Unit III

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UNIT-3
SHAPER, SLOTTER, PLANNER
INTERDUCTION:-
In machining, the excess metal is removed by cutting tool. Metal is removed from work with the tool
moving and work stationary; the work moving and the tool stationary or both the tool and work moving.
Shaper:-
The shaping machine (shaper) is used for machining flat surfaces. The work is held stationary on table,
the tool carried in the tool head reciprocates past the work with the help of horizontal ram.
Slotter:-
The slotter (slotting machine) is similar to shaper except that in a slotter the ram holding the tool
reciprocates in vertical axis, and it is intended to cut grooves, key ways and slots of various shapes.
Planer:-
The planer (planing machine), like shaper is primary intended to produce flat surfaces. The major
difference is that in planer the cutting tool is stationary and table holding the work reciprocates past the
stationary tool.
SHAPER
Working principle of shaper:-
The shaping machine is used for producing flat surfaces. Machining on shaper is more economical with
easier work setting and shaper tooling. The working principle of shaper is shown in fig. in case of shaper
the job is rigidly held in a suitable device like a vice or clamped directly on the machine table and the
cutting tool reciprocates across the work piece. The tool cuts on forward stroke and the return stroke
remains idle as there is no cutting action in that stroke.
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Main parts of shaper:-
Construction:-
The main parts of the Shaper machine is Base, Body (Pillar, Frame, Column), Cross rail, Ram and tool
head (Tool Post, Tool Slide, Clamper Box Block).
Base:-
The base is a heavy cast iron casting which is fixed to the shop floor. It supports the body frame and the
entire load of the machine. The base absorbs and withstands vibrations and other forces which are likely
to be induced during the shaping operations.
Column:-
It is box type cast iron body, mounted on the base and acts as a housing for the operating mechanism of
the machine. It can also act as a support for other parts of the machine such as cross rail and ram..etc. In
case of hydraulic shaper, it carries the hydraulic drive mechanism inside it.
Cross rail:-
It is a heavy cast iron construction attached to the column at its front on the vertical guide ways. It
carries two mechanisms one for elevating the table and other for cross travel of the table.
Table:-
It is made of cast iron and has a box type construction. It holes and supports the work during the
operation and slides along the cross rail.
Ram:-
It is also a cast iron semi-circular in shape and provided with a ribbed constructions for inside rigidity
and strength. It carries the tool head. It carries the mechanism for adjustment for ram position inside it.
Tool head:-
The tool head is attached to the front end of the ram and can be swiveled at any angle on either for
making angular cuts. It is the device in which is held the tool it can slide up and down.
Vice:-
It is a job holding device and is mounted on the table. It holds and supports the work during the
operation. Alternatively, the job can be directly clamped to the machine table.
Specifications of a shaper:-
Shaping machine is specified with the following specifications,
(i) Length of stroke, which indicates the general size of the machine and the size of a cube that
can be held and planed in the shaper.
(ii) Types of drive belt drive or individual motor drive.
(iii) Power input.
(iv) Floor space required.
(v) Weight of the machine.
(vi) Cutting to return stroke ratio.
(vii) Number and amount of feed.
Operations performed on shaper machine:-

