Manufacturing Process – II

Lecture Notes

Course Instructor

Dr. Bipul Das

Assistant Professor
Department of Mechanical Engineering
National Institute of Technology Silchar
Silchar – 788010, Assam, India
ME 1303 MANUFACTURING PROCESS – II L T P C
Fifth Semester 3 0 0 6
(Mechanical Engineering Branch)
Pre-requisite – ME 1111, ME 1203, ME 1202, ME 1208

Module 1: Introduction: Introduction to machine tools, motions of machine tools, generation

of surfaces, types of machine tools, basic elements of machine tools.

Module 2: Mechanics of Machining (Metal Cutting): Geometry of single point cutting tools,
Conversion of tool angles from one system to another, Mechanism of chip formation,
Orthogonal and oblique cutting, Use of chip breaker in machining, Machining forces and
Merchant’s Circle Diagram (MCD), Taylor’s Tool Life Equations

Module 3: Lathe: Principle, classification, specifications, operations performed on a lathe.

Calculation for machining time, parameters and performance. Capstan and Turret Lathes:
introduction, comparison among capstan, turret and engine lathe, turret indexing mechanism,
feeding mechanism, cutting tools and tool holders, turret tooling layout.

Module 4: Shaper: Principle, classification, specifications, shaper mechanisms – crank and

slotted lever quick return mechanism, feed mechanism, operations performed on shaper –
machining horizontal, vertical, angular surfaces, cutting slots, grooves, key ways, machining
irregular surfaces, splines and gears. Cutting speed, feed, depth of cut and calculation for
machining time for shaping operations.

Module 5: Planer: Principle, classification, specifications, comparison between shaper and

planer.

Module 6: Milling machine: Principle, classification, specifications, peripheral milling, up

and down milling, face milling, end milling, different operations performed on milling
machines, dividing heads, methods of indexing – direct, simple, compound and differential
indexing, milling of spur gear, milling cutters.

Module 7: Drilling machine: Principle, classification, specifications, operations performed on

drilling machines, twist drill nomenclature.

Module 8: Grinding machines: Principle, classification, specifications, different grinding

processes, grinding wheel – components (wheel material), grit, grade and structure, standard
marking system of grinding wheels. Glazing and loading in wheels, dressing, truing,
balancing, and mounting of grinding wheels.

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Texts/Reference:

1. P N Rao: Manufacturing Technology Vol 2- Metal Cutting and Machine Tools: Tata
Mc Graw Hill

2. Schey: Introduction to Manufacturing Process: McGraw-Hill

3. S K Hajra Choudhury: Workshop Technology Vol II Machine Tools: Media Promoters &
Publishers Pvt. Ltd.4. G Boothroyd & W A Knight: Fundamentals of Machining and Machine
Tools: CRC Press Taylor & Francis Group

5. H Gerling: All About Machine Tools: New Age Int. (P) Ltd.

6. R K Jain: Production Technology: Khanna Publishers

7. A. Ghosh & A. K. Mallik: Manufacturing Science: Affiliated East-West Press Pvt.

Ltd.

8. B S Raghuwanshi: A Course in Workshop Technology Vol II (Machine Tools): Dhanpat

Rai & Co.

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 MODULE 4: SHAPER

4.1 Introduction

The shaper is a reciprocating type of machine tool intended primarily to produce flat
surfaces. These surfaces may be horizontal, vertical or inclined. In general, shaper can
produce any surface comprised of straight line elements. Modern shaper can also produce
contour surfaces. The metal working shaper was developed in the year 1836 by an
Englishman James Nasmyth.

4.2 Principal parts in a standard shaper

The schematic diagram of a standard shaper in Fig. 4.1 represents various salient parts
in a shaper.

Fig. 4.1 Schematic diagram of a shaper

Base: It is the part which is designed to rigidly clamp the machine with the floor to which it
is attached. It is made of cast iron to resist vibration during operation. It provides the
necessary support to the machine.

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Column: The column is a box like casting mounted upon the base. It encloses the ram
driving mechanism. Two accurately mounted guideways are provided on the top of the top of
the column on which the ram reciprocates. The front vertical face of the column which serves
as the guideways for the crossrail is also accurately machined. The lid on the left side of the
column may be opened for inspection and oiling for the internal mechanism with the column.
The other side of the column contains levers, handles, etc. for operating the machine.

