Welcome to the Lecture

on
Shaper & Milling Machine

Presented by-

Monjur Mourshed
Assistant Professor
Department of Mechanical Engineering
Rajshahi University of Engineering & Technology
RUET, Bangladesh
 Shaper
ShaperMachine
Machine
The shaper is a reciprocating type of machine tool used for producing small
flat surface by removing metal from surfaces in horizontal, vertical and angular
planes by the use of a single point cutting tool, held on the ram that reciprocates
the tool. SHAPER MECHANISM ANIMATION.mp4

The Shaper is a machine tool used primarily for---

Producing a flat or plane surface which may be in a horizontal, a vertical or
an angular plane.
 Making slots, grooves and keyways.
 Producing contour of concave/convex or a combination of these.

Department of Mechanical Engineering, RUET

 Shaper
Shapermachine
machineTerms
Terms
Stroke- The size of the shaper is determined by the length of the stroke
of the ram. It is same as the largest cube it will machine. The position of
the sliding block in the slide determines the length of stroke. The length
of the stroke is changed by changing the radius of the circle in which the
pin on the bull gear rotates.

Feed- The feed is given by the table that moves in the horizontal
direction perpendicular to the cutting direction and termed as cross feed.
When the table turns with an attachment to give the table an automatic
feed across the tool, it is termed as ratchet mechanism.

Department of Mechanical Engineering, RUET

 Classification
Classificationof
ofShaper
ShaperMachine
Machine
Shapers are mainly---
Crank Shapers - A rocker arm, operated by a crank pin from the main driving
gear, gives the ram of the crank shaper a back-and-forth (reciprocating) motion
Gear shapers- are driven by a gear and rack assembly. Gear shapers have a
reversible electric motor or mechanical mechanism which quickly returns the ram,
in readiness for another cut
Hydraulic Shapers- are driven by movement of a piston in an oil-filled cylinder.
Mechanical features on these shapers are the same as those on crank shapers
Depending on whether the ram and the cutting tool reciprocates in the horizontal
plane or in the vertical plane the shapers are classified as-

 Horizontal Shapers- the cutting ram reciprocates in horizontal direction

I) Plain Shapers - the table cannot rotate or swivel
II) Universal Shapers – the table can be swiveled to left or right and rotated in a
full circle
 Vertical Shapers- the cutting ram reciprocates in vertical direction
Department of Mechanical Engineering, RUET
 Main
MainParts
Partsof
ofaaShaper
ShaperMachine
Machine
The major components of a shaper are the ram, which has the tool post
with cutting tool mounted on its face, and a worktable, which holds the
part and accomplishes the feed motion.

Department of Mechanical Engineering, RUET

Shaper
ShaperMachine
MachineCross
CrossSectional
SectionalView
View

Department of Mechanical Engineering, RUET

 Main
MainParts
Partsof
ofaaShaper
ShaperMachine…
Machine…
Base- The base is the necessary bed or support required for all
machines tools. All other parts are mounted on and above the base. The
bed takes up the total dead weight of the machine as well as the dynamic
load during machining operations.

Cross rail-The cross rail is mounted on the front of the body frame
and can be moved up and down. The vertical movement of the cross rail
permits jobs of different heights to be accommodated below the tool.
Sliding along the cross rail is a saddle which carries the work table.

Column-The column of the shaper is a hollow casting and is mounted

on the base. It houses the drive mechanism for the ram and the table.

Department of Mechanical Engineering, RUET

 Main
MainParts
Partsof
ofaaShaper
ShaperMachine…
Machine…
 Table- The worktable of a shaper is fastened to the front of the
column. The table moves across the column on cross rails to give the
feed motion to the job.

 Ram- The ram carries the tool head at its front end and travels in
“guide ways” to give straight line reciprocating motion to the tool. The
ram is either mechanically driven or hydraulically operated. A single
point tool is fastened in the tool post.

 Tool Head- It holds the cutting tool and is fastened to the front of the
ram. The tool is held in a tool holder/tool post similar to the lathe tool
post. The tool post and the tool block fit snugly in the clapper box and is
hinged at the upper edge.

