Houghton international - SECO Inspiration Through Innovation 2018 Event Showcase

SPECIAL EDITION

H O UGHTON SHOWCASE SECO

|

I N S P I R AT I O N T H R O U G H I N N O VAT I O N

F E AT U R I N G

# C N C- TLC

W E LCO ME TO SE C O I NSP I R AT IO N T HROUG H I N N OVATI ON F R O M E V E RYON E AT H OUGH TON

Welcome!

Showcasing FluidTrend

I’d personally like to extend my thanks to you for taking the

I’m delighted that we’ve been able to coincide the official

time to visit our stand. We’re incredibly proud to exhibit at

launch of FluidTrend with ITI2018 – as a technical partner of

ITI2018 for the second time, an event we’re delighted to see

SECO Tools, it felt like a perfect fit to hold the launch during

moving from strength-to-strength.

this important event for us.

During this two-day event, you’ll be able to speak to a range

FluidTrend is a bespoke fluid analysis software that’s

of Houghton experts across numerous departments and

grown and developed organically from internal corporate

witness live machining demonstrations running on Houghton

reflection, alongside account manager and customer input

coolant.

– it’s designed exclusively by Houghton, for new and existing

Alongside this, you’ll also be one of the first to experience

Houghton clients.

our new bespoke software in action, FluidTrend, and

For more information on the products that make up our

several pieces of our new fluid maintenance management

complete fluid maintenance management offering, alongside

equipment.

FluidTrend, please see pages four to twenty-six of this

Thank you again for your continued support, I hope you enjoy the event.

Live Machining Demonstrations Part of what makes ITI2018 so special is its live machining demonstrations – it’s an element of the event that all of us at Houghton look forward to.

The importance of a premium machine coolant is paramount, and the benefits are threefold – a high-quality CNC machine lubricant not only extends the life of a tool, it also reduces the number of additive treatments required alongside waste disposal – benefiting production, the environment, and your bottom line.

brochure. To witness the capabilities of the FluidTrend software in person, please visit our stand and speak to a member of the Houghton Team.

Product Technology - HOCUT 4940 You can witness HOCUT 4940 in action on following pieces of machinery throughout ITI2018: \\ Mazak Nexus – Oil & Gas Sector, Stainless Steel Shaft

Coupling \\ DMG Mori CTX – Oil and Gas Sector, Flange \\ Hermle – Aerospace Sector, Blisk Aero Blade \\ Hermle – Aerospace Sector, Fuel Connector A350 \\ Hermle – Medical Sector, Femoral \\ Hermle – Medical Sector, Tibal Tray

Product Technology - HOCUT 4260 Developed as a new product for Aerospace and general machining applications, especially for large aluminium parts or fuselage. See HOCUT 4260 in action on: \\ Doosan NHP 5000 - Automotive, Alloy Suspension Strut

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FLUIDTREND™ BY HO UG HTO N

DATA DR IV E N S OL U T ION S

#CN C-TLC

Who’s who?

We’ve got a team of Houghton experts on hand over the two-day event to answer any specific questions you might have, including UK Sales Director Matt Bartle, UK Equipment Business Development Manager Rob Davey and myself.

You’ll also be able to meet your regional account manager on stand, who can discuss any service requirements you might have in further detail, during or after the event.

Thank you Consult our sitemap on page five to find us at the event. To find out more about HOCUT 4940, please navigate to page twenty-nine of this brochure or speak to a member of the

MATTHEW BARTLE UK Sales Director Contact for Product & Service  matthew.bartle@houghtonintl.com

Houghton team.



+44 (0) 7968 704 374

I’d personally like to extend my thanks to everyone that contributed to making the event a success – from those customers and exhibition-goers alike that took the time to

ROB DAVEY UK Equipment Business Development Manager Contact for Equipment

visit our stand.

 rob.davey@houghtonintl.com

involved in the organisation of the exhibition, to existing



+44 (0) 161 874 5000

LEE BOWDITCH Commercial & Country Director UK & Ireland

PROBLEM SOLVER S | S O LU TI O N P ROV I DE R S

H OUG H TON IN T E R NAT ION A L

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CONTENTS

F L U IDTREND

INTRO 2 SECO Event Overview 4 Contents 5 Where to find us

FLUIDTREND SOFTWARE 6 Introduction 7 Deliverables & Benefits 8 Dashboard 9 Machines 10 Machine Status 11 Reports

EQUIPMENT 12 Introduction 14 FluidMix Equipment Data 18 FluidMix Case Study 19 FluidWorker Equipment Data 23 FluidWorker Case Study 24 FluidControl Equipment Data

HOCUT PRODUCTS 28 HOCUT 4940 Product Data 32 HOCUT 4940 Case Study 33 HOCUT 4260 Product Data 37 HOCUT 4260 Case Study

4

DATA DR IV E N S OL U T ION S

PROBLEM SOLVER S | S O LU TI O N P ROV I DE R S

11WE ARE HERE!

Exhibition Area

Stairs to Seminars & Tutorials

Reception and infor mation

Refreshments and Lunch

W HE R E TO F IN D US...

H OUG H TON IN T E R NAT ION A L

5

FLUIDTREND: THE BE ATING HE ART OF YOUR M ACHINE M AINTENANCE PROGR A MME #CN C-TLC

This tailored and bespoke software program was developed by Houghton to support our FluidcareÂŽ and your Metalworking Fluid operations. The system is auditable and allows users to identify both performance and cost trends for any given machine or system immediately.

Designed for optimum coolant and lubrication management, all analytical results from each machine test are automatically recorded and promptly displayed on FluidTrend, displaying the condition of the coolant at any time, enabling trends to be displayed and reports generated instantly on an easy-to-use interface.

