Introduction to Manufacturing Processes

(Shaping Operation)
 Shaping and planning
• Shaping and planing are similar Shaping
operations, both involving the use of a
single-point cutting tool moved linearly
relative to the workpart.
• A straight, flat surface is created by this
action.
• In shaping, the speed motion is
accomplished by moving the cutting
tool.
Planning
• In planing, the speed motion is
accomplished by moving the workpart.
• Cutting tools used in shaping and
planing are single-point tools.
• These machine tools are limited to low
speeds due to their start-and-stop
motion
Figure 1 : (a) Shaping and (b) Planing
 Shaping

• Shaping is performed on a machine tool called a shaper.

• The components of the shaper include a ram, which moves relative to a

column to provide the cutting motion, and a worktable that holds the
part and accomplishes the feed motion (mm/stokes).

• Motion of the ram

Forward stroke to achieve the cut
Return stroke to reset for the next pass

• The drive mechanism for the ram can be either hydraulic or mechanical.

• Hydraulic drive has greater flexibility in adjusting the stroke length and
a more uniform speed during the forward stroke, but it is more
expensive than a mechanical drive unit.

• Drives are designed to achieve higher speeds on the return (noncutting)

stroke.
 Shaping

Figure 2: Components of a shaper

 Planing
• The machine tool for planing is a planer.

• Cutting speed is achieved by a reciprocating worktable that moves

the part past the single-point cutting tool.

• Construction and motion capability of a planer permit much larger parts

to be machined.

• Types
Open-side planer or single column planer
Double column planer

• Single column planer has a single column supporting the cross-rail on

which a tool head is mounted.

• The configuration of the open-side planer permits very wide workparts

to be machined.
 Planing

Figure 3: Open side Planer

 Working principle of shaping machine

• The central large bull gear receives its rotation from the motor
through the belt-pulley, clutch, speed gear box and then the
pinion.

• The rotation of the crank causes oscillation of the link and

thereby reciprocation of the ram and hence the tool in straight
path.
Working principle of shaping machine

Figure 5: Kinematic diagram of a shaping machine

 Applications of shaping machine

Machining flat surfaces in horizontal, vertical and inclined planes.

Horizontal surface Vertical surface

Inclined surface

Figure 6: Machining of flat surfaces in shaping machines

 Applications of shaping machine

Forming grooves bounded by short width curved surfaces by using single

point but form tools.

Figure below shows how (a) oil grooves and (b) straight tooth of spur gears
can be made in shaping machine

Grooving
Straight tooth cutting

Figure 8: Making grooves and gear teeth cutting in shaping machine by form tools.
 CUTTING TOOL MATERIAL

The material of the cutting tool used in a shaping machine should

have more hardness and temper

The shaper tools are made of the following materials:

1. High Carbon Steel

2. High Speed Steel

3. Carbide tool

4. Stellite tool
 SAFETY PRECAUTIONS:

1. No alteration or adjustment should be done on the machine parts while the machine is working
2. The machine has to be stopped before cleaning the metal
3. The sharp edges of the work should be handled with care
4. The measuring of the work should be done only after the machine is switched off
5. The operator should not seek the assistance of others for starting and stopping the machine
6. Machining of precise parts and internal surfaces of the work piece are to be carried out with
great care and attention
7. The operator should stay away from direction of the ram movement
 References
A B Chattopadhyay, Metal cutting and machine tool, Online
course, https://onlinecourses.nptel.ac.in

Mikell P. Groover, Fundamental of modern manufacturing:

manufacturing: materials, processes and systems, 4TH edition,
Wiley publications.