LES ~ S333 /FIEFIIAES /, Shaping / Slotting Machines Weightage of Marks = 12, Teaching Hours = 08 2.1 Shaping Machine: Principle of working, Classification, Specification of standard shaper. Basic parts of standard shaping machine and their functions. Quick return mechanism. Different shaping operations. n, Specification. Basic parts of slotting machine Principle of working, Cla 2.2 Slotting Machine: and their functions, 1 FI ICTION OF: SHAPER The shaper is a machine tool used primarily for: 1, Producing a flat or plane surface which may be in a horizontal, a vertical or an angular. 2. Making slots, grooves and keyways. 3. Producing contour of concave/convex or a combination of this surface. .2 WORKING | OF SHAPER Shaper is compact machine highly economical and easy to operate for production of flat surface. ‘on small jobs with high accuracy. The workpiece is held securely in a vice mounted on the table. Tool is mounted on the tool head attached to front end of ram. The ram reciprocates to remove the metal'chips from the workpiece in forward direction. During this, the work Is fed perpendicular to the line of tool motion each time. The metal cutting is done only In forward stroke and return stroke is idle. baMenucturng Processes 2a Shaping Stating aching | Downfeed hand wheel . Patton f stoke adjustment Block locking Apron. oti Ll ae : Ctapor toe | i # Table 4 ieeuel baee) loon ] graduations = ‘Column a i al tng pty Elevating screw. Base as Fig, 2.1: Parts of shaper -3 MAIN PARTS OF SHAPER 1. Base: The base of shaper is heavy and rigid cast iron part used to support all fixed and moving parts of the machine. It absorbs the vibrations and takes up the entire weight of the machine. 2. Column: Column mounted on the base is a box like structure made by casting process. It houses the mechanism for ram movement. For the easy movement of ram, guide ways are provided on the top of column. Column also have guide ways on front face for the cross rail | to move upward and downwards. On the left hand side of column, a lid is provided for the inspection and oiling of the drive mechanism. On the other side of the column, levers and handles are provided for operating machine. | 3. Cross rail: It is a heavy box like structure mounted on vertical guide ways of the column. The table cross feed screw and cross rail elevating screw is provided on it. By rotating cross rail elevating screw, the rail and table can be moved in upward or downward direction. 4. Saddle: Saddle is mounted on the cross rail. Cross feed screw is rotated by hand to move the saddle in the cross-wise direction. 5. Table: Table is sqjid casting having T slots on its top surface. It is mounted on the saddle “ and fixed with bolts. A vise is used on the table to hold the workpiece. The table receives the upward and downward movement from the cross rail and cross-wise movement from the saddle. 6. Ram: Ram Is semi-cylindrical reciprocating part of shaper. Tool head is mounted on front end of ram. It reciprocates on an accurately finished guide ways made on top of the column. Ram Is driven by quick return mechanism, Ram possess screwed shaft within itself to change its position relative the workpiece. 7. Tool head: Tool head Is clamped rigidly to the front end of the ram. It consists of a vertical tool slide and apron. The vertical tool slide has a circular swiveling base graduated in degrees so as to enable It to turn and set required angle with respect to the work. By rotating the down feed screw handle, the tool can be fed or retrieved in vertical or angular direction. Dn\ anutactuting Procest 2. ‘Shaping /Slotting Machines Apron: Apron is fix swiveled to left oy acto the vertical slide by means of clamping screw. The apron can be clapper block ands hel Side with respect to vertical slide. Apron consists of clapper box, hinge pin. Toot post j, 0! post. The clapper block is attached to the clapper box by means of box during the forna g mounted on clapper block which is rigidly supported in the clapper box on hinge to keer” cutting stroke. During the return stroke, the block swings out of ne Keep the tool clear of workpiece making it an idle stroke. 1. Length of stroke, 2. Generally, stroke length is 175 mm to 900 mm. Maximum size of workpiece it can hold and machined on it. 4, Weight of the machine, 5. Type of drive, 6. Cutting to return stroke ratio, 7. Number of ram strokes per minute. 