Professional Documents
Culture Documents
If the gear cutting tool or measuring device you require is not included in our catalogue, please
do not hesitate to contact us for help. Our experienced engineers will readily support you with
solutions that ensure you produce efficiently at all times.
Hobs ............................................................................................................................4
Worm gear hobs ..........................................................................................................5
Hobs for large gears and rotors ...................................................................................6
Milling cutters / saw blade cutters ................................................................................7
Shaper cutters .............................................................................................................8
Scudding® Tools......................................................................................................... 10
Chamfering, deburring and rolling tools ..................................................................... 12
Shaving cutters .......................................................................................................... 14
Master gears .............................................................................................................. 16
Racks resharpening................................................................................................... 18
Coating technology .................................................................................................... 19
Altensa coating ..........................................................................................................20
Service around the world ...........................................................................................22
Samputensili 3
HSS and carbide hobs Worm gear hobs
creating quality efficiently
A wealth of experience in special gear
applications and extensive testing
on many different hobbing machine
makes means that Samputensili worm
gear hobs are tailor-made to your
needs.
Samputensili 4 Samputensili 5
Hobs for large Milling cutters including saw blade and rack cutters
gears and rotors
Samputensili
Sam
Sa
Sam
a mp
put
puutten
u ens
e ns
nsiililillii 6 Samputensili 7
More than 100 years of combined
shaper cutter experience
Our wide range of shaper cutter types Standard bore diameters Profile modifications
features the brands Samputensili,
Fellows and Star-SU with the com- 31.750 mm Semitopping
bined experience of more than 100 44.450 mm Protuberance
years in shaper cutter design and 70.000 mm Topping
manufacture. 100.000 mm Modification of flank for tip and/or
Other bore diameters on request root relief on gear
Modification of pressure angle
Shaper cutter types Taper shanks Combination of several of the
above modifications
Disc-type MK K 2
Deep counterbore-type MK K 3
MK K 4
Quality
Shank-type
Special cutters for sprockets, cams, FK 1 A DIN 1829
splines, timing belts and large FK 2 AA DIN 1829
modules
For pre-finishing
Standard profiles Material
For finishing DIN 3972 - BP I High-alloy HSS-PM steels
Available also unground DIN 3972 - BP II MC90 Keyway types
DIN 3972 - BP III
Dimensions DIN 3972 - BP IV Coatings
Module min./max. 0.5 - 16.0 mm DIN 5480 Gold (TiN)
Max. diameter 320 mm BS 2062 Futura Nano (TiAlN)
Type A Type B Type C Type D Type E Type F
Other dimensions on request Alcrona (AlCrN) without longitudinal clutch keyway, not keyway aligned keyway
Altensa (AlCrNX) keyway keyway keyway aligned on tooth vane aligned on
axis tooth axis
Other coatings on request
Samputensili 8 Samputensili 9
Strategic alliance for Scudding® tools Scudding® is much quicker,
more efficient and productive
The high number of cuts per time unit
not only leads to a very short cycle Gear quality DIN 5-7
time, it produces high quality gears Surface roughness Rz 1-5
Modules 0.7 - 5
with a low surface roughness.
Max. diameter - HSS 200 mm
Max. diameter - Carbide 150 mm
Max. shank size 150 mm
Bore size options 1.75 - 44.45 mm
Samputensili 10 Samputensili 11
Patented solutions for chamfering, Chamfer-roller tools Why chamfer and deburr?
deburring and rolling For gears with parallel chamfers A burr which is not removed may
For gears with comma type break off during use and damage
chamfers bearings or gears in gearboxes.
Over-carbonizing may result in
With the patented Samputensili too much pressure being exerted
chamfer-roller tool, you can chamfer on sharp gear lateral surfaces
Workpiece after hobbing
and roll your gears at the same time. which might then break.
The secondary burr that is gener- A hardened burr may lead to pre-
ated during chamfering is removed mature wear of tools in subse-
in the very same operation. quent finishing operations.
