MODULE 3

RECIPROCATING MACHINES

1. Shaper
2. Planner
3. Slotter
Shaper machine
Shaper mechanism
 Shaper machine

 The shaper machine is a
reciprocating type
of machine basically used
for producing the
horizontal, vertical or flat
surfaces.

 The shaper holds the single

point cutting tool in ram and
workpiece is fixed in the
table.
Shaper operations
 Main parts of a shaper
1. Column
2. The Motor
3. Ram
4. Table
5. Tool Head
6. Tool Holder
7. Slot With The Clamp
8. Crank Handle
9. Pawl Mechanism
10. Elevating Screw
11. Support Bracket
12. Shifting Levers
Shaper
 Clapper mechnism
• Clapper box carries
the tool holder. The
main function of
the clapper box is to
provide clearance for
tool in return stroke.

• It prevents the cutting

edge dragging the
work piece while
return stroke and
prevent the tool from
wear.
Shaping operations
 Classifications of Shapers
1. According to the ram driving mechanism

 Crank shaper: In a crank shaper, a crank and a slotted lever quick return
motion mechanism is used to give reciprocating motion to the ram. The
crank arm is adjustable and is arranged inside the body of a bull gear (also
called crank gear).

 (b) Geared shaper: In a geared shaper, the ram carries a rack below it,
which is driven by a spur gear. This type of shaper is not widely used.

 (c) Hydraulic shaper: In a hydraulic shaper, a hydraulic system is used to

drive the ram. This type of shaper is more efficient than the crank and
geared shaper.
 Classifications of Shapers
2. According to position and travel of ram

 (a) Horizontal shaper: In a horizontal shaper, the ram

moves or reciprocates in a horizontal direction. This type
of shaper is mainly used for producing flat surfaces.

 (b) Vertical shaper: In a vertical shaper, the ram

reciprocates vertically in the downward as well as in
upward direction. This type of shaper is very convenient
for machining internal surfaces, keyways, slots or grooves.
 Classifications of Shapers
3. According to the direction of cutting stroke

 (a) Push-Cut shaper: In a push-cut shaper, the ram pushes the tool
across the work during cutting operation. In other words, forward
stroke is the cutting stroke and the backward stroke is an idle
stroke. This is the most general type of shaper used in common
practice.

 (b) Draw-cut shaper: In a draw-cut shaper, the ram draws or pulls

the tool across the work during cutting operation. In other words,
the backward stroke is the cutting stroke and forward stroke is an
idle stroke.
 Classifications of Shapers
4. According to the design of the table

 Standard or plain shaper: In a standard or plain shaper, the table

has only two movements i.e., horizontal and vertical, to give the
feed. It can not be swiveled or tilted.

 (b) Universal shaper: In a universal shaper, in addition to the

above two movements, the table can be swiveled about a horizontal
axis parallel to the ram and the upper portion of the table can be
tilted about the other horizontal axis perpendicular to the first axis.
This type of shaper is mostly used in tool room work.
 Specifications of a Shaper
1. Maximum length of stroke is millimeters,
2. Size of the table, i.e., length, width and depth of the table,
3. Maximum vertical and horizontal travel of the table,
4. Maximum number of strokes per minute,
5. Power of the drive motor,
6. Type of quick return mechanism.
7. Floor space required, and
8. Weight.
Shaper mechanism
 Ratchet and Pawl Mechanism
(Automatic Feed Mechanism for the Table)
 Ratchet and Pawl Mechanism
Automatic Table Movement
 The table of a shaping machine travels in a cross direction when
the crossfeed screw is rotated.
 The cross feed screw is attached to the ratchet wheel.
 A spring loaded ‘pawl’ is positioned to be placed between the
teeth of the ratchet wheel.
 The pawl is housed within a frame known as rocker arm.
 The pawl makes the ratchet to rotate by a small amount in one
direction only.
 As the cross feed screw is attached to the ratchet wheel, the
rotation of the ratchet wheel will make the table to move in a
cross direction.
Ratchet and Pawl Mechanism
PLANER
Shaper v/s Planer
 Planning machine
 The planer (also called planing machine) is a machine tool
used to produce plane and flat surface by a single point
cutting tool.

 It is similar to a shaper but its size is very large and is adopted

for producing flat surfaces of much larger work than a shaper.

 The fundamental difference between a planer and shaper is

that in a planer, the tool remains stationary and the work
reciprocates whereas in the shaper, the work remains
stationary and the tool reciprocates.
 Types of Planers

1. Standard or double housing planer

2. Open side planer

3. Pit planer

4. Edge or plate planer

5. Divided table planer

Standards or double housing planer
Standards or double housing planer
 The columns are connected at the top by a cast iron support.