Department of Mechanical Engineering, RUET

 Main
Main Parts
Partsof
ofaaShaper
ShaperMachine…
Machine…
 ClapperBox
 The clapper box houses the clapper block which is connected to it by means
of hinge pin
 The tool post is mounted upon the clapper block to prevent interference
between the tools and work piece on the return stroke
 On the forward cutting stroke the clapper block fits securely to the clapper
box to make a rigid tool on the work
 It prevents the tool cutting edge form dragging and wear
 The work surface is also prevented from any damage due to dragging

Department of Mechanical Engineering, RUET

Working
WorkingofofaaCrank
CrankType
TypeShaper
ShaperMachine
Machine
The shaper changes the rotary motion of the motor to a reciprocating
motion at the ram by the following mechanism---

 The motor gives power to a pulley which is a small gear called pinion
or driving gear
 Pinion turns a large bull gear which rotates in a clockwise direction at
an uniform rate
 A rocker arm pivoted at the base while the other end is connected to
the arm of the shaper through a link arm
 A sliding block fits into a slide in the rocker arm and a crankpin fits
into a hole in the sliding block is attached to the bull gear
 The crankpin is positioned in or out radially on the bull gear from an
external control to change the length of stroke
As the crankpin on the bull gear revolves, the sliding block is forced to
move up and down in the slide. This forces the rocker arm to swing back
and forth on the hinge pins in an arc, forcing the ram to reciprocate.
Department of Mechanical Engineering, RUET
Working
WorkingofofaaCrank
CrankType
TypeShaper
ShaperMachine...
Machine...

Department of Mechanical Engineering, RUET

 Quick
QuickReturn
ReturnMechanism
Mechanism
The tool is held in the tool post of the reciprocating ram and perform the
cutting operation. During the forward motion of the tool cutting is
performed, while in return stroke tool only slides.

In order to reduce the time wasted during the return stroke, shaping

machines are fitted with a quick-return mechanism to make the return
stroke faster. Quick return mechanism.mp4

In quick return mechanism the ram moves forward on the cutting stroke,
the driving pin moves through an arc at 220°. On the return stroke, the
pin travels through only 140° of arc. Thus the ram travels faster and
takes less in return stroke compared to the forward stroke.

It may be noted that during the back word stroke of the ram, the tool
does not remove material from the work piece.
Department of Mechanical Engineering, RUET
Quick
QuickReturn
ReturnMechanism…
Mechanism…

Department of Mechanical Engineering, RUET

 Planner
PlannerMachine
Machine
The machine tool for planning is a planer. The planner or planning
machine carries the work on a table, fully supported by a heavy bed an d
capable of sustaining heavy loads. The table slides on ways over the bed.
Most planner cuts in one direction but some in both directions.
Cutting speed is achieved by a reciprocating worktable that moves the
part past the single-point cutting tool. Construction and motion capability
of a planer permit much larger parts to be machined than on a shaper.

Department of Mechanical Engineering, RUET

 Planning
Planningand
andShaping
Shaping
Planning and shaping are similar operations, which differ in the
kinematics of the process. Planning is a machining operation in which
the primary cutting motion is performed by the work piece and feed
motion is imparted to the cutting tool. In shaping, the primary motion is
performed by the tool, and feed by the work piece.

Department of Mechanical Engineering, RUET

Planning
Planningand
andShaping
Shaping

Department of Mechanical Engineering, RUET

 Planning
Planningvs.
vs.Shaping
Shaping
SHAPER PLANER
1. These are light in construction 1. These are large and heavy in construction
2. Requires less floor space area 2. Requires more floor space area
3. Tool reciprocates over a 3. Work piece reciprocates across the
stationary work piece stationary tool
4. Work is usually feed across the 4. The tool is fed across the stationary work
tool piece
5. Only one tool use 5. More than one tool can be used
6. Perfect accuracy is not obtain 6. Maximum accuracy can be obtained
7. Adopted for small work 7. It is adopted for large work
8. Used for batch or job shop 8. Used for mass production
production 9. Cost of machine is high
9. Cost of machine is less

Department of Mechanical Engineering, RUET

 Milling
MillingMachine
Machine
Milling is the process of machining flat, curved, or irregular surfaces by feeding
the work piece against a rotating cutter (milling cutter) containing a number of
cutting edges (teeth).

