Обработка магниа

[hagi 0]

Привет всем!

интересует технология обработки магниа , (для изготовления клище) кто сталкивался.

интересует все!

режимы, охлаждение. тонкости

[Художник 47]

интересует технология обработки магниа , (для изготовления клище) кто сталкивался.

интересует все!

режимы, охлаждение. тонкости

<{POST_SNAPBACK}>

Мои партнёры гравируют магниевые клише на Roland. Я тоже пробовал. Режимы примерно такие же, как на дюрали, но скорости подач выше, магний менее проблемный, менее вязкий, более сыпучий. Использовали специальные тарированные магниевые пластины для полиграфии. Сож - масло прикапывали, можно масляный туман.

[MFS 248]

Да, магний хорош весьма - сыпется, не наматывается на фрезу, но! темнеет под простой эмульсией (резать можно и вообще без орошения зоны резания) и может загореться.

А это будет задница - в Питере маниевое клише спалило весь станок нафиг. Первую, кстати в Питере Cielle BETA.

[hagi 0]

в Питере маниевое клише спалило весь станок нафиг. Первую, кстати в Питере Cielle BETA.

<{POST_SNAPBACK}>

именно этого и опасаюсь.

Станок серии Станок Woodpecker RS6590 система охлаждения

не имеется!

Вообщем как я понял надо от станка далеко не уходить..

[MFS 248]

Аха. Знакомый оборотов больше 15000 не ставит - тоже боицца.

[Kurt 0]

Обрабатываю магниевые сплавы крупными сериями. Могу дать любые советы, как по ОТ так и по режимам. kurt01@mail.ru

[DWL-E 0]

Kurt, а чем обрабатываете? каким инструментом и на каком станке? применяете ли сож?

[Kurt 0]

Инструмент: Сандвик, искар, и т.д. Обязательно с СОЖ. Оборудование: EMAG (о.ц. Германия)

[MFS 248]

Обязательно с СОЖ.

А какой?

[ausital 0]

from: <noindex>http://www.autofieldguide.com/index.html</noindex>

How To Machine Light Metals

Here are some recommendations that can help you make the move to machining aluminum and magnesium.

By Colleen DeJong, Senior Associate Editor

While die casting experts are working on producing die cast parts to net shape, machine tool and machining system builders are busy producing machines that remove the not-so-net excess more efficiently. These machines are different from the ones designed for heavier metals.

First of all, the amount of power needed for working the lighter metals is much less than with cast irons or steels. Secondly, metal removal rates can increase substantially. Surface feet per minute (sfm) values are much higher than with heavy metals (up to 1200 SFM with uncoated carbide). The exception to this rule is magnesium. "You have to submerge the part, and go much slower," explains John S. Klimach, president & CEO at Ex-Cell-O Machine Tools, Inc. (Sterling Heights, MI). "If you don't the part will catch fire."

Mark Tomlinson, vice president of engineering at Lamb Technicon Machining Systems (Warren, MI), feels that there's also a basic change in tooling philosophy between cast iron machining and aluminum machining. "The tooling technologies that are used and the types of tools and inserts that can be used are different," he explains. "What that corresponds with is actual tool life. In cast iron, you're looking to get one or two shifts worth of production out of a tool. With aluminum, you're looking at a whole year's worth." But to actually achieve this kind of productivity, the machine's spindle has to be much more robust. Why?

For starters, spindles require much higher speeds, and less low-end torque than when machining steel or other materials. And they have to be stiffer, to hold tolerance under the faster conditions. Miles Arnone, president and COO at Boston Digital Corp. (Milford, MA), recommends using HSK tapers for added rigidity and accuracy. He also recommends that if very fast tool changes are required, closed-loop motorized spindles should be used to reduce the rotating inertia.

The higher spindle speed also lends to increased frictional heat in the bearings, so a cooling system has to be added. And since light metal machining is not a dry operation, the spindle has to be well sealed against coolant infiltration.

But the spindle isn't the only factor to take into consideration. Here are a few more:

Coated-carbide tools, such as TiAlN, should be employed to extend tool life and to increase SFM levels up to 5,000 surface-feet-per-minute.

Everyone is "Wowed" by high feed rates, but the ability to quickly accelerate or decelerate is more important than maximum feedrates when machining 3D contoured surfaces. CNC features such as gain switching (changes servo parameters on the fly) or contour optimization (lets you set a contour tolerance and automatically manages feed rate) are also important as axis feed rates rise when machining light metals.

