The New ULTRA & XTREM Gear Cutting Tools
The Challenge of Increasing Productivity in Gear Cutting
Gear cutting operations require an extremely delicate balance between:
- tool stability
- cutting precision
- surface finish quality
- tool life
Increasing cutting speed or feed rates often leads to premature wear or unstable machining.
Instead of pushing conventional limits, Diametal engineers approached the problem differently:
They redesigned the tool architecture itself.
The objective was to create a tool capable of distributing cutting forces more efficiently, improving both productivity and machining stability.
The Key Concept: Maximizing the Number of Teeth
The fundamental innovation behind the ULTRA and XTREM concept lies in increasing the number of cutting teeth for each tool diameter.
This design change transforms the way the tool interacts with the workpiece.
Advantages of increased tooth density
- lower load per cutting edge
- improved stability during machining
- reduced tool wear
- more efficient chip evacuation
- more consistent surface finish
Instead of relying on a few heavily loaded cutting edges, the load is distributed across many smaller and more stable engagements.
The result is higher machining efficiency without compromising precision.
Real Industrial Results: Up to +83% Productivity
The concept was validated through real industrial testing.
For example, in one test performed on a Ø24 mm hob cutting PFINODAL material, the following results were observed:
| Parameter | Standard Cutter | ULTRA Cutter |
|---|---|---|
| Number of teeth | 15 | 26 |
| Pieces produced | 180 | 330 |
The result:
+83% productivity improvement
This demonstrates how increasing the number of teeth can directly impact manufacturing efficiency when the tool design ensures sufficient stability.
Two Generations of Tools: ULTRA and XTREM
The new product family introduces two complementary solutions, designed for different production environments.
ULTRA – Maximum Productivity and Tool Life
The ULTRA series is engineered for manufacturers seeking maximum productivity and extended tool lifetime.
Key characteristics:
- 3 to 4 guaranteed regrinds
- extended service life
- improved surface finish
- optimized gear profile precision
ULTRA tools are particularly suited for high-volume production environments where maximizing tool performance is critical.
XTREM – Efficient and Cost-Effective Performance
The XTREM series follows the same technological principles but offers a simplified solution optimized for specific production strategies.
Key features:
- 1 guaranteed regrind
- extended service life
- improved surface finish and profile quality
XTREM tools provide an efficient solution for shorter production runs or cost-sensitive machining environments.
What This Means for Manufacturers
For manufacturers in high-precision industries, productivity improvements must never compromise quality.
The ULTRA and XTREM solutions were developed precisely with this challenge in mind.
By combining:
- optimized gear cutting geometry
- high-toughness carbide substrate
- mirror-polished cutting edges
Diametal has created a new generation of gear cutting tools capable of delivering:
✔ dramatically higher productivity
✔ extended tool life
✔ superior surface finish
✔ stable and repeatable machining
All while maintaining the precision standards required in micromechanics and advanced manufacturing.