Crossrail: The crossrail is mounted on the front vertical guideways of the column. It has two
parallel guideways on its top in the vertical plane that are perpendicular to the ram axis. The
table may be raised or lowered to accommodate different sizes by rotating and elevating
screw 15 which causes the crossrail to slide up and down on the vertical face of the column.
A horizontal cross feed screw which is fitted within the crossrail and parallel to the top
guideways of the crossrail actuates the table to move in a crosswise direction.

Saddle: The saddle is mounted on the crossrail which holds the table firmly on its top.
Crosswise movement of the saddle by rotating the cross feed screw by hand or power causes
the table to move sideways.

Table: The table which is bolted to the saddle receives cross wise and vertical movements
from the saddle and crossrails. It is a box like casting having T-slots both on the top sides for
clamping the work. In a universal shaper the table may be swivelled on horizontal acis and
the upper part of the table may be tilted up or down. In a heavier type of shaper, the front face
of the table is clamped with a table support make it more rigid.

Ram: The ram is the reciprocating member of the shaper. This is semi cylindrical in the form
and heavily ribbed inside to make it more rigid. It slides on the accurately machined dovetail
guideways on the top of the column and is connected to the reciprocating mechanism
contained within the column. It houses a screwed shaft for altering the position of the ram
with respect to the work and holds the tool at the extreme forward end.

Toolhead: The toolhead of the shaper holds the tool rigidly, provides vertical and angular
feed movement of the tool and allows the tool to have an automatic relief during its return
stroke. The vertical slide of the toolhead has a swivel base which is held on the circular seat
on the ram. The swivel base is graduated in degrees, so that the vertical slide may be set
perpendicular to the work surface or at any desired angle. By rotating the downfeed screw
handle, the vertical slide carrying the tool executes downfeed or angular feed movement

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while machining vertical or angular surfaces. The amount of feed or depth of cut may be
adjusted by a micrometer dial on the top of the downfeed screw. Apron consisting of clapper
box, clapper block, and tool post is clamped upon the vertical slide by a screw. By releasing
the clamping screw the apron may be swivelled upon the apron swivel pin either towards left
or towards right with respect to the vertical slide. This arrangement is necessary to provide
relief to the tool while making vertical or angular cuts. The two vertical walls on the apron
called clapper box houses the clapper block which is connected to it by means of a hinge pin.
The tool post is mounted on the clapper block. On the forward cutting stroke the clapper
block fits securely to the clapper box to make a rigid tool support. On the return stroke a
slight frictional drag of the tool on the work lifts the block out of the clapper box a sufficient
amount preventing the tool cutting edge from dragging and consequent wear. The work
surface is also prevented from any damage due to dragging. Figure 4.2 represents toolhead of
shaper.

Fig. 4.2 Schematic of a toolhead used in standard shaper

4.3 Types of shaper

Shapers are classified in a number of ways depending on the general features of

design or the purpose for which they are intended. Shapers are classified as follows.

A. According to the type of mechanism used for reciprocating motion to the ram:

a. Crank type
b. Geared type
c. Hydraulic type

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B. According to position and travel of ram

a. Horizontal type
b. Vertical type
c. Travelling head type

C. According to the type of the design of the table

a. Standard
b. Universal

D. According to the type of cutting stroke

a. Push type
b. Draw type

Crank shaper: This is the most common type of shaper in which cutting tool is given a
reciprocating motion equal to the length of the stroke desired while the work is clamped in
position on an adjustable table. In construction, the crank shaper employs a crank mechanism
to change circular motion of a large gear called “bull gear” incorporated in the machine to
reciprocating motion of the ram. The bull gear receives power either from an individual
motor or from an overhead line shaft if it is a belt driven shaper.

Geared type: The reciprocating motion in some type of shaper is affected 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 a gear train. The speed and direction in which the
machine will traverse depend on the number of gears in the gear train. This type of shaper is
not very widely used.

