In booth #237013 at IMTS 2024, Star Cutter Company is unveiling its newest generation tool grinder – the FLX, which will be shadow grinding throughout the show to demonstrate its capabilities.  This 5-axis grinder has been designed with a focus on flexibility, enabling users to modify features to exactly match their grinding needs. At the same time, the FLX has automation and wheel change features that make it well-suited for high-volume, lights-out manufacturing.

“The FLX is designed to accommodate up to 15 wheel pack locations and a robot that can handle both tool and grinding wheel changeovers,” said Aaron Remsing, Star Cutter product manager. “This allows the machine to produce up to 1200 tools (3-7mm diameters) before unloading. Additionally, the new wheel magazine design is achieving a 30% reduction in typical wheel changeover time.”

Key to the system’s performance is Flexium Pro CNC, the newest control platform from NUM, which offers a tenfold increase in computing power. This helps to streamline operations and allows for a reduction in power consumption. Additionally, Flexium Pro improves data security while using a smaller electrical panel footprint.

With a grind zone of up to 228 mm in length and 20mm in diameter, the FLX accommodates a wide variety of tool sizes. It also has two spindle options – a 7 kW, 24,000 RPM HSK synchronous for general manufacturing or a 15kW, 24,000 RPM HSK synchronous for manufacturing, regrinding and higher RPM applications.

The FLX grinder has an ergonomic design with adjustable features that allow personalized setup to ensure operator comfort. Additionally, the machine can be equipped with a selection of modular automation options that make field implementation easy while providing for optimal part quantity and wheel changing – accommodating wheels up to 6” in diameter.  The system flexibility makes it suited for either manned or unmanned production.

FLX is designed to be precise and accurate in both controlled and uncontrolled climate conditions, giving it broad application across industry, even in harsh environments. It features reduced warmup time, elimination of redundant chiller systems, and 35mm linear carriages for durable machine movement and longevity.

The FLX has a footprint of 72” W x 55” D (94.5” D with the automation model), and a height of 73.3”. Machines weigh 7,000 lbs. (9,000 lbs. with automation). Other options include a bolt-on tooling rail with T-slot construction, runout minimizer, and a two-wheel changer (for non-automated machines).