Are you still measuring, or have you already started milling? For the untrained eye, a crankshaft cutter might just look like a big, heavy disc with multiple blades. But professionals know that crankshaft milling cutters are highly specialized tools that require strict tolerances—especially when it comes to radial and axial runout.

A full set of crankshaft milling cutters can cost five digits or more, which means every user wants these expensive tools to perform perfectly on the machine and last as long as expected. To achieve this, proper setup is essential. That means the crankshaft cutter must be pre-set and measured before use. But how much does this preparation really cost? The simplest—and riskiest—approach is to rely solely on the tool manufacturer’s claims, the quality of the indexable inserts, or the skill of the assembler. However, we all know that this isn’t reliable. Who today would take such a big risk? Some may try using a granite slab and a ruler, but this method is outdated and unable to meet modern demands. It's not only inaccurate but also time-consuming and subjective, leaving no clear record of the results. Using presetting and measuring devices equipped with image processing technology offers a more accurate and automated solution. However, not all systems are equal. Traditional devices often struggle with multi-blade tools, where the spacing between blades is tight. The overlapping images from adjacent blades can obscure the target blade, making it hard to focus and measure accurately. This process is complicated and often beyond the capabilities of most systems. But is it impossible to measure crankshaft cutters properly? Of course not!

Venturion

As a global leader in precision tool presetting and measurement, ZOLLER has been offering advanced solutions for crankshaft milling and turning tools for over a decade. Their equipment, such as the »gemini« and Venturion 800, not only allows full positioning, focusing, and measuring of the cutter but also includes automatic blade cleaning.

Gemini

ZOLLER has further improved its systems with new control electronics and software, such as »pilot 3.0«, which enhances focusing and measurement accuracy for multi-blade tools. When measuring a crankshaft cutter using a ZOLLER device, the tool is placed on the machine, fixed in position, and the data set is loaded. The measurement then begins automatically. **Unique Results:** - For example: Measure 120 blades (or rows) in just 70 seconds with micrometer-level precision. **Measurement Items Include:** - Vertical dimension of each blade - Lateral dimensions of each blade - Blade radius per blade - Blade angle of each blade - Radial runout - Axial runout Once the measurement is complete, the results are displayed on the screen, and the »pilot 3.0« software visualizes them in tables or charts. If any blade is out of tolerance, the user can easily select it, and the system automatically positions it within the camera’s view. This makes it simple to clean, replace, rotate, or reset the blade.

ZOLLER’s advanced technology in crankshaft milling setup and measurement is not limited to just crankshafts. It can be applied to a wide range of precision tools. With the introduction of the new control unit »pilot 3.0«, ZOLLER experts in Leidelsheim continue to deliver groundbreaking innovations and unmatched solutions, creating real value for users around the world.

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