Hydraulic shaper: In hydraulic shaper, the reciprocating movement of the ram is obtained
by hydraulic power. Hydraulic oil under high pressure is pumped into the operating cylinder
fitted with a piston. The end of the piston rod is connected to the ram. The high pressure oil
first acts on one side of the piston and then on the other causing the piston to reciprocate and
the motion is transmitted to the ram. The piston speed is changed by varying the amount of
liquid delivered by the pump. One of the most important advantages of this type of shaper is
that the cutting speed and force of the ram driven are constant from the very beginning to the
end of the cut. It also offers great flexibility of speed and feed control, eliminates shock and
permits slip or slowing up of motion when the cutting tool is overloaded, protecting the parts

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or the tool from damage. Another advantage is that this type of shaper does not produce noise
like other shapers.

Horizontal shaper: In a horizontal shaper, the ram holding the tool reciprocates in a
horizontal axis. Horizontal shapers are mainly used to produce flat surfaces.

Vertical shaper: In a vertical shaper, the ram holding the tool reciprocates in a vertical axis.
In some of the vertical machines provision is made to allow adjustment of the ram to an angle
of about 10° from the vertical position. Vertical shapers may be crack driven, rack driven,
screw driven or hydraulic power driven. The work table of a vertical shaper can be cross,
longitudinal and rotary movement. The tool used on a vertical shaper is entirely different
from the one used in horizontal shaper. Vertical shapers are very convenient for machining
internal surfaces, keyways, slots or grooves. Large internal and external gears may also be
machined by indexing arrangement of the rotary table. There are vertical shapers which are
specially designed for machining internal keyways. Those are called keyseaters.

Travelling head shaper: In a travelling head shaper the ram carrying the tool while it
reciprocates moves crosswise to give the required feed.

Standard or plain shaper: A shaper is termed as standard or plain when the table has only
two movements, vertical and horizontal, to give the feed. The table may or may not be
supported at the outer end.

Universal shaper: In an universal shaper, in addition to the two movements provided on the
table if the standard shaper, the table can be swivelled about an axis parallel to the ram ways,
and the upper portion of the table can be tilted about a second horizontal axis perpendicular to
the first axis. As the work mounted on the table can be adjusted in different planes, the
machine is most suitable for different types of work and is given the name universal.

Push type shaper: This is the most general type of shaper used in common practice. The
metal is removed when the ram moves away from the column, i.e., pushes the work.

Draw type shaper: In a draw shaper, the metal is removed when the ram move towards the
column of the machine, i.e., draws the work towards the machine. The tool is set on a
reversed direction to that of a standard shaper. The ram is generally supported by an overhead
arm which ensures rigidity and eliminates deflection of the tool. In this shaper the cutting

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pressure acts towards the column which relieves the crossrail and other bearings from
excessive loading and allows taking deep cuts.

4.4 Shaper size

The size of a shaper is determined by the maximum length of stroke or cut it can
make. The usual size ranges from 175 mm to 900 mm. The length of stroke indicates, in
addition to the general size of the machine, the size of a cube that it can be held and planned
in the shaper. Thus, in a 250 mm shaper the length of the stroke may be adjusted from 0 to
250 mm, the cross feed adjustment of the table will be 250 mm and the extreme bottom
position of the crossrail will permit the tale to accommodate a workpiece 250 mm high. The
length of a stroke of a shaper merely indicates the overall size of the shaper. Other
particulars, such as the type of drive: belt drive or individual motor drive power input, floor
space required, weight of the machine, cutting to return stroke ratio, number and amount of
feed etc. are also sometimes necessary.

4.5 Shaper mechanism

In a shaper, the rotary movement of the drive is converted into reciprocating motion
of the ram by the mechanism contained in the column of the machine. In a standard shaper
metal is removed in the forward cutting stroke, while the return stroke goes idle and no metal
is removed during this stroke. To reduce total machining time it is necessary to reduce the
time taken by the return stroke. Thus, the shaper mechanism 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 on the type of work material and machining
condition, 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 known as quick return mechanism. The
reciprocating movement of the ram and the quick return mechanism of the ram and the quick
return mechanism of the machine are usually obtained by any one of the following methods:

A. Crank and slotted link mechanism

B. Whitworth quick return mechanism
C. Hydraulic shaper mechanism

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4.6 Crank and slotted link mechanism

