PLANER

The Planer or Planing machine is a machine tool designed to produce plane and flat surface on
a work piece which is too large or too heavy. The work piece is securely fixed on a table called
platen, and it reciprocates horizontally against a single edged cutting tool. The surface
machined may be horizontal, vertical or at an angle. In a planer,the feed is imparted by the
lateral movement of the tool.
TYPES OF PLANERS
Different classes of work necessitate designing of different types of planing machine to suit to
various requirements of our present day industry. The different types of planers which are most
commonly used are :-
1. Double housing planer
2. Open side planer
3. Pit planer
4. Edge or plate type planer
5. Divided table planer
6. Planer,miller and grinder

PRINCIPAL PARTS OF SHAPER

Bed :- It is a very strong and robust structure made of cast iron. Cross ribs are provided to
make it stronger and stable. The length of the table is usually twice the width of the table, so
the table may have complete stroke on the bed surface. For supporting and permitting the table
to reciprocate in constrained form, ways are provided on the top of the bed. Mechanism for
driving the table is accommodated inside the table.

Table :- The table is supported on bed ways.T-slots are provided throughout the length of the
table for tightening the work piece by T-bolts. A groove is provided at either end of the table to
collect chips. Adjustable dogs are provided at a side of the table which operates some
mechanism for reversing the table automatically at the end of each stroke.some arrangements
are also made to avoid the running away of the moving loaded table.The table is usually casted
in one piece. Long table may be casted several pieces and bolted together.
Housings or column or upright :- The housings are the rigid and upright colum like
castings.These are located near the centre on each Side of the base. The column supports a
horizontal cross rail across the length of the bed. The cross rail may be slide up and down on
the columns and may be clamped at any position within the body of the column. The vertical
feed shaft elevating screw for cross rail and feed screw etc. are accommodated within the body
of the column. The column may also support the side tool heads.
Cross Rail: - The cross rail is a horizontal member supported on the machined ways of the
upright or column. Guide ways are provided on vertical face of each column and that enables
up and vertical movement of the cross rail. The vertical movement of the cross rail allows to
accommodate work piece of different heights. The cross rail carries tool heads usually two in
number for feeding the tool.the feed screws are enclosed in the cross rail.
Tool Heads :- The tool head carries a tool post to hold the cutting tool.Generally two tool
heads are mounted in the horizontal cross rail and one on each of the vertical housing.Tool
heads may be swiveled so that angular cuts can be made. The tool post is hinged on the tool
head for lifting the tool in the return stroke.

PLANER MECHANISMS

The two important mechanisms of planers are :-

1. THE QUICK RETURN MECHANISM FOR PLANER TABLE

The following methods are used for achieving the quick motion in return stroke and slow
motion in cutting stroke of the planer table.

a) Open and cross belt drive b) Reversible motor drive c) Hydraulic drive
2. FEED MECHANISM
In a planer the feed is provided intermittently and at the end of the return stroke. The feed of
a planer both down feed and cross feed is given by the tool. The cross feed is given while
machining horizontal surface on a work mounted on the table. The down feed is applied while
machining a vertical or angular surface by rotating the down feed screw of the tool head. Both
the down and cross feed may be operated either by hand or power by rotating two feed screws
contained with in the cross rail.
The power may be applied by the following methods :-
1. By friction disc
2.By electrical drive

WORK HOLDING DEVICES

A planer table is used to hold very large,heavy and intricate jobs, and in many cases,large
number of identical pieces together.The work may be held on a planing machine by the
following methods :-
1. BY STANDARD CLAMPING
The standard clamping devices are used for holding most of the. work on a planer table. The
devices are as follows:-
a) Heavy duty vises b) Angle plates c) T-bolts and clamps d) Planer jacks

e) Step blocks , clamps and T-bolts f) Planer centres g) Slops

h) Poppets or stop pins and toe dogs i) V-blocks

2.BY SPECIAL FIXTURES
Special fixtures are used for holding a large number of identical pieces of work on a planer
table. Fixtures are specially designed for holding a particular type of work. By using a fixture
the setting time may be reduced coinsiderably compared to the individual setting of work by
conventional clamping devices.

