Gear manufacturing tools
roughing / finishing / checking / reconditioning
Our aim is simple: to
bring an economic
surplus to your
daily manufacturing
life.
The whole world of gear manufacturing tools
in your hands
Since 1949, Samputensili has been supplying a comprehensive range of tools and services for
the manufacture of gears, shafts, worms, rotors and other screw-type workpieces. Together with
Star Cutter, a well-trusted company based in Michigan, USA, Samputensili formed a joint-venture
in 2002 under the name of Star SU Llc. Initially responsible for the sales and distribution of
machines and tools in the North American market, the partnership between the two companies
has been extended to South America in 2014 with the creation of Star SU do Brasil and in China
in 2015 with the creation of Star SU China. Our tools are manufactured in state-of-the-art production plants, according to the the latest process technology.
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
Shaving cutters .......................................................................................................... 12
Master gears .............................................................................................................. 14
Ring and plug gauges................................................................................................ 16
Racks resharpening................................................................................................... 18
X-press delivery programme...................................................................................... 19
Coating technology ....................................................................................................20
New coating Altensa: boost your productivity ............................................................21
Service around the world ...........................................................................................22
Samputensili 3
HSS and carbide hobs
creating quality efficiently
Hob types
Involute gear hobs
Bore and shank-type hobs
Multi-gash and multi-start 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
Quality
A DIN 3968
AA DIN 3968
Samputensili 4
AAA Samputensili standards
A AGMA Standard 120.01
Modifications
Tooth tip chamfer
Protuberance
Topping / Semitopping
Full radius
Tip / root relief
Other modifications
Designs and dimensions
Depending on your application, we
optimise tool geometry in terms of
diameter, number of gashes and
number of starts in the following
ranges:
Module range
0.45 - 22.0 mm
Diameter range
40 - 300 mm
Usable length, max.
400 mm
Larger modules on request
Material
High-alloy HSS-PM steels
Carbides
MC90
Recommended coatings
Gold (TiN)
Futura Nano (TiAlN)
Alcrona Pro (AlCrN)
Altensa (AlCrNX)
Other coatings available on request
Worm gear hobs
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.
Due to the nature of this application,
our engineering department checks
all inquiries for feasibility and optimises tool functionality, taking into
account your specific clamping needs
and the optimum usable cutting length
of the tool.
Module range
Helix angle, max.
Length, max.
Shaft diam. min.
1.0 - 6.0 mm
15
deg
610
mm
18
mm
Other dimensions, and a wide
variety of shaft tapers, are available on request.
Samputensili 5
Hobs for large
gears and rotors
Samputensili represents the cutting
edge technology for hobs for large
gear modules.
Hobs can be supplied in heavy duty
design too, with a maximum of 3 cutting blades.
We recommend the best tool for your
particular gear cutting job by finding
the right tradeoff between productivity,
lot size, tool cost and cost per piece.
Samputensili
Sam
Sa
S
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put
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nsiililillii 6
DIN 3972, BP II / with protuberance
Module 6.0 - 22.0 mm
Also available in heavy-duty
design with up to 3 cutting blades
Milling cutters
including saw blade cutters
Our saw blade cutters are the number
one choice for precision in pitch, runout
and tooth height.
Our saw blade cutters produce saw
blades of a quality comparable to that
of ground saw blades. Saw blade cutters for hacksaw, bandsaw and circular
saw blades come in single or variable
pitch.
The unique production process provides the maximum usable tooth
length. This is especially important on
high-hook angle blades where the tooth
length is very short on the small diameter cutter end. We also design and
build spiral-tapered cutters to suit any
customers sharpening requirement.
Milling cutters at a glance
Types
Dimensions
Shell and shank
Straight and crowned forms,
cutters for steering racks
Interlocked sets
Single piece circular
Intermittent continuous feed
Special tooth forms
incl. chip breakers
Unground and ground forms
Standard or precision quality
Diameter, max.
Length, max.
Spiral gash, max.
250 mm
300 mm
20 deg
Coatings
TiN
TiCN
TiAlN
Altensa (AlCrNX)
We are now also offering ground formrelieved milling cutters for steering
racks, straight and crowned forms.
Samputensili 7
More than 100 years of combined
shaper cutter experience
Our wide range of shaper cutter types
features the brands Samputensili,
Fellows and Star-SU with the combined experience of more than 100
years in shaper cutter design and
manufacture.
