SHAPER, SLOTTER & PLANER MACHINE

SHAPER MACHINE
A SHAPER IS A MACHINE TOOL THAT USES RECIPROCATING LINE MOTION OF THE TOOL AND A PERPENDICULAR FEED OF THE JOB OR THE TOOL.

SHAPER MACHINE - CLASSIFICATION

Shapers

Horizontal Shapers

Vertical Shapers

Special Purpose Shapers

Push cut

Draw cut

Gear shapers

Plain Production Shaper

Universal Tool Room Shaper

COMPONENTS OF A SHAPER MACHINE

BASE COLUMN TABLE RAM TOOL HEAD

TOOL HEAD

TOOL HEAD MOVEMENT

THE TOOL POST AND THE TOOL SLIDE CAN BE ANGLED AS SEEN BELOW. THIS ALLOWS THE SHAPER TO BE USED FOR DIFFERENT TYPES OF WORK
DIA A: The tool post has been turned at an angle so that side of the material can be machined DIA B: The tool post is not angled so that the tool can be used to level a surface. DIA C: The top slide is slowly feed into the material so that a rack can be machined for a rack and pinion gear system.

SHAPER / PLANER TOOLS

The basic assumption to design shaper and planer tool is to withstand high operating impact load. Therefore there are number of different tools used to do machining process a. b. c. d. e. f. g. h. Straight shank roughing tool Bent type roughing tool Side cutting tool Finishing tool Broad nose finishing tool Slotting tool Tee slot tool Gooseneck tool

DRIVING MECHANISM IN SHAPER MACHINE

MECHANICAL RAM DRIVE AUTOMATIC FEED MOTION HYDRAULIC DRIVE

MECHANICAL RAM DRIVE

AUTOMATIC FEED DRIVE

HYDRAULIC DRIVE

ADVANTAGES OF HYDRAULIC DRIVE

OFFER GREAT FLEXIBILITY OF SPEED SMOOTHER OPERATION ABILITY TO SLIP WHEN TOOL IS OVERLOADED ABILITY TO CHANGE LENGTH AND POSITION OF STROKE, WHILE MACHINE IS RUNNING

CUTTING TIME FOR SHAPING

L = LENGTH OF STROKE TO BE SET FOR THE JOB (MM)
N = NUMBER OF RAM CYCLES PER MINUTE V = SUGGESTED CUTTING SPEED (M/S) r = CUTTING-TO-RETURN TIME RATIO

V=

1+

60 1000
1+

m/s

Putting

= C IN ABOVE EQUATION, WE GET

V= N=

60000 60000

m/s cycles / min

FEED F, IN PLANING, SHAPING AND SLOTTING IS RELATIVE MOVEMENT OF THE TOOL IN A DIRECTION PERPENDICULAR TO PRIMARY CUTTING MOTION PER FULL STROKE , MM/STROKE DEPTH OF CUT D, IS THE THICKNESS OF LAYER REMOVED IN ONE CUT

CROSS SECTIONAL AREA OF UNDEFORMED CHIP = T * B = F* D

D = DEPTH OF CUT F = FEED RATE (MM/STROKE) B = WIDTH OF THE JOB (MM) NO. OF STROKES REQUIRED TO min COVER THE WIDTH = B / T= 60000

EXAMPLE
ESTIMATE THE TIME REQUIRED TO MACHINE A CAST IRON SURFACE 275 MM LONG AND 100 MM WIDE IN ONE CUT USING A CUTTING SPEED OF 0.33 M/S AND A FEED RATE OF 0.25MM PER STROKE ON A SHAPER WITH A CUTTING-TORETURN TIME RATIO OF 3/2. THE AVAILABLE RAM STROKE ON THE MACHINE ARE 28,40,60 AND 90 STROKES/MIN. L = 300 MM C = 3/5

N = 39.6 STROKE/MIN
NO. OF STROKE NEEDED = 400 STROKES T = 10 MIN

EXAMPLE
THE 350X200 MM FACE OF A C. I. BLOCK 350X200X100 MM IS TO BE ROUGH MACHINED USING H. S. S. TOOL ON A CONVENTIONAL CRANK SHAPER. ESTIMATE THE MACHINING TIME ASSUMING AN AVERAGE CUTTING SPEED OF 0.33 M/S AND A FEED RATE OF 0.5 MM/STROKE. THE CUTTING TIME TO RETURN TIME RATIO IS 3:2 AND THE RAM CYCLES AVAILABLE ON THE SHAPER ARE 28, 40, 60 AND 90 CYCLES PER MINUTE.

