Production technology lecture at department of production technology in faculty of engineers Zagazig university It's very useful for you and any student at faculty of engineering at any country around the world

1. Production Technology
Chapter 5: Shaping, planning and slotter
By
Dr. Marwa A. Abd El-baky
Associate Professor in Mechanical Design and Production Engineering
Department

2. Shaping process
Is a process used to generate flat surfaces (horizontal, vertical or inclined) using
single point cutting tool.

3. Differences between shaper, planner and slotter

5. Shaper machine

6. planner machine

7. Slotter machine

8. Specifications of shaper machine
• Ram stroke length (mm).
• Work table (length and width).
• strokes per minute.
• Motor power.
Specifications of planner machine
• Maximum W.P dimensions.
• Table speed.
• Tool feed per stroke.
• Motor power.
Specifications of slotter machine
• Ram stroke length (mm)
• Diameter of table.
• distance from the tool post face to bed.
• Motor power.

9. Purpose of quick return mechanism
Shaping working principle
• The metal is removed during the forward stroke of the carriage, and during the back stroke,
no cutting is done.
• To reduce the total operating time, the return time is faster than the cutting time. To achieve
this, Quick return mechanism is used.
 Convert rotational motion from motor to reciprocating motion for ram.
 reducing the total machining time by reducing the return stroke time.

10. 1. Lever rocker arm (shaper)
‫الـ‬ ‫بدوران‬
pinion
‫الـ‬ ‫يدور‬
crank gear
‫الـ‬ ‫يتحرك‬ ‫ثم‬ ‫ومن‬
crank pin(B)
‫الـ‬ ‫تجويف‬ ‫داخل‬
rocker arm
‫الـ‬ ‫فيتحرك‬
rocker arm
‫الـ‬ ‫فيتحرك‬ ‫واليسار‬ ‫اليمين‬ ‫الي‬
ram
‫واليسار‬ ‫اليمين‬ ‫الي‬

11. Adjustment of stroke length
•
‫عن‬
‫الـ‬ ‫موضع‬ ‫تغيير‬ ‫طريق‬
crank pin(B)
‫الـ‬ ‫فيتحرك‬ ‫الخارج‬ ‫الي‬ ‫او‬ ‫الداخل‬ ‫الي‬
rocker arm
‫او‬ ‫الداخل‬ ‫الي‬
‫او‬ ‫المشوار‬ ‫طول‬ ‫فيزيد‬ ‫الخارج‬ ‫الي‬
‫يقل‬
.
Adjustment of stroke position
• Unlock the ram clamping lever.
• Moving the hand wheel for stroke adjustment
.
• Lock the ram clamping lever.

12. Quick return action
𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑟𝑎𝑡𝑖𝑜 =
𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑡𝑖𝑚𝑒(𝑡𝑐)
𝑟𝑒𝑡𝑢𝑟𝑛 𝑡𝑖𝑚𝑒(𝑡𝑅)
=
𝜃𝑐
𝜃𝑅
> 1
𝜃𝑐 + 𝜃𝑅 = 360o

13. 2. Hydraulic return systems (shaper, planner and slotter)

14. 3. Rack and pinion mechanism (planner)

15. •
‫دوران‬
‫الـ‬
slotted disc
‫الـ‬ ‫تحريك‬ ‫الي‬ ‫يودي‬
link
‫الـ‬ ‫فيتحرك‬
ratchet arm
‫الـ‬ ‫فيتحرك‬
pawl
‫اخري‬ ‫الي‬ ‫سنة‬ ‫من‬
‫التغذية‬ ‫فتحدث‬
.
‫الـ‬ ‫مكان‬ ‫بتغيير‬ ‫التغذية‬ ‫قيمة‬ ‫فتتغير‬
crank pin
.
Feed mechanism

16. Tool mounting in shaper machine
•
‫اثناء‬
‫مكانة‬ ‫فياخذ‬ ‫القطع‬ ‫قوى‬ ‫من‬ ‫القلم‬ ‫علي‬ ‫ضغط‬ ‫يحدث‬ ‫القطع‬ ‫مشوار‬
.
•
‫الـ‬ ‫باستخدام‬ ‫االداة‬ ‫تثبيت‬ ‫يتم‬ ‫بالشغلة‬ ‫االداة‬ ‫احتكاك‬ ‫ولتجنب‬ ‫الرجوع‬ ‫مشوار‬ ‫اثناء‬
clapper box
‫علي‬ ‫يحتوي‬ ‫الذي‬
pivot pin
‫الرجوع‬ ‫اثناء‬ ‫بالشغلة‬ ‫االداة‬ ‫تحتك‬ ‫ال‬ ‫وبالتالي‬ ‫االداة‬ ‫بدوران‬ ‫يسمح‬ ‫الذي‬
.