There are four operations are possible:
1. Horizontal cutting 2. Vertical cutting 3. Angular cutting 4 irregular cutting.
1. Horizontal cutting:-
It is most common operation performed on a shaping machine. In this, the work is fed
in a horizontal direction under the reciprocating tool and the surface produced is horizontal and flat. For
this, the work is either held in a vice or clamped on the machine table, depending upon it size. Before
clamping the work, the vice jaws, work seat or table top are tested for accuracy. Parallels are used for
clamping the work, if it is held in the vice. The tool is held in a proper tool holder. The depth of cut is
adjusted and the machine started cross feed to the table is given initially by hand, till the cut starts.
After that power feed can be employed. After the cut is finished, the machine is stopped and the work
inspected. If more material is to be removed, the procedure is repeated till the desired surface is
obtained.
A special precautions is required in setting the tool for horizontal cutting.
i) The tool should be held vertically in such a way that it’s cutting edge point in a direction slightly away
from the work as show in fig.
ii) Tool setting is that its cutting edge should not be projected much below the tool holder and vertical
slide of the tool head should not be made to over hand too far below the ram. If otherwise the tool will
be weakened.
2. Vertical cutting:-
The tool is fed downward in vertical cutting. This sort of tool feed is commonly employed in cutting
grooves, keyways, tongues, parting off and squaring ends and shoulders. For machining the vertical
surface on the work piece, the job is held in a vice or is directly fitted on the table. The surface to be
machined is carefully aligned with the axis of the ram. The type of tool is used for vertical machining is a
side cutting tool. This side cutting tool is set in a tool post and the position and length of the stroke is
adjusted.
The vertical slide is set exactly at zero position and the apron is swiveled in a direction away from the
surface being cut. This enables the tool to move upwards and away from the work during return stroke.
3. Angular cutting:-
The operation of Angular cutting is employed for machining inclined surfaces, beveled surfaces and
dovetails, etc. Here again, the down feed of tool is used. The work piece is set on the table and the
vertical slide of the tool head is swiveled to the required angle towards right or left from the vertical
position. In this type of machining, down feed of the tool is used and the cutting tool set properly. The
down feed is provided by rotating the down feed screw.
4. Irregular cutting:-
For machining irregular surface, the required shape is scribed on the surface of the work. The required
shape is obtained by manipulating vertical and horizontal feeds.
Beside the above operations, the shaper can be conveniently used for cutting splines and
gears by using index Centre.
Quick return mechanism on shaper:-
The ram moves at a comparatively slower speed during the forward cutting stroke. During the return
stroke, the mechanism is so designed to make the tool move at a faster rate to reduce the idle return
time. This mechanism is known as quick return mechanism.
As the ram moves at a faster rate during return stroke, the time taken becomes less. The total
machining time decreases and the rate of production increases. The following mechanisms are used for
quick return of the ram.
1. Crank and slotted link mechanism
2. Hydraulic mechanism
3. Whitworth mechanism.
1. Crank and slotted link mechanism:-
An electrical motor runs the driving pinion(S) at a uniform speed. This pinion makes the bull gear(M) to
rotate at a uniform speed. Bull gear is a large gear fitted inside the column. The point ‘O’ is the Centre of
the bull gear. A slotted link having a long slot along its length is pivoted about the point ‘K’. A sliding
block ‘N’ is fitted inside the slot and slides along the length of the slotted link. ‘P’ is the crank pin and
‘OP’ can be considered as a crank. Figure shows the crank & slotted link mechanism.
When the bull gear rotates, the sliding block also rotates in the crank pin circle. This arrangement
provides a rocking movement to the rocker arm. As the top of the slotted link is connected to the ram,
the ram reciprocates horizontally. So, bull gear rotation is converted into the reciprocating movement
of the ram.
Quick return mechanism:-
Slotter
Working principle of slotter:-

Slotting machine (slotter) is a reciprocating type machine in which ram holding the tool reciprocates in
vertical axis, and the work is supported on a rotary table which is mounted on the carriage. The cutting
motion is produced by the reciprocating moment of the vertical ram. The tool removes the material
from the job during down ward cutting stroke and upward stroke is idle.
Main parts of a slotter:-
The main parts of the slotting machine are shown in figure.
(i) Base (ii) Column (iii) Table (iv) Ram (v) saddle
(i) Base:-
It is a heavy cast iron construction and is also known as bed. It act as a support for the column, the
driving mechanism ram, table and all other fittings. At its top it carriers horizontal ways along which the
table can be traversed.
(ii) Column:-
It is another heavy CI body which acts as a housing for the complete driving mechanism. At its front it
carries vertical ways, along which the ram moves up and down.
(iii) Table:-
Usually a circular table is provided on slotting machines. In some heavy duty slotters, such as a puncher
slotter, either a rectangular or circular table can be mounted. On the top of the table are provided
T-slots to clamp the work or facilitate the use of fixtures, etc.
(iv)Ram:-
It moves in a vertical direction between the vertical guideways provided in front of the column. At its
bottom, it carries the tool post in which the tool is held. The cutting action takes place during the
downward movement of the ram.
(v) Saddle:-
It is mounted on the base and can be moved longitudinally on the guide ways.
The different types of slotting machines are:
1. Punch slotter: a heavy duty rigid machine designed for removing large amount of metal from large
forgings or castings
2. Tool room slotter: a heavy machine which is designed to operate at high speeds. This machine takes
light cuts and gives accurate finishing.
3. Production slotter: a heavy duty slotter consisting of heavy cast base and heavy frame, and is
generally made in two parts.
Slotter machine Specifications:-

