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MF F313: METAL FORMING AND MACHINING

Topic 1-6
Introduction to machining and Various machining
processes

Dr. N. Suresh Kumar Reddy, PhD (IIT Delhi)


BITS Pilani Associate Professor, BITS Pilani, Hyderabad
Hyderabad Campus Campus, India
SWITCH OFF YOUR MOBILES / KEEP IN SILENT MODE IN
CLASS ROOM

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Topic 1- 6

1 Introduction to To be familiar with (TB2) 1.1-


machining machining process. 1.12

2-6 Various To study the various (TB2) 1.1-


machining motions in different 1.12
processes machining process

Refer: B.L. Juneja, G.S. Sekhon and Nitin Seth, Fundamentals of Metal Cutting and Machine
Tools, New Age International Publications, Delhi. 2010.

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Where we use
Shaping and Planing
machines?

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Production of Flat Surfaces

Typical components with flat surfaces

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Production of Flat Surfaces..
Motions for producing Flat Surface

Depth
of cut
Cut
A'
E A
Fe
ed
B' D
B
p i e c e
C
Work
Reciprocating Machine Tools

Different from rotary machine tools


A single-point tool moves linearly
relative to the work part

ShaperShapingtool moves

PlanerPlaningworkpiece
moves
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Shaper/Shaping Machine
Ram v
Tool head
d or f
Tool
Workpiece
Vise
Table Column
f or d

Base
Shaper/Shaping Machine
Main Parts
Base
Column drive, support & guide ram
Table hold & feed workpiece
Ram tool head, clapper box

Types of Shaping M/c


Horizontal Shaper
Vertical Shaper (Slotting M/c)
Typical Shaping Machine
Shaping Operation
Cutting action and functioning
of clapper box in a shaper

Clapper box

Tool cleared Lifted


from machined clapper
surface box
Workpiece
(a) Forward/Cutting stroke (b) Return stroke
Cutting action on shaping machine
Cutting Stroke

Return Stroke
Workpiece
c Lj c Clearance
Length of stroke L

Length of Stroke L = Lj + 2 c
Operating Conditions in a
Shaping Machine
Operating Conditions in a
Shaping Machine
N L (1 )
cutting speed v m/min
1000

where
N = the number of double strokes or
cycles of the ram per min (one double or
full stroke = one cutting and one return
stroke)
L = Length of the ram stroke in mm
= return stroke time/cutting stroke time
Operating Conditions in a
Shaping Machine ..
Feed f
Feed f is the relative motion of the
workpiece in a direction perpendicular
to the axis of reciprocation of the ram
Feed is expressed in mm/double
stroke or simply mm/stroke because
no cutting is done in return stroke
Operating Conditions in a
Shaping Machine ..
Depth of Cut d
Depth of cut d is the thickness of
the material removed in one cut, in
mm

Depth of cut may be given by the


tool head slide or by lifting the table
Machining time
Machining Time

f
mm
w
mm L mm

Width cut in 1 stroke = f


Total width = w or B
No. of strokes to m/c total surface = B or w/f
Strokes/mm = N
Time for machining surface is
t = B (or) w/(f N) min
Machining Time
Time for machining w x L surface
w
t min
f N
From cutting speed
N L (1 ) 1000 v
v N
1000 L(1 )
Machining time
w L w (1 )
t min
f N 1000 v f
Shaping

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Material Removal Rate
Material removal rate (MRR)
MRR = f d L N(1+ ) mm3/min

where d is depth of cut in mm


f is feed in mm/stroke;
N is strokes/min
L is length of stroke in mm
is ratio of return stroke time
to cutting stroke time
Planer/Planing Machine
Housing
Tool heads

Tool head
Reciprocating
table
Tool head
Bed Guideways
Slotter

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Types of Planing Machines
Open Side Planer
Double Housing
Planer
Edge planer
Universal planer,
Pit type planer
Typical double housing planar
Operating Conditions in a Planer
Operating conditions in planer are
similar to Shaping Machine
Size of Shaping and Planing
Machines

Largest Size of Workpiece that


can be Machined
Lxwxh
Difference between
Shaper and Planer
Size of Workpiece
Movement of Tool and Workpiece
Construction
Cutting and Return Speeds
Number of toolheads
Example
Find the machining time required for machining the
surface 600 800 mm, on a shaping machine.
Assume, cutting speed as 8 m/min. The return to
cutting time ratio is 1:4, and the feed is 2 mm/double
stroke. The clearance at each end is 70 mm.
Solution
Lj = 600 mm, w = 800 mm, v = 8 m/min,
m = , f = 2 mm/stroke, c = 70 mm
Example.
Given clearance at each end: c=75 mm
length of stroke:
L = 600 + 270 = 740 mm

N L (1 ) 1000 v
v N 8.65 strokes/mi n
1000 L(1 )
Assume 8.65 strokes/min available
Machining time for 800 mm width
w
t 46 .25 min
f N
Example
Alternately: L w (1 )
t
1000 v f
740 800 (1 0.25)

1000 8 2
46 .25 min
Example

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Example

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BITS Pilani, Hyderabad Campus
From the data given below for a shaper, find the time
required for finishing one flat surface of a plate of size
700 30mm.

Average cutting speed = 9 m/min


Return time to cutting time ratio = 1: 2
Feed = 0.3 mm/stroke
Clearance at each end of stroke = 25 mm
The plate is fixed with 700 mm side along the
direction of tool travel.

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