SPECIAL SOLUTION GEAR-SAF GEAR UP FOR PROFITABILITY

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1 SPECIAL SOLUTION GEAR-SAF GEAR UP FOR PROFITABILITY large range of gear profiles with the same cutter

2 special SOLUTION GEAR-SAF system Reduce tools inventory and achieve greater perfomance With GEAR-SAF Gashing System one tool is able to produce a wide range of different gears, both internal and external, with high productivty rates and outstanding quality. BENEFITs Nearly 30 years of experience and success in Europe Wedge system for inserts clamping (improved tool life, easy and improved inserts clamping) Utilize one tool with inserts for roughing and finishing (only one pass instead of multiple passes) Utilize one tool for different diameters and modules (by changing the inserts) Utilize one tool for internal and external gears (by changing the inserts) We use internal air to each insert Machining of the entrance chamfer optional Avalaible in all Safety s grades for different materials Cutter bodies feature very long life. Body is HRC Experience from M5 to M50

3 EXTERNAL GEARS AND PROTUBERANCE High inserts density Example: M16 ext with protuberance, Zef 12 in a Ø270 mm cutter Excellent finishing, without any step between protuberance and flank (the complete profile in each insert) WEDGE CLAMPING SYSTEM Flexibility Tool body protection Quick inserts indexing INTERNAL COOLANT SYSTEM Air or coolant to each insert is a recommended option to improve insert life and avoid high work piece temperatures

4 REAL CASE One cutter Ø420 mm producing gears from M8/z123 to M16/z 87 Quality for M9/z105: Fα Q7 (DIN 3962) with only one pass REAL CASE One of our customers produces 250 different profiles (internal/external, from M5 to M25.4 ) with only 5 cutters Please, give us your gear drawings and we will see how many cutters do you need to cover all your gear production Delivery time: Less than 10 weeks for tool and less than 8 weeks for insert.

5 What are the main advantages of the flexible system? --> The flexible system of GEAR-SAF allows to produce a huge range of gears with the same cutter by means of changing the inserts. If the customer has a new project he could use the same cutter and only order new inserts. It means lower investment, shorter delivery time and reduced tools inventory. What is the productivity? --> With GEAR-SAF it is possible to machine the gear with only one pass with a really good finishing quality and close to final shape. It reduces dramatiacly the grinding time (if needed). What are the main Safety Engineering Department benefit versus its competitors? --> Safety is a French manufacturer with French factories and we can be very productive, reliable and versatile for the global market.

6 Safety France 51, rue de la Garenne Sèvres - France Tel.: +33 (0) Fax: +33 (0) info.safety@safety-cuttingtools.com Safety Impero Via Bachelet - Località Crocetta S. Polo (Piacenza) - Italia Tel.: Fax: info.impero@safety-impero.com Safety Deutschland Philipp - Reis - Str. 7 D Rodgau - Deutschland Tel.: +49 (0) Fax: +49 (0) info.safety-deutschland@safety-cuttingtools.com Safety Ibérica Pol. Ind. Roca c./ Verneda s/n Martorelles (Barcelona) - España Tel.: Fax: info.safety-iberica@safety-cuttingtools.com B-GEAR-08/11-ENG Safety China Tel.: Fax: info.safety-china@safety-cuttingtools.com

7 gear cutter definition data profil definition Workpiece Normal module Mn Material: Denomination/Hardness Number of teeth Z Gear thickness b Standard pitch diameter d Modification coefficient x machine Normal pressure angle αn Model Helix angle ß Spindle rotation CW/CCW Root diameter dfe Spindle power Addendum coefficient ha* kw Base diameter db Internal air? Y/N Outside/Inside diameter da Max/Min Distance between balls of diameter ø ø Max Min cutter Nom. Base. Tan. Length Over N teeth N Mounting bore diameter Mounting width Stock material before grinding q Mounting type Quality class Radial Keyway, Axial Keyway Standard Maximum or prefered cutter diameter Tip radius of the hob Default 0.38xMn r External gear Outside diameter (da) Root diameter (dfe) PROTUBERANCE Tip radius (r) Internal gear Tip radius (r) Root diameter (dfe) Inside diameter (da) Ball Ø COMMENTS Customer Service - Tel.: +33 (0) Fax: +33 (0)

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