FluidTrend can easily assist with lubrication duties, able to collate data generated during oil top-ups, providing insightful reports by application point, such as top leakers, top users, as well as cost analysis and usage trends. FluidTrend management reports aid compliance with Environmental, Health & Safety (EHS) guidance on the control and disposal of metalworking fluids.

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FLUIDTREND™ BY HO UG HTO N

DATA DR IV E N S OL U T ION S

FluidTrend Delivers

Benefits of the Client Portal

FluidTrend is an intuitive and user-friendly customer portal

\\ Effectively manage and control your metalworking fluids:

allowing machine reports and trends to be generated quickly

increase fluid lifetime and reduce waste disposal, helping

and easily. FluidTrend allows you to make informed decisions in

you reduce your environmental impact

regard to your production activities with complete confidence.

CO MPLIA N CE PRODUCTI V I TY CO ST EFFICIE N CY

\\ Increase productivity, reduce operating costs: improve

tool quality and life, reduce machine downtime and fluid usage \\ User-centric design and built in User Experience (UX) \\ Easy to identify machine issues with traffic light system \\ Easy reporting and cost analysis, generate PDFs for

download & print

The Data Logger scans the QR code at the Point of Application on the machine and test results are submitted. This data can then be viewed on any device through the customer portal, which generates reports within FluidTrend.

PROBLEM SOLVER S | S O LU TI O N P ROV I DE R S

H OUG H TON IN T E R NAT ION A L

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DASHBOARD

FLU IDTREND S O F TWARE

Overview The dashboard is your personalised, central hub of FluidTrend. Here, you can configure reports to your exact specifications and have them instantly

Features & Benefits \\ Easy to use left hand navigation \\ Quick links to other areas of the portal

as you log in.

\\ Add report to dashboard panel

Easily customisable, FluidTrend enables you to

\\ A help area that will guide you through the

view a variety of information including an overview

features of the page you’re on

of test data of machines within your factory, a table of machines that are out of specification (which you can use to diagnose any issues that

\\ Screen mode that automatically slides through

reports on your dashboard in full screen

occur) or graphs that compare the percentage of in-and-out of specification tests.

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FLUIDTREND™ BY HO UG HTO N

DATA DR IV E N S OL U T ION S

MACHINES

FLU IDTREND S O F TWARE

Overview The machines section of FluidTrend gives you

Features & Benefits \\ The machine cards display a range of quick

an overview of the status of all of the machines

information, including days since last cleanout,

within your factory. Using a simple traffic light

bacteria, concentration and pH status

status system, the colour-coded cards allow you to quickly scan across your range of machines – with the ability to click into that machine and investigate deeper into any issues.

\\ Target areas of your factory with easy-to-use

filters that organise your machines by site and location \\ Change the view to your preference – card or

list view

TR A F F I C L I GH T STATU S SYSTEM In Specification Warning Action Required

PROBLEM SOLVER S | S O LU TI O N P ROV I DE R S

H OUG H TON IN T E R NAT ION A L

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M A C H I N E S TAT U S

FLU IDTREND S O F TWARE

Overview The machine status page displays historical data for any given machine, alongside its Point of Applications (POAs). Utilise the traffic light status system to quickly scan and identify any issues.

Date filters allow you to select data for a specific period. The machines profile enables the user to view the machines location, capacity, cleanout

Features & Benefits \\ Determine the costs and usage of a machine \\ See a machine’s performance with historic test

data \\ Detailed, multi-format data analysis \\ Real-time date filters that allow you to access

up to a years worth of information

information, the fluid utilised and its test statuses.

Alongside this, a table summary gives information on the history of each of the core tests - data is then broken down further into each test.

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FLUIDTREND™ BY HO UG HTO N

\\ Trend data for multiple POAs \\ Quickly generate PDF reports on the machine

DATA DR IV E N S OL U T ION S

REPORTS

FLU IDTREND S O F TWARE

Overview

Cost & Efficiency

Standard Reports

Test, Cost & Usage Reports

The reports page allows you to generate 4

Using real-time date filters, data will be displayed

‘Standard Reports’:

that gives a detailed overview to your factory’s performance. The reports page shows machine

\\ Top Leakers - machines with the highest

tests, cost and usage reports, whereby you

amount of volume leaked

can specify particular products, machines and locations to compare and create reports upon.

\\ Top Users - machines with the highest amount

of volume added \\ Machine status - compare the latest results of

all machines across locations \\ Machine History - take a look at a specific

machine’s historic results

Features & Benefits \\ Generate PDF reports, which can be easily

downloaded and printed \\ Real-time date filters that allow you to

access up to a years worth of information \\ Compare costs by product, machine and

location

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#1

HOUGHTON EQUIPMENT: REVOLUTIONISE YOUR METALWORKING FLUID OPER ATIONS #CN C-TLC

Built to work seamlessly alongside your FluidTrend software or independently, Houghton’s fluid maintenance management equipment offering is designed to enhance and optimise production, reduce waste and aid HSE compliance. A comprehensive kit consisting of three stand-alone machines, each unit is able to benefit small to large scale production operations.

Collectively, the combination of FluidTrend along with Houghton fluid maintenance management equipment has the capability to automate, and transform, your metalworking fluid operations – with each piece of equipment providing precision in numerous stages of your CNC production, from accurate coolant mixing, to reliable treatment, to efficient distribution. Neat and compact, Houghton Equipment is designed to slot effortlessly into your production space, able to support operations of many sizes.

Each stand-alone unit has the functionality to work independently if required, making Houghtons product offering entirely customisable, depending on your production requirements. Working alongside Houghton’s bespoke FluidTrend software, Houghton fluid maintenance management equipment ensures precision and peace of mind, every time.