Standard bore diameters
Profile modifications
Shaper cutter types
Taper shanks
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
Dimensions
Module min./max. 0.5 - 16.0 mm
Max. diameter
320 mm
Other dimensions on request
Samputensili 8
31.750 mm
44.450 mm
70.000 mm
100.000 mm
Other bore diameters on request
MK K 2
MK K 3
MK K 4
FK 1
FK 2
Semitopping
Protuberance
Topping
Modification of flank for tip and/or
root relief on gear
Modification of pressure angle
Combination of several of the
above modifications
Quality
A DIN 1829
AA DIN 1829
Standard profiles
Material
High-alloy HSS-PM steels
MC90
DIN 3972
DIN 3972
DIN 3972
DIN 3972
DIN 5480
BS 2062
BP
BP
BP
BP
I
II
III
IV
Coatings
Gold (TiN)
Futura Nano (TiAlN)
Alcrona (AlCrN)
Altensa (AlCrNX)
Other coatings on request
Disc-type shaper cutter, Gold coated
Deep-counterbore-type shaper cutter,
Futura-Nano coated
Shank-type shaper cutters, Gold and
Alcrona coated
Internal shaper cutter, Gold coated
Shaper cutter with block teeth
Keyway types
Type A
without
keyway
Type B
longitudinal
keyway
Type C
clutch
keyway
Type D
keyway, not
aligned
Type E
keyway aligned
on tooth vane
axis
Type F
keyway
aligned on
tooth axis
Samputensili 9
Strategic alliance for Scudding tools
Samputensili and Star SU have formed
an alliance with Profilator to manufacture Scudding tools for the global
market.
Scudding is a continual gear cutting
process which makes both the production of external and internal gears as
well as spur and helical gearing possible.
As another great advantage, the
Scudding 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.
Scudding
can compete with shaping,
broaching, and other gear cutting processes to produce gear and spline
teeth for reduced cycle times and tool
costs.
Samputensili 10
Application
Spur and Helical Involute Gears
and Splines
Tool Types
Wafer
Disc
Shank
Material
PM HSS
Super Alloy HSS
Carbide
MC90
Coating
Alcrona Pro (AlCrN)
Altensa (AlCrNX)
Scudding is much quicker,
more efficient and productive
The high number of cuts per time unit
not only leads to a very short cycle
time, it produces high quality gears
with a low surface roughness.
Machining Speed
Cuts per minute
Gear Quality
Surface Roughness
Modules
Max. Diameter - HSS
Max. Diameter - Carbide
Max. Shank Size
Bore Size Options
2,000 rpm
120,000
DIN 5-7
Rz 1-5
0.7 - 5 mn
200 mm
150 mm
150 mm
1.75 - 44.45 mm
Scudding Wafer Cutters
Scudding Shank Cutter
Scudding Disc Cutter
Samputensili 11
Patented solutions for chamfering,
deburring and rolling
Chamfering tools
Rolling tools
For spur or helical gears
For straight or inclined gear
lateral surfaces
For spur or helical gears
As single tool or separate tools
Rolling tools for burrs and internal
toothing
Deburring tools
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)
Chain sprocket deburring
and rolling tools
Developed exclusively to deburr chain
sprockets, the specially adapted form
of the SPR 1000 type has exactly the
same profile as the flank radius of the
gear tooth and therefore any burrs from
the lateral surfaces of the gear teeth.
The chain sprocket roller tool profile
also corresponds to the gear tooth profile. The special tapered form of the tool
tooth prevents material from building
up along the gear tooth profile during
the contemporary deburring operation.
These tools are ideal for Samputensili
chamfering machines with motorised
tool heads but they can be used on any
standard chamfering machine.
1
2
3
Secondary burr during
chamfering
Deburring the secondary burr on
gear lateral surfaces
Rolling the secondary burr on
gear flanks
Samputensili 12
Chamfer-roller tools
Why chamfer and deburr?
For gears with parallel chamfers
For gears with comma type
chamfers
A burr which is not removed may
break off during use and damage
bearings or gears in gearboxes.
Over-carbonizing may result in
too much pressure being exerted
on sharp gear lateral surfaces
which might then break.
A hardened burr may lead to premature wear of tools in subsequent finishing operations.
Removal of very sharp burrs
reduces the risk of tool handling
injuries.
With the patented Samputensili
chamfer-roller tool, you can chamfer
and roll your gears 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 utilises just one tool
head leaving the second tool
head free for another operation.
1+
1+3
1
+3
+
3
Secondary
chamfer
Workpiece after hobbing
Why roll?
The rolling operation serves to
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.
The rolling process levels out the
surface and causes the material
to sink.
Workpiece after chamfering and deburring
Rolling of a chain sprocket gear
Chamfer
Rolling is performed by a localised levelling out
action which may be described as a second
chamfer with a chamfering angle of about 1.
