Unit 3
Unit 3
Unit 3
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
slotting.
relative reciprocating motion the tool cuts only in forward- working (or
➢ Designed for machining flat surfaces on small sized jobs. If the size of
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
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).
➢ Hydraulic Drive
Whitworth Quick Return Mechanism
1] As shown in the above figure, the link ‘AC’ is fixed.
➢ 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.
➢ 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
➢ 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,
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
3. Cutting of recesses.
There are four types of driving mechanisms used in slotter for driving the ram,