a) Slotting machine are specified by maximum length of the stroke.
b) Maximum size of the job that can be machined easily.
c) Maximum motion of the table sliding with the workpiece.
d) Amount of material that can be machined in a single stroke.
e) Maximum length and width of the base that can withstand heavy jobs.
i. The length of the ram stroke may be 320mm.
ii. The power of the motor may be 7KW.
iii. The whole dimensions of slotter may be 2650×1810×2890mm.
iv. The maximum diameter of the work table of machine may be 360mm.
v. The longitudinal travel of the table may be 650mm and cross 500mm.
vi. Table feed per double stroke of the tool may be circular 0.1-1.4mm, cross 0.2-2.4mm and longitudinal
0.2-2.4mm.
Operations performed on slotter:-

The various slotter operations are as follows,
1. Machining flat surfaces:-
For machining a flat surface the work is mounted on a parallel strip such that the tool will not touch the
work table at the end of the cut. Metal is removed as the tool travels past the work. The cross feed is
given at the beginning of each cutting stroke.
For machining cylindrical surfaces the tool is set radially on the work. The feed is given by rotary table at
the beginning of the cut.
2. Machining the circular surfaces:-
During this process, the work is placed centrally on the table and is clamped at this position by means of
clamps and packing pieces. Before starting the machine the tool is set radially and the saddle is clamped
in position. During machining, the feed is given by rotating the table through the required arc and thus
producing the required circular surface.
3. Machining a rectangular slot, key ways and grooves:-
Internal and external grooves and keyways are cut conveniently using slotter. For cutting equally spaced
grooves on a periphery of work, feed is given by the rotary table. The graduations on the rotary table
facilitates the indexing the work.
4. Machining irregular surfaces and cam profiles:-
For machining irregular contours and cam profiles the work is fed simultaneously in three directions i.e.
by combining cross, longitudinal and rotary feed movements of table.
Planer
Working principle of planer:-
The planning machine or planer is one of the basic machine tools of the industry. It is used for producing
flat surfaces. It is designed with stationary housing for holding tool heads and a reciprocating table for
holding the work piece. Thus the work is mounted on table reciprocates past the stationary tool and the
feed is given by the lateral movement of the tool; metal is cut only in the forward movement of the
table and return stroke is idle and complete quickly.
Main parts of a planer or double housing planer:-
The planer are available in different types for doing different types and sizes of job; the most common
being the standard and double housing planer.
The main parts of the planer are:
1. Bed 2. Table 3. Housing or Column 4. Cross rail 5. Saddle
6. Tool heads 7. Controls.
1. Bed:-
It is a very large and heavy cast iron structure that acts as foundation of the machine. It supports column
and all moving parts of the planer. The length of bed is doubled than the table, it carries over it. At the
top of the bed v- ways (guide ways) are provided to support and guide the table. It accommodates the
table driving mechanism.
2. Table:-
The table is also made of CI with an accurately machine top. It is mounted on the bed the upper surface
of the table has ‘T’ slots to facilitate clamping of work pieces, special fixtures and vices with T-bolts. Its
main function is to hold the workpiece and reciprocate on guide ways to impart motion to job for
planning operation.
3. Housing or Column:-
It is also called as column or uprights. These are long vertical structures places on each side of the bed. It
supports the cross-rail on which the tool heads are mounted. Its front face is accurately machined to
provide guide way for cross-rail. It also supports the mechanism for operating the tool heads.
4. Cross-rail:-
Cross-rail is a rigid casting mounted horizontally on the vertical ways of housings. It can moved vertically
up and down by means of elevating screws located within the ways of the housing. It carries two saddles
with tool heads in which tools are held. The tool head may be moved horizontally on the guide ways of
cross-rail by means of feed screws.
5. Saddle:-
The unit fitted to the ways of cross-rail is known as saddle. The front of the saddle is provided with ways
to hold tool head and feed screws. The saddle can be moved in cross wise direction over the table.
6. Tool heads:-
The tool head is attached to saddle which is mounted on cross rail. It contains tool post for holding the
tools. There are four sets of saddles mounted on a planer a set of two saddle’s mounted on cross rail
and the other two saddles are mounted on columns. Each saddle carries a tool head. Tool heads can be
swiveled through 60 on either side of its vertical position.
7. controls:-
Various controls for starting, operating and stopping the various mechanisms, automatic cutting off
speed and feed regulation and similar other functions are usually provided with in a quick approach of
the operator of the machine.
Operations of planer machine: The planer is used for:
1. Planing flat horizontal, vertical and curved surfaces.
2. Planing at an angle and machining dovetails.
3. Planing slots and grooves.
For planing horizontal surfaces straight tool is clamped in a vertical position on a cross-rail tool heads.
The work reciprocates past the tool. The tool is fed by rotating the cross-feed screw.
For planing vertical surfaces apron is swiveled in a direction so that the tool will swing away from
machined surface during the return stroke. The tool is fed by rotating the down feed screw.
Planing a curved surfaces may be done by feeding the tool simultaneously in both horizontal and vertical
directions.
On planer, slots and grooves are cut by using slotter tool. The method of operation is similar to that of a
shaper.
Specifications of planer:-
The size of the planer is generally specified by the maximum size of the job that can be conveniently
machined. It can be known by
1. The distance between two vertical housings.
2. Distance between the table and the cross-rail when the table is at the topmost position.
3. Maximum length of the table travel.
In addition to this, some of the other particulars are also needed to specify a planer. They
1. Number of feeds and speeds available.
2. Length of bed and table.
3. HP of the motor
4. Type of drive
5. Floor space required
6. Weight of the machined etc.
Types of planers:-
Planers are classified according to the type of housing, and the type of work they can accommodate. The
following list gives the various types of planers which are most commonly used.
1. Double housing planer,
2. Open side planer,
3. Pit type planer,
4. Edge planer, and
5. Divided table planer.
Estimating machine time of shaper:-
Difference between shaper, planer and slotter:-
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UNIT-4
DRILLING AND BORING MACHINES
Introduction: The drilling machine or drill press is one of the most common and useful machine
employed in industry for producing forming and finishing holes in a workpiece. The unit essentially
consists of:
1. A spindle which turns the tool (called drill) which can be advanced in the workpiece either
automatically or by hand.
2. A work table which holds the workpiece rigidly in position.
WORKING PRINCIPLE OF DRILLING:-

