ECOCOOL / ECOCUT Water-miscible and Neat Cutting Fluids 2020/2021 - Fuchs
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2 LUBRICANTS. TECHNOLOGY. PEOPLE. We focus consistently on high-quality lubricants and related specialties. We develop innovative and holistic solutions for a wide variety of applications. We value the high level of commitment of our employees and their trusting interaction with one another.
3 Facts and figures Company: FUCHS SCHMIERSTOFFE GMBH, a company of the FUCHS Group Headquarters: Mannheim Product range: A full range of more than 2,000 products and 6,000 articles Certifications: IATF 16949, ISO 14001, ISO 45001, ISO 50001 Referencen: One of the leading lubricants OEM for the German automotive industry FUCHS has developed, produced and sold lubricants and related specialties for more than 85 years – for virtually all areas of application and sectors. With over 100,000 customers and 62 companies worldwide, the FUCHS Group is the leading independent supplier of lubricants. A team of more than 950 specialists across Germany works to guarantee the satisfaction of our customers. Whatever their requirements, we have the ideal lubricant for their specific applications and processes. In our technol- ogy centre we link interdisciplinary expertise in a quick and efficient way – and work on innovative lubricant solutions to meet the demands of today and tomorrow every single day. FUCHS lubricants stand for performance and sustainability, for safety and reliability, for efficiency and cost savings. They represent a promise: technology that pays off.
4 WATER-MISCIBLE CUTTING FLUIDS FOR METALWORKING OPERATIONS In manufacturing today, the demands made on cutting fluids have increased enormously. As part of the Industry 4.0 concept, the entire added-value chain of people, machines, logistics and cutting fluids should be interlinked and optimized to achieve largely self-organizing production with the help of advanced IT and communications technologies. For this, cutting fluid measurement data must be accessible online, evaluated and corresponding adjustments made. For measured data to be accurately analyzed, high stability cutting fluids are essential.
ECOCOOL / ECOCUT Water-miscible and Neat Cutting Fluids 5 Safe, economical and sustainable Optimum technical properties New cutting fluids with future in use FUCHS cutting fluids fulfil the techni- perspectives FUCHS is the specialist for metalwork- cal requirements and make machining Current discussions about the ingredi- ing operations. Our water-miscible operations more efficient. ECOCOOL ents in cutting fluids such as boric cutting fluids are safe and reliable products guarantee: acid, formaldehyde-releasing sub- and fulfil all legislative requirements stances (FAD), dicyclohexylamine § Optimum cooling and flushing so that their use can be judged to be (DCHA) and 2-aminoethanol (MEA) almost risk-free. The sustainability of § Outstanding lubricity make cutting fluid risk assessments as our ECOCOOL products was factored part of health and safety at work § Excellent wear protection into their formulation. FUCHS cutting difficult. The demand for high-perfor- fluids thus offer long service life even § Effective corrosion protection mance cutting fluids which do not in boron-free versions. contain risky ingredients is high. § Low foaming FUCHS cutting fluids are: § Good material compatibility New and future generations of ECO- COOL cutting fluids satisfy today’s § Free of nitrosamine-forming § Good results with innovative legislative requirements and also secondary amines materials those issues currently being discussed. § Free of nitrite § Excellent EP properties These demand that cutting fluids should be: § Free of hard complexing agents For the ECOCOOL user, this means § Free of boron § Skin compatible more process reliability, more effec- tive and efficient staging and less § Free of formaldehyde-releasing § Free of chlorine, zinc and heavy expensive machine down time. agents metals § Free of 2-aminoethanol (MEA) § Sustainable Available throughout the world Our customers are located through- § Free of dicyclohexylamine (DCHA) § Economical out the world and our cutting fluids are available where they are. This Moreover, ECOCOOL products offer This means more than just workshop means that all raw materials must be the usual high buffering of cutting safety for ECOCOOL users. ECOCOOL registered and comply with chemical fluids containing boron and are low lubricants are also extraordinarily regulations in the respective coun- odour both as concentrates and as long-life and economical. This lowers tries. FUCHS offers water-miscible ready-to-use emulsions. operating, maintenance and disposal cutting fluids under the name ECO- costs. In addition, the carefully select- COOL GLOBAL which can be manufac- ed ingredients increase skin compati- tured anywhere in the world with the bility even at high pH values. same formulation. This allows users to pursue globally-harmonized manufac- turing processes with the same fluids.
