Module III

Shaper, Slotter and Planer machines

Reciprocating machines: Shaping machines – Types – Size – Principal parts –

1
Mechanism
Work holding devices – Operations performed – Tools 1
Cutting speed, feed and depth of cut – Machining time. 1
Slotting machines – Types – Size – Principal parts – Mechanism – Work holding
1
devices
Operations performed – Tools – Cutting speed, feed and depth of cut 1
Planning machines – Types – Size – Principal parts – Mechanism – Work holding
1
devices
Operations performed – Tools – Cutting speed, feed and depth of cut – Machining
1
time- Surface roughness obtainable.

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 Reciprocating machines
Reciprocating machine
In lathes the work piece is rotated while the cutting tool is moved axially to produce
cylindrical surfaces. But in reciprocating machine tools the single point cutting tool is
reciprocating and produces flat surfaces. The flat surfaces produced may be horizontal,
vertical or inclined at an angle. These machine tools can also be arranged for machining
contoured surfaces, slots, grooves and other recesses. The major machine tools that fall in this
type are: Shaper, Planer and Slotter. The main characteristic of this type of machine tools is
that they are simple in construction and are thus economical in operation
Shaping machine
The work is held firmly on the table and the ram is allowed to reciprocate over it. A single
point cutting tool is attached to the ram. When the ram moves horizontally in the forward
direction, the tool removes metal from the work. On the return stroke, metal is not removed.
The ram moves at a slow speed during forward stroke. But during return stroke, the ram
moves at a faster speed. Though the distances of ram movement during the forward and
return stroke remain the same, the time taken by the return stroke is less as it is faster.
The main function of the shaper is to produce flat surfaces in different planes. Because of the
poor productivity and process capability the shapers are not widely used nowadays for
production work. The shaper is a low cost machine tool and is used for initial rough
machining of the blanks
Principal parts

Base
The base is hollow and is made of cast iron. It provides the necessary support for all the other
parts of the machine. It is rigidly bolted to the floor of the workshop.
Column
It is a box like casting mounted vertically on top of the base. Two accurate guideways are
machined on the top of the column. The ram reciprocates on these guideways. The front face
of the column is provided with two vertical guideways. They act as guideways for the cross
rail. Cross rail moves vertically along these guideways. The column encloses the ram
reciprocating mechanism and the mechanism for stroke length adjustment.
Cross rail
It is mounted on the front vertical guideways of the column. The table may be raised or
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lowered by adjusting the cross rail vertically. A horizontal cross feed screw is fitted within
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the cross rail.

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Table
It is an important part useful in holding the work firmly on it. It is mounted on the saddle
which is located above the cross rail. The top and sides of the table are accurately machined
and have T-slots. Work pieces are held on the table with the help of shaper vise, clamps and
straps.
Ram
Ram supports the tool head on its front. It reciprocates on the accurately machined guideways
on the top of the column. It is connected to the reciprocating mechanism placed inside the
column. The position of ram reciprocation may be adjusted according to the location of the
work on the table.
Tool head
The tool head is fitted on the face of the ram and holds the tool rigidly. It provides vertical
and angular feed movement of the tool. The swivel tool head can be positioned at any
required angle and the vertical slide can be moved vertically or at any desired angle to
machine vertical or inclined surfaces.
Types
The shaping machines are classified as follows:
A. According to the type of driving mechanism
1. Crank type
2. Hydraulic type
3. Geared type
B. According to the design of the table
1. Plain shaper/Standard shaper: table has only two movement
2. Heavy duty shaper
3. Universal shaper: table can have swiveled also
C. According to the position and travel of ram
1. Horizontal shaper: tool reciprocates in horizontal axis
2. Vertical shaper
3. Travelling head type
D. According to the type of cutting stroke
1. Push cut shaper: cutting in forward stroke
2. Draw cut shaper: cutting in backward stroke
Crank type shaper
Crank and slotted link mechanism of a crank type shaper converts the rotation of an electric
motor into reciprocating movement of the ram. Though the lengths of both the forward and
return strokes are equal, the ram travels at a faster speed during return stroke. This quick
return is incorporated in almost all types of shaper.
Hydraulic shaper
The ram of a hydraulic shaper is connected to a piston. Oil at high pressure is pumped to the
cylinder of the hydraulic system. As the oil pushes the piston, the ram reciprocates.
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Hydraulic shapers are high power machines and are used for heavy duty work.
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Geared type shaper
The reciprocating motion of the ram is some type of shaper is effect by means of a rack and
pinion. The rack teeth which are cut directly below the ram mesh with a spur gear. The pinion
meshing with the rack is driven by a gear train. The speed and the direction in which the ram
will traverse depend on the number of gears in the gear train. This type of shaper is not very
widely used.
Universal shaper
The universal shaper has a special type of table which can be swiveled and positioned at any
angle about a horizontal axis. Apart from the cross and vertical travel, the table of a universal
shaper can be swiveled to any angle to machine inclined surfaces. These machines are
utilized in precision workshops
Horizontal shaper
In a horizontal shaper, the ram holding the tool reciprocates in a horizontal axis. Horizontal
shapers are mainly used to produce flat surfaces.
Vertical shaper
In a vertical shaper, the ram holding the tool reciprocates in a vertical axis. The work table of
a vertical shaper can be given cross, longitudinal, and rotary movement. Vertical shapers are
very convenient for machining internal surfaces, keyways, slots or grooves. The vertical
shaper which is specially designed for machining internal keyway.
Travelling Head Shaper
In this type of shaper, the ram while it reciprocates, also moves crosswise to give the required feed.