 The table reciprocates on accurate guide ways provided on a

long heavy bed.

 The two tool heads which carry the tool are mounted on the
cross rails.

 These tools may be fed either by hand or by power in

crosswise or vertical direction.
 Principal Parts of a Planer
1. Bed:

 The bed of a planer is a box like casting having

cross ribs.
 It provides the foundation for the machine and
supports the housing and all other moving parts.
 The upper part of the bed is provided with
precision V- type guide ways on which the table
slides.
Principal Parts of a Planer
2. Table:

 The planer table is a heavy rectangular precision machined

casting.
 It reciprocates along the ways of the bed and supports the
work.
 The top face of the table is provided with T-slots and holes
uniformly spaced for fixing the work and work holding
devices over the table with the help of T-bolts, clamps etc.
 The table may be driven by rack and gear, by rack and
double helical gear or by hydraulic system.
Principal Parts of a Planer
3. Housing (Column)

 The housings are rigid column-like castings placed

on each side of the bed.
 The front face of the housings is accurately
machined to provide precision ways.
 The housings enclose the cross-rail elevating screws,
vertical and cross-feed screws for the tool heads,
counter balancing weights for the cross-rail etc.
Principal Parts of a Planer
4. Cross-rail:

 The cross-rail is mounted on the precision

machined ways of the two housings.

 It may be raised or lowered on the housings to

accommodate work of different heights on the table
and to allow for the adjustment of the tools.
Principal Parts of a Planer
5. Tool heads:

 The tool heads are mounted on the cross-rail or housings by

means of a saddle which slides along the rail or housing
ways.
 The saddle may be made to move transversely on the cross-
rail to give cross feed.
 Two tool heads are provided on the cross-rail so that the two
tools may remove the material from the work simultaneously.
 In addition to these two-tool heads, there are other two-tool
heads which are mounted on each housing.
Standard planer
Size and Specifications of a Planer

1. Width of the table in mm,

2. Maximum distance of the table to the cross-rail in
meters,
3. Maximum stroke of the table in mm.
4. Length of bed,
5. Length of the table,
6. Type of drive,
7. Power of the motor, and
8. Number of speed and feed etc.
 Planer Tools
 The planer tools are mostly made of high speed steel.
 The cemented carbide tipped tools are also used on
planers for production work.
 The planer tools are similar to those used on shaper,
but, as the depth of cut are heavier and cutting strokes
are large, the planer tools are large in size.
 A planer tool many be classified as roughing or
finishing and right hand or left hand type.
Planner tools
Planner tools
Planer operation
 Cutting speed
 In both shapers and planers, the tool or table starts from
rest, picks up speed and then again slows down to zero
speed during the forward or cutting stroke.

 It is customary to calculate cutting speed on the basis of

average speed during the forward stroke. Feed and depth
of cut are both expressed in mm.

 In case of feed, it is the lateral distance moved by the

tool (on the cross-rail) per cutting stroke.
Work holding devices in planer
Work holding devices in planer
Difference b/w planer and shaper
Planer Shaper
1. It is a heavy duty machine tool. 1. It is a light duty machine tool.
2. It requires more floor area. 2. It requires less floor area.
3. It is adopted for large works. 3. It is used for small works.
4. More than one cutting tool
can be used at a time. 4. Only one cutting tool is used at a time.
5. Tool is fixed and work moves. 5. Work is fixed and the tool moves.
6. Planer table is either driven
by gears or by hydraulic means. 6. It is normally driven by crank and slotted lever
quick return motion mechanism.
7. Heavier feeds are applied. 7. Lighter feeds are applied.
8. It can take deep cuts. 8. It cannot take deep cuts.
9. Work setting requires much
of skill and takes longer time. 9. Work may be clamped easily and quickly.
10. Tools used are of larger size. 10. Tools used are of smaller size.
Components manufactured by planning/shaping
processes
Slotter machine
 Slotter machine
 The slotting machine is a reciprocating type of
machine tool similar to shaper.

 The major difference b/w slotter and shaper is the

ram holding the tool reciprocates in a vertical axis.

