Magnesium Forged Components

for Structural Lightweight Transport

Applications

Contract #: COLL-CT-2006-030208
Document type: Deliverable report
Title: Deliverable D5.2.2. Machining
Authors: I. Ferreres (IDEKO), J. Pérez (IDEKO)
Issued by: Dr. ing. Ion Bădoi (INTEC, WP5 leader)
Dissemination level: RE

Collective Research Project funded by the European Community within the Framework of the
Specific Research and Technological Development Programme “Integrating and Strengthening
the European Research Area” (Sixth Framework Programme 2002–2006)
 TABLE OF CONTENTS

1. Introduction 9. Influence of machining fluids

2. Properties of light weight materials 9.1. Oil as machining fluid
and iron 9.2. Water based emulsion as
3. Chemical composition and machining fluid
mechanical properties of wrought 9.3. Dry machining
magnesium alloys 10. Machining process
4. Machinability of magnesium alloys 10.1 Face milling
5. Energy for machining of magnesium 10.2. Circular milling
6. Chip formation 10.3 Drilling and boring
6.1 Chip formation: lamellae and 10.4. Reaming
particles
10.5. Tapping and thread milling
6.2 The influence of the feed into the
10.6 . Turning
chip formation
11. Machine tool
7. Influences of temperature on
dimensional quality 12. Machine tool and safe machining
8. Machining tools and parameters 13. Machine tool for net oil machining
 TABLE OF CONTENTS

14. Extract chips and from machine tool 17.4 . Briquetting of magnesium chips
15. Dry machining and chip recovery 17.5. Test of magnesium solid
15.1. Schematic view of chip transport briquettes
inside the machine tool 18. Safe machining
16. Environmental friendly machining 18.1. Fire extinguishing system
process 19. Storage of magnesium chips
16.1. Minimum quantity lubrication 19.1. Wet chips and venting hole
(MQL) machining
20. Conclusion and recommendations for
16.2. Experimental results in Mg safe machining and handling of
17. Recycling process for Mg chips magnesium chips
17.1. Crushing of magnesium chips 21. References
17.2. Cleaning of magnesium chips
17.3 . Oxidation of magnesium chips
 1. INTRODUCTION

» Magnesium is the sixth most abundant element in earth's

surface, amounting to about 2,5% of its total composition.

» Reducing the weight of automobiles is one of the primary

means by which their fuel consumption is lowered.

» The main magnesium parts for automation sector are

steering wheels, tires, gear boxes .
 2. PROPERTIES OF LIGHT WEIGHT MATERIALS AND IRON

Material properties Mg Al Ti Fe
Density, g/cm3 1,74 2,70 4,45 7 7,87
Melting point, ⁰C 651 660 1670 1535
Boiling point, ⁰C 1107 2057 3200 3070
Evaporation enthalpy, x103 J/g • Atom 131.8 293.7 430 354
Ignition temperature, ⁰C 667
Crystal structure hcp fcc hcp bcc
E- modulus, N/mm2 45 400 71 000 104 000 215 000
G- modulus, N/mm2 17 200 26 500 38 000 83 900
Poisson- ratio 0,277 0,339 0,359 0,291
172 204
Thermal conductivity, W/(m • K) 46...139 172 15,5 81
(alloys) (alloys)
Heat capacity, kJ/(kg • K) 1,04 0,94 0,47 0,47
Thermal expansion, 10-6 / ⁰C 26 23,9 8,4 11,5
 3. CHEMICAL COMPOSITION AND MECHANICAL
PROPERTIES OF WROUGHT MAGNESIUM ALLOYS

» The aluminum reference alloy for this component is EN AW 6082.

Standards for this alloy prescribe a minimum yield stress of YS=260 MPa
and a minimum ultimate tensile strength of UTS=310 MPa for forged parts.
» The current results show that the properties of forged AZ80 meet/exceed
this requirement for the longitudinal direction, but are typically lower for
the transverse direction.
 4. MACHINABILITY OF MAGNESIUM ALLOYS
» Magnesium alloys are known as construction materials with excellent machining
properties as far as tool life and applicable cutting conditions are concerned
» The absence of abrasive particles from the microstructure allows for long tool
life even at high speed cutting conditions
» Concerning to machin ability of magnesium alloys limitations are: max.
spindle speed and rate of feed of machine tools; permissible speed of rotating
tools; dimensional and surface quality of the machined component; softening
of the material due to thermal load from the cutting and interceptive chip
formation.
 5. ENERGY FOR MACHINING OF MAGNESIUM

