Parts produced by planning, shaping and slotting

Process description

Shaping, planning and slotting operations are similar type of machining process which
provide a cutting action as a result of straight-line reciprocating motion between the tool
and the work. In all the processes single point cutting tools are used. In shaping and
planning operations, straight and flat surfaces are created. In shaping operation, the speed
motion is accomplished by moving the cutting tool, while in planning the motion is
accomplished by the work piece. Shaping is performed in a machine tool called shaper
whereas the machine tool for planning is called planer. (Refer Figure M3.5.1)

Figure M3.5.1: Shaping Operation

Slotting process is identical to shaping except that the motion of the ram is vertical
instead of horizontal.

Characteristics and applications of planer-machined parts

When the part is large and flat, planners are recommended for machining operation.Few
examples of such parts are, machinery bases, diesel engine blocks, and locomotive and
ship parts commonly undergo planer operations. In fact, large, rough castings and welded
assemblies that require some afterweld machining are suitable for planning. The
recommended dimension for the work-piece to be used in planer is 1 by 1 by 4 m.
Surfaces shorter than 300 mm cant be used to machine on a planer.

Figure M3.5.2: Typical parts and surfaces machined on a shaper.

Characteristics and applications of shaper-machined parts

Parts used in shaper are usually smaller than those run on planers. The size is such that it
can be moved easily by hand and clamped in a vise-type work holder on the machine
table. Surfaces machined with shapers are usually, but not necessarily, flat and can be in
the horizontal, vertical, or angular plane. The maximum stroke length of shaper is 900
mm. A Minimum length is less than 13 mm, with the usual case about 150 to 400 mm. A
width of around 20 inch can be handled in 36 inch shaper and is about 10 inch in 20 inch
shaper.

Further, inaccessible surfaces those cant be machined with other types of equipments can
be produced by shaping. Few such parts are deep internal slots and contours in blind holes
or inaccessible places. In addition, shapers are frequently used for slot, keyway, and
spline cutting. These operations often require the use of a dividing head mounted on the
shaper table. (Refer Figure M3.5.2. for typical shaper machined part)

Materials for planning, shaping, and slotting

Planers, shapers, and slotters can machine difficult alloys and high hardness (to
approximately Rc46). The machinability data available in Table M3.5.1 are also
applicable to planer, shaper, and slotteroperations, also provides relative machinability of
various materials used on planers and shapers.

Table M3.5.1: Effects of Material Properties.(Source: Design for Manufacturability

Handbook by James G Bralla, 2nd Ed)

Decrease in Machinability Finishability Tool life

Material factor
Strength/hardness Improves None Improves

Ductility Improves Improves Improves

Strain hardenability Improves Improves Improves

Coefficient of friction Improves Improves Improves

Heat conductivity None None Reduces

Heat capacity None None Reduces

Chemical reactivity None Improves Improves

Grain size Improves Improves Reduces

Abrasive insoluble Improves Improves Improves

Free-machining additions Decreases Decreases Decreases

Design recommendation
Planers, shapers, and slotters are very much flexible in terms of capability of machining
different shapes and size. Hence, there are very few restrictions on the design of parts to
be machined. Few recommendations are provided below for economy of the operation or
for dimensional control.

1. Design parts to be rigid enough to withstand cutting tool forces, withstand deflection
and to be solidly clamped to the work table. (Refer Figure M3.5.3.)

Figure M3.5.3: Design planer and shaper-machined parts to be rigid to withstand

cutting-tool forces and to be solidly clamped

2. It is preferred to have machined surfaces in the same plane to reduce the number of
operations required. (Exception: multi-tooled planer can machine both surfaces
simultaneously)
3. Multiple surfaces that are not parallel in the direction of reciprocating motion of the
cutting tool are to be avoided. Otherwise these would require additional setups.
4. Machined surfaces too close to an obstruction at the end of the cut are to be avoided.
5. When surface machining is required for a flat thin pieces, first equal amount of rough
machining is done from both side followed by finish machine on both the sides.
(Refer Figure M3.5.4.)
 Figure M3.5.4: Avoid machined surfaces too close to an obstruction

6. The minimum size of holes in which a keyway or a slot can be machined with a
slotter or shaper is about 1 inch. Slots and contours should not be longer than 4times
the largest dimension of the opening or the hole diameter (Figure M3.5.5).

Slot
Figure M3.5.5: Recommended minimum-size hole in which a keyway slot, or other
contour can be shaper-machined

7. Slots and contours should not be longer than 4 times the largest dimension of the
opening or the hole diameter. Long cutting tool lacks in rigidity (Refer Figure
M3.5.6.)

Figure M3.5.6: Recommended minimum-size slot

Dimensional factors and tolerances
The major dimensional variations might occur from human factors. These are

Design and condition of the part

Clamping method

It is important to have a square and flat clamping surface of the work piece. A distorted piece
in clamping will spring back after machining and will not have a true surface. This is very
crucial in planer machined parts when cutting forces are really high. Hence, the solidity of
clamps, supports, and stops is quite important.

Table M3.5.2: Recommended tolerances for dimensions and surfaces produced on planers,
shapers, and slotters. (Source: Design for Manufacturability Handbook by James G Bralla,
2nd Ed)

Preferred tolerance for Average Closest

manufacturing (mm) tolerance (mm) tolerance (mm)
Flatness
In 0.5 m2 (planers) 0.13 0.05 0.013
In 0.1 m2 (planers or 0.08 0.025 0.013
shapers)
In 65 cm2(shapers) 0.05 0.025 0.013
Surface finish
Cast iron 3m 1.5m 0.8m
Steel 6m 3m 0.8m
Surface location
Small surfaces 0.25 0.13 0.025
Large surfaces, over 0.4 0.2 0.05
0.1m2
Contour to specified position
Manual feed 1.0 0.7 0.4
Tracer feed 0.13 0.05 0.025
Further, dimensional error might arise due to movement of the work piece and deflection of
the part as a result of cutting forces Due to release of internal stresses in the material during
machining (especially flat pieces) warp age also might occur.

In slotting operations or in the shaping of internal surfaces when there is substantial overhang
of the tool or tool holder, the aspect of rigidity comes into picture.

In addition to the above, the factors which will improve accuracy in tooling are slower cutting
speeds, lighter cuts with finer feeds, and the use of lubricants and facilitate smooth finish are,
sharp tools, correctly ground, and fine feeds. Table M3.5.2 provides the recommended
tolerances for dimensions and surfaces produced on planers, shapers, and slotters.