PLANER OPERATIONS
Operations performed in a planer are similar to that of a shaper. The only difference is that a
planer is specially designed for planing large work whereas a shaper can machine only small
work.The common operations performed in a planer are :-

1.Planing flat horizontal surface 2. Planing vertical surfaces 3. Planing curved surfaces

4.Planing slots and grooves 5.Planing at an angle and machining dovetails

PLANER TOOLS

The cutting tools used in planers are all single point cutting tools. They are in general similar in
shapes and tools angles to those used on a lathe and shaping machine. As a planer has to take
up heavy cut and coarse feed during cutting stroke.The tools may be solid,forged type or bit
type. The typical tools used in shaper are :-
1.Right hand round nosed roughing tool for cast iron
2. Right hand round nosed roughing tool for steel
3.Square nosed side – facing roughing tool for cast iron
4.Goose neck finishing tool for cast iron and steel
5.Left hand dovetail end cutting roughing tool for cast iron

SIZE OF A PLANER

The size of a standard or double housing planer is specified by the largest rectangular solid that
can reciprocate under the tool.The size of the largest solid is known by the distance between
the two housings,The height from the top of the table to the crossrail in its uppermost
position,and the maximum length of travel.
The size of an openside planer is specified by the size of the largest job that can be
machined on its table.The height of the largest job is determined by the height of the crossrail
from the top of the table,the maximum length of the table travel and the planning width.The
maximum width of the job that can be machined is known as planning width,which is
determined by the distance from the table side of the column to the tool in the outer toolhead in
a vertical position.
In addition to these basic dimensions,other particulars such as number of speeds and
feeds available,power input,floor space required,net weight of the machine,type of the drive
etc.are required to be stated inorder to specify the planer fully.

CUTTING SPEED
As in a shaper,the cutting speed of a planer is the rate at which the metal is removed during the
forward cutting stroke,This is expressed in m/min
FEED
The feed in planning machine is the distance the tool head travels at the beginning of each
stroke expressed in mm per double stroke.
DEPTH OF CUT
It is the thickness of the metal removed in one cut and is measured by the perpendicular
distance between the machined and no machined surface expressed in mm.
 SLOTTING MACHINE
The slotting machine or slotter is a reciprocating machine tool in which ,the ram holding the
tool reciprocates in a vertical axis and the cutting action of the tool is only during the
downward stroke.A slotting machine is used for cutting different types of slots and it certainly
proves to be most economical. Its other uses are in machining irregular shapes, circular
surfaces and other premarked profiles. lts construction is similar to that of a vertical shaper.

TYPES OF SLOTTING MACHINE

The different types of slotting machines are:
1. Punch slotter :- A heavy duty rigid machine designed for removing large amount of metal
from large forgings or castings.
2. Tool room slotter :- A heavy machine which is designed to operate at high speeds. This
machine takes light cuts and gives accurate finishing.
3. Production slotter :- A heavy duty slotter consisting of heavy cast base and heavy frame,
and is generally made in two parts.

PRINCIPAL PARTS OF SLOTTING MACHINE

1. BASE OR BED:
The base 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.

2.COLUMN:-

The column is a 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.

3.SADDLE:-
The saddle is mounted upon the guide ways and may be moved towards 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 accurately finished to provide guide ways on the base.
4.CROSSSLIDE:- The cross slide is mounted upon the guide way of the saddle and may be

moved parallel to the face of the column.

5.ROTARY TABLE:- The rotary table 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.In some machines the table is graduated in degree that enables the
table to be rotated for indexing or dividing the periphery of the job in equal number of parts. T-
slots are cut on the top face of the table for holding the work by different clamping devices.

6.RAM AND TOOL HEAD ASSEMBLY:.

The ram is the reciprocating member of the machine mounted on the guide ways of the column
,It Supports the tool at its bottom end on a tool head. A slot is cut on the body of the ram for
changing the position of stroke.

7.RAM DRIVE MECHANISMS

A slotter removes metal during downward cutting stroke only whereas during upward return
stroke no metal is removed. The usual types of ram drive mechanisms are :-

1. Whitworth quick return mechanism .

2. Variable speed reversible motor drive mechanism

3. Hydraulic drive mechanism.

FEED MECHANISM

In a slotter the feed is given by the table. A slotting machine table may have three types of feed
movements:-

1.Longitudinal 2.Cross 3.Circular

If the table is fed perpendicular to the column towards or away from its face.The feed
movement is termed as longitudinal. If the table is fed parallel to the face of the column the
feed movement is termed as cross.If the table is rotated on a vertical axis, the feed movement is
termed as circular.