Push type shaper

This is the most general type of shaper used in common practice. The metal is removed when
the ram moves away from the column, i.e. pushes the work.
Draw type shaper
In this type, the metal is removed when the ram moves towards the column of the machine,
i.e. draws the work towards the machine. The tool is set in a reversed direction to that of a
standard shaper. In this shaper the cutting pressure acts towards the column which relieves
the cross rail and other bearings from excessive loading and allows to take deep cuts.
Vibration in these machines is practically eliminated.
Size
The size of a shaper is determined by the maximum length of stroke it can make. Shapers
with maximum stroke length of 175mm to 900mm are available. Machines with maximum
stroke length of 300mm, 450mm and 600mm are used widely.
To specify the machine further, the following points are to be provided.
1. The type of drive (Individual motor, Belt driven)
2. The method of obtaining different speeds
3. Horse power of the motor
4. Cutting to return stroke ratio
5. Number and range of speed arrangement
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6. The type of the table

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Drive mechanism of a shaper (Mechanism of shaping process)
1. Drive Mechanism for reciprocating movement of ram (with quick return mechanism)
2. Drive Mechanism for table to movement automatically
In a shaper, rotary movement of the drive is converted into reciprocating movement of the
ram by the mechanism contained within the column of the machine. In a standard shaper
metal is remove the forward cutting stroke and during the return stroke no metal cutting is
taking place.
The shaper mechanism should be so designed that it can allow the ram to forward cutting
stroke and during the return stoke 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 total machining
time decreases and the rate of production increases.
The reciprocating and the quick return of the ram are usually obtained by using any one of
the following mechanisms.
1. Crank and slotted link mechanism
2. Hydraulic mechanism
3. Whitworth mechanism
Crank and slotted link mechanism
Motor runs the driving pinion at a uniform speed which makes the bull gear to rotate. A
slotted link having a long slot along its length is pivoted about the point ‘K’ and sliding block
is fitted inside the slot and slides along the length of the slotted link. OP can be considered as
a crank length. When the bull gear rotates, the sliding block slides and also rotates in the
crank pin circle. As the top of the slotted link is connected to the ram, the ram reciprocates
horizontally.

The rotation of the crank ‘OP’ in clockwise direction through the angle P1RP2(α) refers to the
forward cutting stroke. The rotation of the crank in the same direction through the angle
P2LP1(β) refers to the return stroke. As the angle P2LP1 is smaller than the angle P1RP2, the
time taken for the return stroke is less than that of forward stroke. So, it is evident that the
speed at which the ram travels during return stroke is more
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Adjustment of Stroke length shaping machine
The stroke length of a ram is the distance the ram moves forward or backward. Since the
length of a job varies, provision is made on shapers to change the stroke is required.It
depends upon the distance between the centre of the bull gear and the centre of the sliding
block which can be changed as shown.

Crank pin adjusting to change the stroke length changing the position of stroke
Adjusting the position of stroke
It is the fixing the start point and end point of stroke. The position of the ram relative to the
work can also be adjusted. The ram block which is mounted upon the screwed shaft acts as a
nut. By turning the hand wheel as shown in figure, the ram block position can be changed.
Hydraulic drive quick return mechanism
A constant speed motor drives a hydraulic pump which delivers oil at a constant pressure to
the line. A regulating valve admits oil under pressure to each end on the piston alternately, at
the same time allowing oil from the opposite end of the piston to return to the reservoir.

