Sharper machine ppt

1. SHAPER MACHINE

2. Introduction of shaper machine
 The metal working shaper was developed in
the year 1836 by James Nasmyth.
 The shaper is a reciprocating type of machine
tool used for producing flat surfaces
 Sometimes irregular or curved shape also
produce by shaper.
 It is widely used in machine shop
 It is easy to setup and operate.

3. Image of shaper machine

4. Working principle
 The job is held in the suitable device (vice)
clamped rigidly on the machine table.
 The cutting tool is held in the tool post
mounted on the ram of the shaper.
 The ram move in reciprocate motion so it cut
the material from work piece during the
cutting stroke.
 The job is given a feed motion perpendicular
to the direction of tool movement.

5.  Generally cutting action take place in the forward
stroke, which is also known as cutting stroke.
 No cutting material take place during the return
stroke of the arm its called the idle stroke.
 At the end of one cycle consisting of one to and
fro motion of cutting tool.

6. Principle parts of shaper
 Base :
it consist of a heavy cast iron structure, which
supports all the other parts of the machine.
 Column:
it act as a housing of eclectic circuits and
operating mechanism of shaper.

7.  Table:
it is box type construction with T-slots cut on it to hold
vice and the job rigidly.
 Ram:
it is reciprocating part of shaper, semi circular in
shape.
 It gets it drive from quick return mechanism, which is
inside the column

8.  Tool head:
The tool head of shaper is used for holding
the tool rigidly.
It is also provides vertical and angular feed
movement of the tool and allow tool to lift
automatically to provide relief during idle
stroke.

9. Classification of shaper
1. According to the length of the stroke
 30 cm shaper
 45 cm shaper
 60 cm shaper
2. According to the movement of the ram.
 Horizontal type
 Vertical type

10. 3. According to the type of design of the table
 Standard shaper
 Universal shaper
4. According to the type of the drive
 Geared type
 Crank type

11. 6. According to the type of the cutting stroke
 Push type shaper
 Draw type shaper

12. 1. Horizontal shaper:
 it is very popular type of shaper.
 In this shaper ram is holding the tool head
reciprocate in the horizontal axis.
2. Vertical shaper:
 The ram holding the tool reciprocates in a
vertical axis.

13.  In some of the vertical mechanism provision is
made to allow the adjustment of the ram to an
angle of about 10 degree from the vertical
position.
 Vertical shaper may be crank drive or hydraulic
drive.
 It is for key way, groove or slots.

14. 3. Crank shaper
 This is the most common type of shaper in
which crank and slotted mechanism is used
to give the reciprocating motion to the ram.
4. Geared shaper
 The reciprocating motion of the ram is given
by means of a rack and pinion.
This type of shaper in not very widely used

15. 5. Push type shaper
 This is the most general type of shaper.
 Metal is removed in the forward stroke.
6. Draw type shaper
 In this type shaper the metal will remove in
the backward stroke

16.  7. STANDARD OF PLAIN SHAPER:
 A shaper is termed as standard or plain when
the table has only two movements, vertical
and horizontal, to give the feed.

17. Shaper size and specification
 Length of stroke 610mm
 Maximum vertical travel
of table 475mm
 Maximum horizontal
Travel of table 450mm
 Power of the motor 3 HP

18.  Approximate net weight 1750 kg
 Floor space required 1981 x 1067
(mm)

19. Quick return mechanism
 In the standard type shaper metal is remove
by the forward stroke and return stroke goes
idle.
 During this operation period reduce the
machining time it is necessary to reduce the
time taken by the return stroke.
 It required the forward stroke move slowly
and backward stroke move fats to reduce
machining time

20.  This mechanism is known as quick return
mechanism
1. Crank and slotted link mechanism
2. Hydraulic mechanism

21. Crank and slotted link mechanism
Slotted link mechanism
A - Clamping nut
B - Ram
C - Link D
D - Crankpin A
E - Slotted crank B
F - Bull Wheel
G - Slot

22.  Slotted link mechanism is very common in
mechanical shapers. The mechanism is simple and
compact.
 It converts the rotary motion of the electric motor and
gearbox into the reciprocating motion of the ram
 The slotted link mechanism gives the higher velocity
during the return non cutting stroke than during its
forward cutting stroke thereby reducing the time
wasted during the return stroke

23.  The bull gear is driven by a pinion which is
connected to the motor shaft through a
gearbox with four, eight or more speeds
available.
 The bull wheel has a slot. The crank pin A is
secured into this slot; at the same time it can
slide in the slotted crank B.

24.  When the bull wheel rotates, the crank pin A
also rotates and side by side slides through
the slot in the slotted crank B. This makes the
slotted crank to oscillate about its one end C.
 This oscillating motion of slotted crank
(through the link D) makes the ram to
reciprocate. The intermediate link D is
necessary to accommodate the rise and fall
of the crank

25.  The position of the crank pin A in the slot in the bull
wheel decides the length of the stroke of the shaper.
 The further it is away from the centre of bull wheel,
the longer is the stroke.
 The cutting stroke of the ram is completed while the
slotted link goes from left to right.
 Similarly, during return stroke crank pin changes its
position from right to left.

