Basic Manufacturing Processes

Module-VI Machine Tools

Category: Shaper, Planer, Slotter, Broaching Machine

Ashok Acharya, MEEG217

Department of Mechanical Engineering
School of Engineering
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• Workshop Technology By SK Hajra and Chaudhary

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• Basic Manufacturing By Rajendra Singh
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 Introduction to Machining
• Machining is manufacturing process that involves removing materials
using cutting tools for getting rid of the unwanted materials from some
w/p and converting it into the shape you desire.
• Commonly carried out in machine shops or tool room for machining a
cylindrical or flat jobs to a desired shape, size and finish
• Tool is constrained to move relative to the job in such a way that a layer of
metal is removed in the form of a chip
• machining processes are performed on metal cutting machines, more
commonly termed as machine tools using various types of cutting tools
(single or multi-point)
• Machining operations are classified into 3 principle processes and they
are turning, drilling and milling.

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 Machine tools
• Power driven machines that performs material removal
operation with tools, to produce desired shape and size of the
work piece is known as machine tool
• assist in managing the needed relative motion between
cutting tool and the job that changes the size and shape of the
job material
• Working motion is imparted either to work piece or to cutting
tools by the mechanisms so that work and tool travel relative
to each other

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 Machine tools contd...
Machine Tools are used for
– To improve production rates
– To reduce cost of production
– To reduce fatigue of workers
– To achieve better quality
– To reduce wastage

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 Machine tools contd...
• Various types of machine tools used in machine shop
are:
– Lathes
– Shapers
– Planers
– Drilling Machines
– Milling machines
– Grinding machines

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 Lathe Machine
• Lathe is a machine, which removes the metal
from a piece of work to the required shape
&size
• The products produced with the help of the
lathe machine are cue sticks, musical
instruments, candlestick holders, table legs,
baseball bats, gun barrels, camshafts, bowls,
crankshafts and much more.

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Types of Lathe Operation

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 Types of Lathe Operation

Facing
• This is usually the first step of any lathe operation on the lathe machine.
The metal is cut from the end to make it fit in the right angle of the axis
and remove the marks.
Tapering
• Tapering is to cut the metal to nearly a cone shape with the help of the
compound slide. This is something in between the parallel turning and
facing off. If one is willing to change the angle then they can adjust the
compound slide as they like.
Parallel Turning
• This operation is adopted in order to cut the metal parallel to the axis.
Parallel turning is done to decrease the diameter of the metal.
Parting
• The part is removed so that it faces the ends. For this the parting tool is
involved in slowly to make perform the operation. For to make the cut
deeper the parting tool is pulled out and transferred to the side for the cut
and to prevent the tool from breaking.
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 Lathe Cutting Tools

• Carbide tip tools

• Grooving tool
• Cut-Off blade
• Parting blades
• Boring bar
• Side tool

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 Types of Lathe Machine
Engine Lathe
– The most common form of lathe, motor driven and
comes in large variety of sizes and shapes.
Bench Lathe
– A bench top model usually of low power used to
make precision machine small work pieces.
Tracer Lathe
– a lathe that has the ability to follow a template to
copy a shape or contour.

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Types of Lathe Machine..contd
Automatic Lathe
– A lathe in which the work piece is automatically fed and
removed without use of an operator. Cutting operations are
automatically controlled by a
– sequencer of some form
Turret Lathe
– lathe which have multiple tools mounted on turret either
attached to the tailstock or the cross-slide, which allows for
quick changes in tooling and cutting operations.
Computer Controlled Lathe
– A highly automated lathe, where both cutting, loading, tool
changing, and part unloading are automatically controlled by
computer coding.

