1 May 1, 2020

ME6402 – MANUFACTURING TECHNOLOGY - II

UNIT-3
SHAPER, MILLING AND GEAR CUTTING MACHINES

Faculty Name: Mr.I.Sirajudeen, AP/Mechanical

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 CONTENTS
 SHAPER:
 TYPES OF SHAPERS
 SHAPER MECHANISM
 PLANER
 TYPES OF PLANING MACHINE
 MILLING MACHINES
 MILLING MACHINE MECHANISM
 FUNDAMENTALS OF THE MILLING PROCESSES
 Drilling machines
 BORING MACHINES
 Sawing
 Broaching

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 SHAPER:

 INTRODUCTION
 The shaper is a
reciprocating type of
machine tool intended
primarily to produce flat
surfaces.
 These surfaces may be
horizontal, vertical, or
inclined.
 In general, the shaper can
produce any surface
composed of straight line
elements.
 Modem shapers can
generate contoured surface.
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 PRINCIPAL PARTS OF
SHAPER
Base
Column
Table
Cross Rail
Ram
Tool Head
TYPES OF SHAPERS

 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
-Traveling head type.
 According to the type of design of the table:
-Standard shaper
-Universal shaper

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 SHAPER MECHANISM

-In a standard shaper metal is removed in the forward

cutting stroke, while the return stroke goes idle and no
metal
is removed during this period.
-To reduce the total machining time it is necessary to reduce
the time taken by the return stroke.
-During the return stroke it can allow the ram to move at a
faster rate to reduce the idle return time.
-This mechanism is known as quick return mechanism
- The reciprocating movement of the ram and the quick
return
mechanism of the machine are usually obtained by any off
of
the following methods:
-Crank and slotted link mechanism
-Whitworth quick return mechanism
-Hydraulic shaper mechanism
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 PLANER

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 PLANER MACHINE

-A planer is very large and massive compared to a

shaper and capable of machining heavy work pieces
which cannot be accommodated on a shaper table
-The fundamental difference between a shaper and a
planer is that in a planer the work which is supported on
the table reciprocates past the stationary cutting tool
and the feed is supplied by the lateral movement of the
tool,
-The planning machine was developed by Richard
Roberts, an Englishman in the year 1817.
-The design and working principle of the machine, of
course, was almost identical to the present day machine.

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 TYPES OF PLANING MACHINE

Different classes of work necessitate

designing of different types of planning
machine to suit to various requirements of
our present day industry. The different types
of planer which are most commonly used
are:
-Double housing planer.
-Open side planer.
-Pit planer
-Edge or plate planer.
-Divided table planer
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 PLANER MECHANISMS

The two important mechanisms of a planer are:

-Table drive mechanism.

-Feeding mechanism.

The different mechanisms used to drive the table are:

-Open and cross belt drive.

-Reversible motor drive.
-Hydraulic drive

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 MILLING MACHINES

 INTRODUCTION

-A milling machine is a machine

tool that removes metal as the
work is fed against a rotating
multipoint cutter.

-The cutter rotates at a high speed

and because of the multiple
cutting edges it removes metal
at a very fast rate.

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Parts Made with Machining Processes of Chapter 24

Figure 24.1 Typical parts and shapes that can be produced with the
machining processes described in this chapter.
TYPES OF MILLING MACHINE
Column and knee type.
-Hand milling machine.
-Plain milling machine.
-Universal milling machine.
-Universal milling machine.
-Vertical milling machine.
Manufacturing of fixed bed type.
-Simplex milling machine.
-Duplex milling machine.
-Triplex milling machine.
Planer type.
Special type.
-Rotary table milling machine.
-Drum milling machine
-Planetary milling machine.
-Pantograph, profiling & tracer controlled milling
machine.
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MILLING MACHINE MECHANISM
-The milling machine mechanism is composed of spindle
drive mechanism and the table feed mechanism.
-The spindle drive mechanism is incorporated in the
column.
-All modem machines are driven by individual motors
housed within the column, and the spindle receives
power from a combination of gears and clutch
assembly.
-Multiple speed of the spindle may be obtained by
altering the gear ratio.
-The power feed mechanism contained within the knee of
the machine to enable the table to have three different
feed movements, longitudinal, cross, and vertical.
-The power is transmitted form the feed gear box
consisting of change gears to shaft in the knee of the
machine by a telescopic shaft.
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 MILLING CUTTERS

-The milling cutters are revolving tools having

one or several cutting edges of identical form
equally spaced on the circumference of the
cutter.