The control valve will admit the oil to the other side of the piston and the motion of the ram
will get reversed. The return stroke is quicker since the piston area on which the oil pressure
acts is greater as compared to the other end for which area reduced because of the piston rod
Advantages of Hydraulic drive
1. Does not make any noise and operates very quietly
2. Ability to stall against an obstruction without damage to the tool or the machine
3. Ability to change length and position of stroke or speed while the machine is running
4. The cutting and return speeds are practically constant throughout the stroke. This
permits the cutting tool to work uniformly during cutting stroke.
5. The reversal of the ram is obtained quickly without any shock as the oil on the other
end of the cylinder provides cushioning effect
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6. Offers great flexibility of speed and feed and the control is easier.
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Whitworth quick return mechanism
The Whitworth quick return mechanism converts rotary motion into reciprocating motion, but
unlike the crank and slider, the forward reciprocating motion is at a different rate than the
backward stroke. At the bottom of the drive arm, the peg only has to move through a few
degrees to sweep the arm from left to right, but it takes the remainder of the revolution to
bring the arm back. This mechanism is most commonly seen as the drive for a shaping
machine

Feed mechanism of a shaper

The horizontal movement of table is called cross feed is used to machine a flat horizontal
surface. The cross feed of the table is affected by rotating the cross feed screw. This screw is
engaged with a nut fitted in the table. Rotation of the cross feed screw causes the table
mounted upon the saddle to move sideways on the cross rail. Cross feed is given either by
hand or power. If this screw is rotated manually by handle, then it is called hand feed.

Ratchet and Pawl mechanism (Automatic feed mechanism for the table)
If this screw is rotated by power using a ratchet wheel called automatic feed. The table of a
shaping machine travels in a cross direction when the cross feed screw is rotated. The cross
feed screw is attached to the ratchet wheel. When power feed is not necessary for the table,
the pawl is disengaged from the ratchet wheel.
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Work holding devices
The top side of the table is having T-slots for clamping the work piece. The work piece may
be supported by any one of the following work holding devices depending upon the geometry
of the work piece and nature of the operation to be performed.
 Machine vise.
 Clamping work on the table using T bolts, stop pin etc
 Angle plate.
 V-blocks.
 Shaper centre
Machine vise
Vise is the most common and simple work holding device used in a shaper. Different types
of vises are used in a shaping machine according to the need like plain and swivel vise etc

Clamping work on the table

T – Bolts are fitted into the T – slots of the table. The work is placed on the table. The work is
supported by a rectangular strip at one end and by a stop pin at the other side. The screw is
tightened to secure the work properly on the machine table.

T-bolts, Clamp and Step Blocks

The step blocks are used in combination with T-bolts and clamps to hold the work directly on
the machine table. T-bolts are fitted in the T-slots of the machine table. One side of the clamp
holds the work and the other side rests on a step of the step block. The different steps of the
block are useful in levelling the clamp when holding works of different heights.
Angle Plate
It is accurately machined two sides at right angles. Slots are provided on both the sides. One
of the sides is bolted to the machine table and the work pieces are held on the other side.
V – Block
V- block is a metal block having a ‘V’ shaped groove on it. It is used for holding cylindrical
work pieces. Operations like keyway cutting, slot cutting and machining flat surfaces can be
performed on the cylindrical work pieces held on a ‘V’ block.
Shaper centre
This is a special attachment used for cutting equally spaced grooves or splines and gears. A
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shaper centre consists of a headstock and a tailstock, and the work is mounted between two
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centres

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Shaper Tools
Shaper cutting tools are single point tools similar to lathe tools and are frequently held in the
same type of holders. Shaper tools are of two basic kinds: forged tools and tool bits. Tool bits
are more widely used than forged tools because of their economy, cutting life and the ease
with which they are sharpened.
Shaper tool bits may be made up of high speed steel cast alloy or cemented carbide. Since
high speed steel has greater impact toughness than cast alloy or cemented carbide, tool bits
made of high-speed steel are used most often.
Types of shaper cutting tool
According to the shape:
 Straight tool.
 Cranked tool.
 Goose necked tool.
According to the direction of cutting:
 Left hand tool. (when the table moves left to right)
 Right hand tool. (when the tool moves from right to left)
According to the finish required:
 Roughing tool.
 Finishing tool.
According to the type of operation
 Down cutting tool.
 Parting off tool.
 Squaring tool.
 Side recessing tool.
According to the shape of the cutting edge
 Round nose tool.
 Square nose tool.

Shaper and planer cutting tools similar in shape to lathe tools but differ mainly in their relief
angles. These tools are held practically square with the work and do not feed during the cut;
therefore, relief angles are much less than those in turning operations. The little difference
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which a shaper tool has from a lathe, tool is because of the, fact that whereas a lathe tool has

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a constant, fairly uniform cutting pressure exerted on is a shaper tool is subjected to a series
of sudden shocks caused by its repeated hammering into the work. To withstand these shocks,
it is necessary that the shaper tools have a larger nose radius than the lathe tools have. In
many cases the back rake, angle of the shaper tool is negatively ground so that the shock of
each successive cut is taken on the solid part of the tool rather than on its point. Moreover, a
shaper tool is more rigid than a lathe tool. The nomenclature of shaper and planer tools is the
same as that for lathe tools.
Operations performed
Different types of operations are performed in a shaping machine are broadly classified as
1. Regular operations
a. Machining flat surfaces in different planes (horizontal, vertical and angular
planes)
2. Special operations
a) Making features like slots, steps etc.
b) Forming grooves
c) Cutting external and internal keyways
d) Machining of external gears

Advantages of shaping process

1. Simple cutting tool
2. Easy work holding method
3. Easy to change the setting of operation according to the work change
4. Fragile and thin work can be machined
5. Economical cutting
Operational parameters
Cutting speed
It is defined as the average linear speed of the tool during the cutting stroke in m/min. This is
expressed in meter per minute. It depends on the length of stroke and number of stroke per
minute. Cutting stroke means one forward stroke and return stroke.