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HO UGHTON EQU I P ME N T

DATA DR IV E N S OL U T ION S

Houghton Equipment Delivers Whether you’re looking to automate your coolant top-up, outsource your fluid management, or simply looking to optimise your processes, Houghton’s equipment delivers accuracy and piece-of-mind to manufacturers of all sizes.

Benefits of Houghton Equipment \\ Reduce fluid usage \\ Minimise costs \\ Improve concentration control \\ Environmental Health & Safety benefits

FLUIDCO NTRO L FLUIDWO RKE R FLUIDM I X

PROBLEM SOLVER S | S O LU TI O N P ROV I DE R S

\\ Eliminate unexpected operational issues \\ Standalone units – easily able to fit amongst your existing

production units \\ Easily combined with FluidCare and FluidTrend for

ultimate fluid maintenance management

H OUG H TON IN T E R NAT ION A L

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FLUIDMIX

EQU IP MENT DATA & CASE STUDY

14

FLUIDMIX BY HO UG HTO N

DATA DR IV E N S OL U T ION S

FLUIDMIX

EQU IP MENT DATA

COOL ANT MIXING A ND SUPPLY UNI T Description FluidMix is a stand-alone coolant mixing station. Connected to a distribution pipework, the system is capable to automatically mix and distribute water soluble coolant with a pre-set, accurate and consistent concentration to any machine tool sumps throughout an entire workshop on demand or locally via a trigger-nozzle. The operator can choose between four pre-set concentrations which are passcode protected.

Features & Benefits \\ Accurate top-up mix every time for all

machine tools \\ Tight and continued stable emulsion

concentration using innovative mixing technology reducing concentrate & water consumption up to 25% \\ Fast delivery of coolant up to 90 litres

per minute –7 times faster than standard mixing devices \\ High flexibility with either automated

coolant distribution through pipework system or locally via a trigger-nozzle / hose reel \\ Conforms with EU/UK Water Authority

\\ No stored mixed coolant necessary \\ Comes as “plug and play” system with up to

4 pre-set concentrations between a range of 0.5% to 10%, protected by a passcode \\ Low concentrate / low water shut-off with

warning beacon and display notification that safeguards the equipment \\ Optimises space on the shopfloor with a

small footprint and portable design \\ Eliminates operational issues and hazards

e.g. constantly varying concentrations in sumps, manual handling and slip hazards associated with manual mixing, storing and transporting of mixed coolants

Regulations

Health & Safety The manufacturer declares that the equipment is in full compliance with CEstandards.

PROBLEM SOLVER S | S O LU TI O N P ROV I DE R S

H OUG H TON IN T E R NAT ION A L

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FLUIDMIX

EQU IP MENT DATA

Recommendation for Use

Application

The product is compatible with Houghton’s

FluidMix is the ideal solution for customers

soluble cutting fluid portfolio. Please

with a larger number of metal working

configure the FluidMix to the recommended

machines with single sumps or central

mixing concentration for the fluid that you are

systems to automate the top-up. The

using. For more information, please contact

innovative mixing-technology using three

your local Houghton representative.

pumps ensures a very tight and continued

Locate the FluidMix in a position which is convenient to the layout of your machine shop considering main water and electrical supply.

In an ideal situation, the system should be

stable emulsion concentration in the machine tool sumps and eliminates the risk of manually mixing and handling coolant in workshops!

positioned in the centre of the workshop to keep the pipework as short as possible.

Technical Specification

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FLUIDMIX BY HO UG HTO N

SP E CI F I CAT I ON

DE SCRIPTIO N

Width/Depth/Height

1000/1050/1700 mm

Weight

450 kg (empty)

Water Tank Capacity

800 ltr

Electrical

230 Vac ± 10%, 16 A min.

Water Mains Supply

¾” BSP (female) compression fitting, minimum water flow 90 litres/min.

Coolant Conentrate Lance

Suitable for 200 ltr. barrels or 1,000 ltr. IBC-containers

Mixed Coolant Factory Supply

¾” BSP (female) compression fitting, up to 90 litres/min. (for factory supply pipework recommendations please see user manual)

Mixed Coolant Trigger-Nozzle

Dispense mixed coolant locally with up to 90 litres/min.

DATA DR IV E N S OL U T ION S

FLUIDMIX

EQU IP MENT DATA

Dimensions & Connections

Operating Panel / HMI

800 litre Water Tank Inspection / Access Mixed Coolant Trigger-Nozzle

Beacon light

Water Supply Connection 3/4” BSP (female)

FR O N T Mixed Coolant Factory Supply 3/4” BSP (female)

Coolant Concentrate Lance Connection Port

REAR Main Power Isolater

Forklift Truck Channels

800 litre Water Tank Inspection / Access

TO P

This document contains information based on data that is believed to be correct. However, the product may not be applicable to all uses and operating environments. No warranty or guarantee is expressed or implied.

PROBLEM SOLVER S | S O LU TI O N P ROV I DE R S

H OUG H TON IN T E R NAT ION A L

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FLUIDMIX

CASE STUDY : TR AINING 2 0 0 0

NEW EQUIPMENT, F I R ST I NSTAL L ATI O N Houghton International supplied Blackburnbased engineering training centre, The Advanced Manufacturing & Automation Centre (AMAC), with their latest product and cutting-edge development: the FluidMix. As an essential part of the manufacturing process for many sectors, having knowledge of the latest developments in coolant systems and the practical skills for operating them is indispensable.

Houghton’s installation of a FluidMix unit to AMAC, this capital expenditure will allow these trainee engineers to have hands-on experience of working with a state of the art coolant system as part of their education.

