Study on material removal process and temperature during precision milling of magnesium alloys using carbide end mill

Magnesium alloys have great potential for industrial applications due to their very good properties. However, their main disadvantage limiting their use is a tendency to ignite during machining. This also eliminates the possibility of using abrasive machining to improve their quality. Precision machining may be a solution to this problem. Despite the potentially significant benefits of applying this method to magnesium alloys, the amount of research in this area remains negligible. This paper therefore focuses on the analysis of the precision milling process of AZ31B and AZ91D magnesium alloys using a double-flute carbide end mill. The aim of the research is to analyse the material removal process during precision machining, focusing on the observation of chip formation. This will enable to minimise the material ploughing phenomenon, which adversely affects the machining process and surface condition. The study also analysed the formation of burrs, which are also an undesirable effect of machining. As part of the research, temperature measurements were also taken in the cutting zone, which are particularly important in terms of safety. During the study, significant differences in the size of chips formed by cutting flutes were observed, caused by uneven tool operation. Burrs were also observed on the edges of the slot due to the low undeformed chip thickness. It was also shown that the maximum temperature in the cutting zone remained below the ignition temperature, so this machining method can be considered safe.