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INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 14, No. 6, pp. 995-1001 JUNE 2013 / 995
© KSPE and Springer 2013
Experimental Study of the Dry Facing of Magnesium
Pieces Based on the Surface Roughness
Eva Maria Rubio1, Jose Luis Valencia2, Adolfo Jose Saa1,#, and Diego Carou1
1 Dept. of Manufacturing Engineering, UNED, C/ Juan del Rosal, 12, E28040-Madrid, Spain2 Dept. of Statistics and Operation Research III, UCM, Av, Puerta de Hierro s/n, E28040-Madrid, Spain
# Corresponding Author / E-mail: [email protected], TEL: +34-91-3988226, FAX: +34-91-3986046
KEYWORDS: Dry face turning, Magnesium UNS M11917, Surface roughness, Sustainable machining, Optimization, Taguchi design of experiments, ANOVA
This paper shows an experimental study of dry face turning carried out on UNS M11917 magnesium pieces. The work is
focused on repair and maintenance operations which are generally carried out under cutting conditions of low performance.
The main goal is to determine if such type of operations can be reached successfully by dry machining, the most drastic and
sustainable cooling technique that exists, and, if so, what factor or factors among the involved ones in the machining (spindle
speed, feed rate and tool coating) and their possible interactions are more influential in the quality of surface finish. To achieve
this objective, a sustainable methodology that combines Taguchi design of experiment (DOE) and the analysis of variance
(ANOVA) method are considered. The main result is the establishment of a model for estimating the expected surface roughness,
in terms of average roughness, Ra, that allows selecting the best combination of cutting conditions and type of tool to obtain
pieces within a certain range of surface roughness. The principal conclusion is that the dry machining technique can be used
in the face turning repair and maintenance operations of pieces of magnesium producing a very good quality of the surface
roughness and reducing costs and environmental impact.
Manuscript received: October 29, 2012 / Accepted: April 18, 2013
1. Introduction
Magnesium is widely used in industries such as aeronautics and
automotive due to the excellent strength to weight ratio that presents.1-4
Magnesium alloys may be combined with other materials to form
hybrid structures (magnesium-aluminium, magnesium-titanium and
magnesium-sintered steel) in order to reduce the weight and to improve
the strength and the wear and fatigue characteristics.5-9 The high cost of
these components makes necessary to carry out repair and maintenance
operations when they have suffered any damage.
Magnesium alloys usually have a good performance in machining.
However, this material presents problems with the heat generated
during the machining process, since it has a tendency to ignite.8-10 To
ensure adequate cooling for the machining of these alloys is not easy.
On the one hand, the use of refrigerants containing water is dangerous
in case of chip ignition; burning magnesium, in the presence of water,
decomposes to form hydrogen atmospheres which are highly explosive.
On the other hand, the use of lubricants or coolants during machining
is an undesirable factor due to economic and environmental factors.7-9
In general, in order to analyse and, if it is possible, to optimize the
machining processes, it is necessary to investigate, among other
aspects, the influence of the cutting conditions (cutting parameters,
types of tools and use, or not, of coolant/lubricant) in the response
variable or variables selected; usually, the surface roughness of the
mechanized pieces, in terms of average roughness, Ra.11-22
In the present work, in order to improve the knowledge about the
magnesium alloys machining, an experimental study is made. Namely,
the work is focused on the selection of the best cutting conditions to
NOMENCLATURE
d = depth of cut (mm)
D = measuring circle (mm)
f = feed rate (mm/rev)
N = spindle speed (rpm)
R = measuring radius (o)
Ra = average roughness (μm)
T = tool coating
DOI: 10.1007/s12541-013-0132-9
996 / JUNE 2013 INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 14, No. 6
reach a certain surface roughness in pieces of UNS M11917
magnesium alloys obtained by facing cutting under low performance
conditions, own of repair and maintenance operations.
The mechanized has been made without any coolant (dry
machining). This cooling technique is the most drastic but, as well, the
most sustainable and constitutes a good alternative in this occasion
because it has been probed in previous works7-11,23,24 that, under such
low performance conditions, the heat generated in the machining does
not reach values that compromise safety.