Drilling is the process (operation) of making holes in a solid metal (workpiece) by means of a rotating
cutting tool called drill. It is one of the most common operations in the manufacturing industry. In this
operation can’t produce a perfectly true hole. It is considered as a roughing operation. So drill is
followed by another operation called reaming. In reaming operation the required dimensional accuracy
& fine surface finish is obtained means of a multi tooth revolving tool called reamer. In this, the
workpiece is held stationary during the process.
Main parts of the drilling machine:-
The main operating parts of a sensitive machine/drill press are Base, Column, Table, and Drill Head.
1. Base: The base is a heavy casting that supports the machine structure; it provides rigid mounting
for the column and stability for the machine. The base is usually provided with holes and slots which
help to Bolt the base to a table or bench and allow the work-holding device or the workpiece to be
fastened to the base.
2. Column: The column is a vertical post that Column holds the worktable and the head containing
the driving mechanism. The column may be of round or box section.
3. Table: The table, either rectangular or round. Drill machine/press in shape supports the workpiece
and is carried by the vertical column. The surface of the table is 90-degree to the column and it can
be raised, lowered and swiveled around it. The table can be clamp/hold the required the workpiece.
Slots are provided in most tables to allow the jigs, fixtures or large workpieces to be securely fixed
directly to the table.
4. Drilling Head: The drilling head, mounted close to the top of the column, houses the driving
arrangement and variable speed pulleys. These units transmit rotary motion at different speeds to
the drill spindle. The hand feed lever is used to control the vertical movement of the spindle sleeve
and the cutting tool.
Specifications of drilling :-
According to ‘Indian standards’ the drills are specified by their diameters, materials…etc. these data are
mainly based on the material for which the drill is to the normally used.
They are made in 3 types:
1. Type N- For normal low carbon steels,

2. Type H - For hard materials, and
3. Type S – For soft and tough materials.
In British system there are three different ranges of sizes:
1. Normal sizes drill:-
The standard set of number sized drills consists of 60, numbering from 1 to 60, although against special
order drills up to number 80 can also be obtained. In this series of drills higher the number smaller is the
size of the drill and vice versa.
2. Letter sizes drill:-
This series of drills is designated by letters from A to Z, in which A represent the smallest size and Z the
largest. In this series the drill sizes, starting from A (=0.234”), go up in the steps of about 0.01” with the
largest size Z being equal to 0.413.
3. Fractional sizes drill:-

3"
In this series the drill sizes start from 1/64” and go up to 5” in diameter. Up to 1 4 the rise in sizes is
uniform in steps of 1/64 and beyond this the steps are larger.
Different types of drilling machines and their features:-

1. Portable drilling machine 2. Sensitive or bench drill 3. Upright drilling machine (single spindle)
4. Upright drilling machine (Turret type) 5. Radial drilling machine 6. Multi spindle drilling machine
7. Deep hole drilling machine. 8. Gang drilling
1. Portable drilling machine:-
It is a very small, compact and self-contained unit carrying a small electric motor inside. It is used for
drilling holes in components that cannot be transported to the shop floor due to their size or weight or
where lack of space does not permit their transportation to the bigger type of drilling machine. In such
case, the operation is performed on the site by means of the portable electric drill. Portable drills are
fairly light in weight so that they can be easily handled by one or two men only.
2. Sensitive or bench drill:-
This type of drill machine is used for very light work. It construction is very simple and so is