By combining both processes, Removal of very sharp burrs
the machine utilises just one tool reduces the risk of tool handling
head leaving the second tool injuries.
head free for another operation.
Why roll?
1+
1+3
1+3
+3
The rolling operation serves to Workpiece after chamfering and deburring
remove the material that builds up
on the tooth flanks by plastic
deformation during chamfering.
During chamfering/deburring,
structural material changes in the
form of compression may occur.
1
The rolling process levels out the
Chamfering tools Rolling tools surface and causes the material
to sink.
For spur or helical gears For spur or helical gears Rolling of a chain sprocket gear
Secondary Chamfer
For straight or inclined gear As single tool or separate tools chamfer
lateral surfaces Rolling tools for burrs and internal
toothing
Rolling is performed by a localised “levelling out”
Deburring tools action which may be described as a second
Chain sprocket deburring chamfer with a chamfering angle Δ of about 1°.
Secondary burr during
P Type (Standard tool for straight and rolling tools chamfering
2
Chamfering / deburring Chamfering / deburring / rolling
gear lateral surfaces) Use of two tool heads Use of three tool heads, one for each single tool
P 1000 type (Like P type but Developed exclusively to deburr chain Subsequent operation: shaving or profile grinding Rolling tool used as a third single tool with surface
grooved)
PR type (with alternate sections
sprockets, the specially adapted form
of the SPR 1000 type has exactly the
Tool groups contact between rolling tool and workpiece flank.
Subsequent operation – Continuous generating
grinding, shave grinding, honing
for straight gear lateral surfaces same profile as the flank radius of the
radiused to the root) gear tooth and therefore any burrs from Chamfering & deburring / rolling Chamfering & deburring
PR 1000 type (grooved tool for the lateral surfaces of the gear teeth. Use of two tool heads, chamfer-deburring tool on one Monoblock solution
straight gear lateral surfaces tool head and rolling tool on a second tool head. Use of one tool head mounted with a combined
radiused to the root) The chain sprocket roller tool profile Deburring the secondary burr on Subsequent operation – Continuous generating chamfer-deburring tool
also corresponds to the gear tooth pro- gear lateral surfaces grinding, shave grinding Requirements: without step, no use of any 1000 type
A 1000 type (grooved tool for
3
Requirements: without step, no use of any 1000 type deburring tools
inclined gear lateral surfaces) file. The special tapered form of the tool
deburring tools Subsequent operation: shaving or profile grinding
AR 1000 type (same as A 1000 tooth prevents material from building
type but radiused to the root) up along the gear tooth profile during Chamfering & rolling / deburring Chamfering & deburring & rolling
SPR 1000 type (special tool for the contemporary deburring operation. Use of two tool heads, chamfering tool with integrated Monoblock solution
rolling tool on one tool head and deburring tool on a Use of one tool head mounted with a chamfer-roller
chain sprockets)
These tools are ideal for Samputensili second tool head. tool with a combined deburring tool.
T 1000 (grooved tool for chamfering Subsequent operation – Continuous generating Requirements: without step, no use of any 1000 type
chamfering machines with motorised
turning chamfers on the tooth tip) grinding, shave grinding, honing deburring tools
tool heads but they can be used on any
Subsequent operation – Continuous generating
standard chamfering machine. grinding, shave grinding, honing
Rolling the secondary burr on
gear flanks Back: Monoblock chamfering and deburring
solution on one tool head
Samputensili 12 Front: set of rolling tools on one tool head Samputensili 13
Shaving cutters – guaranteeing superior quality Transverse shaving Diagonal shaving Plunge shaving*
Shaving cutter Gear at end Shaving cutter
Shaving cutter
after each sharpening process Gear at start
Gear at start
of stroke
Point of contact
at beginning of
Gear at end of stroke Gear at start
of stroke shaving
of stroke and end of
stroke
Σ Ψ Σ
Point of
Point of contact at end Σ Point of
contact at of shaving contact at begin-
beginning and ning and end of
end of shaving r r shaving
°
90
°
90
of stroke
Point of contact at
beginning of shaving
Samputensili 14 Samputensili 15
Precision tools for measuring, setting, Consultancy, analysis,
optimisation
calibration and correction Our experienced engineering team is
readily available to address any profile
analysis or design queries. Existing
profiles can be optimised using our
internally developed master gear
design software.