𝐿𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑠𝑡𝑟𝑜𝑘𝑒

𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑠𝑝𝑒𝑒𝑑 =
𝑇𝑖𝑚𝑒 𝑡𝑎𝑘𝑒𝑛 𝑏𝑦 𝑡ℎ𝑒 𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑠𝑡𝑟𝑜𝑘𝑒
10

𝐿𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑠𝑡𝑟𝑜𝑘𝑒 (𝐿) 𝑖𝑛 𝑚𝑒𝑡𝑒𝑟𝑠

time taken by cutting stroke =
𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑠𝑝𝑒𝑒𝑑 (𝑉)𝑚𝑒𝑡𝑒𝑟/min
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 𝑡𝑖𝑚𝑒 𝑓𝑜𝑟 𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑠𝑡𝑟𝑜𝑘𝑒 = 𝑡𝑖𝑚𝑒 𝑜𝑓 𝑐𝑢𝑡𝑡𝑖𝑛𝑔 + 𝑡𝑖𝑚𝑒 𝑓𝑜𝑟 𝑟𝑒𝑡𝑢𝑟𝑛 𝑠𝑡𝑟𝑜𝑘𝑒
𝐿 𝑚𝐿
𝑇𝑖𝑚𝑒 𝑓𝑜𝑟 𝑜𝑛𝑒 𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑎𝑛𝑑 𝑟𝑒𝑡𝑢𝑟𝑛 𝑠𝑡𝑟𝑜𝑘𝑒 = +
𝑉 𝑉
𝐿
𝑖𝑒 = (1 + 𝑚)
𝑉

If the rpm of bull gear is N, then N number of strokes takes place per minute. So the time taken for
one stroke and cutting speed can be expressed as below
1 𝐿
𝑖𝑒 = (1 + 𝑚 ) 𝒊𝒆 𝒄𝒖𝒕𝒕𝒊𝒏𝒈 𝒔𝒑𝒆𝒆𝒅 (𝑽) = 𝑵𝑳(𝟏 + 𝒎)
𝑁 𝑉
L  length of cutting stroke
L  Lw  A  O
Lw  length of job
A  approch length
O  over run length
m  ratio between return time to cutting time (2 : 3)
time of return stroke
m
time of cutting stroke
N  rpm of bull gear
V  cutting speed (m / min ute)
w  width of work
f  feed
Total machining time for entire machining
𝑤
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑠𝑢𝑐ℎ 𝑠𝑡𝑟𝑜𝑘𝑒 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑓𝑜𝑟 𝑓𝑢𝑙𝑙 𝑚𝑎𝑐ℎ𝑖𝑛𝑖𝑛𝑔 =
𝑓
𝑳 𝒘
𝑻𝒐𝒕𝒂𝒍 𝒕𝒊𝒎𝒆 𝒇𝒐𝒓 𝒄𝒐𝒎𝒑𝒍𝒆𝒕𝒆 𝒎𝒂𝒄𝒉𝒊𝒏𝒊𝒏𝒈 = (𝟏 + 𝒎) ∗ (𝒎𝒊𝒏)
𝑽 𝒇
Depth of cut
Depth of cut (t) is the thickness of metal that is removed during machining. It is the
perpendicular distance measured between the machined surface and the uncut surface of the
work piece. It is expressed in mm or in inches.
Feed
Feed (S) is the relative movement of the work or tool in a direction perpendicular to the axis
of reciprocation of the ram per double stroke. It is expressed in mm per stroke
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 Slotting machines
Slotter can simply be considered as vertical shaper where the single point (straight or formed)
cutting tool reciprocates vertically and the work piece, being mounted on the table, is given
slow longitudinal and / or rotary feed. The work piece is held stationary. The slotting
machine has a vertical ram and a hand or power operated rotary table. A slotter removes
materials during the down ward cutting stroke only.
The slotting machine is used for cutting grooves, keys and slots of various shapes making
regular and irregular surfaces both internal and external cutting internal and external gears
and profiles The slotter machine can be used on any type of work where vertical tool
movement is considered essential and advantageous. However, it has to be borne in mind that
productivity and process capability of slotting machines are very poor and hence used mostly
for piece production required by maintenance and repair in small industries.
Slotting machines are characterised by:
 Vertical tool reciprocation
 Longer stroke length
 Less strong and rigid
 An additional rotary feed motion of the work table
 Used mostly for machining internal surfaces.
Principal parts of slotter machine
Base
It is rigidly built to take up all the cutting forces and entire load of the machine. The top of
the bed is accurately finished to provide guide ways on which the saddle is mounted. The
guide ways are perpendicular to the column face
Column
It is the vertical member which is cast integral with the base and houses driving mechanism
of the ram and feeding mechanism. The front vertical face of the column is accurately
finished for providing ways on which the ram reciprocates.
Saddle
It is mounted upon the guide ways and may be moved toward or away from the column either
by power or manual control to supply longitudinal feed to the work. The top face of the
saddle is finished to provide guide ways for the cross slide.
Cross slide
It is mounted upon the guide ways of the saddle and may be moved parallel to the face of the
column. The movement of the slide may be controlled either by hand or power to supply
Rotary table
It is a circular table which is mounted on the top of the cross slide. The table may be rotated
by rotating a worm which meshes with a worm gear connected to the underside of the table.
The rotation of the table may be effected either by hand or power
Ram
It is the reciprocating member of the machine mounted on the guide ways of the column. It is
connected to the reciprocating mechanism contained within the column. A slot is cut on the
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body of the ram for changing the position of the stroke. It carries the tool head at its bottom
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Tool head
It holds the tool rigidly. In some machines, special types of tool holders are provided to
relieve the tool during its return stroke.

