SHAPING & RELATED OPERATIONS

Shaping and Planing

Planing and shaping are similar operations, which differ in the

kinematics of the process.

 In shaping, the primary motion is performed by the tool, and

feed by the workpiece. The workpiece is fed at right angles to
the cutting motion between successive strokes of the tool.

 Planing is a machining operation in which the primary cutting

motion is performed by the workpiece and feed motion is
imparted to the cutting tool. Workpiece is reciprocated and
the tool is fed at right angles to the cutting motion.

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 PLANING AND SHAPING

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 Horizontal Shaper

The shaper is a relatively simple machine. It is used fairly often in the

toolroom or for machining one or two pieces for prototype work. Tooling is
simple, and shapers do not always require operator attention while cutting.
The horizontal shaper is the most common type, and its principal
components are shown below, and described as follows:

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 Ram: The ram slides back and forth in dovetail or square ways to transmit power
to the cutter. The starting point and the length of the stroke can be adjusted.

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 Clapper Box: The clapper box is needed because the cutter drags over the
work on the return stroke. The clapper box is hinged so that the cutting too] will
not dig in. Often this clapper box is automatically raised by mechanical, air, or
hydraulic action.
Table: The table is moved left and right, usually by hand, to position the work
under the cutter when setting up. Then, either by hand or more often
automatically, the table is moved sideways to feed the work under the cutter at
the end or beginning of each stroke.

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 Saddle: The saddle moves up and down (Y axis), usually manually, to set the
rough position of the depth of cut. Final depth can be set by the hand crank on
the tool head.
Column: The column supports the ram and the rails for the saddle. The
mechanism for moving the ram and table is housed inside the column.

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 Tool holders: Tool holders are the same as the ones used on at engine lathe,
though often larger in size. The cutter is sharperred with rake and clearance
angles similar to lathe tools though the angles are smaller because the work
surface is usually flat. These cutters are fastened into the tool holder. just as in
the lathe, but in a vertical plane.
Workholding: Workholding is frequently done in a vise. The vise is specially
designed for use in shapers and has long ways which allow the jaws to open up
to 14" or more, therefore quite large workpieces can be held. Work that cannot
be held in the vise (due to size or shape) is clamped directly to the shaper table
in much the same way as parts are secured on milling machine tables.
Shaper Size: The size of a shaper is the maximum length of stroke which it can
take. Horizontal shapers are most often made with strokes from 16- to 24" long,
though some smaller and larger sizes are available. These shapers use from 2- to
5-hp motors to drive the head and the automatic feed.
Shaper Width: The maximum width which can be cut depends on the available
movement of the table. Most shapers have a width capacity equal to or greater
than the length of the stroke. The maximum vertical height available is about 12"
to 15".

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 Types of Work

The tool post and the tool slide can be angled as seen below. This allows
the shaper to be used for different types of work

The tool post has been The top slide is slowly feed
The tool post is not angled so
turned at an angle so that into the material so that a
that the tool can be used to
side of the material can level a surface. ‘rack’ can be machined for a
be machined rack and pinion gear system.

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 Cutting conditions in planing and shaping

The cutting conditions in planing and shaping are illustrated in the figure.
Only the shaping operation is portrayed but the cutting conditions are
essentially the same and for planing:

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 Cutting conditions in planing and shaping

Cutting velocity V in planing is linear and constant along the cutting path.
In shaping, the picture is more complicated. The cutting tool is held in the
tool post mounted in the ram, which reciprocates over the work with a
forward stroke, cutting at velocity V and a quick return stroke at higher
velocity. The cutting velocity is therefore not constant along the cutting
path. It increases from zero to maximum in the beginning of the stroke and
gradually decreases to zero at theend of the stroke. The cutting speed V is
assumed to be twice the average forwarded ram velocity.

Feed f in planing and shaping is in mm per stroke and is at right angles to

the cutting direction.

Depth of cut d is defined as usual as the distance between the work and
machined surfaces.

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 Effect of feed per stroke

Effect of feed per stroke on the flat surface generated in shaper:

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 Clapper box

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 Quick Return Mechanism
The shaping machine is used to machine flat metal surfaces especially where a large
amount of metal has to be removed. Other machines such as milling machines are
much more expensive and are more suited to removing smaller amounts of metal,
very accurately.
The reciprocating motion of the mechanism inside the shaping machine can be seen in
the diagram. As the disc rotates the top of the machine moves forwards and
backwards, pushing a cutting tool. The cutting tool removes the metal from work
which is carefully bolted down.

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 Quick Return Mechanism: Hydraulic

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 Planing Machines

Planing is used for large workpieces too big for shapers

Planing machines have largely been replaced by planing mills
In planing, large workpieces and their support tables are slowly moved
against the tool head.

Figure: Schematic of
planers. (a) Double-
housing planer with
multiple tool heads
and a large
reciprocating table; (b)
single-housing or
open-sided planer.

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 Common Shaping and Planing Geometry

Figure: Types of surfaces commonly machined by shaping and

planing.

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