the operation. It construction of a cast iron base having a fixed table over it. At the top of the column is
provided the drive, which consists of an endless belt running over two v-pulleys one of these pulleys is
mounted on the motor shaft and the other on machine spindle. No gears are used in the drive. The
vertical movement to the spindle is given by the feed handle through a rack and pinion arrangement.
The spindle usually caring No 1 Morse taper.
These drills are normally manufactured having up to 20mm drilling capacity in steel.
3. Upright drilling machine (single spindle):-
It is also known as standard, vertical or pillar drilling machine. It is used for heavier work and has back
hearing arrangement similar to a lathe. Specifically differs from a sensitive drill in its weight, rigidity,
application of power feed and the wider range of spindle speeds. These machines are manufactured in
various sizes having different drilling capacities up to a maximum of 75mm in steel.
4. Upright drilling machine (Turret type):-
It is a production drilling machine, which is very useful when a series of different size holes are to be
drilled repeatedly or a number of different operations, like drilling, reaming, boring, spot facing….etc.
are to be performed in sequence repeatedly.
5. Radial drilling machine:-
This machine is very useful because of its wider range of action. Its principal use is in drilling holes on
such work which is difficult to be handled frequently with the use of this machine, the tool is moved to
the desired position instead of moving the work to bring the latter in position for drilling.
6. Multi spindle drilling machine:-
These machines are mostly used in production work and are so designed that several holes of different
sizes can be drilled simultaneously. Their use facilities an increased rate of production with sufficient
accuracies. In these machines two or more spindles are driven from common driving shaft through
worms and worm gears or belt.
7. Deep hole drilling machine:-
Where very long holes of relatively smaller diameter are required to be drilled these machines are used,
such as in rifle barrels and long spindles. These machines can be obtained both in horizontal as well as
vertical types, according to the requirement. In these machines is provided stock and a carriage. The
work is mounted between these two and the carriage carries the drill, on the head stock. Side, the work
is supported on a spindle, which also rotates the same as the drill is fed slowly.
Special type of drills are used on these machines. In deep hole drilling operation the work rotates at high
speed instead of the drill, while the drill is feed into the work at low feed. The lubricant is feed to the
cutting edges of the drill under pressure in abundance. Both vertical and horizontal designs of these
machines are available, but the horizontal machining are more commonly used.
Applications:-
Deep hole drilling machines are used where very long holes of small diameter are drilled such as in rifle
barrels, long spindles, hollow shafts etc.
8. Gang drilling machine:-
It is nothing but a type of multiple spindle drilling machine, in which the spindles are arranged in a row.
These spindles may be driven either separately or collectively. This machine is very useful when the
nature of work is such that a number of operations like drilling, reaming, boring and tapping…etc. are to
be performed in succession on it. The table may be of stationary type or adjustable type. The work
moves from one spindle to the other after each operation. The no of spindles is not limited. It depends
upon the type of production that is intended to be undertaken. Commonly fore spindles are to be used.
9. Automatic drilling machine:-
These are production machines, arranged in series to perform a no of different operations in sequence
at successive work station. The workpiece, after completion of an operation at one station, are
automatically transferred to the next station for another operation. Thus, it works as a transfer lime.
Different operations can be performed like drilling, reaming, boring…..etc.
Tool holding devices:-