The study is raised following a sustainable approach in which tests
are performed according to a design of experiments (DOE) of Taguchi
that allows maximum information with minimum possible number of
resources.23,25-29
To determine the influence of each factor and their interactions in
the surface roughness, the analysis of the variance (ANOVA) method
is used in the treatment of data.
Finally, a statistical model is also established with the aim of
determining the surface roughness expected for different combinations
of factors.
The main novelties that this work presents versus others ones
existing about magnesium machining can be summarized like this:
- The machining operation selected, the face turning, is an operation
much less studied that the horizontal turning.
- The cutting conditions of low performance (low depths of cut,
cutting speeds and feed rates), own of the repair and maintenance
operations, are used when the usual conditions analysed in the
magnesium machining are at high-speed.
- As in the face turning the cutting speed varies linearly with the
instantaneous radius of cut, the necessary factors and levels to
analyse the surface roughness evolution throughout the workpiece
radius are included in the DOE.
- A ranking for the best combinations of cutting parameters and tool
coatings based on the expected values of surface roughness given by
the statistical model is provided.
2. Experimental procedures
This experimental study is focused on the measurement of surface
roughness in dry facing operations of UNS M11917 magnesium
workpieces, with a chemical composition shown in Table 1. The
workpieces are cylindrical bars with a diameter of 110 mm and an
initial length of 100 mm (see Fig. 1).
As a previous consideration, three potential factors of design that
influence the process have been considered: the spindle speed, N, the
feed rate, f and the tool coating, T. It is suspected that these factors
interact with each other.
As repair and maintenance operations of magnesium alloys are
usually conducted at low values of spindle speed and feed rate, the
levels of the cutting parameters in the experimental tests were chosen
among these of low performance. Three levels were selected for feed
rate (0.04, 0.08, 0.12 mm/rev) and for spindle speed (280, 500, 800
rpm). The depth of cut, d, in these repair and maintenance operations,
needs to be small in order to keep the dimensional tolerances required.
To ensure this, the depth of cut was kept constant at 0.25 mm. These
cutting conditions are expressed in units commonly employed in
manufacturing workshops instead of International System of Units
(S.I.) in order to give a more intuitive description of the used values.
The cutting tools employed in the machining, from SECO
manufacturer, have identical geometry (Fig. 2) but different coatings
since it was taken into account that, in the main aeronautical and
automotive applications, magnesium is normally used as part of hybrid
materials such as magnesium-aluminium, magnesium-titanium and
magnesium-steel.29-34 Thus, three different types of coatings were
selected, one specifically for non-ferrous metals and two for other
materials with a coating of Ti(C,N) + Al2O3 + TiN. The manufacturer
references are: HX, TP200 and TP2500 respectively.
The cylindrical magnesium bars were dry faced on a Pinacho L-1/
200 lathe. The surface roughness of workpieces after each test was
measured with a Mitutoyo Surftest SJ-401 surface roughness tester. For
every test considered in the design of experiments, as the cutting speed
decreases as the machining progresses, surface roughness was
measured in three different zones of the face of the bars to depict the
surface roughness evolution throughout the radius.
Table 1 Chemical composition of the workpieces (mass %)
Al Cu Fe Mg Mn Ni Si Zn
8.3-9.7 ≤ 0.03 ≤ 0.005 90 0.15-0.5 ≤ 0.002 ≤ 0.1 0.35-1
Fig. 1 Workpiece in the machine
Fig. 2 Types of tools employed: (a) HX and (b) TP200 and (c) TP2500
Fig. 3 Measuring zones
INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 14, No. 6 JUNE 2013 / 997
The surface roughness was measured in terms of average roughness,
Ra:
(1)
Fig. 3 shows the measuring zones considered. Two factors were
used to locate each of these measuring zones: the measuring radius, R,
and the measuring circle, D. For the measuring radius, R, three radii
separated one from each other 120o and denoted by R1, R2 and R3 were
selected. And, for the measuring circle, D, three circles concentric with
the centre of the workpiece were established and denoted by D1, D2
and D3 respectively. These two factors -with three levels each- were
also considered as potentially influential, and therefore included in the
experimental design.
Table 2 shows the factors, codes and levels of the experimental
design. In order to analyse the influence of the six factors considered
–five with three levels each, and one with only one level- an L27
orthogonal Taguchi12-14 design with three replications nested was
selected for this study.