The usual mill consists basically of a motor driven spindle, which mounts and
revolves the milling cutter, and a reciprocating adjustable worktable, which
mounts and feeds the work piece.

Milling is an interrupted cutting operation in which the teeth of the milling

cutter enter and exit the work during each revolution. This interrupted cutting
action subjects the teeth to a cycle of impact force and thermal shock on every
rotation. The tool material and cutter geometry must be designed to withstand
these conditions. Cutting fluids are essential for most milling operations.
Department of Mechanical Engineering, RUET
 Specification
Specification of
of Milling
Milling Machine
Machine
Milling machines are specified on the following basis-
 Size of the table, which specifies the actual working area on the table and
relates to the maximum size of the work piece that can be accommodated
 Maximum table travel, which gives the maximum axis movement that is
possible
 Horse power of the spindle, which specifies the power of spindle motor
 Type and model of the milling machine, varies with the purposes and
applications

Department of Mechanical Engineering, RUET

 Classification
Classificationof
ofMilling
MillingMachine
Machine
 Knee and Column Type- general purpose milling machine offering high degree of
flexibility
- Horizontal
- Vertical
- Universal
- Turret type
 Production (bed) Type- industrial mill used mainly for productivity enhancement
- Simplex
- Duplex
- Triplex

 Special Purposes- equipped with special facilities to suit specific purposes

- Rotary table
- Drum type
- Copy milling
- Key way milling
- Spline shaft milling

Department of Mechanical Engineering, RUET

Classification
Classificationof
ofMilling
MillingMachine
Machine

Department of Mechanical Engineering, RUET

 Classification
Classification of
of Milling
MillingMachine…
Machine…
Column and Knee Type Milling Machine
The milling machines having only the three mutually perpendicular table motions (x-y-
z axes) are called plain column and knee type. These are categorized as-
Universal milling machines
-Table can be swiveled/rotated maximum 45° at any side from the middle
position
- It can be worked as horizontal or vertical milling machine

Department of Mechanical Engineering, RUET

 Classification
Classificationof
ofMilling
MillingMachine…
Machine…
Horizontal milling machines Vertical milling machines
- Horizontal arbor - Vertical spindle
- Designed for peripheral milling - Designed for face milling operations
operations - Vertical spindle feed
- Horizontal spindle feed - Milling cutters can be mounted
-Arbor supports the cutter and an over directly in the spindle
arm supports arbor

Department of Mechanical Engineering, RUET

 Classification
Classificationof
ofMilling
MillingMachine…
Machine…
Turret type
Has duel heads that can be rotated about a horizontal axis. This permits milling
to be done horizontally, vertically or at any angle.

Department of Mechanical Engineering, RUET

 Classification
Classification of
ofMilling
MillingMachine
Machine
Bed type milling machines
- Designed for mass production
- Greater rigidity
- Achieves heavier feed rates and depth of cuts, high MRR
-Work table is directly fixed on the bed of the machine tool
-The cutter mounted in a spindle head that can be adjusted vertically along the
machine column
Three types are available with respect to the count of spindles available-
Simplex
Has single spindle

Department of Mechanical Engineering, RUET

 Classification
Classification of
ofMilling
MillingMachine
Machine
Duplex
Has two spindles, permitting simultaneous milling of two surfaces at a single
pass

Triplex
Has three spindles, permitting simultaneous milling of three surfaces at a single
pass
Department of Mechanical Engineering, RUET
 Milling
Milling Operations
Operations
Milling operations can be classified into two broad categories-
1.Peripheral/ Plain Milling4Plain milling.mp4
In peripheral milling, also called plain milling, the axis of the cutter is
parallel to the surface being machined, and the operation is performed by
cutting edges on the outside periphery of the cutter
 The primary motion is the rotation of the cutter. The feed is imparted to the
work piece
 Better surface finish and more stable holding of the cutter

Department of Mechanical Engineering, RUET

 Milling
MillingOperations…Plain
Operations…PlainMilling
Milling
Slab milling
Cutter width extends beyond the work piece on both sides.
Slotting (Slot milling)
Cutter width is less than the work piece width, creating a slot. If the cutter is very thin,
it can be used to cut a work part into two, called saw milling.
Side milling
Cutter, machines the side of the work piece.
Straddle milling
Similar to side milling, but cutting takes on both sides of the work part simultaneously.

