MP GTU Study Material E-Notes Unit-6 06042020034404PM

Contents
6.1 Introduction ........................................................................................................................................ 6.2

6.2 Principle Parts of Shaper Machine ..................................................................................................... 6.2
6.3 Classification of Shaper ..................................................................................................................... 6.4
6.4 Shaper Mechanism ............................................................................................................................. 6.5
6.5 Feed Mechanism ................................................................................................................................ 6.9
6.6 Shaper Operations ............................................................................................................................ 6.11
6.7 Introduction to Planer Machines ...................................................................................................... 6.13
6.8 Types of Planing Machines .............................................................................................................. 6.14
6.9 Main Parts of planer ......................................................................................................................... 6.16
6.10 Planer Mechanism ............................................................................................................................ 6.17
6.11 Advantages and Disadvantages of Planer ........................................................................................ 6.21
6.12 Planer operation................................................................................................................................ 6.21
6.13 Comparison between Shaper and Planer: ......................................................................................... 6.22
6.14 Introduction to Slotting Machines .................................................................................................... 6.22
6.15 Types of Drives ................................................................................................................................ 6.23
6.16 References ........................................................................................................................................ 6.24
6.1 Introduction
 A shaping machine is a reciprocating type of machine tool used for producing flat Surfaces in horizontal,
vertical or angular planes on the small to a medium-sized workpiece.
 It is also used for machining convex and concave surfaces, for key-way cutting, slotting, grooving, etc.
 In shaper, the work is held on the machine table and the ram carrying the tool moves forward and backward
over it during the cutting action in reciprocating motion Refer Fig.6.1
Fig.6.1 – Principle of working of shaper
 As each chip is cut-off, ram and tool return to the end of the stroke and the work is positioned for another
cut.
 This involves moving the table horizontally by an amount equal to one chip thickness so that the work is
ready for the next cutting stroke.
 The machining is performed during the forward stroke only and the return stroke is idle.
6.2 Principle Parts of Shaper Machine
Fig.6.2 – Horizontal shaper machine
1. Base
 The base is a heavy cast iron body that acts as a support for all the fixed and operating parts of the machine
which are mounted on it.
2. Column
 The column is a hollow structure consisting of two walls and cast from cast iron.
 It is a rigid structure and gives support to the ram on its top way and is supported by the base.
 There is a cross-rail carrying the table and the drives, to move the table up and down or crosswise.
Prof. Paras G. Vegada Department of Mechanical Engineering

6.2
Manufacturing Process (3141908) | Unit-6 Shaper, Planer and Slotter
 On the left-hand side of the column, a lid is provided for inspection and oiling of the internal mechanisms.
 For operating the machine, levers and handles are provided on the other side of the column.
3. cross rail
 Cross rail is a box-like structure over which the saddle slides horizontally.
 It is mounted on the front vertical guide-ways of the column.
 The table cross feed screw and the cross rail vertical feed screw are housed inside it.
4. Saddle
 The saddle is mounted on the cross oil.
 By rotating the crossfeed screw by hand or by power, the saddle moves in a cross-wise direction.
5. Table
 The table is made of cast iron and it is also a box-type structure,
 It holds and supports the workpiece during the operation and slides along the cross rail to provide feed to the
workpiece.
6. Ram
 Ram is a reciprocating member and carries the shaper head in its front on which the cutting tool is mounted.
 It is semi-cylindrical in form and slides on the accurately machined guideways provide on the top of the
column.
7. Shaper head (Tool head)
 Tool head is clamped firmly to the front of the ram and consists of a tool slide, tool post, and clapper box.
 The tool head can be swiveled to any angle to enable the tool to take angular cuts. Ref Fig. 6.3.
Fig.6.3 – TooI head

6.3
 Vertical feed to the tool is given by the vertical tool feed screw and the slide movement can be measured by
using a micrometer dial near to the handle.
 The apron is clamped to the vertical slide by clamping screw.
 Apron consists of a clapper box, clapper block, and a tool post.
 The clapper block is connected to the clapper box by using a hinge pin.
 During the forward cutting stroke of the ram, the clapper block is rigidly supported in the clapper box and
on the return stroke, the block hinges outwards swinging on the hinge pin.
6.3 Classification of Shaper

Shapers are classified in a number of ways as follows:
1. According to the type of mechanism used for giving reciprocating motion to the ram
a. Crank type
b. Geared type
c. Hydraulic type
2. According to the position and travel of the ram
a. Horizontal type
b. Vertical type
c. Traveling head type
3. According to the type of design of the table
a. Standard shaper
b. Universal shaper
4. According to the type of cutting stroke
a. Push type
b. Draw type
a. Crank Shaper
 This is the most common type of shaper.
 In this, a single point cutting tool is given a reciprocating motion equal to the length of stroke desired and
the work is clamped on the table.
 The crank shaper employs a crank mechanism for converting a circular motion of a large gear, called a bull
gear, to reciprocating motion of the ram.
 The bull gear receives power from the individual motor.
b. Geared shaper
 ln this shaper, the circular motion of an electric motor is converted into reciprocating motion of the ram by
means of a rack and pinion.
 The rack teeth, which are cut directly below the ram, mesh with a spur gear.
 The pinion meshing with the rack is driven by the gear train.
 This type of shaper is not widely used.

