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Magnesium is a metal used in various applications due to its lightweight and excellent machinability. However, machining magnesium also has some challenges. It may explode if safety precautions are not taken.
You can learn everything about CNC machining magnesium in this guide below.
Why Machine Magnesium?
Magnesium is dangerous to machining, but it is still used for CNC machining, and this could be a debatable topic. If you are also inclined to learn why magnesium is used for CNC machining, even if it is dangerous, then you can learn it here.
Magnesium is one of the lightest metals, and when subjected to machining, it can offer components that have excellent surface finish. It also offers high machinability. However, when safety precautions are taken, the risk associated with machining magnesium can be reduced.
Magnesium also doesn't need much cutting force, and it benefits the machinist in various ways. They can carry out the process of machining quickly, the magnesium chips break in a consistent and clean way, low power is needed and also the cutting tools do not wear out.
Understanding the Risks of Magnesium Machining
Magnesium machining has some risks, and to ensure safety precautions, it is very important to understand these risks. Some of the risks of magnesium machining are given below.
Risk of Fire Hazard
The chips and dust created during the magnesium machining process are extremely flammable and have the potential to cause fire. Hence, in case of excessive heat and sparks which are created during the machining process, fire can break out easily.
Excessive Heat
Magnesium is known for its high heat production in the area where cutting takes place. The high temperature during the cutting process may lead to deformation in the workpiece and also tends to reduce the tool's life.
Lack of Surface Finishing
Magnesium alloys generally, when used for manufacturing components, offer an excellent surface finish when appropriate machining strategies are done. As the burr formation is a risk associated with machining magnesium due to high heat production, hence a lot of caution needs to be exercised.
Getting the Right Fire Extinguisher
A fire caused by the magnesium chip ignition cannot be extinguished using water. In fact, water can make it worse. Hence, it is very important to have a backup for firefighting in a place where magnesium machining is done.
Fire extinguishers are very important to have in place, and there are different types of fire extinguishers that may suit different situations. For instance, a class D fire extinguisher is meant to fight fires caused by metals and contains copper powder and sodium chloride.
Moreover, there should be a sand bucket as well, which can help extinguish fires if they are smaller ones. The sand bucket needs to be placed closer to the machine, whereas the fire extinguisher should be kept further away.
Safety Tips for Machining Magnesium
Some of the safety tips for machining magnesium that should be implemented are given below:
- The magnesium machining process can be carried out at a faster speed, and it doesn't compromise the quality of the component. However, it is suggested to avoid tight clearance angles so that the friction between the tool and workpiece doesn't increase.
- Using shape tools also helps reduce the chance of fire in machining magnesium, as dull tools may cause friction and sparks, leading to a fire.
- Coolants are mostly required using the process of machining but water-based coolants must be avoided as they cause a risk of fire due to hydrogen gas presence in it.
- When machining magnesium, you can make the discontinuous chips as they are less susceptible to ignition compared to ribbon chips.
- When machining magnesium, using the vacuum extraction system to remove chips is a fireproof approach.
Magnesium Part and Chip Storage
Once the magnesium part is manufactured, the risk of ignition may be reduced. But when it comes to magnesium chips, these are always risky. Hence, chips must be stored in steel drums, which are closed and separated from other materials.
However, the container in which chips are stored should be kept at a distance from flammable materials in a shed that is outdoors.
The Advantages of CNC Machining Magnesium
CNC machining magnesium has multiple advantages, and some of these are the following:
High Machinability
Magnesium machining is very quick and easy when done with the CNC machining process. Magnesium offers good machinability and even has a low cutting force requirement which takes care of the tool wear.
Complex Components
Due to the high machinability of magnesium, custom components that have complex geometries can easily be created. The process of CNC machining helps in achieving the precision required by the complex parts, and usually error-free components are achieved.
Recyclable
Magnesium can be recycled very easily and it is also environmentally friendly. Hence, when opting for sustainable manufacturing options, magnesium alloys are usually chosen. Even the waste produced during the process of machining magnesium can be recycled.
Conclusion
Magnesium machining offers high-quality, precise components, but the most important when machining magnesium is safety.
If you are looking forward to getting magnesium components manufactured with high accuracy through CNC machining, we at DEK are experts. We offer the finest quality magnesium components keeping the risks of machining magnesium managed.
FAQs
Which magnesium alloy is the best for machining?
Magnesium alloy AZ31B is usually considered to be the best for machining as it offers high machinability, ductility, and strength.
What are the other flammable metals?
Some of the other flammable metals are lithium, titanium, potassium, plutonium, and sodium.
What are the most common applications for magnesium machining?
Magnesium alloys are widely used in the medical industry due to their lightweight and biocompatibility. Wheelchairs and medical equipment are mostly manufactured using magnesium.