» The low power requirements for machining magnesium alloys permit the
use of deeper cuts and higher feed rates.
 6. CHIP FORMATION

» The hexagonal close packed (hcp) lattice structure of magnesium alloys

has decisive influence on the chip formation and the shape of the chips in
cutting operations
» The hcp magnesium lattice possesses up to temperatures of 225°C only
one crystallographic plane, along which plastic material flow can be
achieved.
 6.1. CHIP FORMATION: LAMELLAE AND PARTICLES
» The lamella chips behave brittle and
show the tendency to break easily into
short pieces
» Besides this positive influence of the
material properties of magnesium there
must be noticed that in course of chip
formation not only lamellae are generated,
but also small dust-like particles
» Both, the severe fissured chips and the
small loose particles expose large highly
reactive surfaces to their environment-
Chemical reactions will take place with
the coolants in wet cut and with the
atmosphere in dry cut
» If emulsions are involved, hydrogen will
be set free-In dry cutting, there is the
danger of ignition and explosion
vc = 4000 m/min, fz=0,1 mm, ap=3 mm,
ae=60 mm, coolant: oil
 6.2. THE INFLUENCE OF THE FEED INTO THE CHIP FORMATION

As the feed increase, the distance between lamellae increase

7. INFLUENCES OF TEMPERATURE ON DIMENSIONAL QUALITY

»The absence of coolant in dry cutting operations affects the thermal

stability of the process
»A rise of temperature of 10º C consumes almost the full tolerance of
quality IT 6 in the range of D=60 mm
 8. MACHINING TOOLS AND PARAMETERS

► Machining magnesium with tools which have very positive rake and
clearance angles
► Cutting edge has to be dead sharp and the surface should have very little
coefficient of friction. Tool material:
► PCD- tipped tools
► diamond coated tools
► ceramic tools
► cemented carbide
► Diamond tipped tools or diamond coated tools perform very well in dry
machining of magnesium
► Depth of cut and feed rates should be chosen as high as possible
► Larger chip particles are formed with a more favourable ratio between size
of the surface and their volume
► The ratio surface/volume should be as small as possible
► Large chip cross sections result in less numbers of chip lamellae per
volume unit and also in less dust particles during lamella formation
 9. INFLUENCE OF MACHINING FLUIDS

► Machining of magnesium materials can be done under wet and in

dry cutting conditions. In wet cutting operations the use of oil and
of emulsion is possible. Both basic types of cooling lubricants have
different advantages and disadvantages
► General arguments for using cutting fluids for machining of
magnesium materials are:
► Reduction of temperature in the contact zone and reduction
of fire risk
► Reduction or elimination of build-up edge formation
► Lesser cutting forces
► Extension of tool life.
► Risks and disadvantages of cutting fluid is the contamination of
the chips that reduces the value of the chips and makes cleaning
prior to recycling necessary
► The main disadvantage of using cutting fluids in magnesium
machining is the safety problems originated by the chemical
properties of fluids and magnesium
 9.1. OIL AS MACHINING FLUID
►Mineral oils with relatively low viscosity (<
20 mm2/s at 40°C) are suitable cutting
fluids for machining of magnesium
materials
► The most important restrictions in the
selection of specific types of oils is the flash
point which should be at minimum 140°C
► The oil should not contain free acid
► Oil as a cutting fluid reduces temperature
in the cutting zone and collects the dust
particles, which are created during chip
formation and this reduces hazards
►Disadvantages: fire risk due to the oil, difficult to recycle chips, the part needs
to be washed fast rotating tools create spray, mist and aerosols in the working
chamber of the machine tool
► Oil mist and aerosols will also be present in the air exhaust systems of the
machine tool
 9.2. WATER BASED EMULSION AS MACHINING FLUID
► The most important fact, which must be known
and considered when water based cutting fluids
shall be used for machining of magnesium and
its alloys, is the generation of hydrogen gas
► Mixtures from hydrogen and air are flammable
if the hydrogen concentration exceeds 4%
► Mixtures from hydrogen and air are flammable
if the hydrogen concentration exceeds 4%.
► Chips should be separated from the aqueous
cooling media as soon and as complete as
possible
► The survey of hydrogen concentration by means of gas sensors is recommended in all
areas which may be subject to hydrogen accumulation Hydrogen generation resulting
from the application of aqueous cutting fluids can be influenced by as follows: fully
desalted water generates less amounts of hydrogen than water with salt content;
elevated salt contents, especially chlorides and sulphates, rise hydrogen generation;
amine- and boron-free cutting fluids reduce hydrogen generation as compared with
amine- and boron-containing media; elevated temperature of the emulsion rises
hydrogen formation; small chips and chip particles generate more hydrogen than
large ones
 9.3 DRY MACHINING
►The specific properties of magnesium
materials allow in principle for dry cutting
► The absence of cutting fluids eases recycling
of the chips
► Ignition and fire of magnesium dust and
chips are hazardous in dry machining
► Dust is defined as particles with grain sizes
below about 500 μm
►Ignitable concentrations of magnesium dust
start in the range of 15-30 g/m3 for dust with
particle size of 50 μm
►Prevention of chip accumulation in the machine tool and permanent removal of
dust out of the working area are necessary measures in order to avoid reduce
and hazards in dry machining
► Design and application of reliable machining processes as well as appropriate
tool monitoring and changing of worn out tools are preconditions to assure
safety in dry cutting
 10. MACHINING PROCESS
 Machining is necessary in order to generate smooth surfaces, to produce holes
and other form elements with high accuracy and to make internal threads
 From such machining tasks result processes like:
 Milling
 Drilling
 Reaming
 Thread cutting and forming
 External and internal turning, boring
 Diamond tooling is first choice if economically reasonable
 Diamond coated cemented carbide inserts are used for milling cutters, large
drilling tools and for boring tools
 Precision operations such as reaming are performed with diamond tipped
tools
 Carbide is often applied as inserts and also for solid rotating tools of small
diameter, such as twist drills, reamers and taps
 Tapping tools may also be made from high speed steel with or without a hard
coating
 Cutting forces of about 70% of those as compared with aluminium alloys will
widen the field of applicable cutting parameters
 10.1. FACE MILLING