6.4
c. Hydraulic shaper
 In hydraulic shaper, reciprocating movement of the ram is obtained by hydraulic power.
 Oil under high pressure is pumped into the operating cylinder fitted with a piston.
 It first acts on one side of the piston and then on the other, causing the piston to reciprocate and the motion
of the piston is transmitted to the ram.
 The piston speed is changed by varying the amount of liquid delivered by the pump.
d. Horizontal shaper
 In this, ram reciprocates in a horizontal plane.
 Usually, a plain table is provided in these shapers and is mainly used to produce flat surfaces.
e. Vertical shaper
 This shaper has its ram reciprocating in a vertical direction.
 The table is of the circular rotary type.
 The ram of vertical shaper; in addition to its vertical movement, can also be adjusted from its vertical position
to about 10° on either side of the vertical axis.
 The worktable can be given a cross, longitudinal and rotary movement.
 These shapers are conveniently used for machining internal surfaces, key-ways, slots, and grooves.
f. Traveling head type
 It is a specially designed shaper.
 The ram carrying the tool, while it reciprocates moves crosswise, to give the required feed.
 Heavy and large workpiece which cannot be held on the table is loaded on the base or floor and then
machined.
g. Universal shaper
 In universal shaper in addition to the two movements provided on a table, the table can be swiveled about an
axis parallel to the ram ways.
 The upper portion of the table can be tilted about a second horizontal axis perpendicular to the first axis.
 This shaper is used in tool room work.
h. Push type shaper
 In this shaper, metal is removed when the ram moves away from the column.
i. Draw type shaper
 In this shaper, metal is removed when the ram moves towards the column of the machine.
 In this shaper, cutting pressure acts towards the column which relieves the cross rail and other bearings from
excessive loading.
6.4 Shaper Mechanism

 In shaper, the rotary movement of the driving motor is converted into the reciprocating movement of the ram
by the mechanism provided in the column of the machine.

6.5
 In shaper, the only forward stroke of the ram is a working stroke, when the metal is removed and there turn
stroke goes idle and no metal is removed during this period.
 To reduce the total machining time, it is necessary to reduce the time taken by the return Stroke.
 To achieve this mechanism known as the quick return mechanism is provided.
 Due to this mechanism, the ram holding the tool is allowed to move at a comparatively slower speed during
the forward cutting stroke, whereas during the return stroke, the ram moves at a faster rate to reduce the idle
return time.
 There are three methods of obtaining a quick return mechanism.
a. Crank and slotted link mechanism

b. Hydraulic mechanism
c. Whitworth quick return mechanism
Fig.6.4 – Principle of a quick return mechanism
 Fig. 6.4 shows the principle of a quick return mechanism.
 When the link is in position CD1 the ram will be at the extreme backward position of its stroke,
andwhenitisatCD2, the ram will reach the extreme-forward position.CD1 and CD2 are shown tangent to the
crankpin circle.
 Therefore, forward cutting stroke takes Place when the crank rotates through the angle B1k B2 and the return
stroke takes Place when the cant rotates through the angle B2 LB1.
 It is clear from the Fig.6.4 that the angle made by forwarding stroke i.e.B1 K B 2is greater than the angle made
by return stroke i.e. B2 L B1.
 The angular velocity of the crankpin is constant during the return stroke and hence it is completed within a
shorter time for which it is called a quick return mechanism.
6.4.1 Crank and Slotted Link Mechanism

 The crank and slotted link mechanism is shown in Fig 6.5
 The crank AB rotates about the fixed center A, the end B having the form of a sliding block that fits the slot
in the link CD.
 As B rotates about A, it slides up and down in link CD and causes this to oscillate about the center c (pivot
point of the slotted link) so that as CD oscillates, the ram is operated backward and forwards.
 The quick return feature is derived from the configuration of the mechanism.

6.6
 When the link in the position CD1 tangential to the pitch circle of B, the ram will be at the extreme backward
position of is stroke and when it is at D2, the extreme forward position of the stroke will have been reached.
 The time is taken by cutting and idle stroke of the ram is proportional to the angles B 2 K B1 and B2 L B1
respectively.
Fig.6.5 – Crank and slotted link mechanism
 The ratio between cutting time and idle time may be determined from the formula
Cutting time B2 KB1