26. Hydraulic Shaper Drive Mechanism
A - Return
stroke
B - Shaper
ram
C - Cutting
Stroke
D - Base
E - 4- Way
value
F - Pump
G - Motor

27.  A hydraulic shaper has the same major parts
as the mechanical one. However, the ram is
driven by a hydraulic cylinder.
 The speeds of the shaper ram and the feeds
of the work table are controlled by hydraulic
mechanism.
 A lever operates a valve that varies the
quantity of oil delivered to the rain cylinder
and thereby governs the ram speed.

28.  In these mechanism oil supply under pressure by the
pump to the left side of the cylinder where it is used
to push the piston and with it ram of the shaper
 Flow control valve is used the regulate the oil supply.
 Oil from the other side of the cylinder is return to the
sump via 4- way valves.
 When the ram reaches far end of the stroke
the position of the for way valves is changed by the
action of pilot valves.

29.  Now oil enter from the right side and return
through the left side.
 The cutting speed of the ram remain constant
throughout most of the stroke.

30.  Advantages and disadvantages:-
 The control of rate of flow and pressure is
quite easy.
 The drive has built the protection against
overload
 Moving parts are less
 Drive has self lubricating properties
 Its smooth and jerk free.
 Power consumption is low

31.  Disadvantages :-
 Primary cost is high
 Not suitable for difficult job
 Oil leakage is major problem
 Any change in the properties of the oil due to
temp. variation may lead to slight variation in
the draive.

32. Shaper feed mechanism
 The feed of the shaper usually obtain by the
means of ratchet and pawl
 Pawl and ratchet type mechanism is used to
move the small distance of machine parts
such as shaper table
 The pawl is move back and forth with help of
eccentricity pushes the ratchet through one or
more teeth in each forward stroke while it just
slide over the ratchet teeth in the backward
stroke

33.  The angular displacement of the ratchet
screw is converted into linear movement of
the sliding member.

35. Slotting Machine
 Introduction:
1. A Slotting machine or slotter may be
consider as a vertical shaper.
2. The slotter has the vertical ram and a
hand or power operated rotary table.
3. In some slotter m/c the ram inclined at
100 to either side of the vertical position
when cutting inclined surface.
4. Slotting machine is use for key way .

36. Principal parts of slotter

37.  Base: The base is rigidly built and is cast
integral with column. The top of the bed and
the front face of the vertical column are
accurately to provide guide ways for the
saddle and ram.
 Saddle: The saddle is mounted on the
guideways and moved towards the column.
 Cross-slide: the cross-slide is mounted on the
guideways of the saddle.

38.  Rotary table: The rotary table is a circular
table mounted on the top of the cross-slide.Its
rotate by hand or by automatic device.
 Ram: Ram reciprocates vertically up and
down. At its bottoms it carries the cutting tool.
A slot is cut on the body of the ram for
changing the position of the stroke.

39. Types of slotting Machines
 Puncher slotter
 Production slotter
 Tool room slotter
 Puncher slotter: The puncher is the heavy
duty machine with power full motor. It is
designed It is designed large amount of metal
from large casting. The length of the stroke is
also large.

40.  Production Slotter: This is the common type
of slotter used for general production work.
The drive of the ram is by means of slotted
disc and connecting ram.
 Tool Room Slotter: This slotting machine is
of precision type is used for very accurate
machining. It is lighter machine and is
operated at very high speed.

41. Specification of Slotter
 Maximum stroke :457 mm
 Diameter of rotary table :915 mm
 Longitudinal movement :762 mm
 H.P required :7.5 HP

42. Operation performed on a slotter
 Machining flat surface
 Machining cylindrical surface
 Machining irregular surface
 Machining slots, keyways and grooves.

44. PLANER MACHINE

45. Planer machine
 A planer is a type of metalworking machine Tool
 That is some what similar to a shaper, but
larger, and with the entire work piece moving
beneath the cutter, instead of the cutter moving
above a stationary work piece. The work table is
moved back and forth on the bed beneath the
cutting head either by mechanical means, such
as a rack and pinion gear, or by a hydraulic
cylinder.

46.  Planers and shapers were used generally for
two types of work:
 generating accurate flat surfaces
 and cutting slots

47. Principle parts of Planner machine

50. Double Housing Planer
 It is the most common type of planer.
 It consists of mainly a massive bed on which the
worktable
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
cross rail.

51.  All the tool heads can be clamped in
position, and can be used collectively or
individually depending on the requirements

52. 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.

54. Pit Type Planer
 Construction and Working of Pit Type of
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. Pit type
planer is preferred for very large work, where
the weight of the work piece and the tool
required table would make reciprocating
movement difficult.

55.  The job is either mounted on a stationary
table, or on the floor inside a pit, and hence
the name pit type planer. Once or two tool
heads are 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.

57. 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.

58. Deference between Shaper and Planer
Machine
Shaper
1. It is comparatively light
machine.
2. Less space required.
3. It is use for small size
and light work piece.
4. Generally single tool is
used.
5. Less time is required to
setting the job.
Planer
1. It is comparatively
heavy machine.
2. Large space required.
3. It is used for large size
and heavy work piece.
4. More than one tool can
used simultaneously.
5. More time is required
to setting the job.

59. 6. Shaper consume 15-20
HP.
7.Stroke length is small.
8. Machine cost is less
6. Palner consume 120
HP.
7. Stroke length is small
8. Machine cost is high.