6 New Synthetic Cutting Fluids Set New Standards The new ECOCOOL S series of synthetic, high-performance Practical application experience confirms the strengths of cutting fluids are an alternative to oil-based products. the ECOCOOL S series: Intelligent combinations of corrosion preventives and poly- § Good corrosion protection mers have given them the performance levels of oil-based cutting fluids and thus significantly broadened their appli- § Absolutely low-foaming cation spectrum. These new synthetic products also show § Leave no sticky residues their strengths in extreme conditions and can not only be used for staining-prone aluminium alloys but also for fer- § Outstanding wetting and flushing rous materials with almost no foaming. § Good lubricity Whereas in the past, oily residues had to be removed And thus in practice offers from machined components by washing, in most cases this § High process reliability cost-intensive operation is no longer necessary. Further- more, the elastomer compatibility and the poor corrosion § Excellent economy protection offered by conventional synthetic cutting fluids were improved by the use of oil-like polymers. The water-miscible cutting fluid world is changing and will need vision and courage to introduce reforms. Exploit the benefits of FUCHS ECOCOOL lubricants for your manufac- turing processes.
ECOCOOL / ECOCUT Water-miscible and Neat Cutting Fluids 7 Water-Miscible Cutting Fluids – DCHA (Dicyclohexylamine)-free, Formaldehyde Depot-free Selection Assistance and Details Product Emul- Boron Mono Cast Steel Alumi- Alumi- Non- Special- Mixing sion free ethanol iron nium nium ferrous materials water type amine- Si 7-12 Si 0,5-1 metals °dH free Fully-synthetic products of the new generation ECOCOOL Solution x – 0-20 S-CP ECOCOOL Solution x – 0-20 S-GFC ECOCOOL Solution GLOBAL S-240 x x 0-20 Reinforced composites ECOCOOL Solution S-CO 5 BF Amine- free x x 10-20 Tungsten carbides ECOCOOL Solution S-G2 x x Aero Al, 0-20 Galvanized materials Boron containing semi-synthetic products ECOCOOL Micro emulsion – – 10-20 R-VHCM ECOCOOL Conventional – – 5-20 R-2030 emulsion ECOCOOL Micro emulsion – – – – 2-15 R-GRINDSTAR Boron-free semi-synthetic products ECOCOOL FERROSTAR Micro emulsion x x 5-20 MBF ECOCOOL Conventional x x – 5-20 HPL 720 GT emulsion ECOCOOL Conventional 2516 MG-DC x x 15-200 emulsion Mg ECOCOOL Micro emulsion x – 5-20 VHCM-1K ECOCOOL Conventional AFC 1515 emulsion x x 5-20 Ti-Cr-Ni ECOCOOL Conventional GT 7x4 emulsion x x Ti-Cr-Ni 5-20 alloys, Aero Al Limited suitability Suitable Highly suitable Perfectly suitable – no x yes Further products on request
8 NEAT CUTTING FLUIDS The right cutting fluids provide the very highest machining performance and outstanding surface finishes. However, their performance is also influenced by their compatibility with the other machine lubricants used. Perfectly matched lubricants therefore make a significant contribution to optimum machining results.
ECOCOOL / ECOCUT Water-miscible and Neat Cutting Fluids 9 Increasing productivity while doing justice to increasing ecological and economic considerations is the key to maintaining international competive- ness in the metalworking industry. Cost analyses have shown that cutting fluids account for a significant propor- tion of total manufacturing costs. FUCHS ECOCUT and PLANTOCUT neat metalworking fluids are formulated in line with the very latest findings. FUCHS supports its customers with far-reaching research and develop- ment activities and by directly inclu- ding expertise from practical trials in new neat cutting fluids. ECOCUT and PLANTOCUT cutting fluids meet all current legislative requirements and fulfil all demands to guarantee efficient and cost-effective metalworking. Expert consultation Industry-specific solutions They offer Our experienced engineers are very With ECOCUT and PLANTOCUT, we well trained and experts in providing offer industry-specific solutions such § Good cooling competent, on-site advice on product as for the medical sector. The materi- § High lubricity selection and the best service with the als used in medicine make the highest aim of reducing process times and demands on cutting fluids, especially § Good flushing complexity and optimizing tool life in terms of lubricity and material com- § Active improvements to machining and process efficiency. patibility. With ECOCUT and PLANTO- performance CUT, FUCHS offers the medical Local and global availability engineering industry a specially tes- § Excellent environmental and health Cutting fluid technology must adapt ted, non-cytotoxic range of cutting protection. to the needs of the worldwide metal- fluids. working industry. Our global FUCHS The interaction between manufactu- team makes sure that selected pro- The perfect product rers, users, developers and researchers ducts are available in other parts of FUCHS has a perfect cutting fluid for generates successful synergies and the world in the same quality. every machining operation in the new product and process innovations metalworking industry. Just contact which drive the development of us, we will be glad to be of assistance. advanced lubricants.
