min, for carbide insert reamers the
maximum speed is up to 260 m/min. However, these
are maximum cutting speeds and in practice the
speed used should be appropriate to the capability
of the machine, and the clamping and rigidity of the
work piece.
Figure 5 REAMER
TAPPING
Standard taps are suitable for small production
quantities or if high tolerances are not required. For
best results taps tailored to magnesium should be
used. Taps should be provided with large polished
flutes. HSS two flute taps with ground threads are
recommended for diameters less than 4.8 mm,
three flute taps for diameters up to 19mm. and four
flute taps for diameters over 19mm. Taps should
be ground to be concentric with the front lead or
cutting portion having a clearance of about 20.
Where there is no form relief, all lands should be
hooked on both sides to give a leading top rake of
about 10 for entering and about 5 for backing out
where required (see figure 6).
Figure 6 TAPS
THREADING
SAWING
DATASHEET 254
CHEMICAL ETCHING
Magnesium alloy components can be reduced in
thickness quite evenly by pickling in acid solution.The
dissolution of metal proceeds uniformly and rapidly
in sulphuric acid of 5% strength or greater. Nitric or
hydrochloric acid can also be used. The part should
be free of metal inserts and must be kept moving in
the acid.
The process is best suited to rough castings but if
tapped holes are present they should be plugged with
plastic plugs.
Considerable heat is generated in the operation and
frothing of the acid occurs because large volumes of
hydrogen and steam are produced. Inspection should
be frequent and gas traps avoided by agitation of
the part.
Since the metal surface is dissolved evenly it is
necessary to make the original casting large enough
to allow for the chemical reduction.
APPENDIX 1
Blasocut BC 37MG
USA
Blaser Swisslube Inc.
31 Hatfield Lane, Goshen, NY 10924
Phone +1 845-294-3200
mailboxusa@blaser.com
UK
Jemtech (UK) Ltd.
Bellbrook Industrial Estate, Uckfield, East Sussex,
TN22 1QL
sales@jemtech.co.uk / www.jemtech.co.uk
Berucool 148MG
GERMANY
CARL BECHEM GMBH,
Weststrae 120, , 58089 Hagen, Germany
Phone +49 2331 935-0
bechem@bechem.de / www.bechem.com
UK
R S Clare & Co. Ltd.
Stanhope Street, Liverpool, L8 5RQ
Phone +44 (0)151 709 2902
info@rsclare.co.uk
Copyright Magnesium Elektron Ltd 2012. The information provided within this document is aimed to assist manufacturers and other interested parties in the use of magnesium alloys. Magnesium Elektron
accepts no liability in whole or in part from use and interpretation of the data herein. All information is given in good faith but without warranty. Freedom from patent rights must not be assumed. Health
and Safety information is available for all Magnesium Elektron products. MAGNESIUM ELEKTRON, The e Logo, MEL, ELEKTRON and ZIRMAX are registered trademarks of Magnesium Elektron Limited.
Magnesium Elektron UK
Magnesium Technology Centre,
Rake Lane, Swinton, Manchester
M27 8BF, England
Tel: +44 (0)161 911 1000