Cutting time B2 LB1
 Cutting time to return time ratio usually varies between 2: 1 and the practical limit is 3:2.
 The cutting speed and return speed is not constant throughout the stroke. It is minimum when rocker arm is
at the two extremities and speed is maximum when the rocker arm is vertical.
Adjustment of the length of the stroke and position of the ram
 The length of the stroke can be varied by changing the distance between the bull gear center and the center
of the crank pin. Refer Fig. 6.5.
 As the bull gear is fixed, the variation in the distance is achieved by moving the slide block and crankpin
away or towards the bull gear center.
 The sliding block can be moved by rotating the bevel gear and turning the spindle.
 Hence it rotates the adjusting lead screw and this will move the sliding block mounted on it.
 This movement of sliding blocks results in the change in the stroke length.
 The position of ram is adjusted after the stroke length is adjusted.
 The total tool travel consists of the tool approach, job length, and tool over travel,
 The position of ram is adjusted by first keeping the handwheel tight and moving the ram back to the extreme
rear position.
 Then the handwheel is released and slide the ram to the required position.
 With the help of a clamping lever, this position of ram is get fixed. Check the travel by moving the ram.
6.4.2 Whitworth Quick Return Mechanism

 The Whitworth quick return mechanism is used in a shaper machine which is shown inFig. 6.6.

6.7
Fig.6.6 – Whitworth quick return mechanism
 In this mechanism driving crank 3 rotates in the clockwise direction with the uniform angular speed.
 The slider C which is attached at the end of the driving link also reciprocates in slotted link 1 and causes to
oscillate the slotted link 1 about pivot point B.
 The link 5 is attached at the end of slotted link 1 which carries the ram and tool.
 When the driving crank moves from position ac" to ac' through an angle Q in a clockwise direction then the
tool moves back from f ' to f ".
 Thus the angle turned by driving crank i.e.  will be for cutting stroke and return stroke will be for angle
or ( 360   ).
 Since driving link 3 rotates at uniform angular speed, the ratio of cutting stroke to return stroke time will be
given by,
Time of cutting stroke Angle 
 
Time of return stroke Angle 360  
 As  is always greater than, therefore the ratio  is always greater than 1. Hence time required for
360  
cutting stroke is greater than return stroke.
 Thus for return stroke, no cutting operation is done in a shaper machine. So it is quicker than cutting stroke.
Hence this mechanism is called a quick return mechanism.
6.4.3 Hydraulic Mechanism

 The hydraulic mechanism is used as a quick return mechanism.
 The shaper ram in the position as shown moves from left to right.
 The oil from the reservoir is drawn through the filter by a gear pump which is driven by an electric motor.
 The pump delivers a constant quantity of oil to the control valve and from the control valve the oil can be
delivered to either side of the piston in the cylinder situated under the ram.
 To which side of the piston the oil will be delivered is determined by the position of the control lever of the
control valve.
 Fig. 6.7 shows a constant volume hydraulic mechanism.

6.8
Fig.6.7 – Hydraulic mechanism
 The same volume of oil is delivered on both sides of the piston, but the intensity of pressure is different due
to the difference in the effective area of the piston.
 Due to the difference in pressure, the ram travels at a faster rate in the return stroke than in the forward stroke.
 The stroke length of the ram is adjusted by adjusting the distance between the two stops.
 The cutting speed is controlled by using the throttle valve during the cutting stroke.
Advantages
 A large range of cutting speeds is available.
 Control of cutting speed is easy.
 Due to the oil present on both sides of the piston, there is a smooth and quick reversal of ram.
 Because of the high speed, there is saving in machining time.
 Higher safety is provided to the machine and cutting tool.
6.5 Feed Mechanism

 In shaper, both down feed and crossfeed movements may be obtained.
 These feed movements are provided intermittently and during the end of return stroke only.
 Vertical or bevel surfaces are produced by rotating the down feed screw of the tool head by hand.
 Crossfeed movement is given by rotating the crossfeed screw either by hand or power.
 Rotation of crossfeed screw causes the table to move sideways through a pre-determined amount at the end
of each return stroke.
 Fig. 6.8 shows the automatic crossfeed mechanism of a shaper.
 In shaper, an automatic cross feed of the table is obtained by a Ratchet and pawl mechanism.
 It consists of a slotted disc that carries a T-slot which is rotated by a bull gear of the shaper.
 In this T-slot an, adjustable pin is fitted and to this connecting rod is attached.
 The other end of the connecting rod is attached to the lower end of the rocker arm of the Pawl mechanism.
 The rocker arm swings about the fulcrum and at its upper end carries a spring-loaded pawl.

6.9
Fig.6.8 – Automatic feed mechanism
 The adjustable pin is set eccentric with the slotted disc center.
 The slotted disc at its back carries a spur gear which is driven by a bull gear.
 As the disc rotates, the adjustable pin being eccentric with the disc center causes the connecting rod to
reciprocate.
 This, in turn, makes the rocker arm to swing about the fulcrum, to move the pawl over one or more teeth and
thus transmit an intermittent motion to the crossfeed screw which moves the table.
 As the lower end of the pawl is beveled on one side, it facilities the power feed tope rate in either direction.
 To reverse the direction of rotation of ratchet wheel and consequently the feed, a knob on the top of the pawl
after removing the pin is rotated through 180 ̊.
 The amount of feed may be altered by shifting the position of crankpin with respect to the center of the
driving disc.
 Greater the throw of eccentricity more will be the rocking movement of the rocker arm.
6.5.1 Advantages and Disadvantages of Shaping Machine

Advantages
 Shaping machine requires less time for process setup.
 Shaping process has a higher production rate.
 Shaping machine employes a quick return mechanism to minimize idle time.
 It uses relatively inexpensive tools.
 It is suitable for light-duty operations.
Disadvantages
 The cost of machining is higher than milling or broaching.
 Due to the higher cost, it confines to the small quantity production.
 It is not suitable for the machining of large parts.
 It can not be used for heavy-duty operations.