The FluidMix from Houghton is the most recent addition to their line of FluidCare equipment solutions for a range of industries, including automotive and aerospace. This stand-alone coolant mixing station is proven to significantly cut

Houghton as market leaders to the sector, with

down production time and reduce water waste in

equipment installations, and service engineer

the mixing process.

coverage to the entire UK and Ireland, as part of its FluidCare packages, servicing and maintaining

Designed to mix and distribute water-soluble

manufacturing facilities, while numerous OEMs

coolants to pre-set, accurate, and consistent

and Tier 1 manufactures rely on FluidCare, with

concentrations as required, the FluidMix is ideal for

the complexities of REACh compliance, the

entire workshops or individual workstations. The

FluidCare offering is now filtering into mid-stream

unit has the ability to store up to four password-

engineering, with FluidCare being a complete

protected pre-set calculations for coolants,

management of companies’ coolant, fluids and

enabling operators to switch between settings

waste solutions.

as necessary while working, and guaranteeing solution percentage accuracy.

Regional Director for Northern EMEA at Houghton, Steve Mayo, said of the investment:

In addition to the FluidMix, Houghton has worked

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closely with AMAC previously to deliver industry-

“We recognise that effective collaboration

standard workshops, on both coolant care and

between employers and wider-education

understanding the key-benefits of coolants to

providers will result in excellent high-level skills

machine tools and tooling, improving cycle-times

development that benefits our workforce and the

and delivering essential machine maintenance.

wider economy.”

FLUIDMIX BY HO UG HTO N

DATA DR IV E N S OL U T ION S

FLUIDWORKER

EQU IP MENT DATA & CASE STUDY

PROBLEM SOLVER S | S O LU TI O N P ROV I DE R S

H OUG H TON IN T E R NAT ION A L

19

FLUIDWORKER

EQU IP MENT DATA

SIMPLE & SAF E BACTE R I A R E DUCTI O N Description FluidWorker is based on UV technology that keeps bacteria in process fluid under control, secures high productivity and extends the life of the fluid – without exposing employees to allergenic substances or carcinogens.

FluidWorker effectively reduces bacteria in process fluids. The fluid is irradiated with UVC, which reacts with the bacteria’s DNA and makes it unable to reproduce. The bacterial reduction is often very fast, within a few hours 99.9% of the bacteria is decomposed, given dimensioning according to our system analysis.

Features & Benefits \\ Treatment without biocides that can

cause eczema, allergies, respiratory problems, sterility and cancer – safer for end-user \\ Lower costs – the process fluid gets

a longer lifetime and biocide-related expenses are avoided \\ Self-cleaning technology – minimum

maintenance \\ Ensures stable production without

\\ Easy to use \\ Stand-alone unit - installed during

production \\ Break down 99.9% of bacteria within a

few hours, given correct installation and dimensioning \\ Reduced climate footprint – Longer life

of the fluid means fewer chemicals in circulation, reduced waste volumes and fewer transports associated with this

downtime - when the process fluid is continuously purified, the quality is maintained and less fluid changes are needed

Health & Safety The manufacturer declares that the equipment is in full compliance with CEstandards.

2 0 FLUIDWO RKER BY HO UG HTO N

DATA DR IV E N S OL U T ION S

FLUIDWORKER

EQU IP MENT DATA

Recommendation for Use

Application

Product is compatible with the full range of

FluidWorker is the ideal solution for

Houghton’s soluble cutting fluid portfolio. For

customers with a larger number of

more information, please contact your local

metalworking machines with single sumps. It

Houghton representative.

is suitable for 500-1500 litre tanks with waterbased process fluid used for metalworking (machining/deformation) or surface treatment (quenching/washing).

Technical Specification SYST E M Flow adjustable

2.4 - 5.6 m3/h

Number of UV lamps

1

Total lamp power

168 - 202 W

Pump power, adjustable

85 - 280 W

Total power consumption

270 - 500 W

Max ambient operating temperature

45OC

Max fluid temperature

45OC

Suitable for tank volume (system and fluid dependent)

0.5 - 1.5m3

Self priming pump

Yes

Lockable on / off switch

Yes

Pressure sensor

Yes

Service timer

Yes

Automatic cleaning system

Yes

On / off via external switch

Emergency stop

Optional inlet filter

Yes

R E ACTOR Material reactor, inlet and outlet pipe

Stainless steel EN 1.4301

IP class

21

Power input

230V 1-phase, 50 Hz

HMI

5” colour touch screen

D I ME NS I ONS Weight excluding packaging

Approx. 48 Kg

Exterior Dimensions

420 x 360 1340 mm

Lowest possible ceiling height

2400 mm

PROBLEM SOLVER S | S O LU TI O N P ROV I DE R S

H OUG H TON IN T E R NAT ION A L

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FLUIDWORKER

EQU IP MENT DATA

Dimensions & Connections

FR O NT

SIDE

This document contains information based on data that is believed to be correct. However, the product may not be applicable to all uses and operating environments. No warranty or guarantee is expressed or implied.

2 2 FLUIDWO RKER BY HO UG HTO N

DATA DR IV E N S OL U T ION S

FLUIDWORKER

CASE STUDY : VTL GRO UP

F L UIDWORKER INSTAL L ATI O N AT V TL GR O UP Rob Davey, UK Equipment Business Development Manager, has completed a very successful FluidWorker trial at VTL Precision in Bradley, Huddersfield.

The VTL group specialise in the design,

After installation, July 18th 2018 the bacteria

development and manufacture of components

contamination of >10^5 CFU/ml was reduced very

and sub-assemblies for automotive power train

quickly. The pH remained on the same level without

applications. To achieve this VTL are using single

addition of pH booster. The bacteria remained low

machines with tank volumes normally between

during the rest of the trial period, < 10^3 CFU/ml.

400-1500 liters filled with Hocut 4730 and 795 FR. Surprisingly, the FluidWorker reduced the levels of The purpose to install the FluidWorker on one

bacteria very quickly and continued to control with

of the VTL machines, M68 EMAG BA 400 was to

no biocide additions at all, says Rob.

measure how bacteria contamination could be reduced and controlled over a time of 4-5 weeks.