Marking
All Samputensili checking and setting
master gears are engraved according
to DIN 3970 or with any requested
customer-specific data and bear an
individual tracking number enabling
them to be carefully monitored through-
out the whole production process.
Types Material Ring gauges
Certified quality Packaging
Master gears for single and double Gauge steel Module 0.5 – 7.0* mm
gear flank and runout measurement High speed steel Ring outside dia. 20 – 200 mm Master gear design and production Our precision tools are shipped and
Setting masters to adjust and cali- PM steel processes are all carried out using transported in a specially developed
brate quality control instruments Straight and helical teeth special Samputensili software and packaging system.
Rolling gears to measure noise Coatings Involute and special profile modern manufacturing methods.
Rolling gears to reduce burrs and (*) depending on outside diameter All Samputensili checking and setting Drawings, documents and checking
nicks PVD coatings for HSS/PM master master gears are fully tested on CNC protocols are safely stored away in a
Plug and ring gauges gears only inspection equipment and are deliv- separate pocket integrated in the tool
Gold (TiN) ered with a certificate of conformity. box lid.
Dimensions Futura (TiAlN) We produce master gears on specially
designed and optimised machinery
Module 0.8 - 6.0 Gauge master gears steel do not with- in classes from 2 to 6 to DIN 3962,
Diameter 40 - 300 mm stand temperatures exceeding 450°C AGMA and BS standards.
Tooth width 4 - 80 mm and are therefore unsuitable for coat-
Helix angle 0 - 45 deg ing. Protective coatings may only be We therefore guarantee both the
applied to HSS/PM master gears. accuracy of our master gears and the
Quality: 2-6, DIN 3962 quality of the whole manufacturing
Geometry: DIN 3970 Plug gauges process.
or according to drawing
Module 0.5 – 6.0
Corrections Pitch diameter 20 – 150 mm
Samputensili 16 Samputensili 17
High precision rolling racks Coating technology
Samputensili 18 Samputensili 19
Coating Altensa Standard coatings guide
Boost your productivity!
Gold Alcrona Pro Altensa
Composition Titanium Nitride Aluminum Chromium Nitride Aluminium Chromium Nitride
Characteristics The proven coating for Tools coated with ALCRONA Tools coated with ALTENSA
general metalworking pro- PRO can be run with much can work at higher cutting
cesses. High hardness and higher cutting speeds and speed than ALCRONA
a low friction coefficient feeds, so the potential of PRO which caters to latest
enhance wear resistance. modern machine tools is generation machining
Remarkably low chemical tapped to a clearly greater centres.
affinity with most metals. degree.
The coating ALTENSA by Oerlikon These are just some of the main ALTENSA is ideal for markets which
Balzers is the most innovative coating advantages in utilizing ALTENSA on need high cutting speed such as
one can currently find in the market. our tools: automotive. It is recommended in the
following processes:
Application Hobs Hobs Hobs
Its characteristics enable to apply high Reduced machining cost
speeds, obtaining huge productivity Reduced wear at high speed Hobbing Shaper cutters Shaper cutters Shaper Cutters
gains, time savings and cost efficiency. Longer tool life Shaping
Significant improvement for highest Scudding® Deburring tools Scudding® tools
cutting speed conditions for all Master gears/rolling tools
substrate materials (PM-HSS, MC90, Samputensili is always at the state of
carbide) the art of technology in order to provide
Increased productivity the best solution possible!
