Shaping, Planing and Slotting Shaping, Planing and Slotting: Surface Produced by A Shaper

Production Technology (DPE 101)
Dr. M. Atta
Shaping, Planing and Slotting

Processes for machining horizontal, vertical and inclined flat and contoured d surfaces, f slots, l grooves and d other h recesses by b means of f special single point cutting tools. The cutting is intermittent.
Surface produced by a shaper
(e) Grooved block
(e) Dove tail slide
(e) Guide gib
(e) ) V-Block V Bl k
(e) Tee slot
Feb. 2011
Dr. M. Atta
Difference between the three types

Shaper
1
Planer
Slotter
The work is held stationary and The tool is stationary and the The work is held stationary and the tool on the ram is moved workpiece on the table travels the tool on the ram is moved up back and forth across the work. back and forth under the tool and down across the work. Used for shaping much smaller Meant for much larger jobs. jobs It is used for making slots in jobs Jobs as large as 6 metre wide smaller jobs. and twice as long can be machined. Is a light machine It is a heavy duty machine. Slotting is light machine Can employ light cuts and finer feed. Shaper uses one cutting tool at a time The rams are either crank-driven or hydraulically h d li ll driven. di It is less rigid and less robust
3 4 5
Can employ light cuts and finer Can employ heavier cuts and coarse feed. feed. Uses one cutting tool at a time Driven using quick- return link mechanism h i It is less rigid and less robust Several tools can cut simultaneously. The drive on the planer table is either i h by b gears or by b hydraulic h d li means Better rigidity that give more accuracy on machined surfaces.
Feb. 2011
Dr. M. Atta
a) Shaping
b) Planing
c) Slotting
Feb. 2011
Dr. M. Atta
Shaping Specification of shaper

1. 2. 3. 4. Maximum ram stroke (mm) Work table surface (W*L) No. of stroke per min (st/min) Motor p power ( (KW) )
(1) The
column (2) th the motor t (3) the ram (4) the table (5) The tool head (6) clapper box
(7) The slot with the clamp. (8) ( ) The tool slide and feed screw handle. (9) Ratchet and pawl mechanism (10) the elevating screw of the table. (11) S Support t bracket b k t (12) The levers for setting (st/min)
Feb. 2011
Dr. M. Atta
Feb. 2011
Dr. M. Atta
Specification of planer
1. Max. Workpiece dimension (W*L) 2. Table speed (m/min) 3. Vertical tool feed p per stroke ( (mm) ) 4. Table motor power (KW)
Planer
Feb. 2011
Dr. M. Atta
Specification of slotter
1. Maximum ram stroke (mm) 1 2. Work table diameter (mm) 3. Max distance between tool post to bed (mm) 4. Max distance between ram guide and work table (mm) 5 Motor 5. M t power (KW)
Slotter
Feb. 2011
Dr. M. Atta
Quick-return mechanisms
These types of machine tool are of rectilinear cutting motion therefore, the rotary motion of the drive is converted into reciprocating motion. The metal is removed in the forward cutting stroke, while the return stroke goes idle and no metal is removed during this period. The cutting mechanism is so designed that it moves at a comparatively slower speed during forward cutting stroke, whereas during the return stroke it allow the ram to move at a faster speed to reduce the idle return time. This mechanism is known as quick return mechanism mechanism.
Feb. 2011
Dr. M. Atta
The reciprocating movement of the ram and the quick return mechanism of the machine are generally obtained by anyone of the following methods: 1. Lever rocker arm mechanism (shaper). ( ) 2. Slider crank mechanism (slotter). 3. With worth quick return mechanism (shaper and slotter). 4 Hydraulic 4. H d li system t ( all ll the th 3 types). t ) 5. Variable speed reversible motor (slotter and planer). 6. Rack and pinion mechanism (planer).
Feb. 2011
Dr. M. Atta
Hydraulic system
Its advantages;
1. Greater flexibility of speed (infinite variable) 2. Smoother in operation 3. Ability to slip in case of overload, thus eliminating tool and machine damage 4 Possibility of changing speeds and feeds during operation. 4. operation 5. Providing a constant speed all over the stroke.
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Dr. M. Atta
Rack and p pinion mechanism
Feb. 2011
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Dr. M. Atta
Lever rocker arm mechanism
1. Speed p adjustment j 2. Stroke length adjustment

Feb. 2011
position 3. Stroke p adjustment 4. Quick return action

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Dr. M. Atta
Quick return action

tC Time for cutting stroke Cutting ration = = t Time for return stroke R
Angle of cutting stroke t k A Angle l of f return t stroke
= = m R
The length of the stroke is reduced the quick return action (inverse proportional).
Feb. 2011
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Dr. M. Atta
Feed Mechanism
1. Driving disc gp pin 2. Driving 3. Connecting link 4. The pawl carrier 5 Pawl 5. P l 6. The ratchet wheel
How to reverse the direction of the machine table and to make the feeding rate zero.
Feb. 2011
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Dr. M. Atta
Tool mounting
Tool head Back block
Tool post
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Dr. M. Atta
Work holding devices
Feb. 2011
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Dr. M. Atta
Machining time
W .i Tm f .N
NL(1 m) Vc 1000
Vc VR * m
1000 V N 2.Ls
V is the average cutting speed Vc is the mean cutting speed VR is the mean return speed W = w + w 1 + w2 m is the inverse of the cutting ratio
Feb. 2011 17
Dr. M. Atta
Example It is required to machine three slots, in a workpiece, of 20 mm. wide and 30 mm. height by a shaping machine. The stroke length is 450 mm. the shaper makes 30 stroke/min with feed rate 0.25 mm/stroke and cutting angle 210 210. . Take the depth of cut equal 5 mm. Calculate: 1) Average cutting and return speeds. 2) The machining time. 3) How can the feed adjusted if the shaper table cross slide lead screw has 5 mm. pitch and tooth wheel of 75 teeth.
Feb. 2011
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Shaping, Planing and Slotting Shaping, Planing and Slotting: Surface Produced by A Shaper

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Production Technology (DPE 101)