Coolants for machining magnesium alloy

Magnesium alloys have a hexagonal lattice structure, which affects the fundamental properties of these alloys. High speed machining of magnesium and its alloys sciencedirect. Magnesium has been used in manufacturing notebook computer frames, video cameras, digital cameras, pdas and other consumer electronics products because of its high strength to weight ratio. Other than that, the pollution of the environment and reclamation of chips cannot be resolved quickly when using coolants during machining process. May 01, 2017 the machine was a bridgeport gx710 threeaxis vmc. Methods for prevention of ignition during machining of magnesium. This problem has attracted considerable research interests. Magnesium machining practices and precautions magnaloy. Ramesh abstract magnesium alloy is one of the lightest materials which has wide applications in the production of aircraft engines, airframes, helicopter components, light trucks, automotive parts and. Pdf methods for prevention of ignition during machining. Machining, magnesium, hydrogen abstract in machining of. In this study, the effect of both cryogenic and dry machining of az31 magnesium alloy on temperature and surface roughness was examined. Back in the 70s there was a fire from the machining of magnesium at wentworth institute in boston.

Aluminum machining coolants machining coolants dr lubricants machining coolants are formulated to perform a variety of general and specialty machining operations. Optimization of machining parameters for magnesium. Magnesium and magnesium alloys total materia article. Corrosion and surface treatment of magnesium alloys intechopen. Magnesium has very good machining abilities like sawing, punching, drilling, milling, turning compared to other metals.

Straight and soluble oils and coolants for machining and grinding. The small chips and fine dust generated during cutting are also highly flammable and pose a serious fire risk if not properly handled. Machining operations in this plant consist of milling, boring, broaching, drilling, tapping and stud driving. If when necessary to use coolant, a light mineral oil will suffice.

Over the years, semisynthetic machining and grinding coolants have compiled an. We manufacture and custom blend other machining coolants that are not available online. 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. Magnesium is the fastest machining metal and it has a high thermal. Occasionally, lard, animal fat or whale oil was added to improve the oils lubricity. The result is a novel system of extracting magnesium particles by vacuuming them through a hollow cutting tool and spindle, and into a collection container. All coolants, however, contain additives that enhance lubricity, inhibit rust and most bacteria growth, or reduce foaming. Great performance in cast, nodular and grey iron machining and gridning operations with no clickering. International compound 3601 is a true multimetal synthetic and watersoluble coolant that is engineered for machining and grinding. Highfeed machining of hardened steels, alloy steels and many cast irons are often bone dry, and use a continuous blast of compressed air to keep the work area free of chips. Manufacturing with a 3 axis milling machine creates parts and components, and it generates heat. Aug 15, 2018 the alloy series was developed based on long period stacking order lpso nanostructured phases modified by using reduced rare earth content and further microalloying additions to control flammability, corrosion, and to strengthen the primary alpha phase, thereby producing a cast or wrought product with uniform high strength and ductility. Water soluble coolant is not recommended, as magnesium and water are highly reactive.

It is becoming much more common that cast and fabricated magnesium alloy parts will undergo cnc machining. Incoloyr alloy 925 is annealed at 1010c 1850f for 2 h followed by air cooling. The result of this means that there is a reduced load on the cutter and. Alphasyn t high performance, fully synthetic lubricants designed for use in central. The following list of safety precautions and machining tips for machining. Specifications of aluminum machining coolants include 1.

Where coolants are desired, only mineral oil based cutting fluids should be used. The product is designed to be nonstaining and compatible with. Alphasyn t high performance, fully synthetic lubricants designed for use in central lubricating systems and gearboxes operating under harsh conditions, particularly at elevated temperatures. A number of magnesium alloys show promise as engine block materials. Many machinists who will have encountered magnesium know about is potential to combust. Machining titanium is challenging due to its low thermal conductivity which results in very high temperatures at the toolworkpiece interface and in addition there is a tendency for titanium to react with most cutting materials, resulting in surface and subsurface deformation in the workpiece. Hazards of machining magnesium practical machinist. Machine coolants have been used extensively in metal cutting operations for the last 200 years. The specific cutting power is low and the surface is excellent and. Song and stjohn studied the corrosion of a new magnesium alloys amsc1 and magnesium alloy az91 in commercial engine coolants. Our products provide superior cooling, cleanliness and long emulsion stability. Featured synthetic machining and grinding coolants. Generally speaking you can machine magnesium without the need for coolant, if coolant is necessary a light mineral oil will suffice.

