Case Study: FUCHS ECOCOOL 7978 for Electronic Brake Systems

In the competitive landscape of automotive manufacturing, reducing vehicle weight—or lightweighting—stands out as a critical strategy for enhancing fuel efficiency and extending the range of electric vehicles. Aluminum, offering a 60% weight savings over even the lightest high-strength steel, has become a material of choice for many manufacturers. This article delves into a case study from FUCHS, highlighting the benefits of ECOCOOL 7978, a water miscible machining fluid designed for the production of aluminum components in electronic brake systems.

Key Highlights:

  • ECOCOOL 7978: A solution to the challenges of machining 6000 series aluminum.
  • Improved System Cleanliness: Resulting in superior surface finish for brake components.
  • Significant Cost Savings: Coolant usage reduction of 40% and a 30% savings in cost per gallon.
  • Enhanced Tool Life: With a 20% reduction in tool usage.

Challenge Faced by Automotive OEM An Automotive OEM was on the lookout for a new metal machining fluid to use in their stand-alone and central recirculating systems. The goal was to efficiently manufacture 6000 series aluminum components for electronic brake systems. The existing fluid presented issues, such as biologic growth and filtering difficulties, leading to increased residues and carry-off on parts.

ECOCOOL 7978: The Solution FUCHS introduced ECOCOOL 7978, a heavy-duty, low-foaming coolant suitable for a broad range of non-ferrous metalworking applications. Its advanced formulation ensures foam control in soft water and maintains emulsion stability in hard water conditions (up to 2000 ppm). The coolant’s sophisticated lubricity package promises excellent lubrication across various operations, thereby enhancing surface finishes and extending tool life while being ideally suited for high-pressure fluid delivery in through-tool operations.

Documented Results After implementing ECOCOOL 7978, the automotive OEM observed remarkable improvements:

  • 40% reduction in coolant usage
  • 30% cost per gallon savings
  • 20% reduction in tool usage

These efficiencies translated into overall savings of 30% more than the expenditure on the technology, showcasing ECOCOOL 7978 as not just a product but an investment that yields significant returns.

The switch to ECOCOOL 7978 not only addressed the immediate challenges faced by the automotive OEM but also positioned them to reap substantial financial benefits. This case study exemplifies how selecting the right machining fluid can lead to improved production efficiency, cost savings, and ultimately, a competitive edge in the automotive industry.

Learn more about this case study here.

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The Brake Report
The Brake Report

The BRAKE Report is an online media platform dedicated to the automotive and commercial vehicle brake segments. Our mission is to provide the global brake community with the latest news & headlines from around the industry.