 Face milling and circular milling belong to the most important operations for
machining magnesium alloys
 Face-milling cutters with inserts are involved polycrystalline diamond (PCD) is
frequently used as a cutting material; also cemented carbide and cermet allow
for economic machining
 Cutting parameters for wet and dry conditions are based on the range of the
spindle speed and the rate of feed

cutter diameter d mm 80
number of teeth z 6
max. spindle rev n min-1 16000
max cutting speed (PCD) νc mm/min 4000
feed per tooth fz mm 0.5
max feed per minute νf m/min 20
 10.2. CIRCULAR MILLING
 Very important milling variant is circular milling
 The process can be used very flexible
 One important fact is that one tool enables making holes of different
diameters and can also be used for peripheral milling operations and
for facing
 Again, the choice of spindle speeds, tool diameters and
technological data in view of most advanced PCD tipped cutters,
consult the following data

cutter diameter d mm 16-40

number of teeth z 3-6

max. spindle rev n min-1 40000-16000

max cutting speed (PCD) νc mm/min 2000

feed per tooth fz mm 0.4-0.05

max feed per minute νf mm/min 15000-1000

 10.3. DRILLING AND BORING
 Machining of holes in can be split into two tasks: one is making small holes for
threads in the range from M4 to M12, second type of holes are larger holes
 For larger holes, machining takes in two steps, roughing and finishing by
boring or even reaming; the diameters of such holes lie frequently in the
range of 40 to 80 mm

Drill diameter d mm 6-20

max. spindle rev n min-1 40000-16000
max cutting speed (PCD) νc m/min 600-750
feed per tooth fz mm 0.1-1
max feed per minute νf mm/min 4000-25000

Boring tool diameter d mm 40-80

max. spindle rev n min-1 12000-5000
max cutting speed (PCD) νc m/min 1000-1500
Drilling and boring
Number of cutting edges z 1-2 operations
feed per tooth fz mm 0.05-0.3
max feed per minute νf mm/min 800-1500
 10.4. REAMING

 High quality magnesium parts need frequently precision machining by

reaming bores
Reamer diameter d mm 10-60
max. spindle rev n min-1 12000-5000
max cutting speed (PCD) νc m/min 1000-600
feed fz mm/rev 0.05-0.3
max feed per minute νf m/min 0.6-1
 10.5. TAPPING AND THREAD MILLING

 Machining thread is another very often a necessary machining

Tapping tools M5-M16

cutting speed νc m/min 30 - 150

Thread milling with

M6-M24
carbide tools
tool diameter zd mm 4.5-15.9
cutting speed νc m/min 250-600
feed fz mm/rev 0.09-0.6
max feed per minute νf m/min 0.9-8
 10.6. TURNING

