Machining Processes

Shaper, Planer & Slotter

 Working Principle of Shaper
 Shaper is basic machine tools in which machining is accomplished by combining straight
line reciprocating cutting motion with a perpendicular feed motion.
 The surface produced by these machines usually consist of parallel straight line elements.
 Generated flat surfaces are the most common and these may be horizontal, inclined at an
angle or vertical.
 Shapers, slotters and planers use single point tools.
Classification of shapers
 According to type of mechanism used for giving reciprocating motion to the ram :
1. Crank type
2. Geared type
3. Hydraulic type
 According to the position and travel of ram :
1. Horizontal type
2. Vertical type
3. Traveling head type
 According to the type of design of the table :
1. Standard shaper
2. Universal shaper
 According to type of cutting stroke :
1. Push type
2. Draw cut type
Shaper Size:
 The size of a shaper is determined by the maximum length of stroke .
 Usual size ranges from 175 to 900 mm.
 Length of stroke indicates the general size of the machine , the size of a cube that can
be held by shaper.
 For 250 mm shaper, the length of stroke may be adjusted from 0 to 250 mm. cross feed
adjustment of 250 mm and cross rail permit the table to accommodate a work piece of 250
mm high.
• Max Horizontal & Vertical travel of table
• Size of table
• Max distance from table to Ram
• Max Vertical travel of tool slide
• Max Power
• Range of Ram cycles per min
• Net Weight & Floor Space
Shaper Machine
 Shaper drive mechanism :

The shaper machine should be so designed that it can allow the ram holding the tool to move at
a comparatively slower speed during the forward cutting stroke, the cutting speed depending upon
the type of material & machining conditions, whereas during the return stroke it can allow the ram
to move at a faster rate to reduce the idle return time. This mechanism is know as Quick return
mechanism

• Crank & slotted link mechanism ( https://www.youtube.com/watch?v=s3TiMedJKds )

• Whit worth quick return mechanism
• Hydraulic shaper mechanism

Crank & slotted link mechanism:

Since useful work is done only during the forward stroke of ram, the mechanism
driving the ram is so designed that the return stroke is completed in much less time than the
forward stroke. The slotted lever quick return mechanism is illustrated in Figs. 2(a) & 2(b)
Slotted Lever Type Mechanism:
 The crank AB(of adjustable length R) rotates with a uniform angular speed. The crank pin B is in the shape of a die block
which is free to slide inside the slot in the slotted lever OBC . This slotted lever is pivoted at O and the other end C is
connected to the ram by a short link arm as shown in Fig. 2 (a). When the crank AB rotates clockwise from
position AB1to AB2, the ram moves forward from left to right and when it rotates from positionAB2to AB1the ram
returns back to its original position. Clearly the time taken to complete forward stroke is proportional to angle α (refer to
Fig. 2 (b) and the return stroke is completed in less time which is proportional to angle β.
 The ratio between the cutting time & return time determined by

Adjusting the length of stroke

• Greater the distance between Bull

Bull gear sliding block mounting arrangement
gear centre and the centre of crank
pin, Larger will be the angle through
which the rocker arm will swing and
hence, longer will be the stroke of the
ram.
Whitworth Quick Return Mechanism:
 The slider ‘C’ which attached at the end of driving link also reciprocates in slotted link 1 and cause 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 ‘theta’ in clockwise direction, the tool
moves from f’ to f ”.
 When the driving crank moves from position ac” to ac’ through an angle ‘FY’ in clockwise direction, the tool
moves from f” to f’.
 Since driving link 3 rotates at uniform angular speed, the ratio of cutting stroke to return stroke time will be given
by,
Hydraulic Drive For A Shaper:

• For constant volume hydraulic

mechanism, same volume of oil
is delivered to both sides of the
piston.

• The intensity of pressure differs

on both sides due to the
difference in effective area of
the piston.

