ME210-MACHINING

TECHNOLOGY

By
Dr.R.DINAKARAN
ASSISTANT PROFESSOR (STC)
DEPARTMENT OF MECHANICAL ENGINEERING
PUDUCHERRY TECHNOLOGICAL UNIVERSITY
UNIT-III CO 3
Shaper Types, Shaping Operations, Planner Types,
Planning Operations, Slotting Machine and its Operations.
➢ Shaping, planning and slotting can be defined as the

process of removing metal from a surface in horizontal,

vertical and inclined position to produce a flat or plane

surface, slots and grooves by means of a relative

reciprocating motion between the tool and work piece.

➢ The difference between the three processes of shaping,

planning and slotting is that in shaping and slotting, the

tool is reciprocating and the work piece is fed in to the

cutting tool while in planning, the work piece is

reciprocating and the tool is fed in.

➢ The tool reciprocates horizontally in the shaping and vertically in

slotting.

➢ The cutting is intermittent in all the three processes because in the

relative reciprocating motion the tool cuts only in forward- working (or

cutting) stroke followed by the idle-return stroke.

Shaper Types, Shaping Operations
Shaper

➢ Machine tool used for shaping operation is called shaper.

➢ Designed for machining flat surfaces on small sized jobs. If the size of

the job is large, then planing is used.

➢ The work is held in a vice bolted to the work table.
➢ The regular feed is obtained by moving the worktable
automatically at right angles to the direction of the cutting tool
and the tool head gives downward feed at right angles to the
regular feed or any other angle as desired.
Working Principle:

➢ The job is rigidly fixed on the machine table.

➢ The single point cutting tool held properly in the tool post is mounted on a
reciprocating ram.
➢ The reciprocating motion of the ram is obtained by a quick return motion
mechanism.
➢ As the ram reciprocates, the tool cuts the material during its forward stroke.
➢ During return, there is no cutting action and this stroke is called the idle
stroke.
➢ The forward and return strokes constitute one operating cycle of the 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:
It is the main body of the machine. It consist all element of machine. It works as
pillar for other parts. Base is made by cast iron which can take all compressive loads.

Column: It is a vertical member mounted on the bed that holds the reciprocating
mechanism.
Ram:
It is the main part of the shaper machine. It holds the tool and provides the
reciprocating motion to it. It is made by cast iron and move over ways on column. It is
attached by the rocker arm which provide it motion in crank driven machine and if the
machine is hydraulic driven it is attached by hydraulic housing.

Tool head:
It is situated at the front of the ram. Its main function is to hold the cutting tool.
The tool can be adjusted on it by some of clamps.
Table:
It is the metal body attached over the frame. Its main function is to hold the work piece and
vice over it. It has two T slots which used to clamp vice and work piece over it.
Clapper box:
It carries the tool holder. The main function of clapper box is to provide clearance for tool
in return stock. It prevents the cutting edge dragging the work piece while return stock and prevent
tool wear.
Cross ways:
It consist vertical and horizontal table sideways which allow the motion of table. It is attach with some
cross movement mechanism.
Stroke adjuster:
It is attached below the table. It is used to control the stroke length which further controls the ram
movement.
Table supports:
These are attached front side of the table and used to support the weight of table during working.
Specifications of a Shaper
The shaper is specified as follows :
1. Maximum length of the stroke (in mm).
2. Size of the table i.e., length, width and depth of the table.
3. Maximum horizontal and vertical travel of the table.
4. Maximum number of strokes per minute.
5. Type of quick return mechanism.
6. Power of the drive motor.
7. Floor space required.
8. Weight.
Horizontal shapers range in size from small bench models with stroke of 175 mm or 200 mm to
heavy duty models with strokes as much as 900 mm. Shaping machines are commonly provided
with power feed ranging from 0.2 to 0.5 mm/stroke.
Example:
Shaper Machine – Specifications
a. Length of Ram stroke: (457 mm)
b. Range of Ram speeds: (12, 24, 40 & 72 strokes per minute)
c. Working surface of table: (483 mm X 330 mm)
d. Max Table Travel – Horizontal: (610 mm)
e. Max Table Travel – Vertical: (457 mm)
f. Angular movement of table on either side: (600)
g. Maximum size of Tool Shank in Tool Head: (51m X 21mm)
h. Maximum vertical travel of Tool Slide: (152 mm)
i. Maximum swivel of Tool Head: (600)
j. Main Drive Motor: (3 H.P./ 950 rpm)
Classification of Shapers