WORK HOLDING DEVICES

The work is held on a slotter table by a vise.T-bolts and clamps or by special fixtures.T-bolts
and clamps are used for holding most of the work on the table.
SLOTTER OPERATIONS
The operatons performed in a slotter are,
1)Machining flat surfaces
2.Machining cylindrical surfaces
3.Machining irregular surfaces
4.Machining slots,keyways and grooves

SLOTTER TOOLS
The slotter tools are robust in construction and usually of forged type ; bit type tools fitted in
heavy duty tool holders are also used. Key way cutting tools are thinner at cutting edges.Round
nose tools are used for machining circular or countoured surfaces.Square nosed tools are used
for machining flat surfaces.
SPECIFICATION OF A SLOTTER
Slotting machines are specified by maximum length of stroke.The following data should be
furnished in the specification.
• The diameter of table
• The range of stroke
• The amount of feed
• The number of speed and feed
• HP of the motor.

MILLING MACHINE
A milling machine is a machine tool that removes metaI as the work is fed against a rotating
multipoint cutter. The cutter rotates at a high speed and because of the multiple cutting edges it
removes metal at a very fast rate.The machine can also hold one or more number of cutters at a
time.This is why a milIing machine finds wide application in production work. This is superior
to other machines as regards accuracy and better surface finish and is designed for machining a
variety of tool room work.

TYPES OF MILLING MACHINE:-

The usual classifications according to the general design of the milling machine are :-
1. Column and knee type
 (a) Hand milling machine
(b) Plain milling machine
(c) Universal milling machine
(d) Omniversal milling machine
(e) Vertical milling machine
2. Manufacturing or fixed bed type
(a) Simplex milling machine.
(b) Duplex milling machina.
(c)Triplex milling machine
3. Planer type
4. Special type
(a) Rotary table milling machine.
(b) Drum milling machine.
(c) Planetary milling machine:
(d) pantograph profiling & tracer controlled milling machine.

COLUMN AND KNEE TYPE MILLING MACHINE

For general shop work the most commonly used is the column and knee type when the table is
mounted on the knee casting which in turn is mounted on thé vertical slides of the main
column. The knee is vertically adjustable on the column so that the table can be moved up and
down to accommodate work of various heights.The column and knee type milling machine are
classified according to the various methods of supplying power to the table.different
movements of the table and different axis of rotation of main spindle.

PRINCIPAL PARTS OF COLUMN AND KNEE TYPE MILLING MACHINE

The principal parts of column and knee type milling machines are:-
BASE :- The base serves as a foundation member for all other parts which rest upon it.In some

machines,the base is hollow and serves as a reservoir for the cutting fluid.

COLUMN :- The column is the main supporting frame mounted vertically on the base.The

column houses the driving mechanisms for the spindle and table feed. The front vertical face of
the column is accurately machined and is provided with dovetail guide ways for supporting the
knee. The top of the column is finished to hold an over arm that extends outward at the front of
the machine.
KNEE :- The knee is a rigid grey iron casting that slides up and down on the vertical ways of the

column. The knee houses the feed mechanism of the table,and different controls to operate it.
The top face of the knee forms a guide way for the saddle to provide cross travel of the table.

SADDLE :- On the top of the knee the saddle is placed,which slides on the guide ways set

exactly at right angle to the column face. The top of the saddle is accurately machined to
provide guide ways for the table.
TABLE :- The table rests on the saddle and travels longitudinally.The top of the table is

accurately finished and T-slots are provided for clamping the work and other fixtures on it.
SPINDLE :- The spindle of the machine is located in the upper part of the column and receives

power from the motor.The front end of the spindle just projects from the column face and is
provided with a tapered hole in to which various cutting tools and arbors may be inserted.
OVERHANGING ARM :- The overhanging arm that is mounted on the top of the column extends

beyond the column face and serves as a bearing support for the other end of the arbor.The arm
is adjustable so that the 'bearing support may be provided nearest to the cutter.
MILLING MACHINE MECHANISM
The milling machine mechanism is composed of spindle drive mechanism and the table feed
mechanism.The spindle drive mechanism is incorporated in the column. All
modern machines are driven by individual motors housed within the column,and the
spindle receives power from a combination of gears and clutch assembly. Multiple speed of
spindle may be obtained by altering the gear ratio.