The FluidWorker will now be displayed at the

One of the challenges with some of the tanks was

SECO Tools Inspiration Through Innovation

that swarf fills up quickly.

event, October 9-10th 2018, and several trials are scheduled with other customers.

Every 6-8 months the systems were emptied, cleaned and refilled with new emulsion. When a

Robs recommendations in brief:

bacteria and pH drop occurred, tank side biocides, as well as pH adjuster were added to the system.

Occasionally, smell was an unpleasant effect of

\\ Ensure that the inlet is put in the clean tank and

if needed protected by an inlet filter.

bacteria. VTL found the FluidWorker interesting, mainly due to the HSE benefit it would provide.

\\ The controls are password protected so nobody

unauthorised can change the setting.

According to Rob, the FluidWorker was very simple to install, pretty much plug and play; he also

\\ Check the suction filters regularly along with

the pump pressure and maintain above 0.5bar.

explained how the control screen is easy to use and very user-friendly.

As the VTL tank was shallow and filled with swarf, the suction inlet had to be optimised to the cleanest area available. An optional inlet filter was also added to ensure that the pump wasn´t damaged, which could limit the flow. This had actually been a problem in a previous trial, so keep in mind to install the inlet in the clean tank.

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FLUIDCONTROL

EQU IP MENT DATA

2 4 FLUIDCO NTRO L BY HO UG HTO N

DATA DR IV E N S OL U T ION S

FLUIDCONTROL

EQU IP MENT DATA

F UL LY AUTOM ATE D CO NDI TI O N MO NI TO R I NG, ANALYTICS AND AUTO - TO P- UP SYSTE M Description FluidControl automatically measures, analyses and monitors the water-soluble cooling lubricants. The system continuously records all relevant parameters throughout the process and makes them accessible in the FluidControl-Cloud or FluidTrend software from anywhere at anytime. Thanks to a sophisticated cleaning process, the sensors will stay clean for a long time, making FluidControl extremely low-maintenance.

Using real-time measurement analysis results, FluidControl initiates quality assurance methods including automatic control of coolant level in machine sumps as well as coolant concentration, pH, conductivity and temperature.

Features & Benefits \\ Monitoring, analysing and visualisation of

real time data â&#x20AC;&#x201C; from anywhere at any time \\ Easy to use interface of secure, tracable

live data \\ Data visualisation of metal working fluid

conditions \\ Identify fluid irregularities in advance with

a mouse-click \\ Close control minimises cost of fluid

maintenance and usage \\ Increase tooling life-time

\\ New generation comes with touch screen

and isolator switch \\ Can be installed on single sump machines

and/or central systems \\ Automated auto-top-up system available

with FCM900 Pro version \\ Configurable alarm trigger thresholds \\ Documentation for ISO quality control (10

years) \\ Simple handling \\ Simple and quick installation procedure

\\ Increase quality of finished goods

Health & Safety The manufacturer declares that the equipment is in full compliance with CEstandards.

PROBLEM SOLVER S | S O LU TI O N P ROV I DE R S

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FLUIDCONTROL

EQU IP MENT DATA

Recommendation for Use FluidControl is an automated monitoring device that provides real-time measurements on water soluble Metal Working Fluids. It provides live concentration, pH, conductivity and temperature measurements, measures levels and concentration of machines sumps and automatically maintains both the concentration and fluid level.

Technical Specification SP E CI F I CAT I ON Water Inlet Flow Rate

2-6 bar

Internet Connections

LAN/RJ45

Temperature rating

Max 60 deg C

Mains Isolator on / off switch

Yes

Temperature Sensor

Yes

Automatic cleaning system

Yes

Power input

230V 1-phase, 50 Hz

HMI

Touch screen control

Dimensions

395 x 595 x 212 mm

REST API Interface on request For an additional fee we can program a REST API interface so customers can download the raw data from the unit itself, without using the cloud.

2 6 FLUIDCO NTRO L BY HO UG HTO N

DATA DR IV E N S OL U T ION S

FLUIDCONTROL

EQU IP MENT DATA

Dimensions & Connections

FluidControl Analyser & Regulator FluidTrend customer portal or FluidControl cloud Water 100%

X% Tank

Concentrated Fluid

Machine

This document contains information based on data that is believed to be correct. However, the product may not be applicable to all uses and operating environments. No warranty or guarantee is expressed or implied.

PROBLEM SOLVER S | S O LU TI O N P ROV I DE R S

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HOCUT 4940

P RO DUC T DATA & CASE STUDY

Hocut ® 4940 2 8 HO CUT 4940 BY HO UG HTO N

DATA DR IV E N S OL U T ION S

HOCUT 4940

P RO DUC T DATA

ADVANCED, HIGH L UB R I CI TY ME TA L R E MOVA L F L UI D Description HOCUT 4940 is free from boron, chlorine,

HOCUT 4940 is based on an innovative and

formaldehyde-release biocides, and

high performance lubricity package giving

secondary amines of all types. The fluid

outstanding surface finish and exceptional tool

is considered non-hazardous under CHIP

life performance in difficult operations. Tool life

legislation, and requires minimal hazard

improvements of up to 30% can be achieved

warning labelling. The product is compliant

against conventional high lubricity fluids. It

with REACH and seen as a “Future Proof”

can operate extremely well at between 6 – 7%

technology for our customers.

concentrations, typically 2% lower than other high

Houghton’s HOCUT 4940 metalworking

performance fluids.

coolant is a unique technology platform

The advanced formula is compatible with all

characterised by very long sump-life and

material types including titanium, nickel, and

versatile emulsion characteristics. The

sensitive aluminium alloys. HOCUT 4940 will

product has been designed to meet the

enable the use of one metalworking coolant across

demands of high speed turning, milling and

hard metal machining operations increasing the

grinding of arduous aerospace materials

capacity for recycling and waste minimisation.

where coolant pressures can exceed 100 bar.

