Unit 2 Shaper Planer Slotter

Subject: Manufacturing Science & Technology-II [NME-503]
Course Instructor: Shailendra Pratap Singh
Unit 2
Shaper, Planer & Slotter: Construction, operations and drives
Shaper
Contents
1. Introduction
2. Principal parts of shaper
3. Types of shaping machine
4. Specification of shaping machine
5. Operations on shaping machine
6. Drive mechanism
7. Feed drive mechanism
8. Cutting parameters
1
Shaper Machine
1. Introduction
 Shaper is a machine tool which produces flat surfaces in horizontal, vertical or inclined
planes depending upon the orientation of the cutting tool
 Single point cutting tool is used for machining
 Job is held rigidly in the vice which mounted on the table
 Tool is clamped in the tool post mounted on the ram of the machine
 The ram reciprocates to and fro, tool cuts the material in forward stroke
 No cutting during return stroke
 Due to its limited stroke length it is generally adapted to small jobs
 It is used for cutting keyways and splines on shafts
 Although shaping process is quite slow but it is very popular because of its short setup
time, inexpensive tooling and ease of operation
 In comparison to planer it occupies less floor space, consumes less power, costs less, is
easier to operate, and it is about three times quicker in action as stroke length and
inertia forces are less
 Its stroke length is limited as the accuracy decreases for longer strokes due to ram
overhanging
2
2. Principal parts of shaper

I. Base
 It is the main body of the machine
 Base is made of cast iron
 Provides support for other parts of machine
II. Ram
 It is the main part of the shaper machine
 Ram slides on accurately machined guide ways on top of the column
 It holds the tool and provides the reciprocating motion to it
 It is attached by the rocker arm which provides the motion to ram
III. Table
 It is the metal body attached over frame
 Its main function is to hold the vice and work piece over it
 It has T slots which is used to clamp vice and work piece
IV. Tool head

 It is situated at the front of the ram
 Its main function is to hold the cutting tool
 It consists of tool slide, tool post and clapper box
V. Clapper box
3
 It carries the tool holder

 The main function of clapper box is to provide clearance for tool in
return stroke
 It prevents the cutting edge dragging the work piece while return stroke
and prevent tool wear
VI. Column
 Box type casting mounted vertically on top of the base
 It has two guide ways. One vertical guide ways in the front over which a
cross slide moves up and down
 Second horizontal guide way on top over which ram reciprocate
 Reciprocating mechanism is housed inside the column
4
3. Classification of shapers
Basic types
 Horizontal shaper- ram holding the cutting tool moves in horizontal plane
 According to cutting action of stroke
 Push Type Shaper
5
 Metal is removed when the ram moves away from column

 Most common type used in practice
 Unless otherwise specified, the term shaper refers to Push
type shaper
 Draw Type Shaper
 Metal is removed when the tool is drawn towards the
column
 Allows heavier cuts to be made
 Less vibration during cutting
 According to table design
 Standard Shaper
 Work table can be moved vertically & horizontally
 It cannot be swiveled or tilted
 Universal Shaper
 Table can be moved horizontally, vertically, swiveled &
tilted
 This is mostly used in tool rooms
 According to driving mechanism
 Crank Type
 Driving mechanism is by crank and a slotted lever quick
return motion mechanism is used to give reciprocating
motion to the ram
 The crank is adjustable and is arranged inside the body of
bull gear
 Geared Type
 Driven by Rack & Pinion mechanism
 Hydraulic Type
6
 Driven by oil pressure developed by a pump which is run

by an electric motor
 It is more efficient than crank and geared type shapers
 Vertical shaper- the cutting tool moves in vertical plane
 Travelling head shaper- cutting tool reciprocates & moves cross wise
simultaneously
4. Specification of shaping machine

 Maximum length of stroke of the ram
 Maximum tool overhang
 Dimension of table working surface
 Type of drive
 Power input
 Floor space required
 Weight of the machine
 Forward to return stroke ratio
 Feed
5. Operations on shaper machine

1. Regular operations
i. Machining horizontal surfaces
 Horizontal surfaces are machined by moving the work mounted on
the machine table at a cross direction with respect to the ram
movement
 Clapper box can be set vertically to the uncut surface
7
ii. Machining vertical surfaces