8. Power of motor, 9. Floor space required for machine. RSCLASSIFICATION OF SHAPER 1, According to Mechanism used for reciprocating motion of ram. (a) Crank type (b) Geared type (c) Hydraulic type 2. According to position and travel of ram. (a) Horizontal (b) Vertical (c) Travelling head type 3. According to type of cutting stroke used. ASE (a) Push type (b) Draw type 4. According to design of table. (a) Standard shaper (b) Universal shaper SGVICK RETURN MECHANISM OF SHAPER =) a + In shaper, material from workpiece is cut or removed only’ during forward cutting stroke while return stroke is idle. In order to reduce machining time, it is essential to reduce the time taken by the return stroke which is idle. This is achieved by quick return mechanism. * Different types of quick return mechanism provided on shaper are: 1.” Crank and slotted link mechanism. 2. Hydraulic shaper mechanism. 3. Whitworth quick return mechanism. 2.6.4 Crank and Slotted Link Mechanism ism, the ram Is attached to a slotted link, .g motion by a rotating bull gear, whi * In this mecha * Slotted link gets an oscillatin: The point ‘0’ Is the center point of bull gear. A slotted link having a long slot along its length is pivoted about the point \k’ Sliding block ‘N' Is fitted inside the slot and slides along the length of the slotted link, ‘P’ is the crank pin and ‘OP’ can be considered as @ crank. driven by electric motor.Menutaotuing Process _ 24 Saree * AS the top of the slotted tink ts connocted to the ram, the ram reciprocates in hort direction over the column. ony * AS shown In Fig, 2.3, ‘KA’ Indicates the starting point of the forward cutting stroke and ‘a, and of the cutting stroke, The rotation of the crank ‘OP’ In clockwise direction through the angle PARP, refers to the forward cutting stroke, The rotation of the crank In the same di 1 through the angie P:LP, refers to the return stroke, As the angle PsLP, ts smaller ther the aot | iRPas the time taken for the return stroke ts tess than that of forward stroke, So, Tet evigat i that, the speed at which the ram travels during return stroke Is more. nt * The ratlo between the cutting time and return time can be stated as: . Cutting time _ Angle PyRP Return time ™ Angle PalPi * Cutting time to return time practically varies 3 : 2. * Ih crank and slotted link mechanism cutting speed and return speed Is not constant throughoy fhe stroke, Speed ts minimum when the rocker atm is at the two extremities and the specs Bs ‘maximum when the rocker arm is vertical, Handwhe! for position of stroke Clamping lever Pustment Crank Bovel goar Crank pin (P) Driving pinion (8) Sliding block (N) Bull goar ‘ Fig. 2.2: Crank and slotted link mechanism * The stroke length of a ram Is, the c distance, the ram moves forward or 4 backward. It depends upon the distance ae between the centre of the bull gear and mie : the centre of the sliding block. The stroke length of ram can be adjusted and positioned according to the length of the work. Ef eS ‘i K Fig. 2.3 .jotting Machines yo 25 shaping! S! itworth Qui 6.2. Wh ick Return - X sider P) We SA = Connecting rod (SM) i i : Fig. 2.4: Whitworth quick return mecha Whitworth quick return mechanism is used for shaper and slotter. ‘op having fixed point ‘0’, in which slider 'P’ is mounted. Slider ‘P’ cp, Ram is connected to slotted liver by connecting rod ‘SM’. Considering anticlockwise rotation of crank from point P; to point Pz arc PiQPz is used for forward cutting stroke. . Forretum stroke, crank rotates from point P. to point P, through angle B shown by arc PRP. Time of cutting stroke _ Arc P,QP2 _ __o. Time of return stroke ~ Arc PaRP: ~ 360 ~ & 2.6.3 Hydraulic Quick Return Mechanism m It consists of slotted lever is also connected to crank through angle « shown by Piston rod Piston Cylinder if i Tool] ‘Shaper dog Valves Reversing lever hoe ta Throttle vave—> 15 Relief valve Constant discharge ‘oll pump =eSan at ______ testy, = Hydraulic drive of ram consists of hydraulic pump, valve chamber, a cylinder and Piston, aN Cylinder is placed inside ram. Piston rod Is bolted to the ram body. Reciprocating motion of ram is abtalned by supplying oll under pressure from one side OF pis and simultaneously removing oll from other side of piston to reservoir forming forward ra! and direction of oil is changed to constitute return stroke. e * This motion is transmitted to the ram along with the cutting tool, The reversing do Provided along