10 Special Product Solutions: Low-Emission Cutting and Grinding Oils Better for People, Better for Companies FUCHS low-emission oils solve the problems associated The low-emission ECOCUT and PLANTOCUT series of with the use of conventional cutting oils which display products offer double safety: they keep the air in work- pronounced misting and evaporation. Our tried and test- shops clean and they reduce fire and explosion hazards in ed, high-performance series of low-emission products line with BGI/GUV-I 719. stand out with their excellent economy and low emissions. The resulting benefits are: Emissions are almost unavoidable when neat cutting and § Better workshop air improves health and safety grinding oils are used in machining centers for grinding, turning, thread cutting, milling, deep hole drilling and § Reduced fire and explosion hazards reaming. § Extended service intervals for oil separators With the help of special additive technologies, our re- § Lower consumption. search and development laboratories have created low- emission products which are extraordinarily low misting and low evaporation. And the use of carefully selected base oils also reduces evaporation. Vapours in particular, are usually not removed by the most common separators and can be recycled back into the workshop if no extrac- tion system is installed. ECOCUT LE: Formulated with HC base oils The special additives used in these products significantly ECOCUT FT: Formulated with GTL base oils reduce the formation of oil mists during machining opera- PLANTOCUT: Formulated with synthetic esters tions. Our application engineers will be glad to be of assistance.
ECOCOOL / ECOCUT Water-miscible and Neat Cutting Fluids 11 Fundamentally rational Evaporation losses of various base oils / Typical values They do not just fulfil all technical 100 requirements. Their outstanding properties make the use of ECOCUT % Evaporation losses at 250 °C 80 and PLANTOCUT cutting and grinding oils especially economical because 60 they offer: 40 § Low consumption § Good cooling 20 § Good flushing § High lubricity 0 7 10 15 20 30 § Longer tool life. Viscosity at 40 °C in mm2/s PLANTOCUT ECOCUT LE / FT Conventional cutting oil Reduction of cutting fluid fire and explosion hazards according to BGI / GUV-I 719 Tendency Viscosity grade Viscosity at 40 °C Flashpoint accor- Evaporation losses Machining according to according to DIN ding to ISO 2592 at 250 °C according examples DIN 51519 51562 [mm2/s] (Cleveland open to DIN 51581- (ISO 3448:1992) cup) [°C] 1 and 2 (Noack method) [%] ISO VG 5 4,14 – 5,06 > 120 < 85 Honing Reaming Viscosity tends to increase from honing to broaching ISO VG 7 6,12 – 7,48 > 145 < 80 Grinding explosion hazards Declining fire and Deep hole ISO VG 10 9,00 – 11,00 > 155 < 60 drilling Turning ISO VG 15 13,50 – 16,50 > 190 < 25 Milling Drilling ISO VG 22 19,80 – 24,20 > 200 < 15 Thread cutting ISO VG 32 28,80 – 35,20 > 219 < 13 Thread rolling Broaching ISO VG 46 41,40 – 50,60 > 220 < 11 Source: BGI/GUV-I 719
12 ECOCUT FT – Non-water-miscible cooling lubricants based on innovative base oils Used as operating materials, non-water-miscible cooling The properties of the product used, such as its flash point, lubricants not only have a key influence on the process evaporation and foaming behavior, also play a part here. and quality of machined parts, but also make a major Both, the selection of the additives and the quality of the contribution to improving safety and working conditions base oils used, have a major impact on these features. in production halls. FUCHS has many years of experience in formulating high- grade, non-water-miscible cooling lubricants that are based on refined Group III base oils. These products make a significant contribution to improving processes for our customers: § Increased productivity § Improved occupational health and safety § Reduced workplace pollution § High efficiency