-The cutting elements are called a tooth

which intermittently engages the work piece
and remove material by relative movement of
the work piece and cutter.

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 MILLING CUTTER

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 Millingcutters may be classified as:
 According to the constructional
features of the cutter:
-Solid cutter.
-Tipped solid cutter.
-Inserted teeth cutter.
 According to the relief characteristics
of the cutter teeth:
-Profile relieved cutter
-Form relieved cutter
 According to~ the methods of
mounting the cutter:
-Arbor type cutter.
-Shank type cutter.
-Facing type cutter.
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 FUNDAMENTALS OF THE MILLING
PROCESSES
PERIPHERAL MILLING:
 The peripheral milling is the operations performed by a
milling cutter to produce a machined surface parallel to the
axis of rotation of the cutter.

 In peripheral milling the cutting force is not uniform

throughout the length of the cut by each tooth.
UPMILLING
DOWN MILLING

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Milling Cutters and Milling Operations

Figure 24.2 Some basic types of milling cutters and milling operations. (a) Peripheral milling. (b)
Face milling. (c) End milling. (d) Ball-end mill with indexable coated-carbide inserts machining a
cavity in a die block. (e) Milling a sculptured surface with an end mill, using a five-axis numerical
control machine. Source: (d) Courtesy of Iscar. (e) Courtesy of The Ingersoll Milling Machine Co.
Milling Operations

Figure 24.3 (a) Schematic illustration of conventional milling and climb milling. (b) lab-
milling operation showing depth-of-cut, d; feed per tooth, f; chip depth-of-cut, tc; and
workpiece speed, v. (c) Schematic illustration of cutter travel distance, lc, to reach full
depth-of-cut.
Milling and Milling Machines
Milling operations: Slab milling
 Conventional Milling (Up Milling)
 Max chip thickness is at the end of the cut
 Advantage: tooth engagement is not a function of workpiece
surface characteristics, and contamination or scale on the
surface does not affect tool life.
 Cutting process is smooth
 Tendency for the tool to chatter
 The workpiece has a tendency to be pulled upward,
necessitating proper clamping.
Milling and Milling Machines
Milling operations: Slab milling
 Climb Milling (Down Milling)
 Cutting starts at the surface of the workpiece.
 Downward compression of cutting forces hold workpiece in
place
 Because of the resulting high impact forces when the teeth
engage the workpiece, this operation must have a rigid setup,
and backlash must be eliminated in the table feed mechanism
 Not suitable for machining workpiece having surface scale.
 FACE MILLING:
-The face milling is the operation performed by a
milling cutter to produce a flat machine surface
perpendicular to the axis of rotation of the
cutter.
-The peripheral cutting edges of the cutter do the
actual cutting, whereas the face cutting edges
finish up the work surface by removing a very
small amount of material.
 END MILLING:
-The end milling may lie considered as the
combination of peripheral and face milling
operation.
-The cutter has teeth both on the end face and on the
periphery.
-The cutting characteristics may be of peripheral or
face milling type according to the particular
cutter surface used
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DRILLING MACHINE

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TYPES OF DRILLING MACHINE
-Portable drilling machine.
-Sensitive drilling machine.
-Upright drilling machine.
-Radial drilling machine.
-Gang drilling machine.
-Multiple spindle drilling machine.
-Automatic drilling machine.
-Deep hole drilling machine

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 DRILLING MACHINE OPERATIONS
The different operations that can be performed in a drilling
machine are:
- Drilling.
-Spot facing.
- Reaming.
- Tapping.
- Boring.
- Lapping.
- Counter boring.
- Grinding.
-Countersinking.
- Trepanning.