1. According to the type of mechanism used for giving reciprocating motion to

the ram :
(i) Crank shaper :
➢ In this type of shaper, a crank and a slotted lever quick return motion
mechanism is used to give reciprocating motion to the ram.
➢ The crank arm is adjustable and is arranged inside the body of a bull gear (also
called crank gear).
(ii) Geared shaper :
➢ In this shaping machine, the ram carries a rack below it, which is driven by a
spur gear. This type of shaper is not widely used.
(iii) Hydraulic shaper :
➢ In this type of shaper, a hydraulic system is used to drive the ram. This shaper
is more efficient than the crank and geared type shapers.
According to position and travel of ram :
(i) Horizontal shaper :
➢ In this shaping machine, the ram moves or reciprocates in a horizontal direction. This shaper is
mainly used for producing flat surfaces.
(ii) Vertical shaper :
➢ In this shaper, the ram reciprocates vertically in the downward as well as in upward motion.
➢ This type of shaping machine is very convenient for machining internal surfaces, keyways, slots or
grooves.
(iii) Travelling head shaper :
➢ A travelling head shaper has a reciprocating ram mounted on a saddle which travels sideways along
the bed. The ram carries the tool slide.
3. According to the type of cutting stroke :
(i) Push-cut shaper :
➢ In this shaper, the ram pushes the tool across the work during cutting operation. In other words,
forward stroke is the cutting stroke and the backward stroke is an idle stroke. This is the most
general type of shaper used in common practice.
(ii) Draw-cut shaper :
➢ In a draw-cut shaper, the ram draws or pulls the tool across the work during cutting operation.
In other words, the backward stroke is the cutting stroke and forward stroke is an idle stroke.
4. According to the design of the table :
(i) Standard or plain shaper :
➢ In this type of shaper, the table has only two movements namely horizontal and vertical, to give the
feed. It cannot be swiveled or tilted.
(ii) Universal shaper :
➢ In this shaper, in addition to the above two movements, the table can be swiveled about an
horizontal axis parallel to the ram and the upper portion of the table can be tilted about a horizontal
axis perpendicular to the first axis. A universal shaper is mostly used in tool room.
WORK HOLDING DEVICES FOR SHAPING MACHINES
CLAMP IN A VICE
Operations Performed in Shaping Machine
Machining Irregular Surfaces
Advantages, Limitations, and Applications of Shapers:
The following are the advantages and disadvantages of shapers :
Advantages :
1. The set up of shaper is very quick and easy and can be readily changed from one job to another.
2. The work can be held easily.
3. The single point tools used are in inexpensive ; these tools can be easily grounded to any desired shape.
4. Lower first cost.
5. The cutting stroke has a definite stopping point.
6. Because of lower cutting forces, thin and fragile jobs can be conveniently machined on
shapers.

Limitations :
1. A shaper, by nature, is a slow machine, because of its straight line, forward and return (idle) stroke. The
single point tool requires several strokes to complete a work.
2. The cutting speeds are not usually very high since difficulties are encountered in designing machine tools
with high speeds of reciprocating motion due to high inertia forces developed in the motion of the units and
components of the machine. Owing to these reasons the shaper does not find ready adaptability for assembly
and production line.
Quick Return Mechanism
➢ A quick return mechanism is an system to produce a reciprocating effect such that
time taken by system in return stroke is less time taken by it in the forward
stroke.
➢ In quick return mechanism, a circular motion is converted into reciprocating
motion just like crank and lever mechanism but it has return stroke time is
different from forward stroke time.
➢ This mechanism is used in many machines. Some of them are shaper machines,
slotter machines, screw press, mechanical actuator etc. With the help of quick
return mechanism, the time needed to cutting is minimized.
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 system ( all the 3 types).

