shper slotter planner

What is a shaper ?
A Machine which produces flat surfaces A Ram holding the Tool reciprocates Work is fed perpendicular to the tool working principle Cutting Tool repeatedly travels along line A B Work is fed a small distance each time Feed of work & line of tool motion are in same plane but perpendicular The tool line eventually reaches position C D Combination of two movements results in the flat plane ABCD being machined Classification of shapers Basic types: Horizontal Shaper Vertical Shaper Traveling head Shaper Horizontal shaper: Ram holding the cutting tool moves In horizontal plane Vertical shaper: The cutting tool moves in vertical plane Traveling head shaper: Cutting tool reciprocates & moves cross wise simultaneously. 1. Acc. to Cutting Stroke action a) Push Type Shaper b) Draw Type Shaper a) Standard Shaper 2. Acc. to the Table Design: b) Universal Shaper a) Crank type 3. Acc. to Driving Mechanism: b) Geared type c) Hydraulic Shaper Push type shaper Metal is removed when the ram moves away from column Most common type used in practice Unless otherwise specified, the term shaper refers to Push type Shaper Draw type shaper Metal is removed when the tool is drawn towards the column Allows heavier cuts to be made Less vibration during cutting Standard shaper Work Table can be moved

1.Vertically & 2. Horizontally Universal shaper Table can be moved 1. Horizontally 2. Vertically 3. Swivelled & 4. Tilted This is mostly used in Tool Rooms Crank type shaper: Driving mechanism is by crank & gear Geared type shaper: Driven by Rack & Pinion mechanism Hydraulic shaper: Driven by oil pressure developed by a pump, which is run by an electric motor.

Construction of Shaper
Main parts of a shaping machine 1. BASE 5. CROSS RAIL 2. COLUMN 6. SADDLE 3. RAM 7. TOOL HEAD 4. TABLE 8. CLAPPER BOX 1. Base Bottom most part Supports other parts of the machine Acts as a reservoir of lubricating oil Made of Cast Iron 2. Column Vertically mounted on the base Houses Driving Mechanism of Ram Has guide ways on which Ram slides Made of Cast Iron 3. Ram The main moving part of a Shaper It carries Tool Head Connected to Driving Mechanism 4.Table A box like casting with T-slots on its top Shaper vice is fitted in the T-slots Work is fixed in the vice 5. Cross rail Used to move the Table Up & Down Upward movement is controlled by an Elevating Screw Side movement is controlled by lead screw 6. Saddle It is mounted on cross rail It supports the Table Moves across the cross rail left to right Movement obtained by a cross feed screw 7. Tool head It is attached to the front end of Ram Carries Clapper box & Tool post on it Can be swiveled at any angle on either side 8. Clapper box It is hinged to the tool head It houses clapper block

 Swings outward in return stroke Tool post mounted on clapper block Specifications of Shaping Machine Max.length of Stroke of Ram Type of Drive Power input Floor Space required Weight of the Machine Cutting to Return Stroke ratio Feed Shaper Drive Mechanisms Since return stroke does no cutting the ram should move faster during return stroke. The shaper drive system incorporates quick return mechanism. So that the ram moves faster during return stroke Thus minimizing the (idle time) Quick Return time. Shaper Driving Mechanisms Whitworth quick return mechanism Slotted link quick return mechanism Hydraulic quick return mechanism

Whitworth Quick Return Mechanism

Crank BC revolves at a uniform speed. During cutting stroke point C travels from Y to X through Z. Ram returns at high speed as the crank rotates from X to Y through T. Then: Time for cutting stroke 360 - Time for return stroke

Since is smaller than 360 , the time for cutting is more than the idle time. Stroke length can be changed by varying the radius AE On entering the cut the highest pressure on the tool and the slowest speed is available. On entering the cut the maximum pressure is holding the ram down in its slides Crank & Slotted Link QRM

 Crank pin(11) is fitted in the slotted link(9) Bottom end of slotted link (rocker arm) is attached to frame of column(15) Its upper end is connected to ram(2). Electric motor drives pinion (1) Pinion (1) drives the bull gear(14) A Radial slide (16) is bolted at the centre of bull gear. Radial slide carries a sliding block(12) & a crank pin (11) As the bull gear 14 rotates, crank pin 11 rotates. So sliding block 12 also rotates on the crank pin circle. Simultaneously crankpin will move up & down in the slot of the slotted link 9. As the crank pin11 moves, slotted link 9 gets rocking movement. This rocking movement is communicated to the ram. Thus the rotary motion of the bull gear is converted to reciprocating motion of the ram. When the link is in the position PM, ram will be at the extreme backward position. When it is at PN, ram is at extreme forward position PM&PN are tangents drawn to the crank pin circle. Forward cutting stroke takes place through the angle C1 K C2 Return stroke takes place through the angle C2 L C1 of the crank. It is evident that angle C2 K C1 is greater than C2 L C1 Angular velocity of crank pin is constant. So Return stroke is completed in a shorter time. Therefore it is known as quick return motion. Ratio between cutting time & return time. Cutting time : Return stroke = Angle C1KC2 : Angle C2LC1 Cutting time : Return time ratio usually varies bet 2 : 1. Practical limit is 3 : 2 Hydraulic Quick Return Motion Mechanism The Ram with cutting tool has to move slowly in cutting stroke Ram to return quickly in idle stroke The first 2 methods are discussed already The 3rd method is by Hydraulic Mechanism If the Quick Return Motion is obtained by hydraulic means in a Shaper Then such a Shaping Machine is Known as HYDRAULIC SHAPER WORKING Forward Stroke Oil is pumped to Right side of Cylinder Piston moves Left Hand Side Ram moves Forward Stroke Shaper dog hits the reversing lever Reversing lever alters valve position Oil is now pumped to Left side of Piston Piston moves Right Side

