The five specialists in Kirkel manufacture high-quality special tools in a very short time, either as one-offs or in small batches of up to about 500 tools per order. For the past three years—following the sudden death of the company’s founder—Katja Nikolaus has been running the operation with determination and energy alongside her sister Nathalie Schmieden and her mother Elisabeth Nikolaus. As she reports, the tool grinder is highly regarded by medium-sized and even larger manufacturing companies in the Saarland, Rhineland-Palatinate, Hesse, and Baden-Württemberg regions for its flexibility, reliability, and short response times. “The measuring, setting, and inspection units from ZOLLER have made a significant contribution to the continued success of our business model,” explains Katja Nikolaus.

As Katja Nikolaus explains, the tool grinders invested in a »»genius«« measuring machine as early as 2008. At the time, it was primarily the simple operation with the »pilot« software and the graphical, self-explanatory user interface that helped the specialists decide on this technology.

Another factor was that many clients in the region were already using ZOLLER measuring and presetting machines. “This allows us to tailor our quality assurance to our customers’ incoming inspections. In addition, customers place their trust in us much more quickly when they know that we measure and inspect our tools according to the same criteria as they do—and using the same measuring and inspection units,” explains Katja Nikolaus. 

Based on its positive experience with the »»genius«« measuring machine, the tool grinder in Kirkel invested in a universal »»smartCheck«« inspection and measuring machine in 2016. This now made it possible to measure significantly larger tools as well. The specialists also appreciate how especially simple the device's operation is. Furthermore, it has proven to be very flexible. 

The »pilot« software contains measurement cycles for a wide variety of geometries. The operator only selects the appropriate icon on the large touchscreen. The measurement cycle then runs fully automatically. The measuring machine displays the geometry to be measured—for example, a cutting edge—on the magnified screen and enters the data. This data is saved as a data record and can optionally be documented in a log.

Customizable and flexible 

Tool grinders also use the »»smartCheck«« measuring machine to optimize the grinding of special tools. They measure individual geometries, immediately detect deviations from the specified drawing geometry, and adjust the settings on the grinding machines accordingly. As Dirk Forster, a tool grinder in Kirkel, reports, this allows him to grind a special tool that exactly corresponds to the specifications in just a few steps. This is particularly crucial for short lead times and maximum flexibility when producing one-off pieces and small batches of special tools. “Thanks to the fast measurements and fully automated processes, we obtain reliable, concrete data in no time at all. We use this data to optimize the grinding programs and thus grind tool geometries at short notice that correspond exactly to the drawing data,” reports Dirk Forster.

As Dirk Forster confirms, measuring on the »»pomBasicMicro«« proves to be significantly better than working with the microscope that was previously used. “We work reliably and accurately, regardless of the skill and care of the personnel. In addition, we can measure with high accuracy. That was not possible with the microscope,” explains Dirk Forster. 

Assessing Microgeometries 

As an additional benefit, the »»pomBasicMicro«« inspection unit offers optical inspection of ground surfaces. This applies not only to tips and cutting edges but also to chamfers and grooves on small drills and milling cutters. Dieter Müller comments: “On the measuring machine, you can rotate and swivel the clamped tools in virtually any direction and focus on the different positions of the tools. This allows you to view all surfaces and individual geometries on the magnified screen. 

This also allows you to detect scratches, nicks, and tears caused by improperly dressed grinding wheels or unsuitable abrasives.” At Nikolaus Grinding Tech in Kirkel, tool grinders use these functions of the inspection unit to, for example, optimize the groove profile across the steps and the angle at the step for step drills with diameters as small as 0.3 and 1 mm.

Nikolaus Grinding Tech, a tool grinding company in Kirkel that currently employs five tool grinders under the leadership of Katja Nikolaus, Nathalie Schmieden, and Elisabeth Nikolaus, serves as a highly qualified partner to the regional manufacturing industry. 

Using 3D CAD/CAM systems, the specialists develop sophisticated special tools (ranging in diameter from 0.1 to approximately 32 mm) and grind them on high-quality 5-axis tool grinders (Anca). To optimize grinding processes in advance, they are dynamically simulated on the CAD/CAM systems. When grinding and regrinding special tools, the specialists in Kirkel support their clients with comprehensive technical service. 

For example, drawing on their expertise and experience, they suggest different improvements to cutting edges, chamfers, and groove geometries to extend the tool life of the special tools and optimize their process reliability. They also help improve entire production processes, for example by integrating additional manufacturing steps into a stepped tool or by adjusting tip and cutting edge geometries to minimize burr formation during drilling and milling.