 The vertical cut is made while machining the end of a work piece,
squaring up a block
 The feed is given to the tool by rotating the down feed screw of the
vertical slide
 The apron is swiveled away from the vertical surface being machined
iii. Machining angular surfaces

 Machining the inclined surfaces can be done in several ways
 Swivel tool head method- an angular cut is made at any angle other
than a right angle to the horizontal or to the vertical plane
 Universal table method- if the universal table is available in the
shaping machine then table can be tilted to the required position and
work is fitted on that
 Universal vice method- the job may be fixed in the universal vice and
then vice is swiveled to the required angular position
8
2. Special operations
i. Making of internal keyway
 Internal keyways are cut inside the holes of gears and pulleys
 It is done by holding the tool on a special tool holder called snout bar
 The snout bar is directly fitted on the clapper box
ii. Making of external keyway

 Machining external keyways refers to the cutting of long slots along
the length of cylindrical rods
iii. Making of V-block

 The required shape of a V block is marked on the face of the work and
machining is done by any suitable method of angular machining
iv. Making of dovetail
 Dovetail joint is machined on two separate pieces of work as male
and female elements
 A special form tool is used for machining
9
v. Making of rack gear

 Rack gear cutting is a process of cutting teeth elements at linear pitch
on a flat surface
 Firstly the groove is machined with a square nose parting tool
 Then groove is further machined with a form tool conforming the
shape of the teeth
vi. Making of T-slot
 The shape of the T-slot is marked on the face of the work
 A parting off tool is fitted on the tool post and a rectangular slot is
machined at the middle for the required depth
 The broad base of the T-slot is machined by a T-slot cutting tool
Shapers tools
10
6. Drive mechanism
Types of drive mechanism

1. Hydraulic drive
 Inside the hydraulic cylinder a piston reciprocates
 Between the piston and ram a piston rod is connected
 So the ram reciprocates along with the piston
 Two inlets are provided near each end of the cylinders
 A four-way wall control valve connects these two inlets with the reservoir
which contains the fluid
 The reservoir is connected to the valve with the help of a drain pipes and a
supply
 The supply pipe is again connected to the reservoir by a pump and a relief
valve
 The valve is actuated by the lever and trip dog fitted to the ram
 Oil is sucked by the gear pump from the reservoir at a particular pressure
 This high pressure oil goes to the cylinder through the four-way valve
 The oil is allowed from the pump to the left side of the piston which forces
the piston to move the ram towards right
 It is called as forward or cutting stroke
 In this stroke oil flows out on the right side entry to the reservoir through the
four-way valve and drain pipe
 The lever hits one trig dog at the end of this stroke
 Now the lever position is changed due to this the supply pipe supplies the oil
on the right side of the piston which moves the ram towards left called as
return stroke or non-cutting or idle stroke
 This stroke the high pressure oil covers on lesser area on the cylinder
 Due to this the pressure force will increase
11
 Hence this return stroke is faster by supplying the same quantity of oil
2. Crank and slotted lever mechanism

 In this mechanism the ram is actuated by gear drives associated with electric
motor
 First the electric motor drives the pinion gear
 The pinion gear drives the bull gear which rotates in opposite direction due
to external meshing
 A radial slide is provided on the bull gear
 A sliding block is assembled on this slide
 The block can be positioned in radial direction by rotating the stroke
adjustment screw
 The sliding block has a crank pin
 A rocker arm is freely fitted to this crank pin
 The rocker arm sliding block slides in the slot provided in the rocker arm
called as slotted link
 The upper end has a fork which is connected to the arm block by a pin while
the bottom end of the rocker arm is pivoted
12
 When the pinion gear rotates along with the bull gear the crank will also
rotate
 Due to this the rocker arm sliding block also rotates in the same circle
 Simultaneously the sliding block slides up and down in the slot
 This movement is transmitted to the ram which reciprocates
 The angle through which bull gear rotates on the forward stroke is greater
than the angle through which it rotates on the return stroke
 Hence forward stroke is slow and return stroke is quick hence mechanism is
known as quick return mechanism
7. Feed drive mechanism (Table feed mechanism)