SIZE OF MILLING MACHINE

The size of the column and knee type milling machine is designated by the dimensions of the
working surface of the table and its maximum length of longitudinal, cross and vertical travel
of the table.In addition to the above,number of speed,number of feed, spindle nose taper,power
available,net weight and the floor space required etc should also be stated in order to specify
the machine fully.
WORK HOLDING DEVICES
The commonly used devices to hold work on milling machine table are:
1. T- boltsandclamps 2. Angle plates 3. V-blocks
4. Vices
a) Plain vice b) Swivel vice c) Tool maker universal vice

5. Special Fixtures.

CUTTER HOLDING DEVICES

There are several methods of supporting and rotating milling cutters with the machine spindle
depending on the different designs of the cutters.The following are the different devices for
holding and rotating cutters.
1.Arbors :- The cutters have bore at the center and are mounted and keyed on a
short shaft called arbor which is connected with the milling machine spindle with a draw bolt
and driving keys.
2. Collets
3. Adapter
4. Spring Collets
5. Bolted cutters : the face milling cutters of larger diameter having no shank are Bolted
directly to nose of the spindle.
6. Screwed on cutters:- The small cutter having threaded holes at the centre are screwed on
threaded nose of an arbor which is mounted on the spindle in the usual manner.
MILLING MACHINE ATTACHMENTS

The attachments are standard or special auxiliary devices intended to be fastened to or joined
with one or more components of the milling machine for the purpose of augmenting the
range,verstality,productivity or accuracy of operation. The following are the different
attachments used on standard column and knee type milling machine.

1. Vertical milling attachment 2. Universal milling attachment 3. High speed milling

attachment

4. Slotting attachment 5.Universal spiral milling attachment 6. Rack milling attachment

7. Circular milling attachment 8.Dividing head attachment .

MILLING CUTTERS

The milling cutters are revolving tools having one or several cutting edges of identical form
equally spaced on the circumference of the cutter. The cutting elements are called teeth which
intermittently engage the work piece and remove material by relative movement of the work
piece and cutter. Milling cutters may be classified as:

1. According to the constructional features of the cutter:-

(a) Solid cutter (b) Tipped Solid Cutter (e) Inserted teeth Cutter

2. According to the relief characteristics of the cutter teeth:-

(a) Profile relieved cutter (b) Form relieved cutter.

3. According to the methods of mounting the cutter:-

(a) Arbor type cutter (b) Shank type cutter (c) Facing type cutter

4. According to the Direction of Rotation of the Cutter:-

(a) Right hand rotational cutter (b) Left hand rotational cutter

5.According to the direction of helix of the cutter teeth :-

(a) Paralell or straight teeth cutter (b) Right hand helical cutter

(c) Left hand helical cutter (d) Alternate helical teeth cutter
6.According to the direction of helix of the cutter teeth :-
(a) Standard milling cutter (b) Special miling cutter

STANDARD MILLING CUTTER

There are different types of standard milling cutters. They are classified below:
1. Plain milling cutter
(a) Light duty plain milling cutter (b) heavy duty plain milling cutter.
(c) Helical plain milling cutter
2. Side milling cutter
(a) Plain side milling cutter (b) Staggered teeth side milling cutter
(c) Half side milling cutter (d) Inter locking side milling cutter
3. Metal slitting saw
(a) Plain metal slitting saw (b) Staggered teeth metal slitting saw
4. Angle milling cutter
(a) Single angle milling cutter (b) Double angle milling cutter
5. End mill

(a) Taper shank end mill (b) Straight shank end mill

(c) Shell end mill

6. T-slot milling cutter 7. Woodruff key slot milling cutter 8.Fly cutter
9. Formed cutter
a) Convex milling cutter (b) Concave milling cutter
(c) Corner rounding milling cutter (d) Gear cutter (e) Thread milling cutter

10. Tap and Reamer Cutter

MILLING OPERATIONS

The following are the different operations performed in a milling machine :

1. Plain milling 2. Face milling 3. Side milling 4. Straddle milling

5. Angular milling 6. Gang milling 7. Form milling 8. Profile milling

9. End milling 10. Saw milling 11. Milling key ways, grooves and slots

12. Gear cutting 13. Helical milling 14. Cam milling 15.Thread milling
 GEARS

Gears are toothed wheels commonly used to transmit power or motion from one shaft to
another. Generally the following types of gears are used :-
1 Spur gear 2. Helical gear 3. Bevel Gear 4. Rack

GEAR CUTTING (SPUR GEAR)

The cutting of spur gear in a milling machine involves the following procedure :-

1. To determine the unimportant dimensions and proportions of the gear tooth element.
2. To control the spacing of the gem teeth accurately on the periphery of the gear blank.
3. To select the correct number of outer for the required number of teeth on the gear.
4. To determine the proper speed of the cutter, feed of the table, and the depth of cut.
5. To set the cutter and the work and to perform the actual operation.