5. Variable speed reversible motor (slotter and planer).

6. Rack and pinion mechanism (planer).

 Types of Quick Return Mechanism

➢ Whitworth Quick Return Mechanism

➢ Crank and Slotted Link Mechanism

➢ Hydraulic Drive
Whitworth Quick Return Mechanism
1] As shown in the above figure, the link ‘AC’ is fixed.

2] The crank ‘BC’ is pivoted at the end ‘C’ and rotates

with constant angular velocity.

3] The slider ‘B’ is connected at the end of the crank & it

rotates along with crank ‘BC’.

4] The slotted lever ‘AP’ is pivoted at the end ‘A’. As the

slider ‘B’ reciprocates in a slotted bar, the slotted bar
performs oscillatory motion in the circular arc from ‘P1’
to ‘P2’.

5] The one end of connecting rod ‘PR’ is connected to the

slotted bar and another end is connected to the ram ‘R’.

6] The ram ‘R’ reciprocates from ‘R1’ to ‘R2’.

 Forward stroke:-

➢ For forward stroke, the crank ‘B’ has to move from point ‘B1’ to ‘B2’ in a clockwise direction.
➢ In above figure, the forward path of crank ‘B’ is denoted by a green dotted line. At the same instant,
the end of the slotted bar moves from ‘P1’ to ‘P2’ in clockwise direction. And the ram ‘R’ moves
from position ‘R1’ to ‘R2’ in forward direction.

Reverse stroke:-
➢ For return stroke, the slider ‘B’ moves from position ‘B2’ to ‘B1’ in a clockwise direction.
➢ In above figure, the return path for crank ‘B’ is denoted by a red dotted line.
➢ At the same instant, the end ‘P’ of the slotted bar moves from position ‘P2’ to ‘P1’ in an
anticlockwise direction. And the ram ‘R’ moves from ‘R2’ to ‘R1’ in the backward direction.