In order to prevent corrosion of magnesium alloy parts, the free acid content in the cutting fluid should be less than 0. Magnesium alloys are mixtures of magnesium with other metals called an alloy, often aluminum, zinc, manganese, silicon, copper, rare earths and zirconium. The main concern in machining magnesium alloy is the danger of fire ignition when dry cutting. Corrosion of magnesium alloys in commercial engine coolants. A few magnesium alloycoolant systems have been tested under the uscar programme and it is found that systems behave quite differently from one another. Brighton laboratories full product line of machining coolants were developed for the machining and grinding of all ferrous and nonferrous metals. The coolant may be used for machining aluminum, carbon steel, copper, cast steel, alloy steel, tool steel, stainless steel, cast iron, bronze and brass. This book provides a comprehensive account of the corrosion of magnesium alloys. Use a lot of coolant at high pressure, keep speeds down and feeds up, keep the tool in motion when in. Never use a water based coolant as it will react with chips during storage. It is very dangerous because hydrogen is flammable and potentially explosive. Save time and money by filtering your machine coolant. Fire may occur when the melting point of the alloy 400600 degrees celsius is exceeded. The fire was in a lab doing research for the air force and was caused by poor housekeeping.

When magnesium is alloyed with aluminum, the resultant material is very light and strong, and easily machinable. Highstrength, nonflammable nanostructured magnesium alloy. 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. Fire may occur when the melting point of the alloy 400600 degrees celsius is exceeded during machining. In order to achieve a better cooling effect, the cutting oil should have a lower viscosity. The inhibition of magnesium engine block in commercial coolants by kf as an inhibitor to reduce the corrosivity of these coolants to magnesium alloys have been reported by song and stjohn 25. A research consortium has developed a novel way to. Pdf methods for prevention of ignition during machining of. What joe miranda advised should prevent any problems as it is the chips that are easy to ignite, not the solid. Though coolants can be used effectively to prevent ignition, the pollution of environment and reclamation of chips can not be resolved easily.

When working with difficult metals in difficult applications, iccs straight oil coolants are sure to meet and exceed the most demanding capabilities required of today. Never use water based coolant because of the risk of any reaction with the chips during storage. Army and missile defense agency will continue developing highstrength, nonflammable, nanostructured magnesium alloys for lightweighting applications with terves. But some applications demand more than a goodquality coolant or lubricantsome processes and materials require specialty products. The usage of magnesium is also in applications of medicals because of its low weight.

Highspeed tools or carbide tipped tools are preferred for the machining of magnesium. For many years the machining of magnesium alloys has been carried out safely and efficiently without the need for coolants or cutting fluids. Developing a safer way to machine magnesium machining magnesium is risky business, as the chips and dust generated are flammable. The fire was in a lab doing research for the air force and was caused by.

Manufacturing with a 3 axis milling machine creates parts and components, and it generates. Though coolants can be used effectively to prevent ignition, the pollution of. Magnesium has been used in manufacturing notebook computer frames, video cameras, digital cameras, pdas and other consumer electronics products. In the beginning, machine coolants consisted of simple oils applied with brushes to lubricate the machine tool. The oil functions primarily as a coolant, reducing the risk of fire, which is common to magnesium machining. While the primary concerns when machining titanium and its alloys may shift, the methods for mitigating them remain somewhat constant.

Cutting power and machinabilty the mean specific cutting force ks1. Corrosion of magnesium mg alloys in engine coolants. Dry machining, coolants, mineral oil, and emulsions. When machining magnesium alloy with a waterbase coolant, water will reacts with magnesium to create hydrogen. Song, crc for cast metals manufacturing cast, division of materials, school of engineering, the university of. Each coolant for cnc machines is specifically designed to handle light, medium or heavy duty machining. Detailed examples are given on the various machining operations used on magnesium. Masterall 0 a high performing, low foaming semisynthetic fluid designed for high pressure coolant applications such as milling, turning, deep hole drilling, reaming, tapping and sawing. The cutter was a 3inchdiameter shell mill with eight inserts featuring 15degree relief angles and 1. Metallurgical considerations for machining magnesium alloys jstor. The product selection survey submitted by our representatives to the machining coolants technical staff provides a complete picture of your procedures, from stock to finished product. Therefore, one better approach is to control the machining parameters for minimizing ignition hazard of magnesium alloy chips during dry machining. It covers not only the corrosion performances and mechanisms of mg alloys in conventional environments. Think in terms of throughspindle coolant delivery in reverse.

