The New ULTRA & XTREM Gear Cutting Tools
Gear cutting operations require an extremely delicate balance between:
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 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.
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.
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.
The new product family introduces two complementary solutions, designed for different production environments.
The ULTRA series is engineered for manufacturers seeking maximum productivity and extended tool lifetime.
Key characteristics:
ULTRA tools are particularly suited for high-volume production environments where maximizing tool performance is critical.
The XTREM series follows the same technological principles but offers a simplified solution optimized for specific production strategies.
Key features:
XTREM tools provide an efficient solution for shorter production runs or cost-sensitive machining environments.
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:
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.