• With the result ram travels at

faster rate in the return stroke.
 Shaper Feed Mechanism:

 The feed for shapers is usually obtained by means of a pawl and ratchet mechanism actuating the feed screw.
 Pawl and Ratchet type of mechanism are used where a machine part such as a shaper table or the tool head of a planer is
to be moved through small axial distances at regular intervals.
 The pawl which is removed back and forth with the help of an eccentric pushes the ratchet through one or more teeth in
each forward stroke while it just slides over the ratchet teeth in the backward stroke.
 The angular displacement of the ratchet screw is converted into linear movement of the sliding member by screw
principle.
 The feed rate stroke can be changed by adjusting the eccentricity of the crank pin.

 https://www.youtube.com/watch?v=exdGeV9fCc0
Shaper Feed Mechanism
Tool head of Shaper

Main parts of tool head :

1. Vertical slide
2. Swivel plate
3. Feed screw
4. Apron
5. Clapper block
6. Tool holder
7. Tool
Shaper operations :
Holding devices
 Shaper Tools:
 Shaper tools are commonly made of high speed steel because speed are low and tool gets time to get
cooled during the return stroke.
 Since shaping stroke involves interrupted cutting, carbide tools when used should be of brazed or of
disposable insert type.
 The available shaper tools can be classified into the following varieties:
 (1) Roughing and finishing tools.
 (2) Straight and cranked neck tools.
 (3) Left hand and right hand tools.
 (4) Round nose, straight nose and flat nose tools.
 (5) Slot cutting, parting off and side-recessing tools.
 Contd…
 A MS steel plate 400 x 800 x 30 (mm) is to be shaped along its
wider face. Ratio of return time to cutting time is 2:3 and
feed/cycle is 2 mm. Tool approach and over travel respectively
are 50 mm each. Cutting speed is 24 m/min. Calculate machining
time and MRR taking depth of cut as 1 mm.
(12.8125 min and 48,000 mm3/min)
Slotting Machines
 Slotting machines can simply be considered as vertical shaping machine where the
single point (straight or formed) reciprocates vertically and the work piece, being
mounted on the table, is given slow longitudinal and / or rotary feed .
 Only light cuts are taken due to lack of rigidity of the tool holding ram for cantilever
mode of action.
 Shaping machines and slotting machines, for their low productivity, are generally
used, instead of general production, for piece production required for repair and
maintenance.
 Like shaping and slotting machines, planing machines, as such are also becoming
obsolete and getting replaced by plano-millers where instead of single point tools a
large number of large size and high speed milling cutters are used.
 Main Parts of a Slotter(Contd…)

 Base
 Column
 Table
 Ram
 Slotter Drive Mechanism (Cntd…)

 Types of Mechanisms for Driving the Ram:

• Slotted Disc Mechanism
• Slotted Link & Gear mechanism &
• Hydraulic mechanism
 Types Of Slotting Machines (Contd…)

 Puncher Slotters
 Production Slotters
 Tool Room Slotters
Planning Machines
 A planer is a type of metal working machine tool that is some what similar to a shaper, but larger,
and with the entire work piece moving beneath the cutter, instead of the cutter moving above a
stationary work piece.
 Planning is intended to machine large & heavy flat surfaces i.e. either be it Horizontal, Vertical or
Inclined which are almost impractical to be machined on shaper or milling machine.

 Working Principle of a Planer

• Here it is almost reverse case to that of a shaper. Work is held on table, Tool is mounted vertically
on tool head. Work table reciprocates past the vertically held tool; Indexed feed after each cut is
given to the tool during the idle stroke of the table.
 Main Parts Of A Planer (Contd…)
 Bed
 Table
 Housings or Column
 Cross rail
 Tool Heads
 Machine Size & Specifications (Contd…)
 Specified by following main dimensions:
• Horizontal distance between two vertical housings.
• Vertical distance between the Table top & Cross-rail, when later is in top most position.
• Maximum Length of Table travel or Length of Stroke.
 Number of other particulars in order to specify planer fully are:
• Length of Bed
• Length of table
• Method of Driving
• Method of Driving the table Geared or Hydraulic etc.
• H.P. (or kW) of the motor
• Number of additional Tool Heads required.
 Types Of Planers (Contd…)
 Standard or Double housing Planer
 Open Side Planer
 Planer Miller
 Plate or Edge Planer
 Pit Planer
 Divided table planer
 Driving Mechanisms (Contd…)
 Following different methods are employed for driving the table of a Planer:
• Crank Drive
• Belt Drive
• Direct Reversible Drive
• Hydraulic Drive
 Quick Return Mechanism (Contd…)
 Belt Drive
 Direct Reversible Motor Drive
 Hydraulic Drive
 Feeding Mechanisms (Contd…)
 Horizontal feed to the tool is given by moving the tool head along the cross-rail & vertical feed
to vary the depth of cut is imparted by moving the vertical slide of the tool head by means of
Down feed Screw.
 Following three mechanisms are commonly used in a planer :
• Ratchet & Pawl feed mechanism
• Friction Disc Feed mechanism
• Electrical Feed Mechanism