Traditionally a low viscosity oil has been the recommended cutting fluid for magnesium machining. 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. Low foam, excellent corrosion protection and tramp oil. The alloy of magnesium is also used in gearboxes especially in aircrafts. Methods for prevention of ignition during machining of magnesium alloys article pdf available in key engineering materials 447448. Low foam, excellent corrosion protection and tramp oil rejection. Recently, az91d and magnesium engine block alloys amsc1 and nzk have been investigated in a few different commercial coolants, such as total, castrol are caltex. Incoloyr alloy 925 can be cold worked using standard tooling. Without the correct coolant, machines break down, and prior to that happening, product quality suffers. Machining of magnesium and magnesium alloys asm digital library. Soluble oil coolants suresol ep is a heavy duty biostable soluble oil concentrate containing a chlorinated additive for difficult machining operations. Amsc1 is a new alloy with rare earth elements, zinc and zirconium as the main alloying elements, which was developed as an engine block material. Magnesium replacement of aluminum cast components in a.

The key components in this system are cutting tool, tool holder and spindle. So, the same thickness of section in a magnesiumalloy casting as in steel may afford enough strength for a particular purpose. Machining of titanium alloys with and without coolant. The product selection survey submitted by our representatives to the machining coolants technical staff provides a complete picture of your procedures, from stock to finished product, allowing us to find you the best custom metalworking fluids and compounds that match your precise needs. Magnesium machining is normally done without any coolant. Magnesium replacement of aluminum magnesium use after world war ii 1950s racing wheels and truck panels vw beatle engine and gear box 20 kg 42,000 mt mg in 1971 1970s.

Coolants for challenging cuts cutting tool engineering. Machining titanium is challenging due to its low thermal conductivity which results in very high temperatures at the toolworkpiece interface and in addition there is a tendency for titanium to. Though coolants can be used effectively to cool down the cutting area for many other materials and their alloys. Brighton labs coolants are formulated for a broad range of machining applications and materials including aluminum. Corrosion and surface treatment of magnesium alloys. Surface roughness evaluation in drycutting of magnesium. This approach is most effective with cutting tools designed for such work, which depending on the application, have sharp edges and lubricious coatings to reduce friction. Methods for prevention of ignition during machining of. It is very dangerous because hydrogen is flammable and potentially explosive 5,6. Castrols versatile range of synthetic coolants satisfies machining requirements while reducing coolant use. The inhibition of magnesium engine block in commercial coolants by kf as an inhibitor to reduce the corrosivity of these coolants to magnesium alloys have been reported by song and stjohn. The primary worry in machining magnesium alloy is the danger of fire ignition when dry cutting.

In order to achieve a better cooling effect, the cutting oil should have a lower. However, there is a limited choice for coolant when machining magnesium alloy, as it can react with water and other oilbased coolants too. In addition, coolants and lubricants represent 1620% of manufacturing costs, which should be diminished 7. Fire may occur when the melting factor of the alloy 400600 levels celsius is gone beyond throughout machining.

When magnesium is alloyed with light weight aluminum, the resultant material is extremely light and also strong, and quickly machinable. The main ideas are to avoid galling, heat generation, work hardening, and workpiece or tool deflection. International chemical company manufactures triedandtrue straight oil coolants engineered for all. A systematic study was conducted for a few different magnesium alloys including am50a and az91d to understand effect of cutting. International compound 3601 is a true multimetal synthetic and watersoluble coolant that is engineered for machining and grinding operations utilizing metals such as steel, alloy steels, aluminum alloys and copper alloys. Thermal analysis during turning of az31 magnesium alloy.

Straight and soluble oils and coolants for machining and. However, a critical issue for the automotive industry is corrosion of the engine block by the coolant and this could limit the use of. Familiarize yourself with each machines coolant gauge. The main concern in machining magnesium alloy is the danger of fire. The paper describes the experience of magnesium products limited in making the transi tion from dry machining to wet machining with a water base coolant. Mineral seal oils and kerosene have been successfully used as coolants for magnesium alloy processing. Moderate duty synthetic developed for grinding, general machining, and roll forming of ferrous metals including high alloy steels. Magnesium replacement of aluminum magnesium use after world war ii 1950s racing wheels and truck panels vw beatle engine and gear box 20 kg 42,000 mt mg in 1971 1970s demand for greater power az81 lacked creep resistance as41 and as21 developed ae42 developed high cost alloy 1980s.