Department of Mechanical Engineering, RUET

 Milling
Milling Operations…Plain
Operations…PlainMilling
Milling
Conventional/ Up milling
- Wheel or cutter rotates opposite to the table feed direction, thus heavy duty machine is needed
- The chip formed by each cutter tooth starts out very thin and increases its thickness upto the
maximum
- The length of the chip is relatively longer and there is a lot of chips recutting
- Surface finish is worse because chips are carried upward by teeth and dropped in front of cutter
- Tool has a tendency to rub the work piece before starts cutting and thus the tool get dull as well
as tool life is getting relatively shorter
-The cutter has a tendency to lift the work piece from the table and thus need more clamping
force to hold the work part still
- Great pressure is required to break through the distance being milled and more power is
required to conventional mill than climb mil
- Suitable for heavy duty cutting

Department of Mechanical Engineering, RUET

 Milling
Milling Operations…Plain
Operations…Plain Milling
Milling
Climb/ Down Milling
- Wheel or cutter rotates to the same direction of table feed and light machine is satisfactory
- The chip formed by each cutter tooth starts out maximum thickness and leaves out thin
-The length of the chip is relatively short and less chip recutting
-Fine finish on the work piece can be obtained because chips are dropped behind the cutter, thus
less recutting
-Less wear, with tools lasting up to 50% longer
-Climb milling also allows greater feeds per tooth
-Require less power for milling, needs less clamping force to hold the work part still
- Sometimes tool slides over the work piece instead of cutting
- As the tool and table moves in the same direction, if there exists a backlash in the table lead
screw and interfere with table motion, causing the work piece or cutter broken
- Suitable for machining thin or fragile parts

Department of Mechanical Engineering, RUET

 Milling
MillingOperations…Face
Operations…FaceMilling
Milling
2. Face milling Face Milling.wmv
In Face milling the axis of the cutter rotation is perpendicular to the work surface to be
machined. The cutter axis is vertical, but in the newer CNC machines it often is horizontal.
Face milling is usually applied for rough machining of large surfaces. Surface finish is worse
than in peripheral milling, and feed marks are inevitable.
One advantage of the face milling is the high production rate because the cutter diameter is
large and as a result the material removal rate is high. Face milling with large diameter cutters
requires significant machine power.

Department of Mechanical Engineering, RUET

 Milling
MillingOperations…Face
Operations…FaceMilling
Milling
Face Milling.wmv
Conventional face milling
Diameter of tool is larger than work part’s width.
Partial face milling
The cutter overhangs from one side of work part .
End milling
Cutters diameter is less than the work part’s width.
Profile milling
Outside periphery of flat part is cut.
Pocket milling
Similar to end milling, but the shape created is a shallow pockets in flat surfaces.

Department of Mechanical Engineering, RUET

 Milling
MillingCutters
Cutters

Department of Mechanical Engineering, RUET

 Milling
Milling Cutters…
Cutters…
 The pitch refers to the angular distance between successive or adjacent teeth.
The tooth face is the forward facing surface of the tooth that forms the cutting edge.
 The cutting edge is the angle on each tooth that performs the cutting.
 The land is the narrow surface behind the cutting edge on each tooth.
 The rake angle is the angle formed between the face of the tooth and the centerline of the
cutter. The rake angle defines the cutting edge and provides a path for chips that are cut from the
work piece
 The hole diameter determines the size of the arbor necessary to mount the milling cutter.

Department of Mechanical Engineering, RUET

 Indexing
Indexing
Indexing is the process of evenly dividing the circumference of a circular work
piece into equally spaced divisions, such as in
- cutting gear teeth,
- cutting splines,
- milling grooves in reamers and taps,
-rotate work piece at predetermined ratio to table feed rate

The index head of the indexing attachment is used for this purpose.