SPUR GEAR TERMS

1.Pitch circle :- It is the Imaginary circle which passes through the centre of working depth of
the teeth The gear calculations are based on this circle. The diameter of the pitch circle is
called pitch circle diameter.
2.Circular pitch (CP):- The distance from a point of one tooth to corresponding point of
adjacent tooth measured on the pitch circle is called circular pitch.

3.Addendum circle:- It is also called outside circle,which bounds the outer edges of the teeth.

4.Root circle :- It is also called deddendum circle which bound the bottom of the teeth

5.Addendum :- It is the radial distance between root circle and pitch circle

6.Dedendum :- It is the radial distance between the root circle and pitch circle

7.Working depth :- This is the distance of engagement of two mating gears.

8.Whole depth :- This is the height of the tooth which is equal to the addendum plus
dedendum.

9.Diametrical pitch (DP):- It is the ratio of number of teeth to pitch circle diameter.

10.Diametral pitch (DP):- It is the ratio number of teeth to pitch circle diameter.
SPUR GEAR PROPORTIONS IN TERMS OF MODULE(m) AND NUMBER OF TEETH(z)

NAME OF TOOTH ELEMENT TOOTH PROPORTION

Pitch diameter (d) Zm
Addendum (ha) m
Deddendum (hf) 1.25m
Working Depth (2ha) 2m
Tooth Depth/Whole Depth(h) 2.25m
Outside Diameter (d+2ha) m (Z+2)
Tooth thickness 1.5708m
Clearence 0.25m
CUTTER FOR INVOLUTE GEAR TEETH

CUTTER NO NO OF TEETH TO BE CUT

NO.1 135 teeth to rack
NO.2 55 to 134 teeth
NO.3 35 to 54 teeth
NO.4 26 to 34 teeth
NO.5 21 to 25 teeth
NO.6 17 to 20 teeth
NO.7 14 to 16 teeth
NO.8 12 to 13 teeth

INDEXING

The Indexing is the operation of dividing the periphery of the job into any number of equal
parts.In cutting spur gear,equal spacing of the teeth on the gear blank is performed by indexing.
Indexing is accomplished by using a special type attatchement known as dividing head or
index head. They are of three types:-

(1) Plain or Simple dividing head (2) Universal dividing head

(3) Optical dividing head.

INDEXING METHODS
There are several methods of indexing .The choice of any method depends upon the number
of divisions required and the type of dividing head used.
The following are different methods of indexing:-
1. Direct or Rapid Indexing
2. Plain or simple indexing 3. Compound indexing 4.Differential Indexing
4. Angular indexing
DIRECT INDEXING
It is used when a large number of identical pieces are indexed by very small
divisions.Operation may be performed on both plain and universal dividing head.
RULE FOR DIRECT INDEXING
In case the index plate has 24 holes the formula for indexing is given below:
No. of holes to be moved= 24/N, Where, N = No of divisions required.
SIMPLE INDEXING
It is more accurate and suitable for numbers beyond the range of direct indexing.
RULE FOR SIMPLE INDEXING
In case of worm wheel to worm ratio of the dividing head is 40:1
Index Crank movement = 40/N
Where, N= number of divisions required.
DIFFERENTIAL INDEXING

In differential indexing the required division is obtained by a combination of two movement

1. The movement of index crank similar to the simple indexing.

2. The simultaneous movement of the index plate, when the crank is turned.

RULES FOR DIFFERENTIAL INDEXING

The following are the rules for determining gear ratio and indexing movement of the crank
1. Gear ratio = Driver/ driven == (A-N) x 40/A
Where, A = the selected number which can be indexed by plain indexing
N = The number of divisions to be indexed.
2. Index crank movement = 40/A , Where, A is the selected number.