 A vertical shaper and slotter are almost similar in

operation.
Slotter machine
 Types of slotting machine

1. Crank driven slotter

2. Puncher slotter

3. Precision tool room slotter

 Puncher slotter:
 Intended for removing large amount of metal from
heavy works.

 heavy and rigid machine

 Ram driven by rack and spiral pinion mechanism

 Used for machining large castings and forgings

 Precision tool room slotter:

• Used for tool room work, where accuracy important

• Lighter in construction
• Fitted with quick return mechanism
• Operates at high speeds and designed for light cuts
• Gives accurate finish
• Suitable for small to medium size work pieces
Slotting machine
 Slotter machine parts
 Base
 Column
 Saddle
 Cross slide
 Rotating table
 Ram and tool head assembly
 Ram drive mechanism
 Feed mechanism
Slotter operation
 Slotter operations

1. Machining flat surfaces

2. Machining cylindrical surfaces

3. Machining irregular surface and cam machining

4. Machining slots, keyways, grooves (internal and

external )
 Feed in Slotter

• In Slotter feed is given by table

• Feed movement is intermittent
• Feed is given at the beginning of the cutting stroke
• Feed may be given either manually or by power
• Table will have three types of feed movements
1.longitudinal
2. cross and
3. circular feeds.
 Machining grooves or key ways

• Slotter is specially intended for cutting internal

grooves.
• External or internal gear teeth can be machined
• Fix up the job between two centers
• Cut first a key way
• Move / Rotate work by the required amount
• Indexing can be done by using graduations on
rotary table
 Difference between vertical shaper and Slotter

• In verticle shaper the tool holding ram can tilt by

about 50⁰ with respect to verticle axis
• In slotter ram cannot tilt at all.
• In all other aspects verticle shaper and slotter are
similar.
 SHAPING, PLANING, AND SLOTTING
PROCESSES

 These processes are used for machining horizontal, vertical,

and inclined flat and contoured surfaces, slots, grooves, and
other recesses by means of special single-point tools.

 The difference between these three processes is that in

planing, the work is reciprocated and the tool is fed across
the work.

 While in shaping and slotting, the tool is reciprocating and

the work is fed across the cutting tool.
Conti…
 The essence of these processes is the same as of
turning, where metals are removed by single-point tools
similar in shape to lathe tools.

 A similarity also exists in chip formation.

 However, these operations differ from turning in that

the cutting action is intermittent, and chips are removed
only during the forward movement of the tool or the
work.
Cont….
 The conditions under which shaping, planing, and slotting
tools are less favorable than in turning, even though the tools
have the opportunity to cool during the return stroke, when
no cutting takes place.

 That is because these tools operate under severe impact

conditions.

 For these conditions, the related machine and tools are

designed to be more rigid and strongly dimensioned, and the
cutting speed in most cases does not exceed 60 m/min.
Characteristics of the 3 machines
 The limited cutting speed and the time lost during the reverse
stroke are the main reasons behind the low productivity of
shaping, planing, and slotting compared to turning.

 The basic machining parameters are

 the average speed during the cutting stroke V cm/s,
 the feed f,
 the depth of cut t, and
 the uncut cross-section area Ac.

 The feed is the intermittent relative movement of the tool (in

planing) or the WP (in shaping and slotting), in a direction
perpendicular to the cutting motion and expressed in millimeters
per stroke.
Shaper, planer and slotter mechanism

QUICK RETURN MECHANISM

1. Shapers and slotters of slotted lever mechanism

2. Hydraulic shapers, planers, and slotters,

3. Planers of rack and pinion mechanism

Quick return mechanism (QRM)
 A mechanism makes the ram to move slowly
during cutting stroke.

 During return stroke ram moves at a faster rate.

 To reduce the idle time, It should return quickly .

The mechanism adopted is known as QRM
Quick return mechanism
 Quick return mechanism
 A quick return mechanism is an apparatus to produce
a reciprocating motion in which the time taken for travel in
one direction is less than in the other.

 It is driven by a circular motion source and uses a system of

links and sliding joints.

 Quick return is a common feature of tools in which the action

is performed in only one direction of the stroke, such
as shapers and powered saws, because it allows less time to
be spent on returning the tool to its initial position.
Quick return mechanism
1. Crank and slotted lever
 Shapers and slotters of
LEVER ARM MECHANISM
Crank and Slotted Link Mechanism
Crank and Slotted Link Mechanism
2. Hydraulic mechanism
Advantages of Hydraulic mechanism

1. Efficient power transmission

2. Smooth operation
3. Highly reliability
4. Less noise and vibration
5. Less moving components
6. Less maintenance
7. Less wear and tear
8. Less skilled operator
3. Rack and pinion mechanism
Speed, Feed and Depth of cut
 Cutting speed is the rate at which material is removed
by the cutting tool. It is defined as the length of
cutting stroke divided by time taken (m/min).

 Feed is given at the end of each return stroke. It is

expressed in mm/stroke.

 Depth of cut is defined as the thickness of material

removed in one cut.
 Machining time
 The time required to complete the job is known as
machining time.

 Tm={ L * B* (1+m)} / 1000 V S

 L= length , B= breadth, S=feed

 m= return time/cutting time
 V= cutting speed
THANK YOU