ECOCOOL / ECOCUT Water-miscible and Neat Cutting Fluids 13 Using innovative base oils allows us to further improve and optimize our non-water-miscible cooling lubricants. ECOCUT FT stands for high-grade grinding and cutting oils. These are based on base oils which are produced using the GTL process (Fischer-Tropsch synthesis). In the Gas-To-Liquid process, a syngas is generated from natural gas using oxygen and hydrogen. This syngas is subsequently converted to liquid hydrocarbons via Fis- cher-Tropsch synthesis. Further steps are then employed to produce fuels and base oils from this. We use these base oils in our ECOCUT FT series of cutting and grind- ing oils. Typical values: Typical values: Flash point in °C Evaporation loss % (GC-Noack) Viscosity at 10 mm²/s at 40°C Viscosity at 10 mm²/s at 40°C 200 70 190 60 Evaporation loss % Flash point in °C 180 50 170 40 160 30 150 20 Conventional roup III G E COCUT FT Conventional roup III G E COCUT FT cutting oil cutting oil cutting oil cutting oil cutting oil cutting oil ECOCUT FT product offer additional benefits: § High flash point – improved fire and explosion protection § Low evaporation – reduced consumption and costs, improved working conditions, increased safety in the event of a fire and better explosion protection § Better air release properties –improved foaming behavior and cooling effect
14 Special Product Solutions: Fluid Families Leakages as cost drivers The complexity of machine tools is reflected in the lubri- are not compatible with each other, high follow-up costs cants it requires: Cutting fluids, hydraulic oils, slideway oils often occur: Increased tool wear, filtration problems, ma- and gear oils. chine damage, lost production and poor surface finishes. Leakages in running machine tools can never be totally If costs should be kept under control, customized cutting eliminated. And if the different lubricants used fluid solutions are necessary.
ECOCOOL / ECOCUT Water-miscible and Neat Cutting Fluids 15 Compatible fluid families – Problem solvers in the The benefits to the user are obvious: case of hydraulic oil leakages § Greater process reliability We have developed compatible system solutions for a broad spectrum of applications which facilitate unprob- § Prolonged tool life lematic, cost-reducing and high-performance machining § Optimum surface finishes operations: § Longer cutting fluid life and lower monitoring and § Universal oils – for machining and machine lubrication maintenance costs. – UNIFLUID § Neat multifunctional oils based on low-evaporation In a nutshell: mineral oils – ECOCUT HFN Greater performance and lower operating costs. § Neat, ester-based fluid families – PLANTOCUT, PLANTOHYD, PLANTOLUBE This diagram of a machine after Reichert Wear Test (RWT): No drawbacks resulting from hydraulic oil the changeover to the HFN series 12 35 ofmultifunctional oils shows how these oils can significantly increase the performance of a machine tool: 11 30 Hydraulic oil share [%] / RWT - wear area [mm2/s] In spite of high hydraulic oil leakages, Cutting fluid viscosity at 40 °C [mm2/s] wear behaviour remains consistently 10 25 good. 9 20 8 15 7 10 6 5 5 0 1 2 3 4 5 6 Jahr RWT – wear area [mm2] Cutting fluid viscosity at 40 °C Hydraulic oil share [%]
16 Special Product Solutions: Minimum Quantity Lubrication (MQL) Products Bildquelle: Bielomatik Leuze GmbH + Co. KG FUCHS PLANTO MIKRO and ECOCUT MIKRO PLUS are PLANTO MIKRO – Ester oil based MQL product series which were specially developed for MQL. § Have a higher boiling and flashpoint even at lower And practical trials have shown that the optimization of viscosities the cutting fluid is what makes Minimum Quantity Lubrica- tion technology economically worthwhile for certain § Create significantly less vapour machining operations. § Form a thin film on components but nevertheless feel dry Special ester oils and fatty alcohols Lubricants based on special ester oils and fatty alcohols ECOCUT MIKRO PLUS – Fatty alcohol based MQL have been shown to be especially suitable for Minimum § Have a lower flashpoint than ester oils of the same Quantity Lubrication applications. viscosity § Evaporate relatively easily so that components dry quickly Over 25 years § Generate moderate cooling. experience in the application of Minimum Quantity Lubrication