T = 14.28 MIN N = 28 CYCLES/MIN

APPLICATION OF SHAPER
EXTERNAL AND INTERNAL KEY WAYS HELICAL GROOVES GEARS RACKS DOVETAILS T-SLOTS OTHER MISCELLANEOUS SHAPES

SLOTTING MACHINE
A SLOTTER SHAPER. IS NOTHING BUT VERTICAL

ITS WORK ON THE SAME PRINCIPLE AS OF SHAPER MACHINE.

THE MAIN DIFFERENCE IS RAM MOVEMENT, WHICH IS IN VERTICAL DIRECTION, WHEREAS IN SHAPER IT IS HORIZONTAL.

MECHANISM OF SLOTTER IS SAME AS SHAPER MACHINE.

COMPONENTS OF A SLOTTER MACHINE

BASE
COLUMN TABLE RAM TOOL

TOOL HOLDER

TYPES OF SLOTTERS

PUNCHER SLOTTER PRODUCTION SLOTTER TOOL ROOM SLOTTER

DRIVE MECHANISM IN SLOTTER MACHINE

SAME AS IN SHAPER MACHINE, SLOTTER MACHINE ALSO HAVE HYDRAULIC DRIVE SLOTTED DISC MECHANISM

SLOTTED DISC DRIVE

OPERATIONS DONE IN SLOTTER

MACHINING FLAT SURFACE MACHINING CYLINDRICAL SURFACE MACHINING IRREGULAR SURFACE

CAM MACHINING
MACHINING SLOTS, KEYWAYS AND GROOVES

SURFACES MACHINED IN SLOTTER AND SHAPER MACHINES

PROCESSES PERFORMED ON SHAPER MACHINE

PROCESSES PERFORMED ON SLOTTER MACHINE

PROCESS PARAMETERS IN SHAPING & SLOTTING

SHAPER ATTACHMENTS

Double cut attachment used in shaping machine

Thread rolling attachment

Mattersons Attachment for gear teeth generation in shaping machine

SLOTTER ATTACHMENTS
SUCH SIMPLE AND LOW COST ATTACHMENT IS MOUNTED ON THE HORIZONTAL SPINDLE FOR PRODUCING KEYWAYS AND CONTOURED SURFACE REQUIRING LINEAR TRAVEL OF SINGLE POINT TOOL IN MILLING MACHINE WHERE SLOTTING MACHINE AND BROACHING MACHINE ARE NOT AVAILABLE. THERE ARE SEVERAL OTHER POSSIBLE ATTACHMENTS WHICH CAN BE USED FOR SOME SPECIFIC APPLICATION NOT INCLUDED IN THE BASIC RANGE OF A PARTICULAR MACHINE TOOL.

NEW

ATTACHMENTS

CAN

ALSO

BE

PLANER MACHINE
A COMMON PLANER IS A MACHINE TOOL DESIGNED TO MACHINE METAL BY COMBINING THE LINE MOTION OF A JOB AND THE PERPENDICULAR FEED OF THE TOOL.

COMPONENTS OF A PLANER MACHINE

BED TABLE HOUSING CROSS RAIL TOOL HEADS

TYPES OF PLANER MACHINES

DOUBLE HOUSING PLANER OPEN SIDE PLANER UNIVERSAL PLANER PIT TYPE PLANER PLATE OR EDGE PLANER

DOUBLE HOUSE PLANER

OPEN SLIDE PLANER

DRIVE MECHANISM

HYDRAULIC DRIVE

VARIABLE SPEED MOTOR

PLANER ATTACHMENTS

Contour forming attachment Other attachments Rotary tool driver attachments Hydraulic tracer control type attachments Milling and grinding attachments

Helical grooving attachment

WORK HOLDING DEVICES IN SHAPER, SLOTTER AND PLANER MACHINES

DIFFERENCE BETWEEN SHAPING, PLANNING AND SLOTTING