 The table feed mechanism is that when the ram is moving in the return stroke the
table should be cross fed so that next time the tool takes cut in different line
 It may be done either manually or automatically
 A arrangement is provided in the shaper in which a gear E is placed concentric to the
bull gear G and the gear E is in mesh with gear F having a slot in it as shown in the
diagram
13
 A slider B can move in this slot and connecting rod is connected to this slider at one
end and pawl arm at the other end
 By changing the position of B the radius R can be changed and thereby the amount
of swing of pawl arm can be adjusted
 The ratchet wheel is rotated a little with the help of swinging of the pawl arm and
cross feed screw is also connected with the ratchet wheel
 For automatic feed the pawl is connected in the ratchet wheel otherwise it is pulled
outside
 The amount of feed per stroke is changed by changing radius R
8. Cutting parameters
1. Length values that are considered in time calculations
 The length of the total stroke results from the length of the work piece,
approach and overrun
14
L  la  l  lo
Where L is length of total stroke, l is length of work piece, l a is tool approach,

lo is tool overrun
 Recommended values for l a = 10 mm and lo = 5 mm
2. The number of stroke per unit of time

 The number of forward and return strokes that can be achieved in a period
of time can be calculated as follows:
v  103[mm / min]
n  m
L 2  L[mm]
where, n L = number of forward and return strokes in min 1
v  average velocity m/min
L= stroke length in mm
3. Machining time
 Machining time in shaping can be estimated
L
Tm 
f  nL
Tm is machining time in min
L is the sum of job length + tool approach + tool overrun
f is feed in mm/stroke
n L number of strokes per min
15
Planer
1. Introduction
 The planer is a machine tool designed to produce plane and flat surface on a work
piece
 The work piece is securely fixed on the table and table reciprocates horizontally
against a stationary single point cutting tool
 The surface machined may be horizontally, vertical or inclined, angular surfaces are
easier to machine on planer machine
 Planer is similar to shaper but larger in size
 In planer work piece reciprocates but in shaper tool reciprocates
 Planer is used for machining large size work piece because of their capacity for long
table travel and robust construction
 Setting time is of the order 5-6 times that of shaper
 The planer produces large work at lowest cost in comparison to any other machine
tool
2. Operations of planer machine

The planer is used for:
I. Planning flat horizontal, vertical and inclined surfaces
II. Machining dovetails
16
III. Machining slots and grooves
3. Types of planer machine

a) According to general motor construction
I. Double housing planer
II. Open side planer
III. Pit planer
IV. Divided table planer
b) According to drive
I. Gear drive
II. Belt drive
III. Hydraulic drive
a) According to general motor construction
I. Double housing planer
The double planer consists of following parts:
1) Bed
 The bed is very strong and rigid of box type which is made by casting
process
 The table is mounted over the bed
2) Table
 It is also a box type structure which reciprocates on the bed guide
ways
 It is having T-slot as that of shaper for clamping the work
3) Column
 The two long structural member along with guide ways provided on
both sides of the member
 The two columns linked by a cross rail and cross beam
 The cross rail moves on the guide ways
17
 It carries feed mechanism and power transmission links

4) Cross rail
 It is a rigid structural member mounted between two columns and
slides on the guide ways already provided on the columns
 The cross rail can be fixed or fastened at any height
 It moves tool heads
5) Tool heads
 Maximum four tool heads can be mounted on the planer
 Two on cross rail and the other two are on the guide ways of both
columns
 It may tilt to desired angle
18
II. Open side planer

 The only difference in this type is that only one vertical column is provided
on one side of the bed and other side is left open
 Larger and heavier jobs can be mounted on the table
 The construction and working principle are same as that of double housing
planer
III. Pit Planer

 The working principle of this planer is same as that of the other types of
planer
 But the table of this planer is kept in a pit as the floor coincides with the top
surface of the table
 So heavy and large work can be held and machined easily
IV. Divided table planer

 The working principle is similar to that of the standard planer
 But it has two reciprocating tables
 The time required to set the work on planer is more
 To reduce the setting time of work the two same machining are combined by
using two tables
19
 When the first job is machining that the first table will be only reciprocating
and second table is stationary
 On that time the setting of work can be carried out
 After machining the first work piece the table is taken to rest and next one
work is set on it
 On that time second table is in machining operation
4. Specification of planer
 Length of bed
 Width of bed
 Table size (working surface)
 Height under cross rail
 Table surface speed
 Main drive
20
Slotter (Slotting Machine)