6.10
 It can not be employed with heavy cuts and coarse feed.
 It has less accuracy and rigidity than a planer.
6.6 Shaper Operations

 The different operations which can be performed on shaping machine are listed below:
1. Machining horizontal surface 2. Machining vertical surface 3. Machining angular surface
4. Machining a V or Keyway curved 5. Cutting splines or gears.
surface
6.6.1 Machining Horizontal Surfaces

Procedure
 Set the vice jaws length perpendicular to the ram movement.
 Hold the job length-vise parallel to the tool stroke so that the maximum stroke of the tool may be utilized.
Refer Fig. 6.9.
Fig.6.9 – Horizontal shaping
 Adjust the cutting speed and feed depending upon the surface finish required i.e. rough or finish.
 Hold the appropriate tool in the tool head. Set the proper inclination of the tool and depth of cut.
 Give cross feed to the tool initially by hand till the cut start and then employ Power feed.
 After the tool has cut the full width of the job, stop the shaper, inspect the job and set another depth of cut.
Repeat the above-said procedure.
6.6.2 Machining Vertical Surfaces

Procedure
 The tool is fed Repeat the downwards in vertical cutting as swivel the apron from the face of the work to be
cut as shown in Fig.6.10.
 The tool is fed downwards by rotating the down feed screw by hand at the end of the return stroke, Give the
feed about 0.25 mm.
 On the return stroke, the tool wings away from the work and gives clearance which prevents the work from
being scored.
 Start cutting from the highest point towards the bottom.
 Repeat the procedure for another cut.

6.11
Fig.6.10 – Vertical shaping
6.6.3 Machining Angular Surfaces

Procedure
 Set the swiveling hand to the required angle for shaping angular faces as shown inFig. 6.11.
Fig.6.11 – Angular shaping
 The apron is to be swung away from the face to be machined.
 The tool is to be fed by the slide handwheel.
 The tool head is also swiveled in the direction away from the surface to be machined.
 Feed the tool during the return stroke.
 Repeat the procedure to finish the work.
6.6.4 Machining Keyways and Grooves
Fig.6.12 – Shaping grooves

6.12
 For shaping grooves, slots and keyways, a square nose tool similar to the lathe paring tool are to be used.
 Fix the tool in the tool head rigidly.
 Avoid excessively overhung and ensure that the tool clearances are not so great as to weaken the tool.
 Start the machine and give feed during the return stroke
 Repeat the cut till the end of the operation Ref fig 6.12.
6.6.5 Gutting Splines or Gears

Procedure
 Hold the workpiece between the centers.
 Use index head for cutting equally spaced splines and gear teeth.
 Cut the first spline or gear tooth on the workpiece exactly in the way, a keyway is cut.
 Rotate the workpiece by the required amount using the index plate.
 Lock the index plate by engaging the index pin with the corresponding hole in the circumference of the index
plate.
 Cut the second spline.
 Repeat the procedure, till the splines or gear teeth have been cut on the whole circumference of the workpiece.
 Use separate tools for cutting splines and gear teeth.
6.7 Introduction to Planer Machines

 Planing is one of the basic operations performed in machining work and generally preferred for machining
large flat surfaces.
 These surfaces may be vertical, horizontal or inclined.
 The workpiece that can be machined on the planer machine cannot be machined on the shaper machine, due
to limitation of size.
 Also, the Planing machine is most economical for machining for large flat surfaces.
 Fig. 6.13 shows the working principle of a planer machine.
Fig.6.13 – Working principle of planar machine
 The workpiece is rigidly held on the work-table, which can slide on the grooves provided on the base of the
planer.
 The tool is held vertically in the tool-head mounted on the cross-rail which can travel ina direction at the
right angle to the direction of motion of the work-table.

6.13
 Cutting action is achieved by applying the linear primary motion to the workpiece and feeding the tool at the
right angle to this motion.
6.8 Types of Planing Machines

 Following are the types of Planing machines which are generally used:
1. Double housing or standard planer 2. Open side planer
3. Pit planer 4. Edge or plate planer
5. Divided table planer
6.8.1 Double housing planer

 Double housing or standard planer is the most commonly used type of planer.
 It consists of two vertical columns i.e. one on each side of the bed.
 Between these two columns (housings) the cross-rail is fitted which carries one or two vertical tool heads.
 These machines are heavy-duty type and carry a very rigid construction.
 In these machines, cutting speed is very high, but the size of the workpiece is limited because of the width
of the table.
 Due to a long table and larger table travel, on either side of the columns, a number of the workpiece in a
series can be held over the bed length and machining is done.
 This will result in a substantial saving in machining time,
 Also, because of the high rigidity of the machine and robust design of cutting tools, heavier cuts can be easily
taken, which leads to quicker metal removal and reduced machining time.
 Components machined on these machines are extremely large and heavy castings such as machine beds,
tables, plates, slides, and columns.
6.8.2 Open side planer