ECOCOOL / ECOCUT Water-miscible and Neat Cutting Fluids 17 PLANTO MIKRO and ECOCUT MIKRO PLUS lubricants are Minimum Quantity Lubrication for a variety of machining “low-emission” according to the German publication BGI operations 718 “Minimum Quantity Lubrication for Chip-Forming Machining Operations”. Lubrication Turning Suitable for MQ pro- PLANTO MIKRO and ECOCUT MIKRO PLUS products are cesses with geometri- Milling approved by leading Minimum Quantity Lubrication cally-defined cutting equipment manufacturers and are noteworthy for the Sawing edges following properties: Drilling § Good sprayability Thread § Optimum droplet characteristics cutting § Good lubrication Limited suitability for Grinding § Low odour MQL processes with Honing geometrically unde- § Tried and tested Flushing Lapping fined cutting edges PLANTO MIKRO and ECOCUT MIKRO PLUS products are suitable for use with single-channel (AEROSOL BUSTER) and/or two-channel spray systems. Product Spray system Steel Cast iron Aluminium Cu 1 channel 2 channel ECOCUT MIKRO PLUS 20 x x PLANTO MIKRO UNI x x PLANTO MIKRO 30 HD x x – Perfectly suitable Suitable Limited suitability – Not suitable Extract from our Product Program. Further products on request.
18 Neat Cutting Fluids – Selection Assistance Material/ Normal Difficult- Very-difficult- Titanium and Cast iron and Nonferrous Aluminium Process machining tomachine tomachine titanium malleable cast metals and aluminium steels steels steels alloys iron alloys Machining ECOCUT ECOCUT ECOCUT ECOCUT ECOCUT ECOCUT ECOCUT centers HFN LE-Series 600 LE-Series 700 LE-Series 7520 LE-M HFN LE-Series HFN LE-Series HFN LE-Series FT-Series FT-Series FT-Series FT-Series FT-Series FT-Series PLANTOCUT-Series PLANTOCUT-Series Deep hole ECOCUT 515 ECOCUT 515 ECOCUT 515 ECOCUT ECOCUT ECOCUT ECOCUT drilling FT-Series ECOCUT MXB 18 ECOCUT MXB 18 7520 LE-S 1 HFN LE-Series HFN LE-Series HFN LE-Series PLANTOCUT- FT-Series FT-Series FT-Series 600 LE-Series FT-Series PLANTOCUT- Series PLANTOCUT-Series Series Broaching ECOCUT ECOCUT ECOCUT ECOCUT ECOCUT ECOCUT ECOCUT 600 LE-Series 700 LE-Series 800-Series 800-Series HFN LE-Series HFN LE-Series HFN LE-Series 8536 S PLANTOCUT- PLANTOCUT- Series Series Gear cutting ECOCUT ECOCUT ECOCUT – – ECOCUT – HFN LE-Series HFN LE-Series 8532 HFN LE-Series 600 LE-Series 600 LE-Series 700 LE-Series Honing / ECOCUT GBS 5 ECOCUT GBS 5 ECOCUT ECOCUT ECOCUT GBS 5 ECOCUT ECOCUT Finishing PLANTOCUT- PLANTOCUT- HFN 5 LE UNI HFN 5 LE UNI HFN LE-Series HFN LE-Series HFN LE-Series Series Series PLANTOCUT- PLANTOCUT- Series Series Lapping ECOCUT HO 74 ECOCUT HO 74 ECOCUT HO 74 – ECOCUT HO 74 ECOCUT HO 74 ECOCUT HO 74 Grinding ECOCUT ECOCUT ECOCUT PLANTOCUT- ECOCUT ECOCUT ECOCUT HFN LE-Series HFN LE-Series HSG LE-Series Series HFN LE-Series HFN LE-Series HFN LE-Series FT-Series FT-Series FT-Series FT-Series FT-Series FT-Series Thread ECOCUT ECOCUT ECOCUT ECOCUT ECOCUT ECOCUT ECOCUT cutting 500 LE-Series 500 LE-Series 500 LE-Series 7520 LE-M HFN LE-Series HFN LE-Series HFN LE-Series FT-Series 700 LE-Series 700 LE-Series FT-Series PLANTOCUT- PLANTOCUT- PLANTOCUT- PLANTOCUT- FT-Series FT-Series PLANTOCUT- Series Series Series Series 8536 S Series Spark ECOCUT 1520 ECOCUT 1520 ECOCUT 1520 ECOCUT 1520 ECOCUT 1520 – – erosion ECOCUT FE ECOCUT FE ECOCUT FE ECOCUT FE ECOCUT FE Minimum ECOCUT PLANTO PLANTO PLANTO ECOCUT ECOCUT ECOCUT Quantity MIKRO PLUS- MIKRO-Series MIKRO-Series MIKRO-Series MIKRO PLUS- MIKRO PLUS- MIKRO PLUS- Lubrication Series Series Series