Scribd
Upload
4 views22 pages

5.shaping & Planning CHAPTER 5

Uploaded by

Jayed Ahmed
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
4 views22 pages

5.shaping & Planning CHAPTER 5

Uploaded by

Jayed Ahmed
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
You are on page 1/ 22

CHAPTER 5

SHAPING & PLANNING OPERATIONS


Construction, working principle and applications of
shaping, planning machines.
Shaping and Planing
Similar operations
Both use a single point cutting tool
moved linearly relative to the workpart

Figure ‑ (a) Shaping, and (b) planning


Shaping and Planing
A straight, flat surface is created
in both operations
Interrupted cutting
◦ Subjects tool to impact loading when
entering work
Low cutting speeds due to
start‑and‑stop motion
Usual tooling: single point high
speed steel tools
Figure ‑ Components of a shaper
Figure ‑ Open side planer
A photographic view of general configuration
of shaping machine is shown in Fig. 4.4.1.
The main functions of shaping machines are
to produce flat surfaces in different planes.
The cutting motion provided by the linear
forward motion of the reciprocating tool and
the intermittent feed motion provided by the
slow transverse motion of the job along with
the bed result in producing a flat surface by
gradual removal of excess material layer by
layer in the form of chips. The vertical in feed
is given either by descending the tool holder
or raising the bed or both. Straight grooves of
various curved sections are also made in
shaping machines by using specific form
tools. The single point straight or form tool is
clamped in the vertical slide which is
mounted at the front face of the reciprocating
ram whereas the workpiece is directly or
indirectly through a vice is mounted on the
bed.
The photographic view in Fig.
4.4.3 typically shows the
general configuration of
planning machine. Like
shaping machines, planning
machines are also basically
used for producing flat
surfaces in different planes.
However, the major differences between planning machines from
shaping machines are :

o Though in principle both shaping and planning machines produce flat


surface in the same way but in planning machine, instead of the tool, the
work-piece reciprocates giving the fast cutting motion and instead of the
job, the tool(s) is given the slow feed motion(s).

o Compared to shaping machines, planning machines are much larger


and more rugged and generally used for large jobs with longer stroke
length and heavy cuts. In planning machine, the work-piece is mounted
on the reciprocating table and the tool is mounted on the horizontal rail
which, again, can move vertically up and down along the vertical rails.

o Planning machines are more productive (than shaping machines) for


longer and faster stroke, heavy cuts (high feed and depth of cut) possible
and simultaneous use of a number of tools.
Cutting Speed and Machining Time in Horizontal Shapers

Cutting speed on horizontal shapers is defined as the average speed of the


tool during the cutting stroke and depends primarily on the number of ram
strokes per minutes (N) and the length of the stroke (L). The average cutting
speed may be determined by the following formula:

Average Cutting Speed (Va) = 2 L N/C


where; N= strokes per minutes
L= stroke length
C = cutting time ratio = cutting time/ total time=3 /5
Therefore; the average cutting speed is:

(Va) = 10[(L N)/3]

The number of strokes per minute for a desired cutting speed is then:
N = 3 Va/ 10 L

To determine the number of strokes required to complete a job;

S = Width of the work/feed per stroke=b/f


The total machining time is then:

Total Time (T) = Time per stroke ×Number of strokes = (1/N )×S

A general expression, therefore to determine the cutting time knowing the


desired speed and the length of stroke is:

Total Time (T) = (10 . b . L)/(3 . f . V a)

Determine the cutting time to shaper machine a workpiece of dimensions 300 ×


100 × 60 mm if the cutting speed is 30 m/min and the feed per stroke is 2 mm.

Solution:
Machining Time (T) = 10 . b . L/3 . f . Va
= (10 . 100 . 300 )/(3 . 2 . 30 . 1000)
= 1.67 min.
Using Straight Gears and Rack
As shown in Fig. the motion is primarily supplied by the motor to the loose pulley (b). This
motion can be transferred either to the pulley (c) or the pulley (a) using a special mechanical
switch designed according to the length of the machining stroke.
To obtain the cutting stroke, motion is transferred to pulley (a) which it is moving on the shaft
(c1) freely. Then motion is transferred to gear (G2) across gear (G1) which is rigidly connected
to pulley (a). Since gear (G2) is bolted to axis (c2), motion is transferred to gear (G6) and,
then, to the machine table through the rack (R). To obtain motion for the return stroke, the
motion is shifted from pulley (b) to pulley (c) which is bolted to the axis (c1). As axis (c1)
rotates, motion is transferred from gear (G3) to gear (G5) through an intermediate gear (G1).
The motion then is transferred to gear (G6) and then to the machine table. The ratio (R) may
be determined as the inverse ratio between the
teeth of gears (G2) and (G5).
Determine the cutting speed in a planer working using rack and gears
combination if motor speed is 1000 rpm and a reduction ratio of 4.
Assume suitable number of gear teeth.

