Magnets in a speaker

[TheCreator]

Hello.
I'm going to purchase a large magnet (60x60mm) and cut it lengthwise (it is currently 35mm thick).
It's coated in nickle, I need to safely remove this as it could be a danger (to breathe).
I'd like to some advice on this.
Also I understand I'll need to clamp the magnet on either side as I cut it, to ensure the new magnets do not repel each other and break into smaller bits.
Ideally I like the thickness to be 1.5-2mm thick, but perhaps this is unrealisitc?
I'll be putting these into headphone speakers - do I need to recoat them in nickle? Or is another protective coating available/more suitable?


Thanks
Nathan

 

[MagMike]

Why can't you purchase smaller magnets, ones more appropriate for a headphone speaker?

At the very least, you should demagnetize the magnet before grinding it.

 

[TheCreator]

It will be a neodymium magnet.

 

[EdStainless]

So how are you cutting, wet diamond saw? wire EDM?
This material is very hard and brittle.
Yes, you need to fixture the parts, you could pot them into some castable material.
If the magnet is magnetized you won't be able to do it.

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Plymouth Tube

 

[TheCreator]

I was going to use a router, diamond saw or tungsten carbide.

But I've been told not to do this as the shavings are likely to explode.
(I guess an oxygen free environment/partial vacuum would've been required).

The magnet supplier said it would be easier & safer to order the thin discs that I require, and they'll come coated to protect from corrosion.

Thanks for your advice.