Objective Objectives and content Magnesium is the lightest metal to be used in construction and therefore offers the greatest potential for weight reduction. For this reason especially the automotive industry has an upcoming interest in the use of magnesium alloys in order to reduce the fuel consumption of vehicles. A changing of the material spectrum from iron- and aluminium-based materials to magnesium is therefore strongly supported. When machining magnesium several difficulties and even dangers are likely to occur keeping many potential users from making magnesium the material of their choice: a low quality of the workpiece surface due to adhesive effects between tool and workpiece an insufficient accuracy in geometry and shape due to high thermal expansion of the workpiece the danger of chip ignition safety hazards when using unsuitable cooling lubricants. The aim of the proposal is to introduce safe and high efficient processing of magnesium castings, especially regarding the machining process using adapted tools, cooling lubricants and a high speed cutting (HSC) linear direct driven machining centre with integrated safety devices. The following advantages can be directly attributed to the project: general design rules for magnesium components when turning the workpiece material from cast iron and aluminium to magnesium leading to an increased use of magnesium workpieces. A reduction of fuel consumption of at least 22,5 million l/year (worth: approx. 17 million ECU) and a reduction of an equivalent C02-emission in Europe by of 4.8*108 t especially due to the SF6 replacement in casting is possible. increase of the machined volume of workpiece material per tool life of up to factor 50 when machining magnesium with diamond-coated tools and a reduction of tool costs per workpiece by factor 25. adapted cooling lubricants with doubled life-time leading to a reduction of costs for deposition of up to 2,4 million ECU per year. the first high speed machine tool with linear direct drives will be built, that has integrated safety devices and allows not only high efficient, but also safe machining of magnesium and related materials. The consortium comprises CR-FIAT as one of the biggest European manufacturer of cars, Renault Automation as a builder of machine tools, two competent manufacturers of cooling lubricants, Fuchs Lubricantes and elf mineralolwerke, Plansee Tizit as well known manufacturer of cemented carbide tools CemeCon as innovative manufacturer of tool coatings and only European builder of diamond coating units, Jyskan Metalli as caster being experienced in processing magnesium, the Institut fur Fertigungstechnik und Spanende Werkzeugmaschinen, University of Hannover, (Institute for Production Engineering and Machine Tools, IFW), which has a strong reputation in the research area and Natal as SME and supplier for the automotive industry. Brite/Euram III Industrial Research (IR) areas covered by the proposal are 1.1.7.M (development of new and improved production systems) and 1.1.1.S (adaptation and application of new technologies to reduce costs through-put times and energy consumption while increasing safety and productivity). Fields of science engineering and technologymechanical engineeringtribologylubricationnatural scienceschemical sciencesinorganic chemistryalkaline earth metalsengineering and technologymechanical engineeringmanufacturing engineeringsubtractive manufacturingengineering and technologymechanical engineeringvehicle engineeringautomotive engineeringengineering and technologymaterials engineeringcoating and films Programme(s) FP4-BRITE/EURAM 3 - Specific research and technological development programme in the field of industrial and materials technologies, 1994-1998 Topic(s) 0101 - Incorporation of new technologies into production systems Call for proposal Data not available Funding Scheme CSC - Cost-sharing contracts Coordinator CENTRO RICERCHE FIAT S.C.P.A. EU contribution No data Address Strada Torino 50 10043 ORBASSANO Italy See on map Links Website Opens in new window Total cost No data Participants (7) Sort alphabetically Sort by EU Contribution Expand all Collapse all Cemecon - Ceramic Metal Coatings GmbH Germany EU contribution No data Address 21,Talbotstrasse 52068 Aachen See on map Total cost No data Elf Mineralölwerk Osnabrück GmbH Germany EU contribution No data Address 34,Nuelandstrasse 49084 Osnabrück See on map Total cost No data Fuchs Lubricantes SA Spain EU contribution No data Address 08755 Castellbisbal See on map Total cost No data Jyskän Metalli Oy Finland EU contribution No data Address 40351 Jyväskylä See on map Total cost No data NATAN S.A. Spain EU contribution No data Address 91,Avenida Eduardo Maristany 91 08930 SANT ADRIA DE BESOS See on map Total cost No data Plansee Tizit Gesellschaft mbH Austria EU contribution No data Address 6600 Reute See on map Total cost No data UNIVERSITAET HANNOVER Germany EU contribution No data Address Schlo¯wender Strasse 5 30159 HANNOVER See on map Links Website Opens in new window Total cost No data