Fig. 4.3 Crank and slotted link mechanism

The crank and slotted link mechanism is shown schematically in Fig. 4.3 for
representative purpose. The motion and power is transmitted to the bull gear 14 through a
pinion 1 which receives its motion from an individual motor or overhead line through speed
control mechanism. Speed of all bull gear may be changed by different combination of
gearing or simply shifting the belt on the step cone pulley. Bull gear 14 is a large gear
mounted within the column. Bolted to the centre of the bull gear is a radial slide 16 which
carries a sliding block 10 into which a crank pin 11 is fitted. Rotation of the bull gear will
cause the crank pin 11 to revolve at uniform speed. Sliding block 12 which is mounted upon
the crank pin 11 is fitted within the slotted link 9. The slotted link 9 which is also known as
the rocker arm is pivoted at 15 at its bottom end attached to the frame of the column. The
upper end of the rocker arm is forked and connected to the ram block 8 by a pin. As the bull
gear rotates causing the crank pin to rotate, the sliding block 12 fastened to the crank pin 11
will rotate in the crank pin circle, and at the same time will move up and down the slot in the
slotted link 9 giving it a rocking movement which is communicated to the ram. Thus the
rotary motion of the bull gear is converted to reciprocating movement of the ram.

The principle of quick return motion is illustrated in Fig. 4.4. In the figure, when the
link is in the position PM, the ram will be at extreme backward position of its stroke, and

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when it is at PN, the ram will be at its extreme forward position. PM and PN are shown as
tangent to the crank pin circle with centre at O. The forward cutting stroke, therefore takes
place when the crank rotates through the angle C1KC2 and the return strokes takes place when
the crank rotates through the angle C2LC1. It is evident that the angle C1KC2 made by the
forward stroke or cutting stroke is greater than the angle C2LC1 described by the return
stroke. The angular velocity of the crank being constant, the return stroke is therefore
completed within shorter time for which it is known as quick return motion. Thus, the ratio
between the cutting time and the return time can be defined as follows.

𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑡𝑖𝑚𝑒 𝐶1 𝐾𝐶2

=
𝑟𝑒𝑡𝑢𝑟𝑛 𝑡𝑖𝑚𝑒 𝐶2 𝐿𝐶1

This ratio is usually varied in the range of 2:1 to 3:2. One of the disadvantages of this
mechanism is that speed of the cutting stroke and return stroke is not constant during the
machining process. It is minimum when the rocker arm is at the two extremities and
maximum when the rocker arm is vertical.

Fig. 4.4 Schematic of quick return mechanism obtained through crank and slotted link
mechanism

4.6.1 Adjusting the length of stroke

The schematic of the shaper mechanism with crank and slotted link is presented in
Fig. 4.3. The crank pin 11 is fastened to the sliding block 10 which can be adjusted and the
radius of its travel may be varied. The block 10 is again mounted upon the radial slide 16
bolted to the centre of the bull gear. The bevel gear 18 placed at the centre of the bull gear
may be rotated by a handle causing the bevel gear 17 to rotate. The bevel gear 17 mounted
upon the small lead screw 13 which passes through the sliding block 10. Thus rotation of

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bevel gear 17 will cause the sliding block 10 carrying the crank pin 11 to be brought inwards
or outwards with respect to the centre of the bull gear. Maximum stroke of the ram is
obtained when the crank pin is shifted towards the farthest end of the slide.

4.6.2 Adjusting the position of stroke

The position of the ram relative to the work can also be adjusted. Referring to the Fig.
4.3, by rotating the hand wheel 5 the screwed shaft 3 fitted in the ram may be made to rotate
through two bevel gears 6 and 7. The ram block 8 which is mounted upon the screwed shaft 3
acts as nut. When the machine is in operation, the clamping lever 4 is tightened upon ram
body 2 and the ram block, the screwed shaft, and the ram becomes one unit. In order to set
the position of stroke, clamping lever 4 is loosened and by rotating the hand wheel 5 the
screwed shaft 3 will rotate within the ram block. The nut remaining fixed in position, rotation
of the screwed shaft will cause the ram to move forward or backward with respect to the ram
block according to the direction of rotation of the hand wheel 5. Thus the position of the ram
may be adjusted with respect to the workpiece. The clamping lever 4 must be tightened after
the adjustment has been made.