with reversing levers for altering and changing the direction of piston * The quick return motion is achieved by changing the stroke volume of the cylinder at both the 98 ary Adjustable crank pin Spring Drive ise (0) Reversible pawl (S)- Ratchet whee Cross feeg—+—+Q seew Connecting rod (©) Rocker arm (R) Fig. 2.6: Table feed mechanism of shaper * _ In shaper operations, feed is given to workpiece by movement of table on which workpiece is mounted. The table is moved by a predetermined amount. after each cut and bring uncut Portion of workpiece in path of cutting tool. * Table feed mechanism consists of drive disc ‘l which is T slotted and is provided with adjustable pin ‘P’. There is connecting rod ‘C’ attached to the pin ‘P’ which run eccentrically on disc ‘D’ and causes the connecting rod ‘C’ to reciprocate. This motion is transmitted to the rocking arm ‘R’ results in rocking movement of the arm 'R’. * The arm 'R’ is fitted with a reversible pawl ‘S’ which works on sproketed wheel through feed screw to get required movement. When the paw! is set in Position, the feed shaft will be moved clock-wise as the arm rocks clock-wise. * As the arm reverses, the pawl due to its shape at the point slips over the teeth hence there will be no movement. If the position of the pawl is reversed, the direction of the traverse is also reversed. * For switching OFF, a central OFF position is provided. Variation in feed is obtained by adjusting the pin ‘P’ on the disc 'D’. As the pin is moved away from the centre, the feed will be greater. (28 OPERATIONS PERFORMED ON SHAPER Gua ae ea | ‘The main operations done on shaper are as follows. 1. Machining horizontal surface: Machining of flat horizontal surface is the most common operation done on shaper. The workplece is tightly secured between the jaws of vice or 2 clamp provided with T slot of table. The tool is mounted on tool post with minimu acr ceumemuiais overhang. The stroke 1 Br shaping /Stotting Machi ; en machine iS started, Croce gery f,(2™ IS adjusted. The desired depth of cut Is set and engaged. Of table is initially given by hand, later power feed can be 2, Machining vertical surface, | a clamp provided with ane workpiece is tightly secured between the jaws of vice or overhang. The stroke length go pews Ne tool Is mounted on tool post with minimum then the apron is swiveleg ; of ram is adjusted. The vertical slide Is positioned as zero, enables to Move the tool acute Mifection away from the surface to ve machined. This The downward feed can be sea and away from the work surface during return stroke. machining angular surface y the rotation of down feed screw by hand. a clamp provided with 7 s} on workpiece is tightly secured between the jaws of vice or | overhang. The stroke tence’ Of table. The tool is mounted on tool post with minimum ) angle elther towards len olan 's adjusted. The vertical slide is swiveled to desired | the Work-$0 85 to enable then, from the vertical. The apron is then swiveled away from i tool to feed Is given by rotating the down eae work during return stroke. The downward ‘ing pa i Cutting passages like keyways, orooves and slots: For cutting Keyways or sot 2 to allow the tool to run fe0. Initially, a hole is drilled at the inside end of keyway or slot, Feation are adjusted Ml rely into it at the end of the stroke. The length of stroke and postion an nitially so that the stroke will terminate exactly at the clearance hole. 'yway, groove or slot cutting is done at considerably lower speed. The shaper Is used for external key ways on the shaft, internal key ways on the gear, pulleys etc. Internal key ways are cut by using special tool holder. 5. Cutting splines or gears: Gear or spline can be easily cut on shaper by using index centre. The workpiece is between the two centre and gear tooth or spline is easily cut same as the key way cutting. After first tooth.or spline is cut, the workpiece Is indexed to get the desired position by using index plate. The operation Is repeated to cut gear teeth or spline . on periphery of the workpiece. 6. Machining of irregular surfaces: Shaper can be used for machining convex or concave surface or combination of both. If Irregular surface to be machined is large then a combination of vertical feed to the tool and the horizontal power cross feed to the table is Used, Round nose tool is generally used for this type of machining process. ING MACHINE ee .g machine Is a reciprocating machine like shaper 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. Function of Slotter | 1. Slotter is used for cutting grooves, keys: | 2. Apart from slotting operation, slotter can perform variety of operations such as finishing | external and internal plain surfaces. 