Working principle of a slotter

The vertical ram holding the cutting tool is reciprocated by a ram drive mechanism. The work
piece, to be machined is mounted directly or in a vice on the work table. In slotter, in addition
to the longitudinal and cross feeds, a rotary feed motion is also provided in the work table.
The intermittent rotation of the feed rod is derived from the driving shaft with the help of an
automatic feed mechanism.
Types of slotter
The different types of slotter which are most commonly used are:
1. Puncher slotter.
2. Precision tool room slotter.
3. General Production Slotter
Puncher slotter
It is a heavy, rigid machine designed for removal of a large amount of metal from large
forging or castings. The length of a puncher slotter is sufficiently large. It may be as long as
1800 to 2000 mm. length of stroke is large. Ram is driven by rack and pinion drive.
Precision tool room slotter
It is a lighter machine and is operated at high speeds. The machine is designed to take light
cuts giving accurate finish. Using special jigs, the machine can handle a number of identical
works on a production basis. The precision machines are also used for general purpose work
and are usually fitted with Whitworth quick return mechanism.
General Production Slotter
This is widely used for general purpose production work. This may be divided into two
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classes. These are having solid body construction or having arrangements to tilt the body of
the machine about 10O forward and backward for machining accurate internal and external
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tapers.

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Quick return mechanism for slotter (Ram)
A slotter removes metal during downward cutting stroke only whereas during upward return
stroke no metal is removed. To reduce the idle return time, quick return mechanism is
incorporated in the machine. The reciprocating movement and the quick return of the ram are
usually obtained by using any one of the following mechanisms
1. Whitworth quick return mechanism
The Whitworth quick return mechanism is most widely used in a medium sized slotter for
driving the ram. The same mechanism has been described previous topic can be used.
Circular motion into variable alternating rectilinear motion, by the wrist or crank-pin on
the rotating disk working in the slot of the bell-crank lever. The mechanism which has
been explained is slightly modified in the case of slotter as shown in figure. But the basic
principle and line diagram of Whitworth is the same.

2. Hydraulic drive quick return mechanism (Same as shaping machine)

3. Variable speed reversible electric motor drive
Same as explained in planing machine (Planning machine that mechanism is used for
to and fro movement of table. But in slotter machine, that mechanism is for cutting
tool reciprocating motion)
Feed mechanism of a slotter
In a slotter, the feed is given by the table. Like a shaper or a planer, the feed movement of a
slotter is intermittent and supplied at the beginning of the cutting stroke. The feed movement
may be provided either by hand or power. If the feed screws are rotated manually by a
handle, then it called hand feed. If the feed screws are rotated by power, then it is called
automatic feed
Automatic feed
The power feed mechanism makes use of a ratchet and pawl mechanism. A groove for the cam
is cut on the face of the bull gear of the driving mechanism of the slotter. A roller follower
slides in this groove. The lever is pivoted in the middle and the other end of the lever has a
slot.
The rocking movement of the lever 3 is transmitted to the ratchet and pawl mechanism 6 and
8, so that the ratchet 8 will move in one direction only during this short period of time. The
ratchet wheel is mounted on a feed shaft which may be engaged with cross, longitudinal or
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rotary feed screws individually or together to impart power feed movement to the table.
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Work holding devices used in a slotter
1. Vise,
2. T-bolts and clamps
3. Directly on the top the sliding bed with the help of clamps etc.
4. on the rotary table or in the chuck
5. occasionally in the fixture which is clamped on the flat bed or face plate
6. Special fixtures.
7. Face plate
Operations performed in slotting machine
1. The slotting machine can be used to cut slots, splines and keyways for both
internal and external jobs such as machining internal and external gears.
2. It can be used for works as machining concave, circular, semi-circular surfaces.
3. It can be used for machining vertical surfaces, machining inclined surfaces,
machining of shapes which are difficult to produce on a shaper machine
4. It can be used for internal machining of blind holes
5. Internal keyways and splines, straight tooth of internal spur gears, internal curved
surfaces, and internal oil grooves etc
6. Internal grooves and slots of rectangular and curved section
Specifications or size of a slotter
The slotter is specified by the following parameters:
 The maximum stroke length.
 Diameter of rotary table.
 Maximum travel of saddle and cross-slide
 Type of drive used.
 Power of the motor.
 Number and amount of feeds.
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 Floor area required.