Tool groups
Back: Monoblock chamfering and deburring
solution on one tool head
Front: set of rolling tools on one tool head
Chamfering / deburring
Chamfering / deburring / rolling
Use of two tool heads
Subsequent operation: shaving or profile grinding
Use of three tool heads, one for each single tool
Rolling tool used as a third single tool with surface
contact between rolling tool and workpiece flank.
Subsequent operation Continuous generating
grinding, shave grinding, honing
Chamfering & deburring / rolling
Chamfering & deburring
Use of two tool heads, chamfer-deburring tool on one
tool head and rolling tool on a second tool head.
Subsequent operation Continuous generating
grinding, shave grinding
Requirements: without step, no use of any 1000 type
deburring tools
Monoblock solution
Use of one tool head mounted with a combined
chamfer-deburring tool
Requirements: without step, no use of any 1000 type
deburring tools
Subsequent operation: shaving or profile grinding
Chamfering & rolling / deburring
Chamfering & deburring & rolling
Use of two tool heads, chamfering tool with integrated
rolling tool on one tool head and deburring tool on a
second tool head.
Subsequent operation Continuous generating
grinding, shave grinding, honing
Monoblock solution
Use of one tool head mounted with a chamfer-roller
tool with a combined deburring tool.
Requirements: without step, no use of any 1000 type
deburring tools
Subsequent operation Continuous generating
grinding, shave grinding, honing
Samputensili 13
Shaving cutters guaranteeing superior quality
after each sharpening process
Shaving cutter types
Material
As one of the largest producers of
cutting tools worldwide, and with
particular expertise in shaving technology, we offer a wide range of shaving cutter types:
Choose from different conventional
HSS or powder metals.
Transverse
Diagonal
Diagonal-underpass
Underpass
Tangential
Plunge
Tool design and optimisation are
rooted in the longstanding experience of our shaving cutter design
engineers. Unique software developments implemented on our shaving
cutter grinding machines and test
programmes mean high precision
and efficient resharpening of your
tools.
Internal/external shaving
Unground or finished shaving cutters
All tools are supplied with inspection
and lead test charts.
Dimensions
Module
Max. width
Outside diameter
0.7 - 10 mm*
65 mm
70 - 330 mm
*All shaving cutter serrations from 0.7 to 0.99 are
formed by turning
Samputensili 14
Design and optimisation
Sharpening diagrams for
continuous life cycle control
Samputensili delivers each tool with
a user-friendly sharpening diagram,
enabling you to monitor the life cycle
of your tool and directly control the
sharpening process, providing you
have the right equipment for this high
quality process.
Diagonal shaving
Plunge shaving*
Gear at end
of stroke
Point of contact
at beginning of
shaving
Shaving cutter
Shaving cutter
Gear at start
of stroke
Gear at end
of stroke
Gear at start
of stroke
Point of
contact at beginning and end of
shaving
Underpass shaving
Diagonal-Underpass
shaving**
Tangential shaving**
Shaving cutter
Gear at end of stroke
Shaving cutter
Gear at end
of stroke
Point of contact
at beginning of
shaving
Point of contact
at end of
shaving
Shaving cutter
Point of contact at
beginning of shaving
Gear at end of stroke
Gear at start of stroke
Point of contact at end of
shaving
90
Gear at start
of stroke
Point of
contact at end
of shaving
r
Gear at start
and end of
stroke
Point of contact
at end of shaving
Gear at start of stroke
90
Point of
contact at
beginning and
end of shaving
Shaving cutter
Transverse shaving
Point of contact at
beginning of shaving
* particularly used in the automotive industry.
** these shaving methods are only application variants which are rarely used today.
Twisting profiles
made easy
Samputensili software solutions are
the cornerstone of our mission to provide good service; tool design and
optimisation are based on unique inhouse software solutions implemented
on our shaving cutter grinding machines.
In any case, Samputensili shaving cutters are profile ground and sharpened
on the most modern and productive
machine available on the market
made by Samputensili!
Sharpening and in-machine measurement of shaving cutters on the GS 400
Samputensili 15
Precision tools for measuring, setting,
calibration and correction
Types
Material
Ring gauges
Master gears for single and double
gear flank and runout measurement
Setting masters to adjust and calibrate quality control instruments
Rolling gears to measure noise
Rolling gears to reduce burrs and
nicks
Plug and ring gauges
Gauge steel
High speed steel
PM steel
Module
Ring outside dia.