 This type of machine consists of only one housing i.e. vertically on one side of the bed and the other side is
left open without any obstruction.
 The cross-rail is suspended from the housing as a cantilever.
Fig.6.14 – Open side planar

6.14
 Open side planer is similar to double housing planer, but the former carries three tool heads and the latter
carries four tool heads. Refer Fig. 6.14.
 As one side is open, the components which are difficult to machine on a double housing planer can be easily
machined on these machines.
 As there is only one housing, the machine is subjected to severe twisting forces during the operation.
 Hence, during the designing of the machine special care is needed.
6.8.3 Pit planer

 Pit planer is a special type of Planing machine.
 It is specially designed for machining 1ong, heavy and tall workpiece, which can not be machined on the
conventional types of the planer.
Fig.6.15 – Pit Planer
 The workpiece is mounted on a stationary plate or on the floor inside a pit.
 For clamping of the workpiece, T-slots are provided on the table.
 The machine is provided with two short vertical housings which carry a cross-rail.
 One or two tool heads are mounted on the cross-rail and if required, two side tool posts on the housings.
Refer Fig. 6.15.
 For machining the surface of the workpiece, the whole unit travels along with the horizontal guideways.
6.8.4 Plate or Edge Planer

 This machine is completely different from conventional planer machines in construction as well as working.
 In this machine, the bed and table are a fixed unit and the workpiece is mounted on the table.
 The tool head is mounted on a movable carriage, which can travel longitudinally along the bed.
 While machining, the operator can stand on a platform that is attached to the carriage and travels along with
it.
 Hence during the operation, the workpiece remains stationary, while the tool moves to and fro.

6.15
 It is a single purpose machine constructed for special works such as boilerplates, ship plates, for pipelines
and for welding.
6.8.5 Divided table planer

 In this machine, the table is constructed in two or more parts which can be joined together to hold the long
workpiece or used separately, as required.
 This machine is mainly used for those components for which more machine setting time is required, because
of their heavyweights.
 For such items, particularly when identical parts are to be machined on large scale, this machine with the
divided table is used such that when the workpiece on one table is being machined; the same is being
simultaneously set-up on the other table, for replacing the former after the operation is over.
 This will result in a considerable saving in setting time.
6.9 Main Parts of the planer

 The principal parts of the double housing planer are Refer to in Fig. 6.16
1. Bed 2. Table 3. Housing or columns
4. Cross rail 5. Tool head 6. Driving and feed mechanism
Fig.6.16 – Main parts of a Planer
1. Bed
 It is a heavy box like casting which is provided with cross ribs for added strength and stiffness.
 The length of the bed is twice the length of the table.
 At its top, it carrier V-ways or flatways to support and guide the tableAll the ways are straight, parallel and
accurately machined.
2. Table
 The table is made of cast iron with an accurately machined top.
 At its top, it carries T-slots and holes to accommodate the clamping bolts and other devices.

6.16
 The work is directly mounted and clamped on the table by using various devices.
 On its sides, the table carries adjustable stops to reverse its motion at the end of each stroke.
 Also, in the planer table, there is the provision of a suitable safety device to prevent the heavily loaded
reciprocating table from running out in case of failure.
3. Housings or columns
 Columns are vertical members situated on both sides of the planer bed.
 Inside them, they carry the different mechanisms for the transmission of power to the upper parts of the
machine, from the main drive.
 The front face of each housing are accurately machined, to provide guideways on which the cross-rail slides
up and down, for accommodating different jobs of different heights.
 Two side tool heads also slide vertically along the same guideways.
4. Cross-rail
 It is a horizontal member of a heavy structure that connects the two vertical housings of the machine.
 By means of elevating screws provided in housings, it can be raised or lowered on the front face of the
housings and can be clamped at any desired position.
 In order that the cross-rail is moved up and down uniformly on both ends, both the
 Elevating screws are rotated simultaneously by a horizontal shaft, mounted on the top of the machine, through
a set of bevel gears.
 The front face of the cross-rail is accurately machined, to provide guideways for the tool head.
 The cross-rail encloses the screws for vertical and cross feed of the tool heads.
5. Tool heads
 The tool head consists of a saddle, swivel base, vertical slide, apron, clapper box, clapper block, tool post
and down feed screw.
 The saddle is fitted on the ways of the cross-rail on which the tool heads may be fitted. The tool heads on the
cross-rail are independently operated,
 At most four tool heads can be mounted in a planer and any or all of them can be used at a time.
6. Driving and feed mechanism

 For driving the table various mechanisms like quick return mechanism, feed mechanism, etc. are provided
with the planer.
6.10 Planer Mechanism

 In planer, the forward stroke is a working or cutting stroke and return stoke is id1e.
 Hence, to reduce the time required for return stroke different mechanisms are used.
The mechanisms are :

1. Open and cross belt drive
2. D.C. reversible motor drive (Ward Leonard drive)
3. Hydraulic drive.
6.10.1 Open and Cross Belt Drive

 Most of the planers are having this system of the drive for a quick return of their tables.

