How To Reduce Deformation During Magnesium Alloy Parts Machining
Magnesium alloy has the character of small cutting force, low cutting energy consumption, less heat during cutting, easy chip breakage, and small tool wear. So high-speed and large cutting volume can be used in magnesium alloy machining . In principle, cutting tool in any material, including ordinary carbon steel can be used for processing magnesium alloy. When high-volume cutting, we usually choose hard alloy cutting tools. Diamond tools are mainly used in strict requirement of surface quality, however it also can be used in magnesium alloy turning process. Magnesium alloy has low burning point (650 ℃), during processing, mineral oil must be used for strong cooling. Rapid removal of magnesium chips from the processing zone is also necessary. In addition, when high-speed cutting, the magnesium alloy may generate BUE on the surface of cutting tools. So we can take below steps to reduce deformation.
(1) Technical specifications: Separate roughing and finishing, remove most of the margin in the roughing stage. For framework of magnesium alloy machined parts, especially thin-walled parts, you can take the method of pasting damping material to reduce the cutting vibration deformation. Consider damping treatment during processing, reducing the cutting allowance and temperature difference. Arrange artificial or natural aging and temper heat treatment between roughing and finishing processes, to release the internal stress as far as possible and reduce parts deformation after processing.
(2) Reasonable tool geometric parameters: use large rake angle, in general γ is 20°~30 °. Take a smaller value when rough processing, and α is 10°~ 15°when finishing. Large side rake can increase cutting force. Meanwhile, the impact of flank wear on the cutting force should be considered. Therefore, control the flank wear to maintain the sharpness of the tool is also an effective way to reduce the cutting force. The edge angle has a direct effect on the cutting force, reducing the edge angle, increasing the ratio of cutting depth and feed movement has a very good effect on heat dissipating in cutting zone. In general main angle Hγ is 30°~ 45 °.
(3) Choose appropriate cutting amount: use high-speed milling technology for machining, cutting heat are basically taken away by chips. You can also choose a large feeding amount and cutting depth.
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