To avoid the influence of uncontrollable factors, the experimental
runs were conducted in randomized order. Table 3 shows the
orthogonal array of the design and the order of the randomized
experiments.
3. Data analysis and discussion of results
The results of the surface roughness values measured in each
experimental run are given in Table 4.
The analysis of variance was applied to identify the influential
factors. An ANOVA fixed-effect analysis was performed by removing
one factor each time (with p-value greater than 0.05) considering
Snedecor’s F as the statistical test. The final results of the analysis of
variance are shown in Table 5. In this table, DF represents the degrees
of freedom of each factor or interaction. The information given in the
last column represents the probability that Snedecor´s F distribution
had a value greater than the computed F value. When this probability
is greater than 0.05 (p-value > 0.05), it is considered in this analysis
that the effect corresponding to this factor is not statistically significant.
The statistical analysis was performance with SAS® software.35
Throughout the ANOVA it was found that factors D and R are not
statistically influential. The interactions of D and R with T, N and f,
Ra1
L--- Y x( )
0
L
∫ dx=
Table 2 Factors, codes and levels for the experimental design
Factor Code Level 1 Level 2 Level 3
Feed rate (mm/rev) f 0,04 0,08 0,12
Spindle speed (rpm) N 280 500 800
Depth of cut (mm) d 0,25
Tool coating T HX TP200 TP2500
Measuring radius (o) R 0 120 240
Measuring circle (mm) D 18,33 55 91,67
Table 3 Randomized experiment orthogonal array L27 with three
replications nested
Test f T N Ra1 Ra2 Ra3
1 1 1 3 D3 R2 D2 R1 D1 R3
2 3 2 2 D1 R2 D3 R1 D2 R3
3 3 1 2 D1 R2 D2 R3 D3 R1
4 3 1 1 D2 R2 D1 R1 D3 R3
5 3 1 3 D1 R3 D3 R2 D2 R1
6 1 2 3 D2 R2 D1 R3 D2 R1
7 2 1 2 D2 R3 D1 R2 D3 R1
8 3 3 3 D3 R2 D2 R1 D1 R3
9 1 1 2 D2 R3 D1 R2 D3 R1
10 2 3 2 D1 R2 D2 R3 D3 R1
11 1 3 2 D2 R3 D1 R2 D3 R1
12 3 2 3 D3 R2 D1 R3 D2 R1
13 1 3 3 D1 R3 D3 R2 D2 R1
14 2 1 1 D3 R3 D2 R2 D1 R1
15 1 2 1 D3 R3 D2 R2 D1 R1
16 3 3 1 D1 R1 D2 R2 D3 R3
17 1 2 2 D1 R2 D3 R1 D2 R3
18 2 2 1 D1 R1 D2 R2 D3 R3
19 2 3 3 D2 R1 D1 R3 D3 R2
20 1 1 1 D1 R1 D2 R2 D3 R3
21 3 2 1 D1 R1 D2 R2 D3 R3
22 1 3 1 D1 R1 D3 R3 D2 R2
23 2 2 3 D1 R3 D3 R2 D2 R1
24 2 2 2 D1 R2 D3 R1 D2 R3
25 3 3 2 D1 R2 D3 R1 D2 R3
26 2 1 3 D1 R3 D2 R1 D3 R2
27 2 3 1 D1 R1 D2 R2 D3 R3
Table 4 Experimental results of surface roughness, Ra
TestFactor
Surface roughness, Ra
(µm)
f T N Ra1 Ra2 Ra3
1 0.04 HX 800 0.34 0.22 0.28
2 0.12 TP200 500 0.64 0.71 0.68
3 0.12 HX 500 0.78 0.76 0.73
4 0.12 HX 280 0.82 0.76 0.75
5 0.12 HX 800 0.74 0.78 0.76
6 0.04 TP200 800 0.22 0.22 0.24
7 0.08 HX 500 0.45 0.49 0.44
8 0.12 TP2500 800 0.68 0.71 0.68
9 0.04 HX 500 0.23 0.28 0.24
10 0.08 TP2500 500 0.74 0.73 0.71
11 0.04 TP2500 500 0.29 0.31 0.24
12 0.12 TP200 800 0.71 0.69 0.73
13 0.04 TP2500 800 0.24 0.24 0.24
14 0.08 HX 280 0.44 0.41 0.40
15 0.04 TP200 280 0.22 0.21 0.22
16 0.12 TP2500 280 0.67 0.62 0.70
17 0.04 TP200 500 0.32 0.31 0.34
18 0.08 TP200 280 0.41 0.33 0.41
19 0.08 TP2500 800 0.36 0.41 0.42
20 0.04 HX 280 0.28 0.27 0.29
21 0.12 TP200 280 0.63 0.61 0.59
22 0.04 TP2500 280 0.24 0.19 0.20