Because speeds and feeds are so high, thermal growth can be a major problem when working with light metals. Seek machines with good thermal control systems, and glass scale feedback on all axes. A high-performance machine should provide thermal control of the spindle and major structural elements, such as the column in a VMC. For high precision applications (tolerances better than ±0.0005"), temperature controlled coolant should be considered as well.

Chip removal can be a big issue when working in light metals such as aluminum. Because so much material can be removed in a short period of time, it is important that the machine tool be well designed for chip evacuation.

Even though the cutting forces to machine aluminum are less than when working with steel, for example, it is still very important to have a stiff, well-damped machine. While cutting forces are lower, dynamic forces due to accelerations and decelerations are very high.

But with Magnesium…

These suggestions and observations apply to aluminum machining very well, but if you tried to do the same things with magnesium, you'd be in big trouble (remember Klimach's warnings of fire?). Safety is the big issue here, and there are a few ways you can safely machine magnesium.

•SLOW DOWN. The high speeds you enjoy with aluminum create heat, and heat is not good here.

•Water-based cutting fluids are okay, but use a cutting fluid with a high pH-value. This will reduce the amount of hydrogen gas produced as the water and magnesium react.

•Since hydrogen gas explodes under pressure, maintain good ventilation to dissipate any gas that may be produced.

•If a fire does occur, DO NOT throw water on it, the chemical reaction will actually cause the fire to get bigger. Smothering the fire is the better option. Klimach mentioned one company that kept a barrel of cast iron chips near by when machining magnesium. If fire broke out, they'd shovel the chips on top of it.

•The National Fire Protection Association (NFPA) adds these safety guidelines for handling chips: separate the fluid and chips using a centrifuge system, and do so as soon as possible after machining. Letting the chips sit around lets the fluid and magnesium interact further, increasing the potential for fire. Also, make sure the storage containers are nonflammable, ventilated containers. If not properly ventilated, the possibility of dangerous hydrogen concentrations increases. Store the containers in isolated areas so that if a fire or explosion does occur, it is away from employees, machines, and other flammable materials.

These suggestions for machining magnesium may seem a bit alarmist and silly, industry-wide, magnesium is considered a "problematic" metal to machine. Recent developments in magnesium alloys have somewhat dampened its fiery nature without sacrificing its light weight charac-teristics, but users should still be cautious.

[Крэк 0]

СОЖ - ECOCOOL 2516 MG- компания FUCHS/ Не забудьте приобрести: биоцид; ингибитор коррозии; антивспениватель; чистещее средство. Совет: не забывайте, что магний является активным металлом, прижимное приспособление должно быть выполнено идеально из дюралюминия. Иначе будет происходить электро-химическая коррозия. Удачи.

[KAVKAZMEN 0]

Собираемся обрабатывать магний МА2-1. интересуют следующие вопросы:

1. Скорость резания твердосплавным инструментом?

2. На Д20 черновую фирмы ИСКАР какая глубина, ширина, подача на зуб? (относительно данной черновой фрезы буду смотреть другие черновые.)

3. На чистовую Д20?

4. Плоскость Можно обрабатывать торцевыми фрезами со сменными пластинами? Какие пластины по геометрии? Как под All?

5. Если у детали высокие стенки 100мм, а толщина дна 2мм - деталь не поведет т.е. не согнет? Какие тонкости (фишки при обработке магния?)

6. Инстремент у Вас с внутренним подводом СОЖ?

7. Сверление Д12 на глубину 85мм. посколько за раз сверлить т.е. в цикле глубокого сверления на станке шаг задать какой? Если сверло такое только быстрорез - на него какие режимы?

8. Как реагирует магний на тупой инструмент? Тенят ли заусенцы?

9. В гидравлические тиски с каким усилием зажимать? на 1 ставить или 7? Лучше в ручную?

Пожалуй пока ВСЁ.

Заранее благодарю за ответы

[KAVKAZMEN 0]

Как говорится: молчание - золото!

Мож кто откликнется?

2Kurt и не только: Если деталь 600*500*100 - торцевой фрезой имеет смысл плоскость делать или только концевыми?

Не хочется $ впустую коту под нос!

Изменено 12 ноября 2006 пользователем KAVKAZMEN