4.7 Whitworth quick return mechanism

The Whitworth quick return mechanism is shown in Fig. 4.4. The bull gear is
mounted on a large fixed pin A upon which it is free to rotate. The crank pin 4 is pivoted
eccentrically upon the fixed pin at 5. Fitted on the face of the bull gear is the crank pin 2 on
the top of which is mounted the sliding block 3. Sliding block 3 fits into the slot provided on
the crank plate 4. At the other end of the crank plate 4, a connecting rod 6 connects the crank
plate by a pin 9 and the ram 8 by a pin 7. When bull gear will rotate at constant speed the
crank pin 2 with the sliding block 3 will rotate on a crank circle of radius A2 and the sliding
block will cause the crank plate to rotate about the point 5 with a variable angular velocity.
Pin 9 fitted on the other end of the crank plate 4 will rotate in a circle and the rotary motion
of the pin 9 will be converted into reciprocating movement of the ram similar to the crank
and connecting rod mechanism. The axis of reciprocation of the ram passes through the pin 5
and is normal to the line A5.

When the pin is at position C the ram will be at extreme backward position but when
the pin is at position B, the extreme forward position of the ram will have been reached.
When the pin 2 travels from C to B the crank pin 9 passes through the backward position to

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the forward position in the cutting stroke, and the return stroke is completed when the pin 2
travels from B to C or the pin 9 passes from the forward position to the backward position.
As the angular velocity of the crank pin is uniform, the time taken by the crank pin 2 to travel
through an arc covering CEB is greater than the time taken to move through an arc covering
BDC. Thus a quick return motion is obtained by the mechanism. The length of the stroke of
the ram may be changed by shifting the position of pin 9 closer or away from the pivot 5. The
position of the stroke may be altered by shifting the position of the pin 7 on the ram.

Fig. 4.4 Schematic of Whitworth quick return motion mechanism

4.8 Feed mechanism

In shaper both downfeed and crossfed movements may be obtained. Unlike in lathe
these feed movements are provided intermittently and during the end of return stroke only.
Vertical or bevel surfaces are produced by rotating the downfeed screw of the toolhead by
hand. Crossfeed movement is used to machine a flat horizontal surface. This is done by
rotating the crossfeed screw either by hand or power. Rotation of the crossfeed screw causes
the table mounted upon the saddle to move sideways to a predetermined amount at the end of
each return stroke so as to bring the uncut surface of the work in the direct path of the
reciprocating tool.

Figure 4.5 illustrates the automatic crossfeed mechanism in a shaper. The rotation of
the bull gear causes the driving disc 8 to rotate in a particular direction. The driving disc 8 is
T-slotted and the position of the crank pin 9 attached to the connecting rod may be altered to
give different throw of eccentricity. The other end of connecting rod is attached to the
rocking arm by a pin 7. The rocking arm is fulcrumed at 6, the centre of the ratchet wheel 5.
The ratchet wheel 5 is keyed to the crossfeed screw. The rocking arm houses a spring loaded

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pawl 4 which is straight on one side and bevel on the other side. As the driving disc rotates,
the connecting rod starts reciprocating and the rocking arm rocks on the fulcrum 6. When the
driving disc rotates through half of the revolution in the clockwise direction, top part of the
rocking arm moves in the clockwise direction and the pawl 4 being slant on one side slips
over the teeth of the ratchet wheel 5 imparting it no movement. As the driving disc rotates
through the other half, the top of the rocking arm now moves in the anti clockwise direction
and the straight side of the pawl engages with the teeth of the ratchet wheel causing the wheel
to move anti clockwise direction only. As the driving disc is connected to the bull gear the
table feed movement is effected when the bull gear the driving disc rotates through half
revolution, i.e., during the return stroke only. Rotation through other half does not impart any
feed movement. To reverse the direction of rotation of ratchet wheel and consequently the
feed, a knob I on the top of the pawl 4 after removing the pin is rotated through 180°. The
amount of feed may be altered by shifting the position of crank pin 9 with respect to the
centre.