6.17
 It consists of the main driving motor situated over the housings.
Fig.6.17 – Belt drive for a planer
 The motor drives the countershaft through an open V-belt.
 The countershaft carries two driving pulleys; one for the open belt and the other for the belt.
 The main driving shaft is situated below the bed.
 One end of it passes through the housings and carries a pinion, which meshes with a rack provided under the
table of the machine.
 The other end of this shaft carries two pairs of pulleys: Each pair consisting of a pulley and a loose pulley.
 One of these pairs is connected to one of the driving pulleys by using an open belt the other to the second
driving pulley by using a cross belt.
 A speed reduction gearbox is mounted on the main driving shaft. Refer Fig. 6.17.
 During the cutting stroke, greater power and less speed are required.
 The cross belt giving a greater arc of contact is used, to drive the table during the forward cutting stroke.
 The position of the cross belt is on the larger diameter fast pulley on the main driving shaft.
 The open belt is on the smaller diameter losses pulley.
 Since loose pulley is free to rotate on the main driving shaft, no motion is transmitted to the table by an open
belt. During the cutting stroke, the cross belt is shifted to the loose pulley and the open belt on a fast pulley
of the other set.
 Therefore, during the return stroke, the motion is transmitted by an open belt.

6.18
 Since the open belt connects a larger diameter driving pulley on countershaft with smaller diameter fast
pulley on the driving shaft, the table will run at a faster speed.
6.10.2 D.C. Reversible Motor Drive

 This type of drive is observed generally in modern planer machines.
 In this drive, a d.c. the reversible motor is directly connected to the main shaft.
 The direction of rotation of d.c. a reversible motor can be changed by reversing the polarity, by operating
two different switches which are actuated by using trip dogs provided at each end of the table.
Fig.6.18 – Ward Leonard Drive
 A very popular electric drive, which is widely used in modem planers, is Ward Leonard Variation drive.
 This type of drive is very popular because of its capability of reversing the table movement almost infinite
times without losing its reliability and flexibility,
 It consists of an a.c. induction motor, d.c. generator and variable speed reversible d.c motor. Refer Fig. 6.18.
 An a.c. the motor is driven by the Powel obtained from the mains supply, which drives the d.c. generator and
the generator drives variable speed d.c. motor.
 The d.c. the motor is then connected to the cable drive gear mechanism through the reduction gears, to
transmit motion to the table.
 The exciter is also a small generator and it is used for exciting the fields Fg and Fm of the generator and d.c.
motor respectively.
 A variation in the speed of the d.c. motor (machine tool) can be obtained by varying the resistance in the
rheostat R1 i.e. the resistance in the field of the generator.
 Further variation in the speed of the d.c. the motor can be obtained by varying the resistance in the rheostat
R2 i.e. the resistance in the field of the motor.
 The main a.c. the motor always revolves at a constant speed.
Advantages
 It is safer than the belt drive.
 Its control is easier, faster and accurate,
 The return speed of the table can be made much faster and hence a lot of saving of time.
 Variation in the cutting speed is possible.

6.19
6.10.3 Feed Mechanism
 In a planer, the horizontal feed to the tool is given by moving the tool head along the cross-rail and vertical
feed, to vary the depth of cut, is imparted by moving the vertical slide of the tool head by means of the down
feed screw.
 In many machines, ratchet and pawl feed mechanism is used but, a more popular mechanism for planer is
friction disc feed mechanism.
Friction disc feed mechanism
 It is fitted on the side of the vertical column.
 It consists of a friction disc at the bottom and a rack and pinion at the top.
Fig.6.19 – Friction disc feed mechanism of a planer
 The friction disc carries the radial T-slot which carries a sliding block.
 A knurled knob of the screw shaft can be rotated to adjust the position of a block with respect to the center
of the friction disc.
 A connecting rod is connected to the sliding block at one end and the tack at the other end which moves
inside the guide.
 The eccentricity of the sliding block decides the length of rack movement, and hence the amount of feed.
Gears G1, G2, and pinion Pare mounted on the pinion shaft A S3. Pinion P meshes with the rack.
 The friction disc D is connected to the drive mechanism of the planer table and is driven by the latter.
 The disc is rotated by a certain amount to one direction at the beginning of the cutting stroke and by the same
amount of rotation in the reverse direction at the beginning of an idle stroke.