Time for the forward stroke = Time to cover angle β by crank

Time for the return stroke = Time to cover angle α for the crank.
Time for forward stroke > Time for return stroke
Crank and Slotted Link Mechanism
•In crank & slotted link mechanism. Power is transmitted from the bull gear by
a pinion that receives its power from an individual motor.
•In a two-gear system, smaller gears are called pinions, and larger gears are
called bull gears.
Working of Crank & Slotted Link Mechanism:-
➢ The radial slide is moved to the center of the bull gear. This
radial slide consists of a sliding block that fits the crank pin.
➢ The crank will rotate at the same speed as the bull gear
rotates.
➢ The sliding block mounted on the crank pin is fitted to the
crankpin, which is fitted within the slanted link. This slanted
link is attached to the column frame, with its lower end
pivoted. The uppers end of the sliding link is bisected and
connected to the ram block by a pin.
➢ When the bull rotates the gear, the crankpin rotates at a
uniform speed. the sliding block fastening the crankpin will
rotate on the crank pin circle, and at the same time, this
slider will slide up & down in the sliding link.
➢ As the slider moves inside the sliding link, it will provide a
rocking movement to the sliding link, and this movement
will provide motion by being transferred to the ram.
➢ Hence the rotary motion of the bull gear is converted into
reciprocatory motion of ram.
Strokelength of a ram is the distance the ram moves forward or
backward. It depends upon the distance between the centre of the bull
gear and the centre of the sliding block. it is adjusted according to the
length of the work.
QUICK RETURN MOTION
Hydraulic Drive
Working of Hydraulic Drive :-
➢ In hydraulic drive, there is a tank at the bottom which contains the hydraulic fluid. This tank is also known
as oil reservoir.
➢ At first the oil from the reservoir. This oil is passed through the valve chamber present in the right of the oil
cylinder exerting pressure on the piston.
➢ Any oil present in the left side of the piston is discharged to the reservoir through the throttle valve.
➢ At first the fluid in the tank is pumped out and this fluid passes through the passage present in the right side
of the cylinder .
➢ This fluid exerts pressure on the piston and the ram of the machine performs forward stroke.
➢ When the ram moves forward, the lever changes its position and hits the reversing dog. As the lever
changes its position, the three valves connected to the lever also change their position and now the oil can
pass through the passage present in the left side of the cylinder.
➢ After the forward stroke is completed, the valves changes its position and now the pumped fluid from the
reservoir moves from the passage present in the left side of the piston. Also, the passage through which the
oil return to the reservoir opens and get connected to the right passage and the fluid present on the right
side of the piston is discharge to the reservoir.
➢ As the fluid moves towards the left side of the piston, the piston which is attached to the ram moves
towards right and return stroke is performed by the ram.
➢ At the end of the return stroke, another dog hit against the lever and the direction of the lever as well as the
stroke changes. In this way, the forward and the return stroke of the ram is repeated.
➢ The quick return takes place due to difference in the stroke volume of cylinder at both ends.
➢ The volume of passage at the left side is less than the volume of the passage on the right
side.
➢ As the pump is constant discharge pump, same amount of oil will be passed on the both
passage. So the pressure on the passage with less volume will be more and the return stroke
will be faster than the forward stroke.
➢ The cutting speed can be controlled by controlling the flow of oil which can be controlled by
using the throttle valve.
➢ When the throttle valve is lost the excess valve is cut through the relief valve to the reservoir
maintaining uniform pressure during the cutting stroke.
Planner Types, Planning Operations
➢ The planer or planing machine is a machine tool, which like the shaper produces flat
surfaces in horizontal, vertical or inclined plane.
➢ The fundamental difference is that the planer operates with an action opposite to that
of the shapers, i.e., the work piece reciprocates past one or more stationary single
point cutting tools.
➢ Planers are meant for machining large sized work pieces, which cannot be
machined by the shaping machines. In addition to machining the large parts it is also
possible to mount many small parts in line on the table of planer and machine them
simultaneously.
➢ The work table is moved back and forth on the bed beneath the cutting head either by
mechanical means , such as a rack and pinion gear or by a hydraulic cylinder.
Principal Parts of a Planer
1. Bed :
➢ It is a big cast iron structure.
➢ The upper part of the bed is provided with precision Vee-type guideways on
which the table slides.
2. Table :
➢ It is made of cast iron and its top surface (flat) is machined accurately.
➢ It reciprocates along the ways of the bed and supports the work.
➢ Its top surface is provided with slots to clamp the workpieces.
➢ It may be driven by rack and gear, by rack and double helical gear or by
hydraulic system.
3. Column or Housing :
➢ The columns or housings are rigid column-like castings placed on each side of the bed.
➢ The front vertical surface of the column has guideways to enable movement of the cross-rail
vertically up and down.
4. Cross-rail :
➢ It is mounted on the precision machined ways of the two housings.
➢ It may be raised or lowered on the housings to accommodate work of different heights on the table
and to allow for the adjustment of the tools.
5. Tool heads :
➢ These are mounted on the cross-rail or housings by means of a saddle which slides along the rail or
housing ways. The saddle may be made to move transversely on the cross-rail to give cross feed.
CLASSIFICATION OF PLANNER

Planers are generally divided in to five types

1) Double housing planer

2) Open side planer

3) Edge type planer

4) Pit type planer

5) Divide table planer

One drawback-Limits the width of work piece due to presence of two housing on
each side of bed.
 4) Pit type planer
➢ This machine has a heavy construction in which the table is kept in a pit.

➢ This planer machine works against the working principle of the planners as in this

machine table is kept stationary inside the pit whereas the tool reciprocates along with

columns and cross rail.

➢ The table of the planer machine is generally kept at level to the ground, so that very

heavy work can be mounted over the work table with certain ease.