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Department of Mechanical Engineering SSET

Slotter tools
A slotter tool differs widely from a shaper tool as the tool in a slotter removes metal during
its vertical cutting stroke. This changes the cutting condition. In a shaper tool the cutting
pressure acts perpendicular to the tool length, whereas in a slotter tool the pressure acts along
the length of the tool. The slotter tools are robust in cross section and usually forged type.
Round nose tools are used for machining contoured surfaces. Square nose tools are used for
machining flat surfaces. The rake angle and clearance angle of a slotter tool look different
from a shaper tool.

Cutting speed feed and depth of cut definition is same as before. The machining time
calculation is also same as shaping process

Difference between shaper and slotting machine

shaper machine slotting machine

used for horizontal surface grovees, slots and key ways etc

used for rigid work used for light work

stroke length is more stroke length is less

reactangular table round table with additional rotary motion

tool moves mostly horizontally tool moves verticaly

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 Planning machines
Planing machine
Like shaping machines, planing machines are also basically used for producing flat surfaces
in different planes. But planers are very large and massive compared to the shapers. Planers
are generally used for machining large work pieces which cannot be held in a shaper. 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.

This machine tool also does the same operations like shaping machine but the major
differences are:
 In planing the job reciprocates for cutting motion and the tool moves slowly for the
feed motions unlike in shaping machine.
 Planing machines are usually very large in size and used for large jobs and heavy duty
work
 In planing 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.
 Planing 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.

Advantages of planning process

1. Large work can be handled
2. Heavy cut can be performed
3. Good work support
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4. No tool overhang
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Department of Mechanical Engineering SSET

The principle parts of the planer
 Bed
 Table
 Column
 Cross rail
 Tool head
Bed
 The bed of a planer is large in size and heavy in weight
 It supports the column and all other moving parts of the machine
 It is made slightly longer than twice the length of the table so that the full-length of
the table maybe moved on it
Table
 The table supports the work and reciprocates along the ways of the bed
 The top face of the table is accurately finished in order to locate the work correctly
 T-slots are provided on the entire length of the table so that the work and work
holding devices may be bolted upon it
Column
 These are rigid box-like vertical structures placed on each side of the bed and are
fastened to the sides of the bed
 The cross rail may be made to slide up and down for accommodating different heights
of work
Cross rail
 It is a rigid box-like casting connecting the two columns
 It may be raised or lowered on the face of the housing and can be clamped at a desired
position by manual or electrical clamping devices
Tool head
 Tool heads are mounted on the cross rail by a saddle
 The saddle may be made to move transversely on the cross rail to give cross feed
Classification of Planer
Planers are generally divided into 5 types:
1. Double Housing Planer
2. Open Side Planer
3. Edge Type Planer
4. Divide Table Planer
5. Pit Type Planer
Double Housing Planer
It is the most common type of planer. It consists of mainly a massive bed on which the work
table reciprocates, and two vertical columns or housing, one on each side of the bed. Each
column carries a tool head that can be slide up and down on the column. A cross rail fitted
between the two columns may carry one or two tool heads that can slide horizontally on the
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cross rail. All the tool heads can be clamped in position, and can be used collectively or
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individually depending on the requirements.

Department of Mechanical Engineering SSET

Open Side Planer
Open side planer consists of only one vertical column or housing on which the cross rail is
mounted. The column and the cross rail carry single and double tool heads respectively. This
type of machine permits machining of wide work pieces

Edge Type Planer

This type of machine is used for machining the edges of heavy work pieces. The work piece
is clamped on the bed and the side mounted carriage supporting the cutting tool is
reciprocated along the edge of the work piece. Cutting can take place during both directions
of carriage travel
Divide Type Planer
It is also called tandem planer and consists of two work tables, which may be reciprocated
together or separately. In such cases, divided table planer can be used, where in, one
worktable can be used for setting up a new work piece, while the second worktable carrying
work piece is being machined. The two tables can be joined together to hold large work
pieces. Setting time for work can be reduced.