17. How tool can be swiveled to machine inclined surfaces

18. Work piece holding devices in shaper machine
Machine vice

19. T-slots (T-bolts)

20. Shaping analysis
Machining time (𝑻𝒎)
𝑇𝑚 =
𝑊 𝑥 𝑖
𝑓 𝑁
W = 𝑤 + 𝑤1 + 𝑤2
𝑤 ∶ 𝑊𝑜𝑟𝑘 𝑝𝑖𝑒𝑐𝑒 𝑤𝑖𝑑𝑡ℎ
𝑤1 : 𝐴𝑝𝑝𝑟𝑜𝑎𝑐ℎ 𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒
𝑤2 : 𝑂𝑣𝑒𝑟 𝑡𝑟𝑎𝑣𝑒𝑙 𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒
Where:
𝑖: No. of depth of cut

21. 𝑖: No. of depth of cut
𝑖 =
𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑡𝑜 𝑏𝑒 𝑟𝑒𝑚𝑜𝑣𝑒𝑑 ‫ازالتها‬ ‫المطلوب‬ ‫التخانة‬
𝑑𝑒𝑝𝑡ℎ 𝑜𝑓 𝑐𝑢𝑡 ‫القطع‬ ‫عمق‬
N=
1000 𝑉
2 𝐿𝑠
𝑁 : Speed (stroke/min)
𝑉 : Average cutting speed → V =
Ls
time
stroke/min
𝐿𝑠 : Cutting stroke length ‫القطع‬ ‫مشوار‬ ‫طول‬
1
N
: Time of one stroke ‫واحد‬ ‫مشوار‬ ‫زمن‬

22. shaper working on a 500 mm stroke length makes 25 cycles per minute with feed of 0.5
mm/stroke. The path of driving pin in the cutting stroke is through 240o. The transverse
approach of the tool from each side of W.P is 5 mm. calculate:
1. cutting ratio.
2. Average cutting and return speed.
3. Machining time (W.P width= 115 mm).

23. Given : Req.:
𝐿𝑠 = 500 mm (a) cutting ratio
𝑁 = 25 stroke/min (b) Average cutting and return speeds
𝑓 = 0.5 mm/stroke (c) Machining time at w=115 mm
𝜃𝑐 = 240o
𝑤1 = 𝑤2 = 5 mm
Solution
− 𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑟𝑎𝑡𝑖𝑜 =
𝜃𝑐
𝜃𝑅
=
240
360 − 240
= 2 (a)
− Time of one stroke =
1
𝑁
=
1
25
= 0.04 𝑚𝑖𝑛

24. 𝑡𝑐 = 0.02667 𝑚𝑖𝑛
− 𝑉
𝑐=
𝐿𝑠
𝑡𝑐
=
500 𝑥 10−3
0.02667
= 18.75 𝑚/𝑚𝑖𝑛 (b)
𝑡𝑅 = 0.04 − 𝑡𝑐 = 0.04 − 0.02667 = 0.01333 𝑚𝑖𝑛
− 𝑉𝑅=
𝐿𝑠
𝑡𝑅
=
500 𝑥 10−3
0.01333
= 37.5 𝑚/𝑚𝑖𝑛 (b)

25. − Machining time (Tm)
W = 𝑤 + 𝑤1 + 𝑤2 = 115 + 5 + 5 = 125 𝑚𝑚
𝑇𝑚 =
𝑊 𝑥 𝑖
𝑓 𝑁
=
125 𝑥 1
0.5 𝑥 25
= 10 𝑚𝑖𝑛

26. It is required to remove 5 mm from the height of a work piece of width 100 mm using
shaping machine. The stroke length is 450 mm. The shaper makes 30 stroke/min with feed
rate 0.2 mm/stroke and cutting angle 210⁰. Take the depth of cut equal 2 mm. Calculate:
a. Average cutting and return speeds.
b. The machining time.

27. GOOD LUCK
Marwa A. Abdelbaky