Dedicated coolant cuts magnesium working costs
A
Master Chemical Europe product story
Edited by the Engineeringtalk editorial team
Sep 22, 2006
Inappropriate choice of metalworking fluid can cause a number of production problems when working with magnesium.
Magnesium is widely recognised for its favourable strength-to-weight ratio and eminent suitability for casting.
It is rarely used in pure form for structural elements and is generally alloyed for the production of parts for the automotive, aerospace and electronic sectors.
Magnesium alloys are amongst the easiest of the structural metals to machine.
They require the least power of any commonly machined metal, for example, 50% less than aluminium alloys and 90% less than nickel and cobalt based super alloys.
Indeed they can be shaped and fabricated by most metalworking processes and are easily welded.
It is not all plain sailing however as a subcontractor to a major magnesium die-caster can confirm.
Although it agrees that magnesium alloys are easy to machine, the process requires careful management.
Inappropriate choice of metalworking fluid can cause a number of production problems and for one particular subcontractor these included short sump life, residue build-up and inefficient pump-out and recharge.
The odour of the fluid also prompted a lot of operator complaints so health and safety was an issue too.
With these prevailing problems the company was keen to trial the new dedicated coolant developed by Master Chemical, Trim E737.
It has been developed as a cost competitive product that is compatible with virtually all magnesium alloys up to 4000ppm.
It has been formulated to provide exceptionally clean running and to maintain tool sharpness for optimal cutting.
The results were impressive.
As Trim E737 virtually eliminates hydrogen generation, the residue build-up the subcontractor had been experiencing with its previous water-based fluid disappeared immediately.
The product's extreme hard water tolerance also had a positive effect in this regard.
As a result machines became cleaner allowing easier part changes and maintenance.
The excellent biostability of Trim E737 proved over the length of the trial to provide a long sump life without the need for any additive.
Complaints about the smell of the product were eliminated and coolant disposal costs were cut by a substantial 40%.
"By changing to Trim E737 we have reduced our operating costs per machine", confirmed a company spokesman.
"This product is affordable, effective and has helped reduce production costs for a significant part of our business".
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