Samputensili 21
With you all the way
throughout the life of your tool Hoffman Estates/IL Farmington Hills/MI
Beijing
Seoul
Shanghai
Queretaro
Pune
Stay connected
Your Samputensili service centre helps
you enhance the productivity, precision
and turnaround of your production tools. Chemnitz
Get in the
driver's seat
Samputensili Total Tool Life Cycle Take control of the cost-per-piece
Management meets your every pro- performance of your tools.
duction need by optimising each tool Consider all tool supply and
life cycle step and enhancing the cost- maintenance costs.
With Samputensili tool service, you per-piece performance of your tools. Optimise all steps in your process
benefit from more than 50 years of ex- Services Samputensili CMS By guaranteeing a certain cost-per- chain in-house.
perience in tool design, manufacture piece, you need no longer worry about Keep a check on maintenance costs.
and testing, as well as comprehen- Project consultancy, design and actual tool cost, potential tool life or
application testing + Lower direct and indirect labour future servicing requirements.
sive tool management know how. To-
... mputensili
day, some of the world’s leading gear costs and lower indirect charges.
manufacturers rely on Samputensili to Sharpening of hobs, shaper cut- + Reduced tool storage costs. E on y
SA
manage special tool cribs or to han- ters and shaving cutters G with Sa our
too V
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+ Quality guaranteed by the l r
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E. rpening co
dle their complete tool supply through
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original manufacturer throughout
MA
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commodity management supply sys- Regrinding of master gears
ro
On-time delivery
lp
tems. the complete life cycle of the tool.
oo
Understanding processes
ire t
Stripping, preparation and recoat- + Longer tool life. Monitoring stock & availability
your ent
ing of tools at our in-house coat-
+ Complete range of services for Analysing cost saving potential
ing centres
Cost-per-piece strategy tailored to your needs
gear tools from a single source.
Monitoring of tool wear & servicing rates
Stripping, preparation and recoat-
yo
ing of CBN- and diamondplated Quality inspection & verification
Standard tool coatings
... at
u r
IZ and flo
tools Resharpening, reconditioning
ove
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Cleaning, recoating
ral
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Gold (TiN)
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Pickup and delivery service, to
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On-time pickup
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and from your tool crib Futura Nano (TiAlN) CEsts per pie
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IM too
Alcrona Pro (AlCrN)
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CMS for tool groups and product IN ... ce
Altensa (AlCrNX)
life cycle management of single
M
tool types.
Samputensili 22
HQ Samputensili Cutting Tools S.r.l. Samputensili GmbH Samputensili France S.a.r.l.
Via Saliceto, 15 Marienberger Str. 17 79 rue de la Tour
40010 Bentivoglio (BO) 09125 Chemnitz 42000 Saint Etienne Cedex
Italy Germany France
Tel.: +39 (051) 63 19 411 Tel.: +49 (0371) 576 257 Tel.: +33 (0477) 92 80 50
Fax: +39 (051) 37 08 60 Fax: +49 (0371) 576 259 Fax: +33 (0477) 93 72 03
info@samputensili.com contact@samputensili.com info@samputensili.fr
Star SU LLC Star SU Indústria de Ferramentas Ltda. Star SU International Trading (Shanghai) Co. Ltd.
5200 Prairie Stone Parkway, Suite 100 Rod. Dom Gabriel Paulino Shenxia Road, 358 Shanghai Forward High
Hoffman Estates, IL 60192 Bueno Couto Km 66,3 - C.P. 849 Tech Zone, Jiading District,
USA CEP13201 - 970 Jundiai, SP, Brazil 201818 Shanghai - P.R. China
Tel.: +1 (847) 649 1450 Tel.: +55 (011) 21 36 5199 Tel.: +86 21 59900890
Fax: +1 (847) 649 0112 Fax: +55 (011) 4582 7921 Fax: +86 21 59900887
sales@star-su.com brasil@star-su.com.br info@star-su.com.cn