 PCD tools are first choice, whenever possible, if not cemented carbide
should be used.
 In case of dry turning cutting speed is limited to 1000 m/min for
interceptive chip formation avoiding
Cutting speed m/min 1500-500
Feed per revolution. Roughing fz mm/rev 0.25-2
Feed per revolution. Finishing fz mm/rev 0.08-0.65
Depth of cut. Roughing ap mm 2-6
Depth of cut. Finishing ap mm 0.2-1
 11. MACHINE TOOLS

Design criteria
 Magnesium good machinability characteristics allow the application of
really high speed cutting conditions
 Higher level of responsibility for the machine behaviour – higher feed
rates to maintain the production rates
 Good ratio between a low mass and a sufficient stiffness in the
structural moving parts
12. MACHINE TOOLS AND SAFE MACHINING

Mist exhaust
system

System trapdoor

Chip
expulsion
system

Fire extinguishing
system
 13. MACHINE TOOLS FOR NET OIL MACHINING

 Design of tool machines depends on

the cutting fluids
 If oil is used as coolant during
machining of magnesium alloys, the
machine tool should incorporated
these devices for safe machining:
mist exhaust system to remove the
mist, aerosol and dust generated in
the working chamber, fire detection
and extinguishing system, chip
expulsion system from working area,
security trapdoor in case of explosion
 14. EXTRACT CHIPS AND FROM MACHINE TOOL
 It is recommended to extract chips as soon as possible and avoid chips
accumulation in working area
 In order to avoid chip accumulation, in the working are space of the machine
tool, there are ramps and oil pressure conduits
 Oil pressure jet facilitates the evacuation of chip
 Canals located in the sides of the machine accelerate the extraction of chip
from working are
 When magnesium alloys are machined, it is necessary a suitable filtrate of oil.

Oil pressure conduit lines

Chip extraction canals

 15. DRY MACHINING AND CHIP RECOVERY

 Requirements of tools: high thermal conductivity and wear resistance, low

friction tool, cutting edges with large positive rake angle, tool design for
optimized quick chip removal
 Use of MQL techniques for critical machining operations: deep drilling,
reaming, boring
 Minimum working area space
 Stainless steel interior
 Chip extraction with aspiration
 No horizontal sheets or parts
in the working area
 MQL through the spindle
 Automatic fire extinguishing
system
15. 1. SCHEMATIC VIEW OF CHIP TRANSPORT
INSIDE THE MACHINE TOOL

chip transport flow

 15. 2. CHIP TRANSPORT AND RECOVERY

Clean air

chip
transport
Argon
delivery

Automatic
fire
extinguishing
system

chip
recovery
 16. ENVIRONMENTAL FRIENDLY MACHINING PROCESS

 By abandoning conventional cooling lubricants and using the technologies of

dry machining or minimum quantity lubrication (MQL), this cost component
can be reduced significantly
 Besides an improvement in the efficiency of the production process, such a
technology change makes a contribution to the protection of labor and the
environment
 16.1. MINIMUM QUANTITY LUBRICATION (MQL) MACHINING

MQL consists on the injection of a high-speed air jet with suspension micro-
drops of biodegradable oil. The flow of air with acts in three different ways:
 it removes the heat generated in the cutting by convection of the
injected air and by partial evaporation of the oil.
 it decreases friction between the chip and the rake face of the tool,
since the oil drops are small enough (usually smaller than 2 "m) to
impregnate the tool interface.
 it evacuates chips from the working area helped by the pressurised air.

MQL system: injection of high-speed air Cutting parameters for MQL and dry
jet with micro-drops of oil cutting are lower than for emulsion or oil
 16.2. EXPERIMENTAL RESULTS

Cutting operation

 Face milling
 Drilling
 Tapping
 Circular milling
 Boring
 17. RECYCLING PROCESS FOR MG CHIPS

 Concern for the environment has grown in recent years

 Magnesium alloys are fully recyclable. Energy required to produce metal from
raw materials is much higher than the energy used for recycling
 The recycling process can be split into different steps:

Mg Chips
cleaning
Mg parts
crushing (centrifugation briquetting foundry
machining
process)

Oil recovery
 17.1. CRUSHING OF MAGNESIUM CHIPS

 This process makes uniform the size of the chip and makes it easier the
briquetting process.

Chip crushing system

 In general, magnesium chips obtained in a high speed machining process are

small, and for this reason, crushing phase is not necessary.
 17.2. CLEANING OF MAGNESIUM CHIPS

 It is necessary to remove the oil from the chips.

