SHAPER, SLOTTER & PLANER SUBMITTED TO PROF. DEEPAK SHARMA SUBMITTED BY ANKIT SHARMA ME-I (III YEAR)

introduction Shaper is a machine which is used for producing flat surfaces. These surfaces may be horizontal, vertical or inclined. This machine involves the use of single point cutting tool held in a properly designed tool box mounted on a reciprocating ram.

Working Principle The shaper is used to machine flat surfaces which may be horizontal, vertical or angular planes. While primarily used to machine flat surfaces, a skilful machinist can manipulate a shaper to cut curved and irregular shapes, slots, grooves and keyways. Because of the way the machine operates, the cutting tool travels back and forth over the work. The shaper usually cut in one direction, so that the return stroke is lost time. So the return stroke is made up to twice the speed of the cutting stroke.

Schematic diagram

Principle parts of shaper COLUMN: It is a hollow structure consisting of two vertical walls and cast from cast iron. It is a rigid structure, gives support to the ram and is supported by the base. BASE: It supports the whole machine and is bolted to the floor with the help of foundation bolts.\ CROSS-RAIL: It is a box like structure over which the saddle slides horizontally. The cross rail is maintained accurately to the column. The table cross feed screw and the cross rail vertical feed are housed inside it.

RAM: Ram is a reciprocating member and it carries shaper head in the front, on which the cutting tool is mounted. SADDLE AND TABLE: The table is bolted on the saddle and the table is capable of moving in horizontal and vertical direction. It can be fitted in inclined position also. The job is supported on the table with the help of vice or some simple fixture.

Shaping operations Horizontal flat surface machining: This is achieved by moving table under the tool. Automatic feed can be given or manual table is moved at the end of the return stroke. Length of the stroke should be 20mm longer than the job. Depth should be mm. Vertical surface machining: Vertical feed is given to the tool by rotating the down feed screw by hand. It should be 0.25mm at the end of the return stroke. Machining angular surface: The vertical slide of the tool head is swivelled to the required angle in either direction. The down feed is given by rotating the down feed screw.

Cutting slots and keyways: For cutting slots or keyways a square nose tool similar to a parting tool is selected. External keyways are cut on a shaft by firs drilling a hole at the blind end of keyways. Irregular surface: Shaper can produce a convex or concave surface or a combination of the above surface by a forming tool. If the curve is sufficiently large, power cross-feed in conjugation with manual down feed is so adjusted that the tool will trace the required centre.

Advantages It provide economical and simple tooling. A shaper is easy to set up and can be used on any flat or angular surface Disadvantages Due to simple point tooling shaper is not suited for production work The amount of metal removed with one tool is insignificant as compared to other machining methods.

SLOTTER MACHINE

Introduction The vertical shaper, sometimes called as slotter. The slotting machine is a reciprocating machine tool in which, the ram holding the tool reciprocates in a vertical axis and the cutting action of the tool is only during the downward stroke. Working principle Slotter has vertical ram with table and saddle similar to the horizontal shaper. If a rotary table is mounted on the regular table, a number of slots can be made at quite accurately spaced intervals. The machine can work either outside or inside a part, provided that the interior opening is larger than the tool head.

Slotter Machine

Principle parts Base – It is rigidly built and is cast integral with the column. The top of the bed and the front face of the vertical column are accurately machined to provide guideways for the saddle and ram. Saddle- It is mounted on the guideways and may be move towards or away from the column.The top of the saddle is accurately finished to provide guideways for cross slide. Cross slide- It is mounted on the guideways of the saddle and may be moved parallel to the phase of the column. Ram- It reciprocates in a vertical direction. Ram carries a cutting tool at its lower end. A slot is cut on the body of the ram for changing the position of the stroke.

Operations performed on slotter Cutting slots and keyways: For cutting slots or keyways a square nose tool similar to a parting tool is selected. Irregular surface: Slotter can produce a convex or concave surface or a combination of the above surface by a forming tool. Machining cylindrical surfaces- A cylinder can also be machined both on its external and internal surfaces. Machining flat surfaces- Both the external and internal flat surfaces of a workpiece can be machined. The workpiece is supported in such a way so that the tool will have clearence from the table when it is extremec downward position of the stroke.

Planer machine

introduction A Machine which produces flat surfaces Consists a stationary housing for holding the tools A table holding the work reciprocates Large works, that con not be accommodate on shapers The tool is stationary but the work moves

Working principle The table on which work is clamped is imparted a reciprocating movement Cutting takes place during the forward stroke of table During return stroke the cutting tool is slightly lifted Tool is fed for each forward stroke Table is driven by an electric motor Length of table stroke can be adjusted Speed of return stroke is also regulated

diagram

Principle parts Bed Large box like casting Length is nearly twice the table length Consists guide ways on which table moves Houses the driving mechanism of table Made of Cast Iron Table Also called Platen Large rectangular casting mounted on bed ways Holds the work & reciprocates along bed ways Top surface has T slots Work is clamped on T slots

Housing or Column Large vertical structures on each side of the bed Supports cross rail on which tool heads are mounted Also supports the mechanism for operating the tool heads Cross rail A rigid casting mounted horizontally on the column Can be moved up & down by elevating screw Carries two slides with tool heads Tool heads can be moved horizontally on the guide ways of cross rail Tool heads Contains tool posts for holding the tools Tool post (clapper block) is hinged to the head During return stroke cutting tool will be lifted Tool heads can be swiveled through 60 º on either side of its vertical position

operations Planing Horizontal Surfaces Planing Vertical Surfaces Planing Angular Surfaces / Dovetails Planing Curved surfaces Planing Slots & Grooves Planing with two or more tools simultaneously. Hot planing to improve metal removal rate by 5- 7 times. Double cutting tool boxes.

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