1. Chucks 2. Spindle 3. Sleeve 4. Socket 5. Floating holder
1. Chucks:-
It is the most popular and useful device for holding parallel shank drill and other small tools. It is design
to hold different drills of different sizes. A sleeve or socket can hold one size of tool shank only but a
chuck may be used to hold different sizes of tool shanks within a certain limit. These drill chucks have
tapered shanks which are fitted into the drilling machine spindle. The drill chuck can be tightened or
loosened with the help of a chuck key. During the drilling operation, the jaws of the drill chuck are
forced inwards or outwards from the drill which grips the driving tool or drill.
Two types of chucks are commonly used.
i. Quick change chuck ii. Three-jaw self-centering chuck.
2. Spindle:-
Most of the drilling machines have the spindle, bored out to a standard taper to receive the taper shank
of the tool. The taper in spindle is standardized to 1:20, while fitting the tool in shank is forced into the
tapered hole thereby the tool is gripped by friction.
3. Sleeve:-
The spindle of the drill is made to hold only one size of shank. If the taper shank of the tool is smaller
than the taper in the spindle hole, a taper sleeve is used. The outside taper of the sleeve conforms to
the drill spindle taper and the inside taper holds the shanks of the smaller size tools or smaller sleeves.
4. Socket:-
Drill sockets are used to hold the tool when the tapered tool shank is longer than the spindle. Drill
sockets are longer than the drill sleeves.
A drill socket consists of a solid shank attached to the end of the cylindrical body.
5. Floating holder:-
When a reamer or tap needs to follow a previously drilled or bored hole, a floating holder is used.
Twist drill:-
Twist drill is the most widely used tool in modern drilling practice. It has two cutting edges and two
helical grooves. These helical grooves are called flutes. The flutes are admit coolants and allows the chip
to escape during drilling operation. Twist drill consists of a cylindrical body carrying two spiral flutes cut
on it. Twist drills are usually made of high speed steel.
The standard twist drill is shown below. It has two main parts 1. Body 2. Shank.
The body is the cutting unit with flutes, cutting edges and drill point. Its point angle is ground to 118°.
The shank is the part of drill which held in machine spindle and driven by it. So the shank which is
gripped in the drill chuck or sleeve. The twist drills are classified into mainly two types:
i). parallel shank twist drill,
ii). Tapper shank twist drill.
Advantages using twist drills are:-