 One of the most common method used in the industry to remove the oil from
chips is the centrifugal process.

 After the centrifugation process, oil content of the chips is still too high.
 17.3. OXIDATION OF MAGNESIUM CHIPS

 On of the main problem of Magnesium recycling is the oxidation of the

magnesium chips.
 Magnesium reacts with air, water …
 Cutting fluid a great influence in the corrosion of Mg chips.

Subjective oxidation level using nine different cutting fluids

 17.4. BRIQUETTING OF MAGNESIUM CHIPS

 Magnesium chips can be pressed into solid briquettes and then reused as
raw material. It is possible to decrease up to 40 times the volume.
 Centrifugal process can be avoided because most of the oil is removed
when using briquetting process.
 Pressing forces of up to 5000 kg/cm2 guarantee an adequate reduction in
the amount of cooling lubricants.
 17.5. TEST OF MAGNESIUM SOLID BRIQUETTES

 The size of the chips has a great influence in the briquette manufacturing.
 Large sizes of chip make it difficult the packaging that can be rather poor even
at very high pressures because the deformation suffered by the chips during
the compact process is not enough for filling the empty spaces.

 Foundry is final step of the recycling of magnesium. Magenisium solid

briquettes can be reused as high-grade secondary raw material.
 18. SAFE MACHINING

 The cutting of magnesium alloys includes acute fire risks because magnesium
dusts and chips are classified as "easily flammable or self ignitable".
 The machines must be equipped with fire protection systems according to the
place of employment regulation and the law on technical working equipment.
Automatic fire extinguishing system
• Trapdoor in the roof for possible
explosions.
• Thermo-speedometric sensors.
• Two hydrants of argon.
 18.1. FIRE EXTINGUISHING SYSTEM

Manual and automatic trigger

The activation of the fire extinguishing system requires the all the
doors to be closed - 67 liters of argon are discharged accompanied
by a luminous and sonorous signal.
 19. STORAGE OF MAGNESIUM CHIPS

 If chips are wet, they must be dryed until chips are storage.
 Magnesium wet chip cannot be storage because it reacts with water,
producing hydrogen.
 Dry operation should be place in open space; are necessary about 50
hours to get dry until a grey skin appears in the magnesium alloys.
 Centrifugal machines could be used in order to dry chips faster.

wet chips dried 4 hours at 25ºC

wet chips stored in barrels

without drying
 19.1. WET CHIPS AND VENTING HOLE
 Magnesium chips contaminated with water or water-based coolants
should be stored in well vented steel containers.
 The hydrogen concentration in the containers is effectively kept below the
lower explosion limit of 4% with a 25 mm venting hole.
 It is recommended to use three venting holes with a diameter of 25 mm
just below the top cover of the container.
 The storage area and the transport vehicle must also be properly
ventilated to prevent accumulation of flammable hydrogen-air mixtures.
 20. CONCLUSION AND RECOMMENDATIONS FOR SAFE
MACHINING AND HANDLING OF MAGNESIUM CHIPS

» Magnesium alloy are easy to machine due to the compact

hexagonal structure.
» Fire risk is always present when machining magnesium that is
why a certain basic rules must be followed:
»High feeds must be programmed to produce thicker chips
»Avoid friction in the cutting zone between chip-tool-workpiece
»Avoid any fire sources near the chips
»Working area must be kept clean and free of magnesium chips
»Fire extinguishing agents must be kept near while machining
magnesium parts (dry cast iron chips, dry sand, D type fire
extinguishers.
 20. CONCLUSION AND RECOMMENDATIONS FOR SAFE
MACHINING AND HANDLING OF MAGNESIUM CHIPS

»In case of using coolants, net oil or specially approved

synthetic coolants to minimize the formation of hydrogen
should be employed
»The enclosed working areas of the machines must have a
good ventilation in case of wet machining to avoid high
concentrations of hydrogen
»Chips should be transformed into briquettes for safe
handling and transporting
»In case briquetting is not possible, the barrels containing
magnesium chips should be ventilated for storage and
transport tasks.
 21. REFERENCES

X. Alza Aizpitarte, Deliverable D2.1.2; Learning Module 2, Project

MagForge, January 26, 2007.

A. Mendia (SORALUCE), I. Ferreres (IDEKO), J. Pérez (IDEKO), Deliverable

D2.4.1; new machining tools designs and processing parameters for
finishing of magnesium wrought alloys, Project MagForge, March 6,
2008.