Section

4
PRINCIPLES OF
MANUFACTURING AND
PRODUCTION ENGINEERING
LINEAR CUTTING
PROCESSES
 CONTENTS

 SHAPING AND PLANING

 BROACHING
 SAWING

by Ali Khubbakht 2
 SHAPING AND PLANING

SHAPING AND PLANING

by Ali Khubbakht 3
 SHAPING AND PLANING

• Similar operations:
• They differ in the kinematics of the process.
• Both use a single point cutting tool moved linearly relative to the workpiece.
• A straight, flat surface is created in both operations.

• Low cutting speeds due to start-and-stop motion.

• Typical tooling: single point high speed steel (HSS) tools.

Speed motion
(tool)

Feed motion
(tool)

Feed motion

(workpiece) Speed motion

(workpiece)

Shaping Planing

by Ali Khubbakht 4
 SHAPING AND PLANING
Shaping
(HORIZONTAL) SHAPING MACHINE
Components of a shaper.
• Tool has reciprocating motion.
• Workpiece is clamped on the table
which is stationary.
by Ali Khubbakht
VERTICAL SHAPING MACHINE
OR SLOTTER MACHINE
Components of a slotter machine.
• Identical machine to a horizontal shaping machine
but inclined 90º.
• It allows a higher cutting power as the workpiece
better hold on the working table.
is
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 SHAPING AND PLANING

Planing

• Tool is stationary.
• Workpiece is clamped on the table which has
reciprocating motion.
• It allows machining of much larger parts.

Components of a planer.

Parts made by a shaping and planing.

by Ali Khubbakht 6
 BROACHING

BROACHING

by Ali Khubbakht 7
 BROACHING

• It is a machining process that uses a multiple-tooth cutting tool, called broach, moved linearly relative to
the workpiece. Each tooth is successively higher than the previous tooth.
• The material is removed in one stroke (pulling or pushing) (main difference in comparison with shaping
and planing).
• Most broaches are made of HSS, although carbide inserts (brazed or mechanically attached) also
exist.
• It works best on soft materials: aluminium, bronze, brass, wood, plastics, composites, graphite,…

 Dimensional tolerance ~ IT6 – IT8

 Surface finish (Ra) ~ 6,3 – 25 μm

Advantages:
• Suitable for mass production.
• Cutting time is quick.
• Variety of work shapes possible.

• Owing to complicated and often

Disadvantages:
custom-shaped geometry, tooling is expensive.
• Valid only for light cuts.
• Only through hole and surfaces can be machined.

by Ali Khubbakht 8
 BROACHING

Surface broaching

• It is used to cut flat surfaces.

• The tool is a simple flat bar with multiple rows of cutting teeth.
• Surfaces may be flat, concave, convex, serrated or cam-shaped.

Parts made by surface broaching Surface broaching machine

by Ali Khubbakht 12
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 BROACHING

Internal broaching

• It is used for enlarging long holes.

• A starting hole must be predrilled in the part to insert the broach at the beginning of the stroke.

Typical parts made by internal broaching Internal broaching machine

IDEO
VIDEO
by Ali Khubbakht 10
 SAWIN
G

SAWING

by Ali Khubbakht 11
 SAWIN
G

• Sawing consists in cutting a narrow slit in a workpiece using a tool consisting of a series of narrowly
spaced teeth.
• The tool is called a saw blade and the teeth are typically made of carbon steel, HSS, carbide or
diamond.
• Typical functions:
• Separate a workpart into two pieces.
• Cut off unwanted portions of part .

Teeth are deviated in order to reduce friction

between saw blade and part.

by Ali Khubbakht 12
 SAWIN
G

50 HRC

HSS teeth
welded on a steel blade

Carbide inserts
brazed to blade teeth

Teeth type depending on the cutting material

by Ali Khubbakht 13
 SAWIN
G
Sawing machines

Manual hacksaw Hacksaw or reciprocating Band saw machine

saw machine

HORIZONTAL VERTICAL
Circular saw

VIDEO

by Ali Khubbakht 14
 SAWIN
G
Sawing operations

Examples of various sawing operations.

by Ali Khubbakht 15