23 0.08 TP200 800 0.32 0.37 0.36
24 0.08 TP200 500 0.38 0.32 0.36
25 0.12 TP2500 500 0.68 0.66 0.68
26 0.08 HX 800 0.32 0.38 0.40
27 0.08 TP2500 280 0.37 0.34 0.37
998 / JUNE 2013 INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 14, No. 6
neither appear in the final ANOVA results because were also not
significant. The feed rate, f, is the factor that most influences by far, and
on a much lesser degree have also statistical influence, by this order,
interaction tool coating-feed rate, T*f, spindle speed, N, interaction
spindle speed-feed rate, N*f, interaction tool coating-spindle speed,
T*N, and the tool coating, T.
Table 6 includes the percent contribution of the factors and
interactions that were found to statistically influence the variability of
Ra. Nearly 85% of the variability of Ra is caused by the feed rate
(89,4% of the controlled variability).
Equation (2) models the variability of surface roughness from
ANOVA. In this equation, µ is the intercept, fi, tj and nk, represent the
effect of the levels of feed rate, tool coating and spindle speed; (ft)ij,
(fn)ik and (tn)jk represent the interactions feed rate-tool coating, feed
rate-spindle speed and tool coating-spindle speed respectively; and, åijk,
represents the error of the model. Table 7 shows the estimates of the
model parameters given by Equation (2).
(2)
The hypotheses of the model were checked, and there was no
evidence or lack of normality (Table 8). Neither has been found
evidence of existence of any pattern nor heteroscedasticity (Fig. 4).
The graphs of box-and-whiskers serve to see the dispersion of the
response variable values versus each factor when they are considered
in isolation. Fig. 5 collects the graphs of box-and-whiskers of the
surface roughness, in terms of Ra, versus the factors: (a) feed rate, (b)
spindle speed and (c) tool coating. Fig. 5(a) shows that the best surface
finishes are obtained machining with a low feed rate value (0.04 mm/
rev) and that Ra increases when feed rate increases. In Fig. 5(b) the
intermediate spindle speed (500 rpm) presents the highest Ra average
value but the lesser dispersion. And, finally, regarding the type of tool
coating, Fig. 5(c) shows as the TP200 tool provides slightly better
values of the Ra than the other two coatings (lesser Ra average values
and dispersion).
yijk μ ft tj nk ft( )ij fn( )ik tn( )jk εijk+ + + + + + +=
Table 5 Final results of analysis of variance
Source DF Sum of squares Mean square F Pr > F
T 2 0.04557284 0.02278642 8.63 0.0005
N 2 0.06459506 0.03229753 12.23 <.0001
f 2 2.73520247 1.36760123 517.69 <.0001
T*f 4 0.09080494 0.02270123 8.59 <.0001
T*N 4 0.05941235 0.01485309 5.62 0.0006
N*f 4 0.06249383 0.01562346 5.91 0.0004
Error 62 0.16378765 0.00264174
Total 80 3.22186914
Table 6 Percent contribution factors to Ra variability
Source Model (%) Variability (%)
f 89.4% 84.9%
T*f 3.0% 2.8%
N 2.1% 2.0%
N*f 2.0% 1.9%
T*N 1.9% 1.8%
T 1.5% 1.4%
Total 100% 94.9%
Table 7 Estimation of parameters in the model of equation (2)
Parameter EstimateStandard
errort Value Pr> |t|
Intercept µ 0.6788 0.0249 27.27 <.0001
f = 0.04 f1 -0.4578 0.0313 -14.63 <.0001
f = 0.08 f2 -0.2519 0.0313 -8.05 <.0001
f = 0.12 f3 0 . . .
