The five specialists in Kirkel manufacture high-quality special tools within a very short time, either as individual items or in small series of up to around 500 tools per order batch. Following the sudden death of the company's founder, Katja Nikolaus has been running the business decisively and energetically for the past three years together with her sister Nathalie Schmieden and her mother Elisabeth Nikolaus. She reports that 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 short response times. "The measuring, setting, and inspection devices from ZOLLER have made a significant contribution to the ongoing success of our business concept," 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 in favor of this technology.

Another criterion was that numerous customers in the region were already working with ZOLLER measuring and adjustment devices. "This allows us to tailor our quality assurance to the incoming inspections at our customers' premises. In addition, customers trust us much more quickly when they know that we measure and test our tools according to the same criteria as they do and also use the same measuring and inspection equipment," 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 device in 2016. This now made it possible to measure significantly larger tools. The specialists also appreciate the particularly simple operation of this device. In addition, it has proven to be very flexible. 

The »pilot« software contains measuring cycles for a wide range of geometries. The operator simply selects the appropriate icon on the large touchscreen. The measuring cycle then runs completely automatically. The measuring device displays the geometry to be measured, for example a cutting edge, on the enlarged screen and records the data. This data is stored as a data set and can be documented in a report if desired.

Individual 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. As Dirk Forster, a tool grinder in Kirkel, reports, this allows him to grind special tools that precisely meet the specifications in just a few steps. This is particularly important for short throughput times and maximum flexibility when it comes to individual tools and small series. "Thanks to the fast measurements and fully automated processes, we obtain reliable, concrete data within a very short time. We use this data to optimize the grinding programs and thus grind tool geometries that correspond exactly to the drawing data at short notice," reports Dirk Forster.

As Dirk Forster confirms, measuring with the »pomBasicMicro« is significantly better than working with the microscope that was previously used. "We work reliably and accurately, regardless of the skill and diligence of the staff. We can also take highly accurate measurements. That wasn't possible with the microscope," explains Dirk Forster. 

Assessing microgeometries 

As an additional advantage, 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 different positions of the tool. This allows you to view almost all surfaces and individual geometries on the magnified screen. 

This also allows you to detect scratches, nicks, and breakouts caused by inadequately dressed grinding wheels or unsuitable abrasives." At Nikolaus Grinding Tech in Kirkel, tool grinders use these functions of the inspection device to optimize the groove pattern across the steps and the angle at the step, for example, in step drills with diameters of only 0.3 and 1 mm.

The tool grinder Nikolaus Grinding Tech in Kirkel, which currently has five tool grinders under the leadership of Katja Nikolaus, Nathalie Schmieden, and Elisabeth Nikolaus, is a highly qualified partner to the regional manufacturing industry. 

The specialists develop sophisticated special tools (between 0.1 and approx. 32 mm in diameter) on 3D CAD/CAM systems and grind them on high-quality 5-axis tool grinding machines (Anca). In order 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 extensive technical service. 

For example, based on their expertise and experience, they suggest various improvements to cutting edges, chamfers, and groove geometries in order to extend the service life of the special tools and optimize their process reliability. They also help to 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.