1. The chips and cutting of the metal are automatically driven out of the hole through the flutes.
2. Cutting edges are retained in good condition for a fairly longtime, thus avoiding the frequent
regrinding of the drill.
3. Heavier feeds and speeds can be employed quite safely resulting in a considerable saving of time.
4. For the same size and depth of the hole they need less power in comparison to other forms of drills.
Twist drill nomenclature:-
Axis:-
It is the longitudinal centerline of the drill running through the centers of the tang and the chisel edge.
Body:-
It is the part of the drill from its extreme point to the commencement of the neck, if present.
Otherwise, it is the part extending up to the commencement of the shank. Helical grooves are cut on
the body of the drill.
Shank:-
It is the part of the drill by which it is held and driven. It is found just above the body of the drill. The
shank may be straight or taper. The shank of the drill can be fitted directly into the spindle or by a tool
holding device.
Tang:-
The flattened end of the taper shank is known as tang. It is meant to fit into a slot in the spindle or
socket. It ensures a positive drive of the drill.
Neck:-
It is the part of the drill, which is diametrically undercut between the body and the shank of the drill. The
size of the drill is marked on the neck.
Point:-
It is the sharpened end of the drill. It is shaped to produce lips, faces, flanks and chisel edge.
Lip:-
It is the edge formed by the intersection of flank and face. There are two lips and both of them should
be of equal length. Both lips should be at the same angle of inclination with the axis (59°).
Land:-
It is the cylindrically ground surface on the leading edges of the drill flutes adjacent to the body
clearance surface. The alignment of the drill is maintained by the land. The hole is maintained straight
and to the right size.
Flutes:-
The grooves in the body of the drill are known as flutes. Flutes form the cutting edges on the point. It
allows the chips to escape and make them curl. It permits the cutting fluid to reach the cutting edges.
Angles:-
Chisel edge angle:-
The obtuse angle included between the chisel edge and the lip as viewed from the end of the drill. It
usually ranges from 120° to 135°.
Helix angle or rake angle:-
The helix or rake angle is the angle formed by the leading edge of the land with a plane having the axis
of the drill. If the flute is straight, parallel to the drill axis, then there would be no rake. If the flute is
right handed, then it is positive rake and the rake is negative if it is left handed. The usual value of rake
angle is 30° or 45°.
Point angle:-
This is the angle included between the two lips projected upon a plane parallel to the drill axis and
parallel to the two cutting lips. The usual point angle is 118°. When hard alloys are drilled the value
increases.
Lip clearance angle:-
The angle formed by the flank and a plane at right angles to the drill axis. The angle is normally
measured at the periphery of the drill. The lip clearance angle ranges from 12° to 15°.
Drilling machine operations:-

Though drilling is the primary operation performed in a drilling machine, a number of similar operations
are also performed on holes using different tools. The different operations that can be performed in a
drilling machine are:
10
1. Drilling:-
It is the main operation done on this machine. It is the operation of producing a circular hole in a solid
metal by means of a revolving tool called drill.
2. Reaming:-
It is the operation of finishing a hole to bring it to accurate size and have a fine surface finish. The
operation is performed by means of a multi tooth tool called reamer. The operation serves to produce a
straight, smooth and accuracy hole. The accuracy to be expected is within ± 0.05mm.
3. Boring:-
11
It is an operation used for enlarging a hole to bring it to the required size and have a
better finish. It involves the use of an adjustable cutting tool having single cutting edge. In addition to
the above objective, this operation can be used for correcting the hole location and out of roundness.
The accuracy to be expected is within ± 0.125mm.
4. Counter boring:-
It is the operation used for enlarging only a limited portion of the hole is called counter boring. If can be
performed either by means of a double tool boring bar or a counter boring tool.
5. Counter sinking:-
It is the operation used for enlarging the end of a hole to fine it a conical shape for a short distance. This
is done for providing a seat for the countersunk heads of the screws, so that the lather may be finish
with the main surface of the work. The standard counter sinks caring included angles of 60°, 82° or 90°.
12
6. Tapping:-
It is the operation done for forming internal threads by means of the tool called tap. To perform this
operation the machine should be equipped with a reversible motor or some other reversing mechanism.
7. Spot facing:-
This operation is used for squaring and finishing the surface around and at the end of a hole so that the
same can provide a smooth and true seat to the underside of bolt heads or collars…etc.
13
Boring
Boring is the process of using a single point tool to enlarge and locate a previously made hole. Drills tend
to wander or drift, thus, where greater accuracy is required, drilling is followed by boring and reaming.
Classification of boring machines:-