Fig. 4.5 Automatic feed mechanism in shaper (ratchet and pawl mechanism)

5. Shaper operations

A shaper is a versatile machine tool primarily designed to generate a flat surface by a

single point cutting tool. But it may also be used to perform many other operations. The
different operations that a shaper can perform are as follows.

a. Machining horizontal surface

b. Machining vertical surface

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 c. Machining angular surface
d. Cutting slots, grooves, and keyways
e. Machining irregular surfaces
f. Machining splines or cutting gear

Machining horizontal surface

Figure 4.6 illustrates the process of machining horizontal surface on a workpiece. A

shaper is mostly used to generate flat surfaces. For this process, the job is hold in the bed
mounted over the saddle firmly with holding devices. A shaper tool is set on the tool post
with minimum overhang. The table is raised to a suitable clearance between the tool and the
workpiece. The length and position of stroke is then adjusted. After that proper cutting speed,
feed and depth of cut is adjusted. The depth of cut is adjusted by rotating the downfeed screw
of the toolhead. The amount of the depth of cut is adjusted by a micrometer dial. Both
roughing and finishing cuts can be performed on shaper. For roughing cut speed is decreased
but feed and depth of cut is increased. While for finishing cut depth of cut is decreased with
increase in speed and feed.

Fig. 4.6 Machining of horizontal surface

Machining vertical surface

Figure 4.7 illustrates the machining of vertical surface on a workpiece. A vertical cut
is made while machining the end of a workpiece, squaring up a block or cutting shoulder. The
work is mounted in the vise or directly on the table and the surface to be machined is
carefully aligned with the axis of the ram. A side cutting tool is set on the tool post and the
position and length of the cutting stroke is adjusted. The vertical slide is exactly at zero
position and the apron is swivelled in a direction away from the surface being cut. This is

14
necessary to enable the tool to move upwards and away from the work during return stroke.
This prevents the side of the tool from dragging on the planned vertical surface during return
stroke. The downfeed is given by rotating the downfeed screw by hand. Both roughing and
finishing cuts are performed to complete the job.

Fig. 4.7 Machining of vertical surface (1. Workpiece 2. Tool post with apron)

Machining angular surface

Figure 4.8 illustrates machining of an angular surface on a workpiece. An angular cut

is made at any angle other than a right angle to the horizontal or to the vertical plane. The
work is set on the table and the vertical slide of the toolhead is swivelled to the required angle
either towards left or towards right from the vertical position. The apron is then swivelled
away from the work so that the tool will clear the work during the return stroke. The
downfeed is given by rotating the downfeed screw. Angular surface can also be machined in
a universal shaper or by using a universal vise without swivelling the toolhead.

Fig. 4.8 Machining of angular surface

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Cutting slots and keyways

With suitable tools a shaper can very conveniently machine slots or grooves on a
work or cut external keyways on shafts and internal keyways on shafts on pulleys or gears as
schematically shown in Fig. 4.9.

Fig. 4.9 Machining slots and keyways using shaper

Cutting speed, feed and depth of cut

In shaper, the cutting speed is the rate at which the metal is removed by the cutting
tool. This is expressed in meter per minute (m/min). In lathe as the cutting action is
continuous the cutting speed is expressed by the peripheral speed of the work or the job. But
in shaper the cutting action is intermittent. In shaper the cutting speed is only considered
during the forward stroke or the cutting stroke.

Cutting speed calculations

The cutting speed in shaper is expressed by the following mathematical relationship

𝑙𝑒𝑛𝑔𝑡𝑕 𝑜𝑓 𝑡𝑕𝑒 𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑠𝑡𝑟𝑜𝑘𝑒

𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑠𝑝𝑒𝑒𝑑 =
𝑡𝑖𝑚𝑒 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑏𝑦 𝑡𝑕𝑒 𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑠𝑡𝑟𝑜𝑘𝑒

In practice, to calculate the cutting speed, it is difficult to measure exactly the time
taken during the cutting stroke. The ratio between the return time to cutting time and the
number of double strokes per minute or revolutions per minute of the bull gear should be
known. The cutting speed can be obtained from the equation as mentioned above.