Solution
Speed on axis (c1) = 1000/4 = 250 rpm.

Assume that:
Z for G1 = 30 teeth Z for G2 = 68 teeth
Z for G3 = 30 teeth Z for G4 = 20 teeth
Z for G5 = 30 teeth Z for G6 = 40 teeth
D for G6 = 100 mm.

Cutting Speed (Vc) =π × 100 × (1000/4) (30/68) = 34.65 m/min.

Return Speed (Vr)= π × 100 ×(1000/4)(30/20)(20/30)=78.54 m/min.

R = Vc / Vr = 0.44.
Hydraulic System

As shown in Fig. 6, this technique operates by pumping hydraulic oil from reservoir
(K) through the pump (P) to a cylinder (C) from two opposite sides (C1) or, (C2).
The machine table is connected to the rod of the cylinder (R). To obtain the cutting
stroke, the valve (V1) is opened while the other valve (V2) is closed as described
by the dotted position of the lower piston. The pumped oil is fed to the cylinder
through its right valve (V1). This pushes the piston (S) causing the cutting action in
the direction described by the figure. This motion continues until socket (d1) hits
the lever (L) at the right position making it to rotate around its center (O).

This pushes the piston rod (r) to the new position described in the figure by the
continuos line. This allows the oil to be pumped through the valve (V2) through the
other end (C2) causing the return stroke to start. This continues until the lever (L)
hits the left socket (d2) opening the right valve (V1) and closing the left one
allowing another cutting stroke. The rapid return speed is obtained since there is a
reduction in the cylinder area due to the existing of the piston rod.
Fig. Hydraulic Rapid Return
Speed Technique
Determine the speed ratio (q) in a planning operation using a hydraulic
system. The oil pressure is 1.1 kp/mm2 and flow of 0.1 m3/min. The
piston diameter is 50 mm with a rod of a 30 mm diameter.

Solution

Flow (Q) = Flow Speed × Area

Cutting Speed (VC) = 0.1/[(π/4)(50/1000)2]= 50.93 m/min.

Return Speed (Vr) = 0.1/[(π/4)((50/1000)2)-(30/1000)2)]=79.58 m/min.

Speed Ratio (q) = (Vr) / (Vc) = 1.56


As in shaping machines, in Shaping machines
planning machines also; It is already mentioned that
Δ The length and position of shaping machines are neither
stroke can be adjusted productive nor versatile.
Δ Only single point tools are However, its limited applications
used include :
Δ The quick return persists Δ Machining flat surfaces in
Δ Form tools are often used for different planes. Fig. shows how
machining grooves of curved flat surfaces are produced in
section shaping machines by single point
Δ Both shaping and planning cutting tools in (a) horizontal, (b)
machines can also produce vertical and (c) inclined planes.
large curved surfaces by using
suitable attachments.

(a) horizontal surface (b) vertical surface


(c) inclined surfaces (dovetail slides and guides)

Fig. Machining of flat surfaces in shaping machines


Making features like slots, steps etc. which are also bounded by flat surfaces. Fig.
visualizes the methods of machining (a) slot, (b) pocket (c) T-slot and (d) Vee-block
in shaping machine by single point tools.

Δ Forming grooves bounded by short width curved surfaces by using single point
but form tools. Fig. typically shows how (a) oil grooves and (b) straight tooth of spur
gears can be made in shaping machine

Δ Some other machining applications of shaping machines are cutting external


keyway and splines, smooth slitting or parting, cutting teeth of rack for repair etc.
using simple or form type single point cutting tools. Some unusual work can also be
done, if needed, by developing and using special attachments.
(a) slotting (b) pocketing (c) T-slot cutting

Fig. 4.4.8 Machining (a) slot, (b) pocket (c) T-slot and (d) Vee block in
shaping machine
(a) Grooving (b) Straight teeth cutting for spur gear
Fig. Machining in shaping machine

However, due to very low productivity, less versatility and poor process
capability, shaping machines are not employed for lot and even batch
production. Such low cost primitive machine tools may be reasonably used
only for little or few machining work on one or few pieces required for repair
and maintenance work in small machine shops.

You might also like