Coatings
Straight and helical teeth
Involute and special profile
(*) depending on outside diameter
Dimensions
Module
Diameter
Tooth width
Helix angle
0.8 - 6.0
40 - 300
4 - 80
0 - 45
Quality: 2-6, DIN 3962
Geometry: DIN 3970
or according to drawing
Corrections
Flank corrections
Topological corrections
Samputensili 16
mm
mm
mm
deg
PVD coatings for HSS/PM master
gears only
Gold (TiN)
Futura (TiAlN)
Gauge master gears steel do not withstand temperatures exceeding 450C
and are therefore unsuitable for coating. Protective coatings may only be
applied to HSS/PM master gears.
Plug gauges
Module
Pitch diameter
0.5 6.0 mm
20 150 mm
0.5 7.0* mm
20 200 mm
Consultancy, analysis,
optimisation
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.
Regrinding & recoating
Master gears wear with use and need
regrinding to ensure continued quality performance. Samputensili is wellequipped for this task.
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 throughout the whole production process.
Certified quality
Packaging
Master gear design and production
processes are all carried out using
special Samputensili software and
modern manufacturing methods.
All Samputensili checking and setting
master gears are fully tested on CNC
inspection equipment and are delivered with a certificate of conformity.
We produce master gears on specially
designed and optimised machinery
in classes from 2 to 6 to DIN 3962,
AGMA and BS standards.
Our precision tools are shipped and
transported in a specially developed
packaging system.
Drawings, documents and checking
protocols are safely stored away in a
separate pocket integrated in the tool
box lid.
We therefore guarantee both the
accuracy of our master gears and the
quality of the whole manufacturing
process.
Samputensili 17
Rack cutters resharpening
Samputensili supplies its customers with a high efficient resharpening
service of cold forming racks in our
Brazilian plant.
These high precision tools guarantee
highest contact ratios during forming
with minimal thermal effects. Grooves
are kept free from debris.
Axial tapering enables easy fitting of
spline shafts. Simultaneous machining
of several profiles is possible.
Types for
Gear profiles
Serrations
Grooves
Threads
Quality
DIN 5480
ISO 4156
GOST 6033-51
ANSI B 92.1-1970
ANSI B 92.2M-1980
Designs and dimensions
Module range
0.3 - 2.0
Workpiece length, max. 1,000
Profile length, max.
180
Helix angle, max.
< 25
Pressure angle
> 25
Samputensili 18
mm
mm
mm
deg
mm
Coating technology
Sharpened tools
must deliver the
same performance
as coated new
tools.
To ensure a manufacturing line performs to plan, sharpened tools must
deliver the same results as coated new tools.
In collaboration with the worlds leading manufacturers of coating technology, we optimise innovative coatings for gear cutting tools to improve
abrasion resistance, wear resistance and consequently tool life. Automated
cleaning equipment further optimises 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 antiwear coatings are made available to you immediately.
Samputensili 19
New coating Altensa
Boost your productivity!
The new coating ALTENSA by Oerlikon
Balzers is the most innovative coating
one can currently find in the market.
These are just some of the main
advantages in utilizing ALTENSA on
our tools:
Its characteristics enable to apply high
speeds, obtaining huge productivity
gains, time savings and cost efficiency.
Reduced machining cost
Reduced wear at high speed
Longer tool life
Significant improvement for highest
cutting speed conditions for all
substrate materials (PM-HSS, MC90,
carbide)
Increased productivity
ALTENSA is ideal for markets which
need high cutting speed such as
automotive. It is recommended in the
following processes:
Hobbing
Shaping
Scudding
Samputensili is always at the state of
the art of technology in order to provide
the best solution possible!
Save up to 20% of your
production costs by
increasing your cutting
speed
Samputensili 20
Alcrona Pro
200 m/min
Altensa
300 m/min
Standard coatings guide
Gold
Alcrona Pro
Altensa
Titanium Nitride
Aluminum Chromium Nitride
Aluminium Chromium Nitride
(TiN)
(AlCrN)
(AlCrNX)
2,500
3,200
3,800
0.4
0.35
0.35
Residual compressive stress (GPa)
- 2.5
-3
-5
Layer thickness (um)
1-4
2-5
2-5
Temperature resistance, max. (C / F)
600 / 1,100
1,100 / 2,000
1,200 /2,100
Colour
Gold yellow
Bright grey
Grey
Tools coated with ALCRONA
PRO can be run with much
higher cutting speeds and
feeds, so the potential of
modern machine tools is
tapped to a clearly greater
degree.
Tools coated with ALTENSA
can work at higher cutting
speed than ALCRONA
PRO which caters to latest
generation machining
centres.
