The five specialists in Kirkel produce high-quality custom tools in a very short time, either as one-offs or in small batches of up to approximately 500 tools per order. For the past three years, following the sudden death of the company’s founder, Katja Nikolaus has been running the business with determination and energy alongside her sister Nathalie Schmieden and her mother Elisabeth Nikolaus. As she reports, the tool grinder is highly valued by medium-sized and larger manufacturing companies in the Saarland, Rhineland-Palatinate, Hesse, and Baden-Württemberg regions for its flexibility, reliability, and quick response times. “The measuring, setting, and inspection devices 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 back in 2008. At the time, it was primarily the ease of use with the »pilot« software and the graphical, self-explanatory user interface that contributed to the specialists’ decision to choose this technology.

Another factor was that many clients in the region were already using ZOLLER measuring and adjustment equipment. “This allows us to tailor our quality assurance to match our customers’ incoming inspections. In addition, customers trust us much more quickly knowing that we measure and inspect our tools using the same criteria as they do and on the same measuring and inspection equipment,” explains Katja Nikolaus. 

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

The »pilot« software contains measurement cycles for a wide variety of geometries. The operator simply selects the appropriate icon on the large touchscreen. The measurement cycle then runs fully automatically. The measuring device displays the geometry to be measured—such as a cutting edge—on the magnified screen and captures the data. This data is saved as a data set and can optionally be documented in a report.

Customizable and flexible 

Tool grinders also use the »smartCheck« measuring device 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 precisely meets the specifications in just a few steps. This is particularly crucial for short lead times and maximum flexibility when producing one-offs and small batches of custom tools. “Thanks to the fast measurements and fully automated processes, we obtain reliable, concrete data in no time. 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 with 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 staff. In addition, we can take highly precise measurements. That wasn’t possible with the microscope,” explains Dirk Forster. 

Assessing microgeometries 

As an added benefit, the »pomBasicMicro« inspection device 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 device, you can rotate and swivel the clamped tools almost at will and focus on the tool’s various positions. This allows virtually all surfaces and individual geometries to be viewed on the magnified screen. 

This also allows you to detect scratches, nicks, and chips caused by improperly dressed grinding wheels or unsuitable abrasives.” At Nikolaus Grinding Tech in Kirkel, tool grinders use these functions of the inspection device to, for example, optimize the groove path 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 currently employing 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. 

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

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