Boring machines are manufactured in various different designs and sizes. They can broadly be classified
into the following three types:
1. Horizontal boring machine,
2. Vertical boring machine,
3. Jig boring machine.
The above three, the first two types include production machines, used in general production work, last
one is a precision machine used for precision boring operations, such as jig boring.
Jig boring machine:-
14
How do you calculate machining time in boring:-

Machining time in boring is determined by the formula,
𝐿+𝐴
T=
𝑓𝑟 × 𝑁
Where, T = Machining time in minute
L = Length of the workpiece in mm
A = Allowance for tool approach and exit
𝑓𝑟 = Feed rate, mm/rev
N = Revolution of the cutter for boring in rev/min.
****************THE END*********************

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Main parts of shaper:-

Operations performed on shaper machine:-

1. Horizontal cutting 2. Vertical cutting 3. Angular cutting 4 irregular cutting.

A special precautions is required in setting the tool for horizontal cutting.

Quick return mechanism on shaper:-

1. Crank and slotted link mechanism

1. Crank and slotted link mechanism:-

Quick return mechanism:-

Working principle of slotter:-

Main parts of a slotter:-

The main parts of the slotting machine are shown in figure.

The different types of slotting machines are:

Slotter machine Specifications:-

b) Maximum size of the job that can be machined easily.

c) Maximum motion of the table sliding with the workpiece.

d) Amount of material that can be machined in a single stroke.

i. The length of the ram stroke may be 320mm.

ii. The power of the motor may be 7KW.

iii. The whole dimensions of slotter may be 2650×1810×2890mm.

Operations performed on slotter:-

1. Machining flat surfaces:-

2. Machining the circular surfaces:-

3. Machining a rectangular slot, key ways and grooves:-

4. Machining irregular surfaces and cam profiles:-

Main parts of a planer or double housing planer:-

The main parts of the planer are:

1. Bed 2. Table 3. Housing or Column 4. Cross rail 5. Saddle

6. Tool heads 7. Controls.

Operations of planer machine: The planer is used for:

1. Planing flat horizontal, vertical and curved surfaces.

2. Planing at an angle and machining dovetails.

3. Planing slots and grooves.

1. The distance between two vertical housings.

3. Maximum length of the table travel.

1. Number of feeds and speeds available.

2. Length of bed and table.

5. Floor space required

6. Weight of the machined etc.

1. Double housing planer,

2. Open side planer,

3. Pit type planer,

4. Edge planer, and

5. Divided table planer.

Estimating machine time of shaper:-

Difference between shaper, planer and slotter:-

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2. A work table which holds the workpiece rigidly in position.

WORKING PRINCIPLE OF DRILLING:-

Main parts of the drilling machine:-

They are made in 3 types:

1. Type N- For normal low carbon steels,

In British system there are three different ranges of sizes:

1. Normal sizes drill:-

2. Letter sizes drill:-

3. Fractional sizes drill:-

Different types of drilling machines and their features:-

1. Portable drilling machine:-

2. Sensitive or bench drill:-

3. Upright drilling machine (single spindle):-

4. Upright drilling machine (Turret type):-

5. Radial drilling machine:-