T = HX t1 0.1037 0.0313 3.32 0.0015
T = TP200 t2 0.02 0.0313 0.64 0.5249
T = TP2500 t3 0 . . .
N = 280 n1 -0.05630 0.0313 -1.80 0.0768
N = 500 n2 0.0467 0.0313 1.49 0.1408
N = 800 n3 0 . . .
T = HX*f = 0.04 (ft)1,1 -0.0622 0.0343 -1.82 0.0742
T = TP200*f = 0.04 (ft)1,2 0.0222 0.0343 0.65 0.5190
T = TP2500*f = 0.04 (ft)1,3 0 . . .
T = HX*f = 0.08 (ft)2,1 -0.1689 0.0343 -4.93 <.0001
T = TP200*f = 0.08 (ft)2,2 -0.1222 0.0343 -3.57 0.0007
T = TP2500*f = 0.08 (ft)2,3 0 . . .
T = HX* f = 0.12 (ft)3,1 0 . . .
T = TP200*f = 0.12 (ft)3,2 0 . . .
T = TP2500*f = 0.12 (ft)3,3 0 . . .
N = 280*f = 0.04 (fn)1,1 0.0233 0.0343 0.68 0.4984
N = 500*f = 0.04 (fn)1,2 0.0533 0.0343 1.56 0.1247
N = 800*f = 0.04 (fn)1,3 0 . . .
N = 280*f = 0.08 (fn)2,1 0.0522 0.0343 1.52 0.1326
N = 500*f = 0.08 (fn)2,2 0.1600 0.0343 4.67 <.0001
N = 800*f = 0.08 (fn)2,3
N = 280*f = 0.12 (fn)3,1 0 . . .
N = 500*f = 0.12 (fn)3,2 0 . . .
N = 800*f = 0.12 (fn)3,3 0 . . .
T = HX*N = 280 (tn)1,1 0.0533 0.0343 1.56 0.1247
T = HX*N = 500 (tn)1,2 -0.09778 0.0343 -2.85 0.0059
T = HX*N = 800 (tn)1,3 0 . . .
T = TP200*N = 280 (tn)2,1 0.0056 0.0343 0.16 0.8717
T = TP200*N = 500 (tn)2,2 -0.0956 0.0343 -2.79 0.0070
T = TP200*N = 800 (tn)2,3 0 . . .
T = TP2500*N = 280 (tn)3,1 0 . . .
T = TP2500*N = 500 (tn)3,2 0 . . .
T = TP2500*N = 800 (tn)3,3 0 . . .
Table 8 Tests for normality
Test Statistic p Value
Shapiro-Wilk W 0.991488 Pr < W 0.8761
Kolmogorov-Smirnov D 0.062836 Pr > D > 0.1500
Cramer-von Mises W-Sq 0.03453 Pr > W-Sq > 0.2500
Anderson-Darling A-Sq 0.232754 Pr > A-Sq > 0.2500
Fig. 4 Residuals versus predicted Ra values
INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 14, No. 6 JUNE 2013 / 999
Fig. 6 shows the dependence of surface roughness versus the feed
rate for: (a) each tool coating and (b) each spindle speed. Fig. 6(a)
shows that, for the three types of tool coatings (HX, TP200 and
TP2500), the two first (HX and TP200) have a very similar
behaviour; being slightly better the Ra values obtained with the
TP200 coating. Besides, for the lowest feed rate (0.04 mm/rev) the
three coatings provide low and very similar Ra values (almost
coincident). It can be seen as well, that the highest values of Ra are
reached at the highest feed rate (0.12 mm/rev), obtaining the worst
values of Ra with the HX coating. Fig. 6(b) shows that, for the three
spindle speeds probed: 280 rpm, 500 rpm and 800 rpm, the surface
roughness versus the feed rate has a very similar behaviour at
280 rpm and at 800 rpm and, in general, presents a worse behaviour
for the intermediate value of 500 rpm (that only presents better Ra
values for high values of the feed rate than the obtained ones using
the highest spindle speed, 800 rpm).