➢ There is no side tool head, instead two vertical head is mounted on the cross rail. Thus,

only top surface can be machined by this planner at a time.

 Size or Specifications of a planing machine
1. Distance between two columns
2. Stroke length of the planer
3. Radial distance between the top of the table and the
bottom most position of the cross rail
4. Maximum length of the table
5. Power of the motor
6. Range of speeds and feed available
7. Types of drives required
 Work Holding Devices
➢T-Bolts & Clamps (most jobs done by bolts & clamps)

➢ Stop Pins (supports the work piece)

➢ Toe Dogs (holding thick work piece)

➢Vices (common work holding device)

➢ Fixtures (special purpose work holding device)

Planer Tools
Planer Operations
The following operations can be performed on planer :
1. Planing horizontal surfaces.
2. Planing vertical surfaces.
3. Planing curved surfaces.
4. Planing slots and grooves.
5. Planing at an angle and machining dove-tails.
6. Planing a helix.
7. Gang or multiple planing.
 Planer Shaper
Planer table reciprocates moves and also moves In shaper ram, moves back and forth in a straight
back and forth line
It operates by moving the workpiece back and the cutting tool moves back and forth in a
forth under a stationary cutting tool. straight line
Planers are designed for machining large They are suitable for machining smaller
workpieces workpieces
Several tools can be mounted and employed Usually one tool is used on a shaper.
simultaneously, usually four as a maximum,
facilitating a faster rate of production.

Planers are known for their high cutting power Shapers are capable of producing finer finishes
and ability to remove large amounts of material and achieving greater precision compared to
in a single pass. planers.
Work setting requires much of skill and takes a Clamping of work is simple and easy.
longer time.
Slotting Machine and its Operations
➢ Basically the slotting machine is a vertical axis shaper.
➢ The main difference between a shaper and a slotter is the direction of the
cutting action ; the tool moves vertically rather than in horizontal direction.
➢ The slotter has a vertical ram and a hand or power operated rotary table. On some
machines, the ram may be inclined as much as 10° to either side of the vertical
position when cutting inclined surfaces.
➢ The stroke of the ram is smaller in slotting machines than in shapers to account
for the type of work that is handled in them.
Principal Parts of a Slotting Machine:
1. Base :
➢ It is also known as bed and is a heavy cast iron construction.
➢ It acts as a support for the column, the driving mechanism ram, table and all other
fittings.
➢ At its top it carries horizontal ways, along which the table can be traversed.

