PRODUCTION ENGINEERING

DAY 10
Shaper machine
 The shaper machine is a reciprocating type of machine basically used for
producing the horizontal, vertical or flat surfaces.
 The shaper holds the single point cutting tool in ram and workpiece is fixed in the
table.

Clapper mechanism
• Clapper box carries the tool holder. The main function of the clapper box is to provide
clearance for tool in return stroke.
• It prevents the cutting edge dragging the work piece while return stroke and prevent the
tool from wear.

Classifications of Shapers
1. According to the ram driving mechanism

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 (a)Crank shaper: In a crank shaper, a crank and a slotted lever quick return motion
mechanism is used to give reciprocating motion to the ram. The crank arm is adjustable
and is arranged inside the body of a bull gear (also called crank gear).
(b) Geared shaper: In a geared shaper, the ram carries a rack below it, which is driven by
a spur gear. This type of shaper is not widely used.
(c) Hydraulic shaper: In a hydraulic shaper, a hydraulic system is used to drive the ram.
This type of shaper is more efficient than the crank and geared shaper.
2. According to position and travel of ram
(a) Horizontal shaper: In a horizontal shaper, the ram moves or reciprocates in a
horizontal direction. This type of shaper is mainly used for producing flat surfaces.
(b) Vertical shaper: In a vertical shaper, the ram reciprocates vertically in the downward
as well as in upward direction. This type of shaper is very convenient for machining internal
surfaces, keyways, slots or grooves.
3. According to the direction of cutting stroke
(a) Push-Cut shaper: In a push-cut shaper, the ram pushes the tool across the work during
cutting operation. In other words, forward stroke is the cutting stroke and the backward
stroke is an idle stroke. This is the most general type of shaper used in common practice.
(b) Draw-cut shaper: In a draw-cut shaper, the ram draws or pulls the tool across the work
during cutting operation. In other words, the backward stroke is the cutting stroke and
forward stroke is an idle stroke.
4. According to the design of the table
(a)Standard or plain shaper: In a standard or plain shaper, the table has only two
movements i.e., horizontal and vertical, to give the feed. It can not be swiveled or tilted.
(b) Universal shaper: In a universal shaper, in addition to the above two movements, the
table can be swiveled about a horizontal axis parallel to the ram and the upper portion of
the table can be tilted about the other horizontal axis perpendicular to the first axis. This
type of shaper is mostly used in tool room work.

Specifications of a Shaper
1. Maximum length of stroke is millimeters,
2. Size of the table, i.e., length, width and depth of the table,

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 3. Maximum vertical and horizontal travel of the table,
4. Maximum number of strokes per minute,
5. Power of the drive motor,
6. Type of quick return mechanism.
7. Floor space required, and
8. Weight.

Ratchet and Pawl Mechanism

(Automatic Feed Mechanism for the Table)

 The table of a shaping machine travels in a cross direction when the crossfeed screw
is rotated.
 The cross feed screw is attached to the ratchet wheel.
 A spring loaded ‘pawl’ is positioned to be placed between the teeth of the ratchet
wheel.
 The pawl is housed within a frame known as rocker arm.
 The pawl makes the ratchet to rotate by a small amount in one direction only.
 As the cross feed screw is attached to the ratchet wheel, the rotation of the ratchet
wheel will make the table to move in a cross direction.

PLANER
 The planer (also called planing machine) is a machine tool used to produce plane and
flat surface by a single point cutting tool.
 It is similar to a shaper but its size is very large and is adopted for producing flat
surfaces of much larger work than a shaper.
 The fundamental difference between a planer and shaper is that in a planer, the tool
remains stationary and the work reciprocates whereas in the shaper, the work remains
stationary and the tool reciprocates.
Types of Planers
1. Standard or double housing planer
2. Open side planer

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 3. Pit planer
4. Edge or plate planer
5. Divided table planer

Standards or double housing planer

 The columns are connected at the top by a cast iron support.
 The table reciprocates on accurate guide ways provided on a long heavy bed.
 The two tool heads which carry the tool are mounted on the cross rails.
 These tools may be fed either by hand or by power in crosswise or vertical direction.

Principal Parts of a Planer

1. Bed:
 The bed of a planer is a box like casting having cross ribs.
 It provides the foundation for the machine and supports the housing and all other
moving parts.
 The upper part of the bed is provided with precision V- type guide ways on which the
table slides.

2. Table:
 The planer table is a heavy rectangular precision machined casting.
 It reciprocates along the ways of the bed and supports the work.
 The top face of the table is provided with T-slots and holes uniformly spaced for fixing
the work and work holding devices over the table with the help of T-bolts, clamps etc.
 The table may be driven by rack and gear, by rack and double helical gear or by
hydraulic system.
3. Housing (Column)
 The housings are rigid column-like castings placed on each side of the bed.
 The front face of the housings is accurately machined to provide precision ways.
 The housings enclose the cross-rail elevating screws, vertical and cross-feed screws for
the tool heads, counter balancing weights for the cross-rail etc.
4. Cross-rail:

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  The cross-rail is mounted on the precision-machined ways of the two housings.
 It may be raised or lowered on the housings to accommodate work of different heights
on the table and to allow for the adjustment of the tools.
5. Tool heads:
 The tool heads are mounted on the cross-rail or housings by means of a saddle, which
slides along the rail or housing ways.
 The saddle may be made to move transversely on the cross-rail to give cross feed.
 Two tool heads are provided on the cross-rail so that the two tools may remove the
material from the work simultaneously.
 In addition to these two-tool heads, there are other two-tool heads which are mounted
on each housing.

Size and Specifications of a Planer

1. Width of the table in mm,

2. Maximum distance of the table to the cross-rail in meters,
3. Maximum stroke of the table in mm.
4. Length of bed,
5. Length of the table,
6. Type of drive,
7. Power of the motor, and
8. Number of speed and feed etc.

Planer Tools

 The planer tools are mostly made of high speed steel.

 The cemented carbide tipped tools are also used on planers for production work.
 The planer tools are similar to those used on shaper, but, as the depth of cut are heavier
and cutting strokes are large, the planer tools are large in size.
 A planer tool many be classified as roughing or finishing and right hand or left hand
type.

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 Cutting speed

 In both shapers and planers, the tool or table starts from rest, picks up speed and then
again slows down to zero speed during the forward or cutting stroke.
 It is customary to calculate cutting speed on the basis of average speed during the
forward stroke. Feed and depth of cut are both expressed in mm.
 In case of feed, it is the lateral distance moved by the tool (on the cross-rail) per cutting
stroke.

Difference b/w planer and shaper

1. It is a heavy duty machine tool. 1. It is a light duty machine tool.

2. It requires more floor area.
3. It is adopted for large works.
4. More than one cutting tool
can be used at a time.
5. Tool is fixed and work moves.
6. Planer table is either driven
by gears or by hydraulic means.
7. Heavier feeds are applied.
8. It can take deep cuts.
9. Work setting requires much
of skill and takes longer time.
10. Tools used are of larger size.
2. It requires less floor area.
3. It is used for small works.
4. Only one cutting tool is used at a time.
5. Work is fixed and the tool moves.
6. It is normally driven by crank and slotted lever
quick return motion mechanism.
7. Lighter feeds are applied.
8. It cannot take deep cuts.
9. Work may be clamped easily and quickly.
10. Tools used are of smaller size.

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