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Pit Type Planer
A pit type planer differs from other planer in the sense that, the table and the work piece
resting on it remain stationary and the tool reciprocates across the work surface. This type of
machine is preferred for very large work, where the weight of the work piece and the tool
required table would make reciprocating movement difficult. The job is either mounted on a
stationary table, or on the floor inside a pit, and hence the name pit type planer. One or two
tool heads can be mounted on the cross rail and two side tool posts the housings, if required.
The entire unit travels along the horizontal ways and fro and, thus the tool moves past the
work surface during operation

The common operations performed in a planer

1. Planning flat horizontal surfaces.
2. Planning vertical surfaces.
3. Planning at an angle and machining dovetails.
4. Planning curved surfaces.
5. Planning slots and grooves
Comparison between shaper and planer

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Drive mechanism of a planer
Two important mechanism of a planer
1. Table drive mechanism
2. Feeding mechanism
The different mechanism used to drive the table are:
1. Open and cross belt drive
2. Reversible motor drive
3. Hydraulic drive
Open and cross belt drive quick return mechanism
In this mechanism the movement of the table is effect by an open belt and a cross belt drive.
The open belt connects the smaller loose pulley, so no motion is transmitted by the open belt
to the main shaft.

During cutting stroke cross belt connects the larger fast pulley, so the motion is transmitted
by the cross belt to the main shaft. The greater arc of contact of the cross belt gives greater
power and the speed is reduced as the belt connects smaller diameter pulley on the counter
shaft and larger diameter pulley on the main shaft. At the end of the forward stroke a trip dog
pushes the belt shifter through a lever arrangement. The belt shifter shifts both the belts to the
right side
The open belt is shifted to the smaller fast pulley and the cross belt is shifted to the larger
loose pulley. Now the motion is transmitted to the main shaft through the open belt and no
motion is transmitted to the main shaft by the cross belt. The direction of rotation of the main
shaft is reversed. The return stroke of the table takes place. The speed during return stroke is
increased as the open belt connects the larger diameter pulley on the counter shaft with the
smaller diameter pulley on the main shaft. Thus a quick return motion is obtained by the
mechanism. At the end of the return stroke, the belts are shifted to the left side by another trip
dog. So the cycle is repeated. The length and position of the stroke may be adjusted by
shifting the position of trip dogs.
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Department of Mechanical Engineering SSET

Reversible motor drive quick return mechanism
All modern planers are equipped with variable speed electric motor which drives the bull gear
through a gear train

This system consists of an AC motor which is coupled with a DC generator, a DC motor and
a reversing switch. When the AC motor runs, the DC motor will receive power from the DC
generator. At that time, the table moves in forward direction. At the end of this stroke, a trip
dog actuates an electrical reversing switch. Due to this action, it reverses the direction of
current in DC generator with increased current strength. Now, the motor rotates in reverse
direction with higher speed. So, the table moves in the reverse direction to take the return
stroke with comparatively high speed.
The distinct advantages of electrical drive over a belt drive are:
1. Cutting speed, stroke length and stroke position can be adjusted without stopping the
machine.
2. Large number of cutting speeds and return speeds are available.
3. Quick and accurate control
Return speed can be greatly increased reducing idle time.
Hydraulic drive quick return mechanism
The hydraulic drive is quite similar to that used for a horizontal shaper. More than one
hydraulic cylinder may be used to give a wide range of speeds. The main drawback of the
hydraulic drive on long planers is irregular movement of the table due to the compressibility
of the hydraulic fluid.

Feed mechanism of a planer

In a planer the feed is provided intermittently and at the end of the return stroke similar to a
shaper. The feed of a planer, both down feed and cross feed, is given by the tool head. The
down feed is applied while machining a vertical or angular surface by rotating the down feed
screw of the tool head. The cross feed is given while machining horizontal surface by rotating
the cross feed screw passes through a nut in the tool head.
 Down feed: Bevel gear meshes with other bevel gear slides on the splined shaft
 Cross feed: The spur gear meshes with another spur gear which is keyed to the cross feed
screw. The power from the splined shaft is transmitted to the cross feed screw. Then the
rotation is transmitted to the tool head through a nut. The tool head moves horizontally. It
is known a cross feed. At the end of the time, the pawl slips over the ratchet. The ratchet
wheel does not rotate.
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Department of Mechanical Engineering SSET

Automatic feed mechanism
The power feed may be applied by
 Friction disc
 Electrical drive
Modern planers which are equipped with electrical drive. It uses a separate motor to operate
the feed mechanism with reversing mechanism.
Cutting tools for planer
Cutting tool used on planers are all single point cutting tools. They are in general similar in
shapes and tool angles to those used on a lathe and shaping machine. As a planer tool has to
take up heavy cut and coarse feed during a long cutting stroke, the tools are made heavier and
larger in cross section. Planner tools may be solid, forged type or bit type. Bits are made of
high speed steel, satellite or cemented carbide and they may be brazed, welded or clamped on
a mild steel shank. Cemented carbide tipped tools are used for production work. A planer tool
may also be classified as right hand or left hand and roughing or finishing

Size of planer machine/Specifications of a planer

 Size of the largest rectangular solid that can reciprocate under the tool
 Maximum length of the table and maximum stroke length of table.
 Power of the motor.
 Range of speeds and feeds available.
 Type of feed and type of drives required.
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 Horizontal distance between two vertical housings.