5. ‘The alotter machine ean be used on any type of work where vertical tool movement If considered essential and advantageous, 2HOPRINCIPLE OF WORKING OF SLOTTER fi s a reciprocating machine tool in which, the ram holding the tool ‘d the cutting action of the tool Is only during the downward The slotting machine | Teciprocates in a vertical axis art stroke,The slotter can be considered as a vertical shaper. 1 HP required: 2 HP. ‘cified by following parameters: Maximum stroke length 300 mm. Helght between table and tool head 450 mm. Maximum diameter of workpiece that can be machined 900 mm. Diameter of table 500 mm, Longitudinal feed given to the table 450 mm. Transverse feed given to the table 350 mm. Face of the head 575 x 250 mm, }—column |. 2.7: Basic parts of slotter The main parts of slotter are: Base: It has rigid base to take up all load and cutting forces. Top of base is accurately | finished to provide guide ways on which saddle is mounted. Guideways are perpendicular to the column face. Column: Column is integral casting with base. Column is vertical member which contains driving mechanism of ram and feeding mechanism. Front face of column is accurately finished for providing the ways on which ram reciprocates, Saddle: Saddle is mounted on guide ways. Saddle can be moved towards or away from Top face of saddle is accurately finished to provide guide ways for the cross slide. | ‘These guide ways are perpendicular to the guide ways on the base. | J Gross slide: Cross slide Is mounted on the guide ways provided on saddle so as to move Parallel to the face of column, column.tis Circul; lar in sha © rotated by rotating cn eUed On top of cross slide. Table Is called rotary 2 worm Which meshes with a worm gear connected to the under slide of the ¢ . ‘able, If so that Job periphery can p " Some machines, table is provided with Indexing mechanism ; : ed provided With T slot for holdine meee int® AnY number of equal parts. Top of the table is ing the workpiece by different clamping devices. mbly: 6, Ram and tool head asse guide Ways of colume, nn Ram Is reciprocating member of machine mounted on machines, special type or aaa the tool at its bottom end of tool head. In some Rarok. ©! holders are provided to relieve the tool during its return 7. Ram drive mechanism: Slotter remo while upward stroke ie ves metal during downward cutting stroke only, Paid rottaaee ty [etn stroke in which cutting tool is retrieved back without any 7 idle return time, quick return mechanism is incorporated machine. | General types of ram drive mechanism used are: (a) Whitworth quick return mechanism, (b) Variable speed reversible motor drive mechanism. (©) Hydraulic drive mechanism. 8. Feed mechanism: In slotting machine, feed to the workpiece is given by movement of table on which workpiece is mounted. Three types of feed given are: (a) Longitudinal feed: If table is fed perpendicular to the column towards or away from its face, the feed movement is termed as longitudinal. (b) Cross feed: If table is fed parallel to the face of the column, the feed movement is termed as cross feed. (c) Circular feed: If the table is rotated on a vertical axis, the feed movement is termed as circular feed. : : ES OFSLOTTER = — The different types of slotting machines are: 1. Punch slotter: Punch slotter is a heavy duty rigid machine designed for removing large amount of metal from large forgings or castings. The length of puncher slotter is very large. Tt may be as long as 1800 to 2000 mm. The ram of puncher slotter is usually driven by spiral pinion meshing with rack teeth cut on underside of the ram. Pinion Is driven by variable speed reversible electric motor. iter: Punch room slotter is a heavy machine which is 2 ter or Precision slot fen aaa ‘at high speeds. This machine takes light cuts and gives accurate Panda hie ster ‘can also be used for general purpose work. This type of slotter Is inishing. This usually fitted with Whitworth quick return mechanism, ter Is a heavy duty slotter consisting of heavy cast ot 3 Pr ion slotter: Production sl bese and neav frame, and Is generally made In two parts.