6.20
 The amount of rotation of the disc is limited between fixed pins P1 and P2 and a projecting pin attached to a
disc.
 These rotations of the disc are transferred to the rack through the connecting rod.
 The rotation of the disc in one direction will move the rack upwards and rotation in the reverse direction will
pull it downwards.
 This will rotate the pinion, first in the clockwise direction and then in the anticlockwise direction. Refer Fig.
6.19.
 The gear G1 is free on the shaft, while G2 is keyed to the shaft.
 The direction of rotation of these gears can be controlled by the double pawl, which can be engaged with the
teeth of gear G 2, to allow it to locate in any one direction as desired.
 The double pawl is fitted on the face of the gear G1 by means of a pin' Any one of the two arms of the pawl
is engaged with the gear G2 With upward movement of the rack the gear G2 will rotate in a clockwise direction
which will rotate gear G1 through the pawl.
 During downward movement of the rack, gear G 2and gear G1, will not receive any motion through arm
slipping over the teeth of gear G2.
 In this way in one double stroke of the rack, and hence of the planer table, the gear G 1 will rotate through a
part of its revolution in one direction only.
 Since this gear is meshed with one gear on down feed shaft and another gear on crossed shaft these gears
will get motion from it to impart equal feed to gear the tool each time the G 1 rotates partially by an equal
amount.
 The direction of feed can be changed by changing the position of pawl.
6.11 Advantages and Disadvantages of Planer

Advantages
 The Planer machine is suitable for machining of large parts. It is used to machine multiple small parts held
in a line. It is suitable for heavy-duty operations.
 It can take heavier cuts and coarse feed.
 Planers can be provided with multiple tools.
Disadvantages
 Higher stresses are developed due to higher cutting and return speed.
 Due to heavy workpieces and rapid acceleration change, the higher inertia forces are developed.
 Hence, the fastening process of workpieces should be very efficient.
6.12 Planer operation

 The planing machine is used for the larger and heavier workpiece. Also, the surfaces machined on a planer
are much larger and wider. The common operations performed on a planer are as follows :
o The planing of horizontal flat surfaces
o The planing of vertical flat surfaces
o Planing at an angle
o Planing curved surfaces

6.21
o The planing of different types of slots and grooves
o Planing a helix.
 For performing above planer operations, one has to adjust the cutting tool in a proper position with respect
to the workpiece and then the necessary motion is given to the tool, so as to cut either in the horizontal or
vertical direction or along a curved path.
6.13 Comparison between Shaper and Planer:

 Shaper and planer are both reciprocating types of machine tools and both of them are primarily intended to
produce flat surfaces, but they differ very much in construction Operation and use. The main differences are:
Table 6.1 -Comparison between Shaper and Planer
Sr. No. Shaper Planer

1. It is a comparatively light-duty machine. It is a heavy-duty machine.
2. The tool is held on the ram which The work mounted, on the table reciprocates
reciprocates and works mounted on the while the tool is rigidly held on the machine
table is stationary. frame.
3. It requires less floor area It requires more floor area.
4. The work may be clamped directly on the The work may be clamped directly on the table
table or held in a vice or chuck. by using a fixture or clamping device
5. Very heavy cuts and coarse feeds can not Heavier cuts and coarse, feeds Can be employ
be employed.
6. Usually, only one tool is used. Several tools can be mounted and employed
simultaneously (usually four) facilitating a
faster rate of production.
7. Cutting takes place by moving the cutting Cutting takes place by reciprocating the work
tool over the job. under the tool.
8. The setting of work is easy and quick Work setting requires much skill and takes
long, time.
9. Used for machining relatively small Used, for, machininglargeflat surface.
surface
10. Indexed feed is given to the work during Indexed feed is given to the tool during the idle
the ideal stroke of the ram stroke of the work table
11. Light, small and has less cost. Heavier, large and costlier
6.14 Introduction to Slotting Machines

 The slotting machine is a reciprocating type of machine tool which operates on the same principle as that of
the shaper, except that the ram of the slotter reciprocates in the vertical direction.
 In a slotter, the ram holding the tool reciprocates in a vertical direction; the work mounted on the table
remains stationary and provides the feed.

6.22
 It is very useful for cutting grooves, keyways, straight and curved slots, for machining regular and irregular
surfaces (both internal and external), machining of dies, cutting off external and internal teeth of large gears.
 The slotters may be puncher slotter and precision slotter.
 The slotting machine consists of a base, which acts as a support for column, driving mechanism, ram, table,
and all other parts. Refer Fig 6.20
 The column is an integral part of the base.
 It is a vertical member. At its front, it carries vertical guideways along which the ram reciprocates. It houses
the driving mechanism.
 The saddle is mounted on the bed ways and provides a longitudinal feed on the saddle cross slide is mounted
in the guide Waycross slide can be moved in a direction perpendicular to the movement of the saddle.
 A rotor table is mounted on the top of the cross slide and can be rotated by hand or power by means of worm
and worm gear mechanism situated underside the table.
Fig.6.20 – Block diagram of a slotter
 The table is graduated in degrees, which enables it to be rotated for indexing' T-slots are also provided on
the top of the table.
 Ram is a reciprocating member which moves vertically up and down. The cutting takes place during the
downward stroke of the ram.
 A special type of toolbox is provided to relieve the tool during its return stroke.
6.15 Types of Drives

 There are mainly four types of mechanisms used in slotters for driving the ram:
1. Slotted disc mechanism

2. Variable speed reversible motor drive
3. Hydraulic drive
4. slotted link mechanism
1. Slotted disc mechanism
 It is the simplest of all the ram drive mechanisms and is very commonly used in size slotting machines.
 In this mechanism, the driving pinion gets drive from a pulley that runs through the belt by a motor.
 The pinion rotates the gear which in turn rotates the slotted driving disc.