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Components Lathe

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SHAPER

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 Shaper- introduction
• Machine w/ reciprocating tool
• Ram moves the cutting tool forward/backward in a straight line
• Intended, primarily, to produce flat surface by the successive movement of
the tool
• The flat surface may be horizontal, vertical or inclined- any surface of
straight-line elements
• With special tools and attachments, external and internal key ways,
grooves, dovetails and T-slots can be obtained.
• A shaper is used to generate flat (plane) surfaces by means of a single
point cutting tool

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 Shaper contd…
Tool feed handle

Clapper box
Reciprocating ram

tool Driving mechanism

• Relatively slow machine tool

• Used for initial rough machining of the blanks
• Uses single point cutting tool
Table w/ vice • Tool is clamped to toolpost
• Tool post mounted to a clapper box
• Clapper box mounted to reciprocating arm

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 Shaper contd…
• Ram pushes the cutting tool through workpiece to remove the material
• When ram returns, no cutting takes place
• In between cutting and return stroke, table moves in horizontal direction
perpendicular to cutting direction- feed direction
• Generally used for machining flat surfaces in horizontal, vertical or
angular direction

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Principal components
of a Shaper

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 How does a Shaper work?
• A single point cutting tool is held in the tool holder, which is mounted on
the ram
• The workpiece is rigidly held in a vice or clamped directly on the table
• cutting tool held in tool holder, ram reciprocates

• moves forward and backward over the workpiece.

• cutting of material takes takes place during the forward stroke of the ram
• backward stroke remains idle and no cutting takes place during this stroke

• The time taken during the idle stroke is less as compared to forward
cutting stroke and this is obtained by quick return mechanism.

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 Shaper contd…
Tool feed handle

Clapper box
Reciprocating ram

Single point Driving mechanism

Cutting tool

Table w/ vice

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 Working principal- shaper
• Shaper are driven mechanically or hydraulically
• Stroke length can be varied by changing length of crank

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 Working contd...
• Single point cutting tool
Reciprocates.
• Cutting takes over the stationary
work in single stroke.
• Vice and Tool holder can be
swiveled at desired angle to
produce grooves, slots and
Angular cuts
• Shaper can be horizontal or
vertical based on the plane of
movement of ram/tool

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Apron to swivel tool post at angle

Clapper box

Tool

Cylindrical
jobpiece
Chips
Table with vice

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 Working contd...

Clapper box

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 Working contd...
• In a shaper, rotary motion of the drive is converted into reciprocating
motion of the ram by the mechanism housed within the column or the
machine

• metal is removed in the forward cutting stroke

• return stroke goes idle

• shaper mechanism is so designed that it moves the ram holding the tool at
a comparatively slower speed during forward cutting stroke, whereas
during the return stroke it allow the ram to move at a faster speed to
reduce the idle return time- quick return mechanism

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 Working contd...
• The reciprocating movement of the ram and the quick return
mechanism of the machine are generally obtained by anyone
of the following methods:
– Crank and slotted link mechanism
– Whitworth quick return mechanism, and
– Hydraulic shaper mechanism

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 Shaper- classification
(1) According to the type of mechanism used for giving reciprocating motion
to the ram:
(a) Crank type
(b) Geared type
(c) Hydraulic type
(2) According to the type of design of the table:
(a) Standard shaper
(b) Universal shaper
(3) According to the position and travel of ram:
(a) Horizontal type
(b) Vertical type
(c) Traveling head type
(4) According to the type of cutting stroke:
(a) Push type
(b) Draw type

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Shaper parts

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 Parts contd...
• Base
– It is rigid and heavy cast iron body to resist vibration and takes up high
compressive load
– supports all other parts of the machine, which are mounted over it
– bolted to the floor or on the bench

• Column
– box-shaped casting mounted upon the base
– houses the ram-driving mechanism
– Two accurately machined guide ways are provided on the top of the
column on which the ram reciprocates

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 Parts contd...
• Cross rail
– has two parallel guide ways on its top in the vertical plane that is
perpendicular to the rail axis
– mounted on the front vertical guide ways of the column
– consists mechanism for raising and lowering the table to
accommodate different sizes of jobs by rotating an elevating screw
– screw causes the cross rail to slide up and down on the vertical face of
the column
– A horizontal cross feed screw is fitted within the cross rail actuates the
table to move in a crosswise direction (manual feed/auto feed)