We are proud to be able to offer such a product which will ensure compliance and cost effectiveness for years to come.

Chemical & Physical Properties AT T R I B U T E

PRO PE RTY

Appearance

Pale yellow

Emulsion aspect

Milky white

pH in use

8.9 - 9.5

Density @ (20 °C)

0,93 g/cm3

Refractometric factor

1.05

Pack size available

20 L / 209 L / 1000 L IBC

Hocut ® 4940 PROBLEM SOLVER S | S O LU TI O N P ROV I DE R S

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HOCUT 4940

P RO DUC T DATA

Application \\ HOCUT 4940 is recommended for heavy

\\ The versatile formulation is designed to give

duty machining of a wide range of

low foam in soft water and is also compatible

aerospace materials including aluminium

with hard water in the range (10°dH - 70 °dH )

alloys (series 2000 and 7000 in particular), high alloy steels and difficult aerospace materials such as titanium and nickel alloys

centralised systems and single sump machines while the advanced boron-free technology extends emulsion life without the need for regular biocide treatments

AIRFRAME Aluminium & composites

WATER

data Houghton are confident Hocut 4940 can deliver significant tool life benefits in comparison to other high performance fluids

\\ The product is suitable for both

MACHINING

\\ Based on customer feedback and independent

LOW

\\ Its operator-friendly EHS profile and its non-

staining & corrosion-free properties make HOCUT 4940 particularly efficient as an on hard metal aerospace components...

COMPONENTS & ENGINE Aerospace alloys (Ni, Ti...)

MEDIUM

HEAVY

HARD

MEDIUM

Hocut ® 4260

Hocut ® 4940

SOFT

Storage Please refer to section 7 of Safety Data Sheets for handling and storage information, including product shelf life. Product should be stored under cover in clean, dry conditions and protected from frost. Recommended storage temperature is usually between 5°C and 40°C unless otherwise specified. Use stock in delivery rotation.

Hocut ® 4940 30 HO CUT 4940 BY HO UG HTO N

DATA DR IV E N S OL U T ION S

HOCUT 4940

P RO DUC T DATA

Features & Benefits \\ Versatile: Can process various aerospace

\\ Very stable emulsion: Fewer additive

materials, ranging from titanium, nickel,

treatments and lower usage costs

and aluminium alloys as well as ferrous alloys \\ High detergency: Leaves parts and

machine tools clean and free from residues \\ Extended tool life: Thanks to its unique

high lubricity additive package, tool wear is minimised, saving tooling costs \\ Very long sump-life: Incorporates the New

\\ Inhibits aluminium staining: Can be used

on sensitive aerospace alloys including 2000 and 7000 series alloys. \\ Very low foaming: Ideal for the highest

speeds and pressures in soft to hard water (10°dH - 70°dH) \\ Excellent EHS profile: Boron,

formaldehyde, chlorine and phenol-free.

Contains only TRGS 611 approved amines

HOCUT 4000 series emulsion technology and extends intervals between clean outs

Related Product Water-soluble coolants are complemented by our full range of high quality, speciality production fluids including energy saving wash chemicals, low misting neat cutting oils, non-VOC rust preventives and long-life

Approvals & Conformities \\ Airbus 80T-30-4010 & AIMS 12-10-001:

conformance \\ Alenia: conformance \\ Boeing BAC 5008 cat. 5&6: conformance

heat treatment fluids. Fluidcare services complete our value added portfolio with a range of expert services and equipment to help reduce costs and improve productivity.

For more information, please contact your local Houghton representative.

\\ Bombardier BAMS 569-001: conformance \\ Grob: approved \\ Messier Bugatti Dowty: PCS 4001 / PCS

4002 \\ Motor Sich : approved

Health & Safety

\\ Pratt Whitney (UTC): PWA 36604

REACh compliant. Safety data sheets are

\\ Rolls Royce : RRP 5900

available in accordance with Regulations (EC) No 1907/2006 Annex II and (EC) No 1272/2008.

\\ Safran / Snecma : 455-201-0-00 & PR

6300

HOCUT 4940 displays an excellent EHS profile: \\ HOCUT 4940 is only rated Irritant (no ADR)

\\ SAE Aerospace: ASTM F1100/F945/F519/

F483

\\ HOCUT 4940 has reduced labelling with an

exclamation mark

Lab results are available on request.

PROBLEM SOLVER S | S O LU TI O N P ROV I DE R S

Hocut ® 4940 H OUG H TON IN T E R NAT ION A L

31

HOCUT 4940

CASE STUDY : AERO SPAC E

HOCUT® 4940 S H OWS M A JO R I MPR OV E ME NT: AEROSPACE CASE STUDY The Unique Challenge

The Houghton Approach

A leading engineering service provider specialising

To overcome their difficulties, Houghton

in the design and manufacture of solutions for

recommended HOCUT® 4940 coolant with its new,

many prestigious Aerospace OEMs and Tier I

advanced lubricity package and excellent wetting

suppliers (e.g. Airbus, BAE Systems, Bombardier)

properties. HOCUT® 4940 provides superior

was looking to improve operations. The company

cutting performance and reduced tool wear

has five strategic business units supporting the

enabling the customer to better execute titanium

Aerospace sector.

machining with both lower cost of operation and higher productivity.

At one location, a relatively balanced mix of aluminium, nickel, and titanium alloys were

Additionally, HOCUT® 4940’s superior EHS profile

normally machined. However, new contracts

minimises any potential health and environmental

required undertaking more frequent and arduous

impacts so it can be used in all of the customer’s

titanium work. This resulted in machining

global locations…Americas, Europe, and Asia

and tooling difficulties, even at a 15% coolant

including Japan.

concentration.