Hobs
Hobs
Hobs
Shaper cutters
Shaper cutters
Shaper Cutters
Composition
Microhardness (HV 0.05)
Friction coefficient on steel (dry)
Characteristics
Application
The proven coating for
general metalworking processes. High hardness and
a low friction coefficient
enhance wear resistance.
Remarkably low chemical
affinity with most metals.
Deburring tools
Scudding tools
Master gears/rolling tools
Process
Structure
Wet cutting (HSS)
Dry cutting
(HSS, Carbide, MC 90)
Dry cutting
(HSS, Carbide, MC 90)
General purpose
Wet cutting
(HSS, Carbide, MC 90)
Wet cutting
(HSS, Carbide, MC 90)
Single-layer
Single-layer
Nano-layer
Other coatings available
on request
Samputensili 21
With you all the way
throughout the life of your tool
With Samputensili tool service, you
benefit from more than 50 years of experience in tool design, manufacture
and testing, as well as comprehensive tool management know how. Today, some of the worlds leading gear
manufacturers rely on Samputensili to
manage special tool cribs or to handle their complete tool supply through
commodity management supply systems.
Services
Samputensili CMS
Project consultancy, design and
application testing
+ Lower direct and indirect labour
costs and lower indirect charges.
Sharpening of hobs, shaper cutters and shaving cutters
Regrinding of master gears
+ Reduced tool storage costs.
+ Quality guaranteed by the
original manufacturer throughout
the complete life cycle of the tool.
Stripping, preparation and recoating of tools at our in-house coating centres
+ Longer tool life.
+ Complete range of services for
gear tools from a single source.
Stripping, preparation and recoating of CBN- and diamondplated
tools
Pickup and delivery service, to
and from your tool crib
CMS for tool groups and product
life cycle management of single
tool types.
Samputensili 22
Standard tool coatings
Gold (TiN)
Futura Nano (TiAlN)
Alcrona Pro (AlCrN)
Altensa (AlCrNX)
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.
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Jundiai (Sao Paulo)
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Keep a check on maintenance costs.
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Samputensili Total Tool Life Cycle
Management meets your every production need by optimising each tool
life cycle step and enhancing the costper-piece performance of your tools.
By guaranteeing a certain cost-perpiece, you need no longer worry about
actual tool cost, potential tool life or
future servicing requirements.
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Samputensili 23
Star SU LLC
5200 Prairie Stone Parkway, Suite 100
Hoffman Estates, IL 60192
USA
Tel.: +1 (847) 649 1450
Fax: +1 (847) 649 0112
[email protected]
Star SU International Trading (Shanghai) Co. Ltd.
Shenxia Road, 358 Shanghai Forward High
Tech Zone, Jiading District,
201818 Shanghai - P.R. China
Tel.: +86 21 59900890
Fax: +86 21 59900887
[email protected]Samputensili Beijing
Room 1801/1802, Jing Tai Tower,
No. C24 Jian Guo Men Wai Avenue,
100022 Beijing - P.R. China
Tel.: +86 10 6515 6349 - 6515 6350
Fax: +86 10 6515 7150
[email protected]
Star SU Industria de Ferramentas Ltda.
Rod. Dom Gabriel Paulino
Bueno Couto Km 66,3 - C.P. 849
CEP13201 - 970 Jundiai, SP, Brazil
Tel.: +55 (011) 21 36 5199
Fax: +55 (011) 4582 7921
[email protected]SU Korea Co. Ltd.
4 MA- 319 Sihwa Industrial Complex
703-12, Sung-Gok Dong An-San City
Kyungki-Do, Rep. of Korea
Tel.: +82 (031) 497 18 11
Fax: +82 (031) 497 18 15
[email protected]Samputensili GmbH
Marienberger Str. 17
09125 Chemnitz
Germany
Tel.: +49 (0371) 576 257
Fax: +49 (0371) 576 259
[email protected]
Samputensili France S.a.r.l.
79 rue de la Tour
42000 Saint Etienne Cedex
France
Tel.: +33 (0477) 92 80 50
Fax: +33 (0477) 93 72 03
[email protected]Samputensili Equipment & Tools Pvt. Ltd.
246/4, Hinjewadi Gaon, Tal. Mulshi,
411057 Pune
India
Tel.: +91 9764911726
[email protected]www.samputensili.com
tools_en_v005
www.sampspa.com
SAMP S.p.A.
Via Saliceto, 15
40010 Bentivoglio (BO)
Italy
Tel.: +39 (051) 63 19 411
Fax: +39 (051) 37 08 60
[email protected]