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 Parts contd...
• Saddle:
– is located on the cross rail and holds the table on its top
– Crosswise movement of the saddle causes the table to move sideways

• Table:
– box-like casting having T -slots both on the top and sides for clamping
the work
– is bolted to the saddle and receives crosswise and vertical movements
from the saddle and cross rail

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 Parts contd...
• Ram:
– reciprocating part of the shaper, which reciprocates on the guideways
provided above the column.
– connected to the reciprocating mechanism contained within the
column

• Tool head
– The tool head of a shaper performs the following functions-
• It holds the tool rigidly,
• It provides vertical and angular feed movement of the tool, and
• It allows the tool to have an automatic relief during its return stroke

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 Spec. of a Shaper
size of a shaper is specified by
– the maximum length of stroke or cut it can make
– type of drive
– floor space required,
– weight of the machine,
– cutting to return stroke ratio,
– number and amount of feed,
– power input

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 Shaper operations
• primarily designed to generate a flat surface by a single point
cutting tool
• The different operations, which a shaper can perform, are as
follows:
– Machining horizontal surface (Fig.
– Machining vertical surface (Fig. )
– Machining angular surface (Fig. )
– Slot cutting
– Key ways cutting

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Tool Head

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PLANER

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 Planer- Introduction
• Like a shaper, planer is used primarily to produce horizontal, vertical or
inclined flat surfaces by a single point cutting tool
• used for machining large and heavy workpieces that cannot be
accommodated on the table of a shaper
• Planner tool remains stationery and work piece reciprocates.
• Cutting can be horizontal, vertical and angular
• Two or more tools can be operated simultaneously

• Planer is mainly of two kinds;

– open housing planer and double housing planer

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Planer contd…

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 How does it work?
• tool is clamped in the tool holder and work on the table
• work reciprocates past the stationary cutting tool
• feed is imparted by the lateral movement of theworkpiece
• like shaper, the planner is equipped with clapper box to raise the tool in
idle stroke

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 Planer

Precision Planer Miller

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SLOTTER

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 Slotter- Introduction
• Slotter or slotting machine is also a
reciprocating type of machine tool similar
to a shaper or a planer

• may be considered as a vertical shaper

• chief difference between a shaper and a
slotter is the direction of the cutting
action

• the tool moves vertically rather than in a

horizontal direction

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 Slottercontd...
• Vertical shaper is almost similar to the slotter except that in shaper the
tool holder can reciprocate at inclined position, but in slotter the ram
cannot be swiveled not more than 5°
• Slotting machines were developed much earlier than shaper and planer
Slotting machines are available in two types:
1. Punch Slotter
Punch slotter is heavy, rigid machines designed for removal of large
amount of metal from large forgings and castings, with sufficiently large
stroke length (up to 2000 mm)
2. Precision Slotter
Precision slotter is a lighter machine and is operated at high speeds;
designed to take light cuts giving accurate finish

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Slottercontd...

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 Slottercontd…
• Principal parts of Slotter
– Bed/base
– Table
– Hand Wheels
– Column (vertical)
– Ram
– Cross-Slide

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 Slottercontd…
• Operations performed in Slotter:
– for machining vertical surfaces
– to cut slots, splines, keyways
– machining convave, convex, semi curcular
surfaces
– for machining shapes that are otherwise
difficult on shaper

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Slotter cutting tool

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Slottercontd…

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BROACHING

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 Broaching
• Broaching is a method of removing metal by pushing or pulling a cutting
tool called broach
• each successive tooth removes metal
• tooth must be larger or elongated than the previous tooth
• A part is completed on one stoke of machine, from rough cut to finishing

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 Broaching contd...
• Faster Production rate
• Internal and external surface can be broached
• Not recommended for large depth of cut.
• Tool is costly

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Broaching tools

Keyway broach

Broached keyway in a wrench

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Broaching tools

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Broaching Machine

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Broached Products

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END OF SHAPER, PLANER, SLOTTER,
BROACHING MACHINE

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