6.23
 The rotation of the slotted disc is converted into the vertical reciprocating motion ram with the help of a
connecting rod.
 The length of the stroke of ram can be changed by shifting the crankpin towards or from the center of the
slotted driving disc.
 The position of the stroke is adjusted with the help of the hand lever provided for adjustment.
2. Variable speed reversible motor drive

 Such a drive is used in large modem slotting machines.
 Slotting machines have an attached or enclosed motor drive with a multi-speed gearbox to give a range of
speeds to the ram.
 A typical range would be 40 to 150 strokes or cycles per minute.
3. Hydraulic drive
 Hydraulic drive is used in large-modem slotted machines.
 The drive is similar to that employed for the shapers.
 In this drive, the hydraulic cylinder is in a vertical direction.
 Both constant pressure and constant volume type drives are used.
4. Work Holding Devices

 In slotting machines, it is necessary that the workpiece should be held rigidly in a suitable device or clamped
to the machine table, to withstand cutting forces.
 For this purpose following devices are used :
o Clamps
o Vices
o Parallel strips
o Special fixtures
o T-bolts
 These devices' components are placed as in the case of shaper machines.
6.16 References
1. Hajra & Choudhari. “Element of Workshop Technology Vol. II” Media Promoters and Pvt. Ltd
2. B.S.Raghuvanshi “A Course in Workshop technology Vol. II” Dhanpat Rai & Co,
3. R. K. Jain.”Production Technology” Khanna Publications

6.24

MP GTU Study Material E-Notes Unit-6 06042020034404PM

Uploaded by

Copyright:

Available Formats

You might also like

MP GTU Study Material E-Notes Unit-6 06042020034404PM

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

MP GTU Study Material E-Notes Unit-6 06042020034404PM

Uploaded by

Copyright:

Available Formats

Contents

6.1 Introduction ........................................................................................................................................ 6.2

Fig.6.1 – Principle of working of shaper

6.2 Principle Parts of Shaper Machine

Fig.6.2 – Horizontal shaper machine

Prof. Paras G. Vegada Department of Mechanical Engineering

 It is mounted on the front vertical guide-ways of the column.

Fig.6.3 – TooI head

Prof. Paras G. Vegada Department of Mechanical Engineering

 Apron consists of a clapper box, clapper block, and a tool post.

6.3 Classification of Shaper

 This is the most common type of shaper.

 This type of shaper is not widely used.

Prof. Paras G. Vegada Department of Mechanical Engineering

 In hydraulic shaper, reciprocating movement of the ram is obtained by hydraulic power.

 In this, ram reciprocates in a horizontal plane.

 This shaper has its ram reciprocating in a vertical direction.

 The table is of the circular rotary type.

f. Traveling head type

 It is a specially designed shaper.

 This shaper is used in tool room work.

h. Push type shaper

i. Draw type shaper

6.4 Shaper Mechanism

Prof. Paras G. Vegada Department of Mechanical Engineering

 To achieve this mechanism known as the quick return mechanism is provided.

a. Crank and slotted link mechanism

Fig.6.4 – Principle of a quick return mechanism

 Fig. 6.4 shows the principle of a quick return mechanism.

6.4.1 Crank and Slotted Link Mechanism

Prof. Paras G. Vegada Department of Mechanical Engineering

Fig.6.5 – Crank and slotted link mechanism

Cutting time B2 KB1

 The position of ram is adjusted after the stroke length is adjusted.

6.4.2 Whitworth Quick Return Mechanism

Prof. Paras G. Vegada Department of Mechanical Engineering

6.4.3 Hydraulic Mechanism

Prof. Paras G. Vegada Department of Mechanical Engineering

 Control of cutting speed is easy.

 Because of the high speed, there is saving in machining time.

 Higher safety is provided to the machine and cutting tool.

6.5 Feed Mechanism

Prof. Paras G. Vegada Department of Mechanical Engineering

6.5.1 Advantages and Disadvantages of Shaping Machine

 Shaping process has a higher production rate.

 Shaping machine employes a quick return mechanism to minimize idle time.

 It uses relatively inexpensive tools.

 It is suitable for light-duty operations.

 Due to the higher cost, it confines to the small quantity production.

 It is not suitable for the machining of large parts.

 It can not be used for heavy-duty operations.

Prof. Paras G. Vegada Department of Mechanical Engineering

 It has less accuracy and rigidity than a planer.

6.6 Shaper Operations

6.6.1 Machining Horizontal Surfaces

Fig.6.9 – Horizontal shaping

6.6.2 Machining Vertical Surfaces