LECTURE NO.

11

Shaping, and Planning

Course Instructor : Engr. Ali Murtaza
Department : Farm Machinery & Power
 LECTURE OBJECTIVES

To develop an understanding of:

 Shaping and planning,

 Nomenclature
 Operating parameters
 Shaping
The shaper is a reciprocating type of machine tool that is primarily used
for;

 Producing flat surfaces which may be horizontal, vertical, or inclined.

 Making slots, grooves and keyways

 Producing contoured surfaces etc.

 Shaping
 In a shaper the workpiece is fixed in a vise on the table, and metal is
removed from its surface by a single point metal cutting tool, which has a
reciprocating motion.

 Tool is clamped in the tool post mounted on the ram of the machine

 The ram reciprocates to and fro and tool cuts the material in the forward
stroke, but no metal is removed during the return stroke.

 To reduce the total machining time, it is necessary to reduce the time taken
by the return stroke.

 This is ensured by a quick return mechanism

 Principle of working
Slotted lever quick return mechanism
• The crank (of adjustable length R) rotates with a uniform angular speed. The
crank pin B is in the shape of a die block which is free to slide inside the slot
in the slotted lever.
• This slotted lever is pivoted at O and the other end C is connected to the ram
by a short link arm as shown in Fig. (a).
• When the crank rotates clockwise from position AB1 to AB2, the ram moves
forward from left to right and when it rotates from position AB2 to AB1 the
ram returns back to its original position.
• Clearly the time taken to complete forward stroke is proportional to angle α
(refer to Fig. (b) and the return stroke is completed in less time which is
proportional to angle β.
Quick return mechanism
 CUTTING TOOLS USED IN SHAPING
• The cutting tools for shapers are generally made of H.S.S., either solid
or with brazed tips.

• Due to interrupted cuts, tungsten carbide tools are not preferred for
shaping work.

• These tools are made sturdy with fairly generous size for shank and
tip.

• Cutting tool shape varies with the material to be machined and the
type of cut required
CUTTING TOOLS USED IN SHAPING
 Types of Shaping Machines
Shapers are classified in number of ways depending upon the general features
of design or the purpose for which they are intended.

According to the type of mechanism used for giving reciprocating motion to the ram
Crank type
Geared type
Hydraulic type
According to the position and travel of ram
Horizontal type
Vertical type
According to the type of design of the table
Standard shaper
Universal shaper 
 Shaping Parameters
•1.  Cutting speed (V)
Cutting speed is the average linear speed of the tool during the cutting stroke.

Where;
N = No. of double strokes or cycles of the ram per min
L = Length of ram stroke in “mm”
m = Ratio between return stroke time and cutting stroke time
 Shaping Parameters
•2.  Length of stroke
It can be determined by the following formula:

Where;
Lj = Length of workpiece, mm
C = Clearance, mm

3. Depth of cut (d)

It is the thickness of material that is removed in one cut, expressed in mm.
Depth of cut may be given by the tool head slide OR by lifting the table.
 Shaping Parameters
•4.  Machining time
It can be determined by the following formula:

Where,
w = Total width, mm
f = Width of cut in one stroke, mm/stroke
N = no of Strokes/min
 Shaping Parameters
•5.  No. of strokes (N)
As we know that Cutting speed,

So

Then machining tim will be

 Shaping Parameters
•7.  Material Removal Rate (MRR)
It is calcuated as following:

Where;
MRR = Material removal rate, mm3/min.
f = Feed, mm/stroke.
N = no of strokes/min
L = Length of stroke, mm
m = Ratio of return stroke time to cutting stroke time
d= depth of cut (i.e. thickness of material removed)
 Shaping Operations/OPERATIONS PERFORMED ON SHAPERS

 Some of the different operations which a shaper can perform are:

• The machining of horizontal surfaces
• The machining of vertical surfaces
• The machining of angular surfaces
• The cutting of slots, grooves, and keyways
• The machining of irregular surfaces
• The machining of splines, and the cutting of gears using formed tools
 Contour cutting is a very skillful job as it calls for simultaneous operation of
horizontal table feed as well as vertical hand feed of the cutting tool.
Fig. Various operations performed on a shaping machine
Example:1

