Tools – Star SU Europe

Coating

18 January 2016 rtarantino

In collaboration with the world’s leading manufacturers of tool coating technology, we optimize innovative coatings for gear cutting tools to improve abrasion resistance, wear resistance and consequently tool life.

Automated cleaning equipment further optimizes the coating process. Substrates are delivered for coating in a thoroughly clean state to help guarantee the ultimate quality of the coated product. In-house coating units are integrated in Samputensili manufacturing sites all over the world and are frequently updated with the latest process technology. This close co-operation means that any new developments in anti-wear coatings are made available to you immediately.

Nowadays, the new development in the tool coating industry is represented by the new coating ALTENSA by Oerlikon Balzers which represents the latest innovation in the coating market. Its characteristics enable to apply high speeds, obtaining huge productivity gains, time savings and cost efficiency.

The main ALTENSA advantages are:

Reduced machining cost
Reduced wear at high speed
Longer tool life
Significant improvement for highest cutting speed conditions for all substrate materials
Increased productivity

This new coating is ideal for markets which need high cutting speed such as automotive. It is recommended in the hobbing, shaping and scudding® processes.

Main advantages:

Best coating on the market
Wide range of coating in order to satisfy clients’ needs
Better tools performance, thereby more productivity

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Scudding ® Tools

18 January 2016 rtarantino

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The Scudding tools are the result of an alliance between Profilator, Star-SU and us for the global market. The scudding®/power skiving is a continual gear cutting process which makes both the production of external and internal gears as well as spur and helical gearing possible.

This technology allows the machining of internal or external gears/splines without the need of an undercut or groove. The end of the gear can be a defined programmed ramp of radius.

This process is quicker and more productive. In fact, the high number of cuts per time unit not only leads to a very short cycle time, but it also produces high quality gears with a low surface roughness.

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Shaper cutters

20 November 2015 macca_admin

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Our shaper cutters boast over 115 years of experience, thanks to the combined experience of Samputensili, Star-SU and Fellows, and are a guarantee of high quality and efficiency.

We manufacture several different types of shaper cutter:

Disc-type
Deep counterbore-type
Shank-type
Special cutters for sprockets, cams, splines, timing belts and large modules
For pre-finishing
For finishing
Available also unground

We are able to manufacture all type of dimension in line with clients’ needs. The normal shaper cutters dimension range is:

Module min/mx: 0.5-16.0 mm
diameter : 320 mm

Thanks to our tight collaboration with the coating leader company, Oerlikon Balzer, we are able to guarantee the most efficient coating directly in-house. Our shaper cutter coating includes:

Gold (TiN)
Futura Nano (TiAlN)
Alcrona (AlCrN)
Altensa (AlCrNX)

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Shaving cutters

20 November 2015 macca_admin

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As one of the largest producers of cutting tools worldwide, and with particular expertise in shaving technology, we offer a wide range of shaving cutters able to do many types of processing :

Transverse
Diagonal
Diagonal-underpass
Underpass
Tangential
Plunge
Internal/external shaving
Underground or finished shaving cutters

Tool design and optimization are rooted in the longstanding experience of our shaving cutter design engineers. Unique software developments implemented on our shaving cutter grinding machines and test programs mean high precision and efficient resharpening of your tools.

We provide different dimensions of shaving cutters:

Module: 0.7-10mm
width: 65mm
Outside diameter: 70-330mm

We deliver each tool with a user-friendly sharpening diagram, enabling clients to monitor the life cycle of their tools and directly control the sharpening process. Our shaving cutters are profile ground and sharpened in house, ensuring the most productivity.

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Chamfering, chamfer-roller and deburring tools

20 November 2015 macca_admin

chamfering and deburring tools Samputensili

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We are undisputed leader in the manufacturing of chamfering, chamfer-roller and deburring tools.

These tools are extremely important in order to get a high quality final gear. The chamfer and deburr are pivotal process, in fact a burr which is not removed may break off during use and damage bearings or gear in gearboxes, or a hardened burr may lead to premature wear of tools in subsequent finishing operations. Whereas, a roll operation aims to remove the material that builds up on the tooth flanks by plastic deformation during chamfering. This process levels out the surface and causes the material sink.

The chamfering process is essential to prevent edge distortion during heat treatment, protecting the tooth profile against damages that may occur during handling. Our chamfering tools are ideal for spur or helical gears as well as for straight or inclined gear later surface.

We provide a wide range of deburring tools satisfying any applications:

P Type (Standard tool for straight gear lateral surfaces)
P 1000 type (Like P type but grooved)
PR type (with alternate sections for straight gear lateral surfaces radiused to the root)
PR 1000 type (grooved tool for straight gear lateral surfaces radiused to the root)
A 1000 type (grooved tool for inclined gear lateral surfaces)
AR 1000 type (same as A 1000 type but radiused to the root)
SPR 1000 type (special tool for chain sprockets)
T 1000 (grooved tool for chamfering turning chamfers on the tooth tip)

The chamfer-rolling tools enable to make the chamfer and roller process at the same time. The secondary burr that is generated during chamfering is removed in the very same operation. By combining both processes, the machine utilizes just one tool head leaving the second tool head free for another operation. Our chamfer-roller tools are optimal for gears with parallel and comma type chamfers.

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Master

20 November 2015 macca_admin

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Samputensili offers a wide range of master gears to determine the accuracy of work gears, as well as setting masters to adjust your checking equipment for the following types of gears:

Spur gears with or without profile and flank corrections,
Helical gears with or without profile and
Flank corrections and internal gears

We essentially use gauge steel, high speed steel and PM steel material for our master gears. Notwithstanding, thanks to our in-house collaboration with the leader of the coating industry, we can offer several different coating based on client application needs.

We can address any profile analysis or design queries, moreover our in-house developed master gear design software can easily optimize existing profiles.

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 throughout the whole production process. Moreover, they are fully tested on CNC inspection equipment and are delivered with a certificate of conformity.

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Hob

21 October 2015 admin_macca

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We are specialized in manufacturing a wide variety of gear hobs including:

Involute gear hobs
Bore and shank-type hobs
Special profiles/profile modifications
Hobs for special drives
Chain sprocket hobs
Worm gear hobs
Large module hobs
Hobs for splines and timing belt gears
Finishing and pre-finishing hobs
Double gash hob

Depending on your application, we optimize tool geometry in terms of diameter, number of gashes and number of starts. Our gear hobs are available in a wide range of dimensions:

Module Range: 0.45-22.0 mm
Diameter Range: 40-300mm

Thanks to the tight in-house collaboration with the leader of the coating industry, Oerlikon Balzer, we provide the most efficient state-of-the-art coating, satisfying single needs including: Gold (Tin), Futura nano (TiAlN), Alcrona Prto (AlCrN) and Altensa (AlCrX).

Samputensili also represents the cutting edge technology for hobs for large gear modules. They can also be supplied in heavy duty design with a maximum of 3 cutting blades. We have a long history to ensure clients the best tradeoff between productivity, batch size, tool cost and cost per piece.

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