Department of Mechanical Engineering, RUET

 Indexing
IndexingHead
HeadParts
Parts
Index Head Simple (Plain) Indexing.mp4
The index head of the indexing fixture contains an indexing mechanism which is used to control
the rotation of the index head spindle to space or divide a work piece accurately.
A simple indexing mechanism consists of a 40-tooth worm wheel fastened to the index head
spindle, a single-cut worm, a crank for turning the worm shaft, and an index plate and sector arm.
Since there are 40 teeth in the worm wheel, one turn of the index crank causes the worm, and
consequently, the index head spindle to make 1/40 of a turn; so 40 turns of the index crank
revolve the spindle one full turn.

Department of Mechanical Engineering, RUET

 Indexing
IndexingHead
HeadParts…
Parts…
Index Plate
The indexing plate is a round plate with a series of six or more circles of equally spaced holes;
the index pin on the crank can be inserted in any hole in any circle. With the interchangeable
plates regularly furnished with most index heads, the spacing necessary for most gears, bolt
heads, milling cutters, splines, and so forth can be obtained.

Sector
The sector indicates the next hole in which the pin is to be inserted and makes it unnecessary to
count holes when moving the index crank after each cut. It consists of two radial, beveled arms
which can be set at any angle to each other and then moved together around the center of the
index plate.

Department of Mechanical Engineering, RUET

 Indexing
IndexingHead
HeadParts…
Parts…
Index Plate Types

Brown and Sharpe type consists of 3 plates of 6 circles each drilled as follows:
Plate I - 15, 16, 17, 18, 19, 20 holes
Plate 2 - 21, 23, 27, 29, 31, 33 holes
Plate 3 - 37, 39, 41, 43, 47, 49 holes

Cincinnati type consists of one plate drilled on both sides with circles divided as
follows:
First side - 24, 25, 28, 30, 34, 37, 38, 39, 41, 42, 43 holes
Second side - 46, 47, 49, 51, 53, 54, 57, 58, 59, 62, 66 holes

Department of Mechanical Engineering, RUET

 Indexing
IndexingMethods
Methods
Indexing can be done by the following 4-ways-

1. Direct Indexing
2. Simple Indexing
3. Angular Indexing
4. Differential Indexing

Department of Mechanical Engineering, RUET

 Direct
DirectIndexing
Indexing
 Direct indexing is accomplished by an additional index plate fastened to the index head
spindle. A stationary plunger in the index head fits the holes in this index plate. By moving this
plate by hand to index directly, the spindle and the work piece rotate an equal distance.
 Direct indexing plate usually contains three sets of hole circles or slots: 24, 30, and 36 and
offer a quick means of milling squares, hexagons, taps, and so forth.
Any number of divisions which is a factor of 24, 30, 36 can be indexed quickly and
conveniently by the direct indexing method.
 In direct indexing, the index plate is directly mounted on the dividing head spindle ( no worm
shaft or wheel)
 While indexing, the index crank pin is withdrawn from the hole of the index plate than the pin
is engaged directly after the work and the indexing plate are rotated to the desire number of holes
 In this method fractions of a complete turn of the spindle are limited to those available with
the index plate

Department of Mechanical Engineering, RUET

 Example
Example--Direct
Directindexing
indexing
What direct indexing is necessary to mill eight flutes on a reamer blank?
Since the 24-hole circle is the only one divisible by 8 (the required number of divisions), it is the
only circle that can be used in this case.

Slots Direct indexing divisions

24 2 3 4 _ 6 8 _ __ 12 __ __ 24 __ __
30 2 3 _ 5 6 _ _ 10 __ 15 __ __ 30 __
36 2 3 4 _ 6 _ 9 __ 12 __ 18 __ __ 36

Never count the hole or slot in which the index pin is engaged

Department of Mechanical Engineering, RUET

 Simple
Simple Indexing
Indexing
 In simple or plain indexing, an index plate selected for the particular application, is fitted on
the worm shaft and locked through a locking pin

 If the number of turns that the crank must be rotated for each indexing can be found from the
formula
I = 40 / N
Where
I – No. of divisions or index crank needs to rotate
40 – No. of teeth on the worm wheel attached to the indexing plate, since 40 turns of the
index crank will turn the spindle to one full turn
N- No. of teeth to be cut on the blank plate

 To index the work through any required division, the index crank pin is withdrawn from the
hole of the index plate than the work is indexed through the required division by turning the
index crank through a calculated number of whole revolutions and holes on one of the hole
circles, after which the index pin is relocated in the required hole index crank will turn the
spindle to one full turn .