1. Introduction
 A slotting machine or slotter may be considered as vertical shaper
 The slotter has vertical arm and a hand or a power operated rotary table
 A slotter can perform a variety of operations such as finishing of external and
internal plain surfaces in addition to slotting
 Slotters are commonly used for internal machining of blind holes or vertical
machining shapes that are complicated in horizontal shaper
 They are useful for machining keyways, cutting internal and external teeth on
large gears
 Cutting action takes place during downward stroke
 The ram is either crank driven or hydraulically driven
2. Construction
i. Base
 The base is rigidly built and is cast integral with column
 The top of the bed and front face of the vertical column are provided
guide ways for the saddle and ram respectively
ii. Saddle
21
 The saddle is mounted upon the guide ways and may be moved towards
or away from the column
 The top face of the saddle is machined to provide guide ways for cross-
slide
 These guide ways are perpendicular to the guide ways on the base
iii. Cross-slide
 The cross-slide is mounted on the guide ways of saddle and may be
moved parallel to the face of the column
iv. Rotary table
 The rotary table is circular table mounted on the top of the cross-slide
 This table can be rotated by hand or by automatic device
 The angular graduation on the table helps work to be machined at angles
v. Ram
 Ram reciprocates vertically up and down
 Its bottom carries the cutting tool
 A slot is cut on the body of the ram for changing the position of the
stroke
3. Types of slotting machines

i. Puncher slotter
22
 The puncher slotter is the heavy duty machine and equipped with
powerful motor
 It is design to remove large amount of metal from large castings or
forgings
 The length of the strike is large
ii. Production slotter
 This is common type of slotter used for general production work
 The drive of the ram is by means of slotted disc and connecting rod
 The flywheel is fitted to prevent shock at the end of the stroke
iii. Tool room slotter

 This slotting machine is of precision type and is used for very accurate
machining
 It is lighter machine and is operated at high speeds
4. Drive mechanism of a slotter
23
In slotter mainly three drive mechanisms are used:

i. Slotted disc mechanism
ii. Slotted link mechanism

iii. Hydraulic drive mechanism
5. Operations performed on slotting machine

 Machining flat surfaces
 Machining cylindrical surfaces
 Machining irregular surfaces
 Machining slots and keyways and grooves
24
6. Difference among shaper, planer and slotter

S.No. Shaper Planer Slotter
1 Can use lighter cuts and It can used heavier cuts It can used light cuts
finer feeds and coarse feeds and improved feeds
2 Use for smaller jobs Used for much bigger jobs It is used for making
slots in smaller jobs
3 Work is held at stop and Tool is fixed and the work The job is held at a
the tool on ram is moved piece is on the table- stop and the tool is
back and forth moves back and forth on the ram and it
under the tool moves up and down
across the work
4 Use quick return Drive is gears or hydraulic Crank driven or
mechanism hydraulic driven
5 It is lighter machine It is heavier machine It is a lighter machine
25

Unit 2 Shaper Planer Slotter

Hochgeladen von

Dokumentinformationen

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Unit 2 Shaper Planer Slotter

Hochgeladen von

Copyright:

Verfügbare Formate

Subject: Manufacturing Science & Technology-II [NME-503]

Course Instructor: Shailendra Pratap Singh

2. Principal parts of shaper

IV. Tool head

 It carries the tool holder

 Metal is removed when the ram moves away from column

 Driven by oil pressure developed by a pump which is run

4. Specification of shaping machine

5. Operations on shaper machine

ii. Machining vertical surfaces

iii. Machining angular surfaces

ii. Making of external keyway

iii. Making of V-block

v. Making of rack gear

Types of drive mechanism

2. Crank and slotted lever mechanism

7. Feed drive mechanism (Table feed mechanism)

Where L is length of total stroke, l is length of work piece, l a is tool approach,

2. The number of stroke per unit of time

2. Operations of planer machine

III. Machining slots and grooves

3. Types of planer machine

 It carries feed mechanism and power transmission links

II. Open side planer

III. Pit Planer

IV. Divided table planer

Slotter (Slotting Machine)

3. Types of slotting machines

iii. Tool room slotter

4. Drive mechanism of a slotter

In slotter mainly three drive mechanisms are used:

ii. Slotted link mechanism

5. Operations performed on slotting machine

6. Difference among shaper, planer and slotter

Das könnte Ihnen auch gefallen