2. Column :
➢ It is also made of cast iron. It acts as housing for the complete driving mechanism.
➢ The vertical front face of the column is accurately finished for providing ways
along which the ram moves up and down.
3. Ram :
➢ It moves in vertical direction between the vertical guideways provided in front of
the column.
➢ The ram supports the tool head to which the tool is attached. The cutting action
takes place during the downward movement of the ram.
4. Table :
➢ On slotting machines, usually a circular table is provided. However, 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.
➢ The table can be moved is horizontal plane by two perpendicular cross-
slides.
5. Cross-slide:
➢ Cross-slide can be moved parallel to the face of the column. The circular
worktable is mounted on the top of the cross-slide.
6. Hand wheels:
➢ Hand wheels are provided for rotating the table for the longitudinal and cross
traverse.
Working of Slotter Machine
➢ The working of the slotter machine is the same as that of the shaper machine but the difference is that shaper
cuts the metal horizontally and slotter cuts the metal vertically.
➢ First, the workpiece that is to be slotted mounted on the table. The table has t slots that helps the workpiece
to hold firmly on it.
➢ After Clamping the workpiece on the table. An appropriate cutting tool is inserted into the tool head for
cutting the metal. Here the tool is made of HSS (High-speed steel)
➢ And then the machine is ON that allows the ram to move upward and downward in a vertical direction.
➢ As the ram moves downward called a downward stroke, It cuts the metal from the workpiece and then
returns quickly (called as return stroke) without cutting the metal. So we can say that the slotter machine
cuts the metal in downstroke and remains idle i.e. does not cut any metal in return stroke.
➢ Feed in slotter can be worked automatically or manually. There is a mechanism inside it that allows the
movement of the table, cross slide according to the ram movement automatically. The movements of each
part are interlinked with each other and there is no chance of any error in the feed
SPECIFICATION OF A SLOTTER
a. The maximum stroke length.
b. Diameter of rotary table.
c. Maximum travel of saddle and cross slide.
d. Type of drive used.
e. Power rating of motor.
f. Net weight of machine.
g. Number and amount of feeds
h. Floor area required.
The complete specifications of a typical 300 mm stroke slotters are as under :
Stroke maximum = 300 mm ;
Stroke minimum = 0 mm ;
Height between table and head = 450 mm ;
Maximum diameter accommodated when machining at centre = 900 mm ;
Diameter of the table = 500 mm ;
Traverse of table, longitudinal = 450 mm ;
Traverse of table, transverse = 350 mm ;
Face of head = 575 mm × 250 mm ;
Height overall = 2000 mm ; Length of bed = 1375 mm ; Width of bed = 412 mm ; Height of
bed = 575 mm ; Height of head = 1275 mm ; Belt size = 75 mm ; H.P. required = 2 H.P.
Types of Slotters
Various types of slotters are :
1. Puncher slotter. Used for removing large amount of metal from heavy work which
has been forged, stamped or sawn roughly to shape.
2. General production slotters. Mostly used for general production work.
3. Precision tool room slotters. Primarily used for tool room work where accuracy,
in most cases, is of paramount importance.
4. Key seater. Used exclusively for machining keyways on the inside of wheel and gear
hubs.
Operations Performed on a Slotting Machine:
A slotting machine is a very economical machine tool when used for certain classes of work
given as under.
1. The slotting machine can be used to cut slots, splines keyways for both internal and external
jobs such as machining internal and external gears.
2. It can be used for shaping internal and external forms or profiles.
3. It can be used for works as machining concave, circular, semi-circular and convex surfaces.
4. It can be used for machining vertical surfaces, machining angular or inclined surfaces,
machining of shapes which are difficult to produce on a shaper machine and machining dies
and punches.
5. It can be used for internal machining of blind holes.
6. It is used for machining dies and punches.
Slotter Operations

The following operations can be performed on a slotter :

1. Cutting of internal grooves or keyways.

2. Cutting of internal gears.

3. Cutting of recesses.

4. Cutting of concave, circular and convex surfaces etc.

DRIVE MECHANISM OF SLOTTER

There are four types of driving mechanisms used in slotter for driving the ram,

i. Slotted disc mechanism.

ii. Slotted link mechanism.

iii. Variable speed reverse motor driving mechanism.

iv. Hydraulic drive mechanism.

S.No Shaper Planer Slotter
1. In a shaper machine, the In a planer machine, the reciprocating In a slotter machine, the
reciprocating motion is done by the motion is done by the workpiece. reciprocating motion is done by the
tool. tool.
2. In a shaper machine, the In a planer machine, the reciprocating In a slotter machine, the
reciprocating motion is done by the motion is done by the workpiece in a reciprocating motion is done by the
tool in a horizontal direction. horizontal direction. tool in a vertical direction.
3. Both the workpiece and the tool are Only tools are fed into the planer Only workpieces are fed into the
fed into the shaper machine. machine. slotter machine.
4. A small and medium-sized
In a shaper machine, only a small A large workpiece can be hold on a
workpiece can be hold on a slotter
workpiece can be hold. planer machine.
machine.
5. Light tools are used. Heavy and hard tools are used. Medium type tools are used.
6. It is possible to machine several
Only one surface can be machined at a
surfaces simultaneously by using Only one surface can be machined
time.
several tools.
7. Less accuracy is achieved on
Accurate surfaces are obtained due to
machined surfaces due to overhanging Accurate surfaces are obtained.
the rigidity of the tool.
of RAM.
8. This machine occupies less area on the
Occupies more area on the floor. Occupies less area on the floor.
floor.