A DMC 100H Machine 4 was chosen for the trial.

These difficulties were particularly severe in

The Hocut® 4940 concentration was set initially

a plunge milling operation on a titanium block

at 9% and then reduced to 7% as the anticipated

(pictured above). In order to fulfil their new

performance benefits were achieved.

contracts profitably, the company needed to make step-change improvements in their machining

Once HOCUT® 4940 was introduced, there

operations.

were a number of benefits achieved versus the incumbent coolant:

Their primary objectives were to reduce cycle times, increase feed rates, and reduce the number of tool changes per shift. They were losing an average of one hour of productivity for each roughing cycle.

This equated to 4 hours of lost machining time for each 24-hour period. Historically, there have been

\\ Tool life increased by 150% from 20 minutes to

50 minutes \\ Feed rates increased reducing machining cycle

time per component by 1.5 hours yielding a 40% increase in productivity \\ Coolant concentration of the working fluid was

issues with corrosion on machine tool beds with

reduced to 7% versus the competitive fluid

seals and coatings breaking down. Coolant usage

which was run at 15%

per machine tool was one drum of coolant per 2 weeks at an annual cost to the business of nearly 22,000 $US per machine tool.

\\ Coolant usage reduced by 21 drums of

concentrate per year

Hocut ® 4940 32 HO CUT 4940 BY HO UG HTO N

DATA DR IV E N S OL U T ION S

HOCUT 4260

P RO DUC T DATA & CASE STUDY

Hocut ® 4260 PROBLEM SOLVER S | S O LU TI O N P ROV I DE R S

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HOCUT 4260

P RO DUC T DATA

ADVANCED, HIGH L UB R I CI TY ME TA L R E MOVA L F L UI D Description HOCUT 4260 is an advanced technology

\\ Developed as a new product for Aerospace and

product and part of the Houghton Hocut

general machining applications, especially for

4000 series technology family. We expect the

large aluminium parts or fuselage

introduction of this high performance and compliant product to change the face of the metalworking fluid market and replace the already globally best-selling metalworking fluid on the market today - Hocut 795 series.

We are proud to be able to offer such a product which will ensure compliance and cost effectiveness for years to come.

HOCUT 4260 is an advanced, boron-free and

\\ It is also compatible with titanium and carbon-

fibre composites \\ Anticipates future EHS regulations

(exempt of Formaldehyde, Biocide, 2nd Amines…) \\ Specifically developed to prevent staining and

galvanic corrosion of Al alloys, particularly on large parts with long machining cycles

formaldehyde-free emulsion technology giving very long sump-life. A special lubricity additive package gives greatly enhanced machining performance and extends tool life compared to conventional products. HOCUT 4260 is particularly effective on machining aerospace airframe structural components in aluminium alloys including titanium and carbon-fibre composites.

Chemical & Physical Properties AT T R I B U T E

PRO PE RTY

Appearance

Pale yellow

Emulsion aspect

Microemulsion, translucent

pH in use

9,5

Density @ (20 °C)

0,986 g/cm3

Refractometric factor

1,5

Acid split factor

2,1

Pack size available

20 L / 209 L / 1000 L IBC

Hocut ® 4260 34 HO CUT 42 60 BY HO UG HTO N

DATA DR IV E N S OL U T ION S

HOCUT 4260

P RO DUC T DATA

Application \\ HOCUT 4260 is multi-metal compatible

\\ The versatile formulation is designed to give

and is recommended for a range of

low foam and no soaps in soft to hard water

machining applications, including high

(10°dH - 70 °dH cumulated hardness)

speed milling and turning on a wide range of materials including aerospace aluminium alloys, composites, ferrous alloys, titanium and inconel

\\ Its operator-friendly EHS profile and its non-

staining & corrosion-free properties make HOCUT 4260 particularly efficient on aero structural airframes

\\ The product is suitable for both

centralised systems and single sump machines while the advanced boron-free technology extends emulsion life without the need for regular biocide treatments

MACHINING

AIRFRAME Aluminium & composites

WATER

LOW

COMPONENTS & ENGINE Aerospace alloys (Ni, Ti...)

MEDIUM

HEAVY

HARD

MEDIUM

Hocut ® 4260

Hocut ® 4940

SOFT

Storage Please refer to section 7 of Safety Data Sheets for handling and storage information, including product shelf life. Product should be stored under cover in clean, dry conditions and protected from frost. Recommended storage temperature is usually between 5°C and 40°C unless otherwise specified. Use stock in delivery rotation.

Hocut ® 4260 PROBLEM SOLVER S | S O LU TI O N P ROV I DE R S

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HOCUT 4260

P RO DUC T DATA

Features & Benefits \\ Versatile: Can process various materials,

\\ Very long sump-life: New HOCUT 4000

ranging from carbon fibre composites, to

series emulsion technology extends

aero aluminium alloys as well as ferrous

intervals between clean outs

alloys \\ High detergency: Leaves parts and

machine tools clean and free from residues \\ Extended tool life: Thanks to its unique

antiwear, the additive package tool wear is minimised, saving tooling costs \\ Very stable emulsion: Fewer additive

\\ Inhibits aluminium staining: Can be used

on sensitive aerospace alloys. \\ Very low foaming: Ideal for the highest

speeds and pressures in soft to hard water (10°dH - 70°dH) \\ Excellent EHS profile: Boron,

formaldehyde, chlorine and phenol-free.

Contains only TRGS 611 approved amines

treatments and lower usage costs

Related Product Water soluble coolants are complemented by our full range of high quality, speciality production fluids including energy saving wash chemicals, low misting neat cutting oils, non-VOC rust preventives and long life heat treatment fluids. Fluidcare services complete our value added portfolio with a range of

Approvals & Conformities \\ Boeing BAC 5008 cat. 5 & 6 – Meets

conformance requirements \\ Bombardier BAMS 569-001: A, C & D.

