Benefits

Superior rust prevention and cooling! A soluble cutting fluid you dilute in water !
"Is a cutting fluid that combines the excellent economy and cooling effect of a soluble cutting fluid and the strong lubrication and metal deposit prevention of a water insoluble cutting fluid even possible?" This has been a long-term question for users and manufacturers of cutting fluids. HI-CUT SUPER GG is a highly functioning water soluble cutting fluid that combines the strengths of an aqueous solution with those of an oil.

Used as a cutting fluid diluted 10 to 50 times with tap water, it is economical and easy to handle.

• ① Prevents welding deposits
• ② Leaves a clean cut edge, has superior lubrication.
• ③ A cooling effect that reduces friction with the cutting blade.
• ④ Superior rust inhibition means anti-corrosion treatment is unnecessary in the short-term.
• ⑤ The fluid has a long-life, and resists decomposition.
• ⑥ It contains no harmful substances, is environmentally friendly and non-polluting.
• ⑦ Color conditioning

Performance

① Welding deposits prevention

HI-CUT SUPER GG makes use of waters adsorptivity for metallic surfaces and with the skillful combination we have developed of a specialized anti-welding deposit solution and a penetration agent, the wettability of the fluid has been further strengthened. Providing a anti-welding deposit lubrication film that adsorps strongly to metallic surfaces and that forms a layer which penetrates deeply into the composition of metallic particles. This works strongly not only for the material to be cut but also for the cutting tool, preventing the generation of a built-up edge despite the solution being diluted in a large amount of water. The capability of the HI-CUT SUPER GG to prevent built-up edges is proven when drilling holes in stainless steel, which is notorious for the problem of built-up edges, giving a clean cut edge at high-speed with a sharp tool.

② Lubrication performance

HI-CUT SUPER GG exhibits superior lubricating properties. When cutting metal, there is a massive load exerted, when converted to per unit area, on the surface of the rake face which is in contact with the chip. The size of this load can be 10s to 100s of times greater than the load between the shaft and the bearing in a machine. Moreover, the chip slides on extremely quickly under this extreme pressure. If the cutting fluid interposed between the two has insufficient lubricity, when burrs and roughness occur it may lead to damage of the tool.
 As a water soluble cutting fluid HI-CUT SUPER GG has exceptional lubricity. When compared to other lubricating oils, the strength of the lubrication is equivalent to that of a sulfide chloride type extreme pressure lubricant used for broaching etc. When a solution of HI-CUT SUPER GG diluted 100 times was tested by a four-ball tester the result was a massive 13kg/cm², a figure commensurate with the best heavy cutting oils.
 HI-CUT SUPER GG is a strong extreme pressure lubricant, but in order to enhance this capability to the maximum, its surface tension has been lowered. If the surface tension is lowered the capillary action increases and the cutting solution can penetrate the gaps between the tool and the chip. In addition, there is stronger wettability further enhancing cutting properties. For high-speed cutting in particular, the life of the tool is extended to the maximum possible by the fluid swiftly penetrating between the tool and the material to be cut and exhibiting strong lubrication in order to sharpen the edge of the tool and a clean cut finish.

③ Cooling performance

The cooling effect of HI-CUT SUPER GG is unlimited. As this is a water soluble solution it has an infinitely greater cooling effect than water insoluble solution cutting oils. The cooling effect differs slightly depending on the oil it is compared to but generally speaking it is more than seven times that of non-aqueous cutting oils. With the combination of low surface tension and strong wettability the cooling effect is outstanding. It is said the life of a tool is inversely proportional to the square of the temperature of the blade tip. When using HI-CUT SUPER GG, tool life is extended and cutting speed maximized with the combination of the strong cooling effect, anti-welding deposit properties and extreme pressure lubrication capability. An example of improved cutting speed is the increase from 2000 r.p.m to 4000 r.p.m of the spindle of an automatic lathe used for extremely the fine operations required when making aircraft instruments from a nickle chrome alloy while leaving a beautiful clean cut edge finish.

④ Anti-corrosion effect

HI-CUT SUPER GG also has an enhanced anti-corrosion effect. Immersing cast iron, which rusts very easily, in HI-CUT SUPER GG in a ratio of 1:30 can prevent rust for up to two months. Also, painting a polished steel sheet with a 1:100 diluted solution can prevent rust for over 15 days when left inside. (In conditions where humidity is high the period of rust prevention will be shorter. For long periods rust prevention treatment is required).

⑤ Anti-deterioration effect

HI-CUT SUPER GG does not deteriorate. It prevents the proliferation of bacteria. Soluble cutting fluids can deteriorate causing a bad smell and becoming unusable. The foul smell emanating after the holidays in summers heat is caused by the sudden proliferation of anaerobic bacteria. HI-CUT SUPER GG does not contain the fats or protein that are nutrition for bacteria. It does contain a new sequestering medium that prevents bacteria growth. So even a highly diluted solution will not deteriorate. There is no need to extract or replace a working solution. (It is necessary to maintain pH levels). It is possible to keep using the fluid by only replenishing the depleted portion.