Find the machining time required for machining the surface 600
× 800 mm, on a shaping machine. Assume, cutting speed as 8
m/min. The return to cutting time ratio is 1:4, and the feed is 2
mm/double stroke. The clearance at each end is 70 mm.
Solution:
Lj = 600 mm, w = 800 mm, v = 8 m/min,
m = ¼ , f = 2 mm/stroke, c = 70 mm
Given clearance at each end: c=70 mm
• length of stroke:
L = 600 + 2×70 = 740 mm

Machining time for 800 mm width

 Example: 2

Estimate the time required to machine a cast iron surface 250

mm long and 150 mm wide on a shaper with cutting-to return
ratio of 3/2. Use a cutting speed of 21 m/min, a feed of 2
mm/stroke and a clearance of 25 mm. The available ram
strokes on the shaper are: 28, 40, 60 and 90 strokes/min. Also,
determine MRR assuming depth of cut as 4 mm.
Solution:
Given data: Lj = 250 mm, f = 2 mm/double stroke, w = 150 mm,
c = 25 mm, v = 21 m/min, d = 4 mm
The cutting-to-return ratio of 3/2
Given clearance is 25 mm, hence,
L = 250 + 2 × 25 = 300 mm.
We know that
SPEED v = NL(1+m)/ 1000 m/min
From the above equation, we find number of double strokes N per minute required as
N = 42 strokes/min
Nearest available ram strokes is 40 strokes/min. Since calculated value is more than 40, this is
chosen. Normally, we should not exceed the specified cutting speed, as it will affect the tool
life adversely. Hence, select N = 40 strokes/min.
• With a chosen value of N, we get
t = 150 / (40×2) = 1.88 minutes
 PLANER/PLANNING MACHINE
 The fundamental difference between a planer and shaper is that in a planer, the
cutting tool remains stationary and the planer table on which the work piece has been
clamped moves past the cutting tool.
 The feed is given to the cutting tool and not to the table which reciprocates in the
guide ways provided in the machine bed.
 A planer can handle much heavier cuts and more than one tool post is provided on
one machine so that machining can be done quickly.
 Sometimes a horizontal surface and a vertical surface are machined simultaneously.
 The table is provided with T-slots on its top surface, so that the work piece may be
clamped securely on the table.
 Two vertical columns, one on each side of the bed and table are located
 A cross rail can slide up and down on the two vertical columns.
 Usually one or two tool posts (tool heads) are mounted on the cross rail and one side
tool head is mounted on each column.
PRINCIPLE OF WORKING

Fig. Schematic diagram of a planer

 PRINCIPLE OF WORKING
 A number of speeds and feeds are available for the tool heads.
 In planer, the tools cuts material only in the forward stroke of the table, its
return stroke is idle.
 To save idle time, the return stroke takes place at higher speed which is
achieved by a variable speed reversible motor drive and a system of limit
switches fitted on the bed of the machine, which get actuated when the
table reaches the end of its forward and reverse strokes.
 The length of the stroke can be adjusted to suit the length of the work piece
by changing the position of the limit switches.
 CUTTING TOOLS USED ON PLANERS
 The planer tools are made of high speed steel, although tipped carbide
tools are also used occasionally.
 These tools are, in general, similar to shaper tools, but are more robust and
stronger.
 Specially shaped tools are used on planers for operations like T-slot cutting
and dove tail slide cutting.
 In both shapers and planers, the tool or table starts from rest, picks up
speed and then again slows down to zero speed during the forward or
cutting stroke.
 Feed and depth of cut are both expressed in mm.
Fig. Components manufactured by planning/shaping processes
 Specification of planner
1. Max. Workpiece dimension
(W*L)

2. Table speed (m/min)

3. Vertical tool feed per stroke (mm)

4. Table motor power (KW)

Thank you!
• https://www.youtube.com/watch?v=lyRtPFJj8vI
• Impo. Video shaper : https://www.youtube.com/watch?v=_Xn-rSl0ZqE
• https://www.youtube.com/watch?v=PpCnl89ECRE&t=8s
• https://www.youtube.com/watch?v=mF6G9QyNq1I
• https://www.youtube.com/watch?v=l7oV_ud9pVc (gear cutting on shaper)

• Mechanism
• https://www.youtube.com/watch?v=s3G3au-EyAQ

Planer
https://www.youtube.com/watch?v=wEfGJqJRnNQ
https://www.youtube.com/watch?v=euovvU_Ojtg
https://www.youtube.com/watch?v=7P8HDDKNZvM