Let, 𝐿 = the length of the cutting stroke in mm

𝑚 = the ratio between the return time to cutting time

𝑛 = the number of double strokes of the ram per minute or rev/min of the bull gear

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 𝑣 = the cutting speed in m/min

𝒍𝒆𝒏𝒈𝒕𝒉 𝒐𝒇 𝒕𝒉𝒆 𝒄𝒖𝒕𝒕𝒊𝒏𝒈 𝒔𝒕𝒓𝒐𝒌𝒆 𝒊𝒏 𝒎𝒎 𝑳

Time taken by the cutting stroke, min = =
𝒄𝒖𝒕𝒊𝒕𝒏𝒈 𝒔𝒑𝒆𝒆𝒅 𝒊𝒏 𝒎/𝒎𝒊𝒏 𝟏𝟎𝟎𝟎 × 𝒗

𝑟𝑒𝑡𝑢𝑟𝑛 𝑠𝑡𝑟𝑜𝑘𝑒 𝑡𝑖𝑚𝑒

𝑚=
𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑠𝑡𝑟𝑜𝑘𝑒 𝑡𝑖𝑚𝑒

𝑚×𝐿
𝑟𝑒𝑡𝑢𝑟𝑛 𝑠𝑡𝑟𝑜𝑘𝑒 𝑡𝑖𝑚𝑒 = 𝑚 × 𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑠𝑡𝑟𝑜𝑘𝑒 𝑡𝑖𝑚𝑒 =
1000 × 𝑣

Time taken to complete one double stroke =

𝐿 𝑚×𝐿 𝐿
+ = (1 + 𝑚)
1000 × 𝑣 1000 × 𝑣 1000 × 𝑣

Number of double strokes per minute or rev/min of bull gear,

1000 × 𝑣
𝑛=
𝐿(1 + 𝑚)

And

𝑛𝐿(1 + 𝑚)
𝑣=
1000

Example: In shaper, the length of stroke is 200 mm, number of double strokes per minute is
30 and the ratio of return time to cutting time is 2:3. Find the cutting speed.

Feed: Feed is the relative movement of the tool or owrk in a direction perpendicular to the
axis of reciprocation of the ram per double stroke and is expressed in mm. The feed is always
given at the end of the return stroke when the tool is not cutting the metal.

Depth of cut: It is the thickness of metal removed during one cut. It is the perpendicular
distance measured between machined surface and non machined surface of the workpiece.

Example: Estimate the time required to machine a cast iron surface 250 mm long and 150
mm wide on a shaper with cutting-to-return ratio of 3:2. Use a cutting speed of 21 m/min, a
feed of 2 mm/double stroke and a clearance of 25 mm. The available ram strokes on the
shaper are: 28, 40, 60 and 90 strokes/min. Also, determine MRR assuming depth of cut as 4
mm.

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Solution:

Given,

Dimension of workpiece = 250 × 150 mm

Clearance, C = 25 mm

1
Ratio between time for cutting stroke to time for return stroke, 𝑚 = 1.5

Feed, 𝑠 = 2 mm/double stroke

Cutting speed 𝑣 = 21 m/min

Depth of cut, 𝑡 = 4 mm

Length of stroke L = 250 + 25 + 25 mm = 300 mm

Machining time

𝐿. 𝐵 1 + 𝑚
𝑇=
1000. 𝑣. 𝑠

300 × 150 × (1 + 0.67)

𝑇=
1000 × 21 × 2

𝑻 = 𝟏. 𝟕𝟖 𝐦𝐢𝐧

Cutting speed,

𝑛. 𝐿(1 + 𝑚)
𝑣=
1000

1000. 𝑣
𝑛=
𝐿(1 + 𝑚)

Thus, number of double stroke required is n = 42

But, the shaper has available number of cutting stroke of 40. Thus, 40 will be considered for
the estimation of machining time.

Material removal rate,

𝑀𝑅𝑅 = 𝐿. 𝑠. 𝑡. 𝑛(1 + 𝑚)

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 𝐦𝐦𝟑
𝑴𝑹𝑹 = 300 × 2 × 4 × 40 × 1 + 0.67 = 𝟏𝟔𝟎𝟑𝟐𝟎
𝐦𝐢𝐧

Example 2: A shaper is operated at 120 cutting strokes per minute and is used to machine a
workpiece of 250 mm length and 120 mm width. Use a feed of 0.6 mm per double stroke and
depth of cut of 6 mm. Calculate the total machining time for machining the component and
the material removal rate. If the forward stroke is completed in 230°, calculate the percentage
of time when the tool is not contacting the workpiece. Assume a total clearance of 25 mm.

***

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