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 BORING MACHINES
-The boring machine is one of the most versatile
machine tools used to bore holes in large and heavy
parts such as engine frames, steam engine cylinders,
machine housings,
-Which are practically impossible to hold and rotate in
an engine lathe or a drilling machine.
TYPES OF BORING MACHINES
The boring machines may be classified under the four
headings:
Horizontal boring machine.
§Table type.
§Floor type.
§Planer type.
§Multiple head type
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 Boring machine

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 BORING MACHINE MECHANISM
 The machine contains different controls for movements
of the different parts of the machine.
 A table type machine has the following
movements:
-The headstock and the end supporting block may be
moved up and down.
-The spindle may be rotated. The spindle has
different speeds.
-The spindle may be, moved in or out by hand or
power for feeding.
-The saddle and the table may be moved by hand or
power.
-The columns may be moved by hand or power

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 Tapping
machine

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TAPS:
-A tap is a screw-like tool which has threads
like a bolt and three or four flutes cut across the
thread.
-It is used to cut threads on the inside of a hole,
as in a nut.
-The edges of the thread formed by the flutes
are the cutting edges.
-The lower part of the tap is somewhat tapered
so that it can Into the walls of the drilled hole.
-The upper part of the tap consists of a shank
ending in a square for holding the tap in the
machine spindle or by a tap wrench.
-Taps are made from carbon steel or high
speed steel and are hardened and tempered.
Taps are classified as
(1) Hand tap
(2) Machine tap.
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Sawing
 Depending on part tolerance, sawing can be a
vital first operation or the total process.

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Machines Classifications

 Reciprocating saws
 Horizontal hacksaw and
vertical sawing machines
 Light to heavy duty
 Simple and most
economical to operate
 Manual to fully automatic
feed mechanisms
 Uses blades similar to
hacksaw blades

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Machines Classifications

 Circular saws
 Sometimes called cold
sawing machines
 Saw blades are large
and rotate at low
Rpms
 Cutting is similar to a
milling operation due
to geometry of saw
blade

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Machines Classifications
 Band saws
 Irregular shapes
 Very versatile
 Profile cuts
 Internal cuts
 external configurations
 Blades are continuous
 HSS - Carbide tipped
 Diamond impregnated
 Filing

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Machines Classifications
 Band saws

1 3

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Saw Blades

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Saw Blades
 Tooth forms
 Variable positive
 Variable
 Standard
 Skip
 Hook

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Broaching
 Broaching is the process of removing metal
with a tool which has “teeth” arranged in a
row. Each tooth is successively higher than
the previous tooth and removes more
material. In broaching, one stroke or cycle of
the machine produces a finished part.
 Broaching is used to produce both internal
and external features. Production rates are
high and tolerances of +/- .0005” are possible.

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Broaching machines

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Broaching

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Broaching
Tool Feed Direction
Gullet Tool

Depth of
cut per tooth

Workpiece

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Broaching
 Chip Formation
 As long as these three conditions exist, the portion of
the material being machined that interferes with the
free passage of the tool will be displaced to create a
chip.
 Many combinations exist that may fulfill such
requirements.
 Variations in tool material and tool geometry, feed and
depth of cut, cutting velocity, and part material have
an effect not only upon the formation of the chip, but
also upon cutting force, cutting horsepower, cutting
temperatures, tool wear and tool life, dimensional
stability, and the quality of the newly created surface.

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Machines
 Horizontal

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Machines
 Rotary
 Parts are mounted to a rotating table and are moved to
different stations for different operations
 Primarily used on small parts
 Typical operations include:
 Slotting
 Holes
 Key-ways

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Broaching Tools Design & Construction
 Considerations
 Material to be broached
 Size and shape of cut
 Quality of surface finish
 Part tolerance
 Productions rates
 Type of machine
 Work holding method
 Strength of the work piece

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Methods of Operation
 Pull broaching - broach is pulled through or across
stationary work
 Push broaching - broach is pushed through or
across work
 Surface broaching - either the work or the broach
moves across the other
 Continuous broaching - the work is moved
continuously against stationary broaches. The
path of the movement may be straight or circular.

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