T.

SADASIVA RAO
Assistant Professor Mechanical Engineering Department NIT Warangal 506 004
Disclaimer The content presented here is not entirely my own. Some portions are taken from different sources with great regard. This content is solely for class room teaching and not for any commercial use.

Basic geometry for shaping and planing

Fig. Photographic view of a shaping machine

Cutting tool in action

Fig. Principle of producing flat surface in shaping machine Version

Production of Flat Surfaces..

Motions for producing Flat Surface

Cut
E

Depth of cut
A' A D

Fe ed B'
B C

e c e i p Work

Reciprocating Machine Tools

different from rotary machine tools A single-point tool moves linearly relative to the work part

ShaperShapingtool moves PlanerPlaningworkpiece moves

Basics of Shaping

FIGURE: Basics of shaping and planing.

Shaper

FIGURE: The most widely used shaper is the horizontal push-cut machine tool

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)

Shaping Operation ..
Machining of inclined surface on shaping machine

Movement of the slide for feed Inclined machined surface

Tool head & slide (axis parallel to machined surface) Clapper box (axis away from toolhead) Tool holder located at a convenient angle Tool Workpiece Depth of cut

Operating Conditions in a Shaping Machine ..

Cutting Stroke Return Stroke Workpiece c Lj c Clearance

Length of stroke L
Length of Stroke L = Lj + 2 c

1. 2. 3. 4.

Fig. Parts of a standard shaper

Table support Table Clapper box Apron clamping bolt 5. Down-feed hand wheel 6. Swivel base 7. Position of stroke adjustment hand wheel 8. Ram locking handle 9. Ram 10. Column 11. Driving pulley 12. Base 13. Feed disc 14. Pawl mechanism 15. Elevating screw

Shaping Operation
Cutting action and functioning of clapper box in a shaper
Clapper box

Tool cleared from machined surface Workpiece (a) Forward/Cutting stroke

Lifted clapper box (b) Return stroke

1. Down-feed screw micrometer dial 2. Down-feed screw 3. Vertical slide 4. Apron 5. Apron clamping bolt 6. Clapper box 7. Tool post 8. Washer 9. Apron swivel pin 10. Swivel base

Fig. Tool head of a shaper

1. 2. 3. 4. 5.

Driving pinion Ram Screwed shaft Clamping lever Hand wheel for position of stroke adjustment 6. 7. Bevel gears 8. Ram block 9. Slotted link or Rocker arm 10. Bull gear sliding block 11. Crank pin 12. Rocker arm sliding block 13. Lead screw 14. Bull gear 15. Rocker arm pivot 16. Bull gear slide 17. 18. Bevel gears
Fig. Crank and slotted link mechanism

Fig. a) Crank pin near bull gear center (Short stroke length)

Fig. b) Crank pin at farthest end (Long stroke length)

1. 2. 3. 4. 5.

Driving pinion Ram Screwed shaft Clamping lever Hand wheel for position of stroke adjustment 6. 7. Bevel gears 8. Ram block 9. Slotted link or Rocker arm 10. Bull gear sliding block 11. Crank pin 12. Rocker arm sliding block 13. Lead screw 14. Bull gear 15. Rocker arm pivot 16. Bull gear slide 17. 18. Bevel gears

1. 2. 3. 4. 5. 6. 7.

Knob Pin Helical spring Pawl Ratchet wheel Rocker arm fulcrum Rocker arm connecting pin 8. Driving disc 9. Crank pin

Production of Flat Surfaces

Typical components with flat surfaces

FIGURE: Typical surfaces machined by shaping and planing.

Horizontal surface

Machining Vertical surface

Angular surface

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
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

f w mm
L mm

mm

Width cut in 1 stroke = f Total width = w No. of strokes to m/c total surface = w/f Strokes/mm = N Time for machining surface is t = w/(f N) min

Machining Time
Time for machining w x L surface
w t fN min

From cutting speed

N L (1 m) 1000 v v N 1000 L(1 m) Machining time

w L w (1 m) t fN 1000 v f

min

Machining Time
Time for machining w x L surface
w t fN min

From cutting speed

N L (1 m) 1000 v v N 1000 L(1 m) Machining time

w L w (1 m) t fN 1000 v f

min

Material Removal Rate

Material removal rate (MRR) MRR = f d L N(1+m) 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 m is ratio of return stroke time to cutting stroke time

Fig. Photographic view of a planing machine

Cutting tool in action

Schematic of a Planer

FIGURE: Schematic of planers. (a) Double-housing planer with multiple tool heads (4) and a large reciprocating table; (b) single-housing or open-sided planer; (c) interchangeable multiple tool holder for use in planers.

Shaper
The tool reciprocates while the work is given the feed motion. Jobs of small size Accuracy of work is low because of overhang of the ram. Small depths of cut because of less rigidity Single job Work set up is simple Relatively lighter, smaller and less costly

Planer
The work reciprocates while the tool is given the feed motion. Larger jobs Accuracies are high as the tool is rigidly supported. Large depths of cut because of high rigidity. Multiple jobs can be machined with the help of multiple tooling heads. Work set up takes longer time. Relatively heavier, larger and costlier