The model from Equation(2) and the estimates of parameters
illustrated in Table 7 were used to identify the optimal combination of
tool coatings and cutting parameters levels based on the Ra expected
(Table 9). The combination of tool coatings and cutting parameters that
minimized the surface roughness expected is a feed rate of 0.04 mm/
rev, a spindle speed of 280 rpm, and a TP2500 tool coating.
Nevertheless, as the differences between these machining conditions
and the other conditions just following them in the ranking seem small,
attending to economic issues, might be worth considering following
combinations with higher spindle speed.
Fig. 5 Box-and-whiskers plots of surface roughness, in terms of Ra
versus the factors: (a) feed rate, (b) spindle speed and (c) tool coating
Fig. 6 Dependence of surface roughness with the feed rate for: (a) each
tool coating and (b) each spindle speed
Table 9 Ranking of parameter combinations based on the Ra expected
FactorRa expected (µm)
f (mm/rev) T N (rpm)
0.04 TP2500 280 0.188
0.04 TP2500 800 0.221
0.04 TP200 280 0.236
0.04 HX 800 0.263
0.04 TP200 800 0.263
0.04 HX 500 0.265
0.04 TP200 500 0.268
0.04 HX 280 0.283
0.04 TP2500 500 0.321
0.08 TP200 800 0.325
0.08 TP200 280 0.326
0.08 HX 800 0.362
0.08 HX 280 0.411
0.08 TP2500 280 0.423
0.08 TP2500 800 0.427
0.08 TP200 500 0.436
0.08 HX 500 0.477
0.12 TP2500 280 0.623
0.08 TP2500 500 0.634
0.12 TP200 280 0.648
0.12 TP200 500 0.650
0.12 TP2500 800 0.679
0.12 TP200 800 0.699
0.12 TP2500 500 0.726
0.12 HX 500 0.731
0.12 HX 280 0.780
0.12 HX 800 0.783
1000 / JUNE 2013 INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 14, No. 6
4. Conclusions
This work presents an experimental study to determine if it is
possible to carry out repair and maintenance operations by dry facing,
on pieces of UNS M11917 magnesium alloy, own of the aeronautical
and automotive industries, achieving very exigent requirements of
surface roughness as the normally required in such sectors.
Then, in order to reach this objective, an L27 orthogonal Taguchi
design of experiments with three replications nested is selected for the
study along with the ANOVA method. The surface roughness is taken
as response variable for the reasons given above and, as possible
sources of its variability, the next factors: depth of cut, feed rate,
spindle speed, tool coating and measuring zones (defined by the circle
and the radius where the measurements are taken).
From the obtained results, a statistical model for calculating the
values of the expected surface roughness is developed. The model is
defined as a function of the feed rate, the tool coating, the spindle
speed, and the interactions feed rate-tool coating, feed rate-spindle
speed and tool coating-spindle speed; being the feed rate the first
responsible of the variability of surface roughness.
The higher the value of feed the greater roughness and vice versa (at
least in the value range studied). The interaction between spindle speed
and feed rate causes a slight increase in Ra values for intermediate
values of spindle speed when the feed rate also takes an intermediate
value.
This model allows establishing a ranking, based on the surface
roughness expected, and to select the best cutting conditions and tool
coatings for a certain range of surface roughness. The optimal
combination that provides the least surface roughness is the next one:
feed rate, 0.04 mm/rev, spindle speed, 280 rpm and coating TP2500.
Taking into account that all the surface roughness values reached
are very good, even better than those usually needed in the analysed
industries, in future works, it would be possible to increase the values
of the cutting conditions, feed rate and spindle speed, in order to
optimize or, at least, try to reduce the time of repair and maintenance
of magnesium pieces.
ACKNOWLEDGEMENT
The authors thank to the Research Group of the UNED “Industrial
Production and Manufacturing Engineering (IPME)” the given support
during the development of this work, and funding of the Spanish
Ministry of Science and Innovation (Projects DPI2011-27135 and
AGL2010-21501/AGR) and of the Industrial Engineering School-
UNED (Project REF2012-ICF01) to carry it out. Besides, the authors
thank to Grupo Antolín Magnesio S.L. the transfer of part of the
material used in this work.
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