Series The products in a series are available in different viscosities. Disclaimer: The information contained in this product information is based on the experience and know-how of FUCHS SCHMIERSTOFFE GmbH in the development and manufacturing of lubricants and represents the current state-of-the-art. The performance of our products can be influenced by a series of factors, especially the specific use, the method of application, the opera- tional environment, component pre-treatment, possible external contamination, etc. For this reason, universally-valid statements about the function of our products are not possible. Our products must not be used in aircrafts / spacecrafts or their components, unless such products are removed before the components are assembled into the aircraft / spacecraft. The information given in this product information represents general, non-binding guidelines. No warranty expressed or implied is given concerning the properties of the product or its suitability for any given application. We therefore recommend that you consult a FUCHS SCHMIERSTOFFE GmbH application engineer to discuss application conditions and the performance criteria of the products before the product is used. It is the responsibility of the user to test the functional suitability of the product and to use it with the corresponding care. Our products undergo continuous improvement. We therefore retain the right to change our product program, the products, and their manufacturing processes as well as all details of our product information sheets at any time and without warning, unless otherwise provided in customer-specific agreements. With the publication of this product information, all previous editions cease to be valid. Any form of reproduction requires express prior written permission from FUCHS SCHMIERSTOFFE GmbH. © FUCHS SCHMIERSTOFFE GmbH. All rights reserved. 10 / 2020
ECOCOOL / ECOCUT Water-miscible and Neat Cutting Fluids 19 Complete Solutions for all your Manufacturing Processes With system solutions from FUCHS, the world’s largest independent manufacturer of lubricants with the most extensive program of metalworking fluids, you have chosen an absolute specialist. And thus benefit from all the knowhow, years of application engineering experience and customized solutions. Example: Manufacturing gearboxes. ECOCOOL ECOCUT THERMISOL MACHINING: WM* MACHINING: NEAT QUENCHING § High performance § Increased reliability § Low distortion § Economical § Economical § Low consumption § Outstanding lubricity § Low misting and § Good compatibility low evaporation RENOCLEAN RENOLIT RENOLIN CLEANING LUBRICATION: LUBRICATION: OILS § Highly effective GREASES § Compatible § Unproblematic § Compatible § Excellent corrosion processes § Long-term and protection § Outstanding emulsifi- life-long lubrication § Optimum wear cation and demulsifi- § Optimum compatibility protection cation with ANTICORIT CPM PROTECTION FLUID MANAGEMENT § Optimum protection § For all fluids § Clean application § Auditable documen- tation § Better performance § High process reliability § Cost reductions *WM = water-miscible
FUCHS Industrial lubricants Innovative lubricants need experienced application engineers Every lubricant change should be preceded by expert consultation on the application in question. Only then can the best lubricant system be selected. Experienced FUCHS engineers will be glad to advise on products for the application in question and also on our full range of lubricants. FUCHS SCHMIERSTOFFE GMBH Export Division Friesenheimer Straße 19 Friesenheimer Straße 19 68169 Mannheim/Germany 68169 Mannheim/Germany 930129727 10/2020 0.3 Telefon: +49 621 3701-0 Telefon: +49 621 3701-1703 Telefax: +49 621 3701-7000 Telefax: +49 621 3701-7719 E-Mail: zentrale-fs@fuchs.com E-Mail: export-fs@fuchs.com www.fuchs.com/de/en www.fuchs.com/de/en
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