Department of Mechanical Engineering, RUET

 Example
Example --Simple
SimpleIndexing
Indexing
 The indexing required to cut eight flutes:

40
 5 full turns of index crank
8
 The indexing required to cut seven flutes:

40 5
 5 turns of index crank
7 7
The five-sevenths turn involves use of an index plate and sector arms.

Index plate
Circular plate provided with series of equally spaced holes into which index crank
pin engages
Sector arms
Fit on front of plate may be set to any portion of a complete turn
43
Department of Mechanical Engineering, RUET
 Example
Example--Simple
SimpleIndexing
Indexing
Choose any hole circle that is divisible by 7

Index-plate hole circles

Brown & Sharpe 5/7 = 15/21
Plate 1 15-16-17-18-19-20
Index-plate hole circles So, 5 full turns plus 15
Plate 2 21-23-27-29-31-33
Brown & Sharpe holes on 21 hole circle
Plate 3 37-39-41-43-47-49
Plate 1 15-16-17-18-19-20
Plate 2 21-23-27-29-31-33
Plate 3 37-39-41-43-47-49
Cincinnati Standard Plate 5/7 = 20/28
Cincinnati Standard Plate
One side 24-25-28-30-34-37-38-39-41-42-43
One side 24-25-28-30-34-37-38-39-41-42-43So, 5 full turns plus
Other side 46-47-49-51-53-54-57-58-59-62-66
20 holes on 28 hole
Other side 46-47-49-51-53-54-57-58-59-62-66
circle
Department of Mechanical Engineering, RUET
 Angular
Angular Indexing
Indexing

  There are 360 degrees in a complete circle and one turn of the index crank revolves the spindle
1/40 or 9 degrees. Therefore, 1/9 turn of the crank rotates the spindle 1 degree

no. of degrees required

Indexing in degrees 
9
 Work pieces can therefore be indexed in degrees by using a circle of holes divisible by 9

Calculate indexing for 45º

45
Indexing  5
9 5 complete turns
Calculate indexing for 24º30'
First, convert angle into minutes
24 x 60') = 1440' now add 30' = 1470'
Convert 9° to minutes 9°x60 = 540'
Divide 1470'/540' = 2
2 full turns and 13 holes on 18 hole
circle
Department of Mechanical Engineering, RUET
 Differential
DifferentialIndexing
Indexing
Sometimes, a number of divisions is required which cannot be obtained by simple indexing with
the index plates regularly supplied. To obtain these divisions, a differential index head is used.
The index crank is connected to the worm shaft by a train of gears instead of a direct coupling as
with simple indexing. The selection of these gears involves calculations similar to those used in
calculating change gear ratio for lathe thread cutting.
Gear Ratio I = 40/K ( K – Z)
Where
K – a number very nearly equal to Z
For example if the value of Z is 53, the value of K is 50

If K is greater than Z, resulting fraction is positive and the index plate must move in the same
direction as crank (clockwise) . This positive rotation uses an idler gear
If K is less than Z, resulting fraction is negative and the index plate must move in the same
direction as crank (clockwise) . This positive rotation uses two idler gear
Department of Mechanical Engineering, RUET
 Milling
MillingMachine
MachineTerminology
Terminology
 Cutting Speed- Cutting speed is the distance one tooth of the cutter moves in
one minute as measured in feet on its circumference. It is expressed in surface
feet per minute (sfpm). It is also called peripheral or surface speed.
rpm = ; where, sfpm is in feet and D is in inch.

Feed- feed is the rate at which the work piece advances under the cutter.

F = fN

F- feed rate
f- feed per tooth
T- number of teeth
N- rpm of the cutter

Department of Mechanical Engineering, RUET