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 Net weight of machine and Floor area required.

Department of Mechanical Engineering SSET

Work holding devices used in a planer
A planer table is used to hold very large, heavy and intricate work pieces, and in many cases,
large number of identical work pieces. The work should be rigidly fixed on table and work
surface should be in proper position. The work piece may be held on a planer table by the
following methods:
1. By standard clamping.
2. By special fixtures.
Standard clamping devices
The standard clamping devices are as follows:
1. Heavy duty vises.
2. T-bolts, step blocks and clamps.
3. Stop pins and toe dogs.
4. Angle plates.
5. Planer jacks.
6. Planer centres (similar to shaper centre)
7. V-blocks
(Explanation is same as before)
Cutting speed of a planning operation is the rate at which metal is removed during the
cutting stroke expressed in meter/min
Feed in planning process is the distance the tool head travels at cross ward for next cut
expressed in mm per double stroke.
Depth of cut is the thickness of material removed in one cut measured between the machined
and un-machined surface expressed in mm
Machining time
Calculation of machining time is as same as shaping process.
Operations performed in planning machine
1. Planing flat horizontal/vertical/inclined surface
2. Slots and grooves
3. Curved surface etc
Surface roughness obtainable with machining process
Surface roughness is caused, due to the short wavelength irregularities in the surface.
The surface roughness is defined as a quantitative measure of the process marks
developed during the creation of the surface and other factors like the structure of the
component.
The surface roughness is denoted by Ra. The unit of surface roughness is
“m” (micron meter (or) microns
Since machining is often the manufacturing process that determines the final geometry and
dimensions of the part, it’s also determines the part’s surface texture. Surface roughness of a
machined surface depends on:
Factors Affecting the surface finish
The following factors affect the surface finish during machining.
(a) The machining variables
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1. Cutting speed
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2. Feed

Department of Mechanical Engineering SSET

 3. Depth of cut
(b) The tool geometry also influences the surface finish.
1. Nose radius
2. Rake angle
3. Side cutting-edge angle
4. Cutting edge
(c) Properties of work piece and tool materials
(d) Type of the machine tool
(e) Quality of the machine tool

The two most important factors affecting the surface finish are tool geometry (nose radius)
and the feed and cutting speed. In slotting operations or in the shaping of internal surfaces
when there is substantial overhang of the tool or tool holder, the aspect of rigidity comes into
picture. Surface roughness plays an important role in determining how a real object will
interact with its environment. Rough surfaces usually wear more quickly and have higher
friction coefficients than smooth surfaces. Roughness is often a good predictor of the
performance of a mechanical component, since irregularities in the surface may form
nucleation sites for cracks or corrosion. Although roughness is usually undesirable, it is
difficult and expensive to control in manufacturing. Decreasing the roughness of a surface
will usually increase exponentially its manufacturing costs.

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Questions
Answer the following questions in one or two words
1. What type of surfaces are machined on a shaper?
2. Which stroke of the shaper is faster?
3. What is the use of ratchet & pawl mechanism?
4. What type of cutting tool is used in a shaper - a single point or a multi-point?
5. Which part of the shaper is involved in automatic lifting of the tool during return stroke
of the ram?
II. Answer the following questions in one or two sentences
1. Name any four important parts of a shaping machine.
2. What is the use of crank & slotted link mechanism?
3. Define ‘feed’ in a shaping machine.
4. Name any two points in specifying the size of a shaping machine.
5. What is the use of a clapper box?
6. What is the use of swivel tool head of a shaping machine?
III. Answer the following questions in about a page
1. List out the types shaping machines.
2. Write short notes on
a. Changing the stroke length of the ram
b. Position of the ram
3. Explain any two work holding devices used in a shaping machine with diagrams.
4. List out the types of tools used in a shaping machine.
5. Explain any two operations performed in a shaping machine with diagrams.
IV. Answer the following questions in detail
1. Draw a neat diagram of a shaping machine and explain its important parts.
2. Explain the crank & slotted link mechanism of quick return of the ream with a diagram.
3. Explain the ratchet & pawl mechanism with a diagram.
4. Explain any four work holding devices used in a shaping machine with diagrams.
5. Explain any four operations performed in a shaping machine with diagrams.
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