⑥ No drain pollution

HI-CUT SUPER GG does not cause damage when discarded. HI-CUT SUPER GG does not contain P.C.B heavy metals, cyanide or nitrogen compounds. It is slightly alkaline to prevent the formation of rust. By discarding the working solution with an equal or greater amount of water it is possible to bring the COD value and BOD values within effluent standards.

⑦ Color conditioning

HI-CUT SUPER GG becomes a pretty green color when diluted. The color is considered by Labor Science experts to reduce eyestrain and prevent worker fatigue. The color also indicates the level of dilution of the working solution. As a worker gets used to using the solution any differences in the level of dilution can be seen from the color.

Examples

HI-CUT SUPER GG easily dissolves in water and does not separate. So special care while diluting is not necessary. Simply add the specified amount of HI-CUT SUPER GG to the specified amount of water and mix briefly.

(1) For drilling

[Standard dilution ratio for drilling]

	Cast iron	Stainless steel	Carbon steel	Lightweight alloy	Titanium
Drill	1:30 to 1:50				1:10 to 1:30

• (Example)
• Work machine
• Tool
•  
• Material

• An example of end plate working for a large-scale heat exchanger
• Company O large radial drilling machine (single spindle)
• • Standard drill
  • Diameter 32mm
  • SUS304
  • SKH9
  • Point angle 117°
  • Thickness 120mm

Item	Sulfide chloride type water insoluble heavy cutting oil	HI-CUT SUPER GG 1:50 water soluble solution
Drill rotation (r.p.m)	160 to 180	250 to 350
Feed (mm/rev)	0.2	0.4 to 0.6
Number of holes opened per drill bit	10 to 25	110 to 200

(2) For milling

• (Example)
• Material
• Milling
• Incision
• Feed

• Horizontal milling machine
• S55C
• High speed diameter 150mm width 22mm
• 5.5mm
• 0.25mm/point

(3) For a saw

(4) For a lathe

• · Increases speed.
• · Extends tool life.
• · Minimal roughness in the finished surface.
• · Precise dimensions and accuracy.

(5) For a grinder

Using HI-CUT SUPER GG when grinding provides the following benefits.

• ① Supports the grinding performance of the teeth of each grain improving sharpness and reducing surface roughness providing perfect roundness.
• ② There is no clogging so the operation of each independent tooth is preserved. Unnecessary friction from grains is prevented extending the interval between dressings and increasing the degree of processing.
• ③ The transparency of the diluted solution is high allowing observation of the surface being processed during the operation.
• ④ The solution does not foam, eliminating problems due to bubbles.
• ⑤ Excellent separation from chips, preventing clogging by the chips.
• ⑥ Bacteria cannot proliferate in the solution so it will not deteriorate during the summer and can be used for a long time.
• ⑦ The solution is a strong anti-corrosive and prevents the occurrence of rust on machinery and products in the short term.
• ⑧ The solution does not contain substances harmful to people so it is safe to use and has very little odor.

It is also frequently used for sulfur treated whetstones, internal cooling grinding and thread grinding. The dilution ratio of the solution also has an effect on grinding operations. Changing the ratio to suit the operation yields desirable results. Following is the appropriate ratio for each grinding operation.

<Case 1> Outer ring circumferential grinding of bearings

• Conditions

• • Grinding machine
  • Whetstone
  • Material
  • centerless
  • WA80N  Circumferential speed 1500m/min
  • hardened steel bearing  HRC 62

Item	Company B soluble 1:50 solution	HI-CUT SUPER GG 1:50 water soluble solution
Roundness	1.5/1000	1/1000
Precision of finished surface (μmRz)	36	27
Number of processes per dressing	600	3200

<Case 2> For aluminium foil rolling

• Conditions

• Roll grinding
• • Grinding machine
  • Whetstone
  • Material
  • Grinding fluid
  • Large-scale universal grinder (made in Sweden)
  • GC260J
  • S55C hardened HRC55
  • HI-CUT SUPER GG 1:50 water soluble solution

Roundness	0.7/1000
Precision of finished surface (according to an optical interferometer)	0.2/1000
Dressing	Full automatic dresser

(6) Standard dilution ratio by operation

[Dilution ratio]

Operation	Dilution ratio
Metal saw	1:20 to 1:50
Rough grinder	1:10 to 1:50
Drilling	1:20 to 1:40
Finishing	1:10 to 1:30
Turning	1:10 to 1:20
Milling

(7) Other examples ∗ Using a HI-CUT SUPER GG 1:30 diluted solution

Machine	Material
NC lathe (made by Okuma)	Inconel Rotation : 157r.p.m Feed : 0.5 Incision : 1.5mm Cutting tool : K10
Radial drilling machine	SS400 (thickness 82mm)
Saw (made by Amada)	SCM-435

(Note) The dilution ratios are for tests by our firm. The ratio will change according to conditions of use.

(8) Dilution and replenishment

Our water soluble products are diluted with tap water according to the purpose of use. When mixing the solution add the prescribed amount of cutting fluid to a container of water and stir before pouring into a tank. When the cutting fluid has depleted, do not replenish with only water but a properly diluted solution. If only water is added, corrosion may occur.