ASTM D 3946 and Storage stability – Meets conformance requirements \\ Dassault - Approved

expert services and equipment to help reduce costs and improve productivity. For

\\ Airbus AIMS 12-10-001 - Table A7.1 Cleaning

more information, please contact your local

tests, 80T-30-4010 - ASTM F483 and

Houghton representative.

80T-30-4010 - ASTM F1110 - Complies with requirements \\ SAFRAN Engine PR 6300: All materials.

Health & Safety REACh compliant. Safety data sheets are available in accordance with Regulations (EC)

Conforms to Hot corrosion Ti, Al & Ni alloys. Messier Dowty (SAFRAN Equipment): approved

No 1907/2006 Annex II and (EC) No 1272/2008.

HOCUT 4260 displays an excellent EHS profile: \\ HOCUT 4260 is only rated Irritant (no ADR) \\ HOCUT 4260 has reduced labelling with an

exclamation mark

Lab results are available on request.

36 HO CUT 42 60 BY HO UG HTO N

Hocut ® 4260 DATA DR IV E N S OL U T ION S

HOCUT 4260

CASE STUDY

IMPROVED ECONOMI CS AND ENVIRONMENTAL LY F R I E NDLY Current Situation \\ Product: Quakercool 7200 BAF (Without

Amines). Rich Emulsion \\ 2016 consumption: 50 T \\ Material: 70% aluminum, 2000/5000/7000 and

2050 Lithium series, 30% .Titanium TA6V, Parts development in Inconel

The Houghton Approach \\ Product: HOCUT 4260 \\ Aluminum test machine: Mazak Vortex 1400

Machining GV (18000 rpm): Tray 1200 Lt. \\ Titanium Test Machine: Mazak. 500 Litre Tray

passes small parts. \\ Machining on inconel and stainless steel Z5

\\ Machine concentration: 6-7% Aluminum,

8-10% Titanium Inconel, Addition of 3 to 4.5% according to CU \\ Large Premium Client Aerotec (German, former

Airbus factory). \\ Please note: Chip Presses and Recycling 100%

of drips

Objectives \\ Decrease overall consumption \\ Solve foaming issues on some CU \\ Maintaining quality parts (at the surface level

and holding tools) APPROVAL will be launched for standard Airbus 80T-30-4010 & AIMS 12-10-001

\\ Return to a better cosmetic appearance of

Aluminum parts.

Aluminium Parts

Titanium Parts

TARGET CONCENTRATION: 6 - 7%

TARGET CONCENTRATION: 8 - 10%

\\ Additions: 3.5% (3 hours machining cycle)

\\ Additions: 2.5%. Machining cycle (8 hours)

\\ Less time to produce large parts

\\ Environment much cleaner machine.

\\ Facilitates chip removal, in less time

\\ No more foaming

\\ Cosmetic appearance greatly improved.

\\ No sticky residue or machine. Safety glass on

Brighter pieces \\ Good release of tramp oils

machine remains clear \\ No degradation of tool

\\ Consumption slightly lower (3.5% instead of 4

to 4.5%)

PROBLEM SOLVER S | S O LU TI O N P ROV I DE R S

H OUG H TON IN T E R NAT ION A L

A GLOBAL ORGANISATION WITH STRONG LOCAL COMMITMENT HOUGHTON IN TER N AT IO N A L

\\ Houghton is one of the world’s largest independent

speciality lubricant companies \\ Houghton is 100% focused on speciality lubricants for

metalworking industries \\ Our Product Management teams focus our resources in

key ranges

\\ All our key products are developed and manufactured in

house \\ We design high performance, safe, environmentally

friendly products \\ Our global corporate Headquarters are in Valley Forge, Pa. \\ We employ 1900 people in 32 countries

\\ 173 qualified chemists work in Houghton laboratories

worldwide

\\ We sell products and services to 82 countries worldwide \\ Global sales over $1 billion in 2016 ($450 million Fluidcare)

SOLUBLE CUTTING FLUIDS BRANDS: Hocut • Adrana • Sitala • Metalina • Houghto-Grind

HEAT TREATMENT FLUIDS BRANDS: Aqua-Quench • Voluta • Houghto-Quench • Mar Temp

DEGREASING / CLEANING BRANDS: Houghto-Clean

NEAT CUTTING OILS BRANDS: Cut-max • Garia Macron

FIRE RESISTANT FLUIDS & LUBRICATION BRANDS: Houghto-Drive • Sta-Put Houghto-Safe • Hydra-Vis • Cosmolubric Hydrolubric • Isocor

FORMING PRODUCTS BRANDS: Cindol / Cindolube • Fenella oil • Fenella fluid • Houghto-Draw Hydro-Draw • Tube-Draw • Tandemol

METAL PROTECTION BRANDS: Rust veto • Ensis

38 FLUID PARTNE R S HI P S M A KI N G A WO RLD O F D I F F E RE NC E

DATA DR IV E N S OL U T ION S

P ROB LEM SO LV E R S S O L U TI ON PROV IDE R S There’s a reason why the World’s leading OEM’s trust and rely on Houghton, including over 300 UK and Ireland customers.

Houghton believes that it is simply not enough to supply our customers with the best possible metalworking fluids. Our fluid management packages start from weekly visits from our dedicated engineers to up to 6 full-time staff members on your site. We can ensure you get the very best value from our fluids, maximising performance over an extended lifetime. We meet your specific requirements with service, training, technical support and equipment.

PROBLEM SOLVER S | S O LU TI O N P ROV I DE R S

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FLUIDTREND.SOLUTIONS # C NC-TLC

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