Ram performs Return Stroke Oil on the Right side of Piston goes to reservoir At the end of Return stroke another trip dog hits reversing lever Reversing lever changes direction of stroke of Piston Thus the Cycle is repeated

QRM is obtained Due to the difference in stroke volume Volume on Left side of piston is small due to presence of piston rod Right side volume is larger ( absence of piston rod) Pump pumps same amount of oil both sides As volume is small on Left side, pressure increases Increase in pressure causes Speed of ram to increase in Return stroke Advantages of Hydraulic Shaper Cutting tool works uniformly during cutting stroke Reverse stroke is obtained without any shock More no. of cutting speeds are obtained Good control on cutting speed Relief valve ensures safety i.e. Machine is not overloaded

Shaper Operations
Machining Horizontal Surfaces Machining Vertical Surfaces Machining Angular Surfaces Cutting Slots, Grooves & Key ways Machining irregular surfaces Machining Splines / Cutting Gears Steps for Machining Work is properly held in a vice Table is raised to a gap of 25 to 30 mm between tool & work The length & position of stroke are adjusted The length of stroke should be nearly 20 mm longer than the work The approach & over run should be 10 & 5 mm respectively. Depth of cut is adjusted by rotating down the feed screw of tool head Feed is adjusted about half the width of cutting edge of tool Machining Horizontal Surfaces Fix the work properly on the table Adjust the length of stroke Set the required cutting speed Give required feed of the table Fix an appropriate tool in the tool head Give suitable depth of cut for rough cuts Finishing the job by giving less depth of cut Machining Vertical Surfaces Fix up the job on the table firmly Align the surface to be machined properly Fix up a side cutting tool in the tool head Set the vertical slide exactly at zero Swivel the apron away from the job Switch on the machine Rotate down feed screw by hand to give down feed Feed in about 0.25 mm Machining Angular Surfaces Angular shaping is carried out to machine inclined surfaces, bevelled, dove tail etc., Set the work on the table

 Swivel the vertical slide of tool head to the required angle ( to the left or right) Set apron away from work Give down feed as per requirement Cutting Rack or Splines Fix up a square nose tool in tool head Adjust the length & position of stroke Reduce the cutting speed Give suitable depth of cut Feed the work properly to get equal splines Cutting Key ways Fix up the job between two centres Cut first spline similar to a key way Move / Rotate work by the required amount Use index plate for this purpose Machining irregular surfaces Fix up a forming tool in tool post Give cross feed in conjunction with down feed Swivel the apron suitably according to the contour required Clamping the Work on a Shaper Work should be properly & firmly fixed on the Shaper table Work is fixed on the table by 3 methods. Using a Swivel Vice Using T bolts & Clamps Using Angle plate & C Clamps Slotting machine A Machine which produces flat surfaces A Ram holding the Tool reciprocates Ram reciprocates in verticle direction Work is fed perpendicular to the tool Slotter - working principle Cutting Tool repeatedly travels along line A B Work is fed a small distance each time Feed of work & line of tool motion are in same plane but perpendicular The tool line eventually reaches position C D Combination of two movements results in the flat plane ABCD being machined Work is supported on a rotary table. Table can have longitudinal and rotary movements Straight and rotary cuts can be produced. CLASSIFICATION According to design and purpose the slotters are classified into two types Puncher Slotter Precision tool room Slotter Puncher slotter: Intended for removing large amount of metal from heavy works. heavy and rigid machine Ram driven by rack and spiral pinion mechanism used for machining large castings and forgings Precision tool room slotter: Used for tool room work, where accuracy important Lighter in construction

 Fitted with quick return mechanism Operates at high speeds and designed for light cuts Gives accurate finish Suitable for small to medium size work pieces Difference between vertical shaper and Slotter in verticle shaper the tool holding ram can tilt by about 50 with respect to verticle axis In slotter ram cannot tilt at all. In all other aspects verticle shaper and slotter are similar Main parts of a slotter 1. Base 5. Cross slide 2. Column 6. Saddle 3. Ram 7. Tool head 4. Table 1. Base Bottom most part Supports other parts of the machine Acts as a reservoir of lubricating oil Made of Cast Iron Base Rigidly built to take up cutting forces Top of bed is accurately finished Guide ways are provided for saddle Guide ways are perpendicular to column face Column Vertically mounted on the base Houses Driving Mechanism of Ram Has guide ways on which Ram slides Made of Cast Iron Also houses feeding mechanism Ram Reciprocating vertically up and down of a slotter Mounted on guide ways of column It carries Tool Head / cutting tool Connected to Driving Mechanism An arrangement is provided on the body of ram to change length of stroke Table It holds the work piece. A circular casting with T-slots on its top Movement of table can be linear or rotary Table is graduated in degrees so indexing can be done Slotter vice may be fitted in the T-slots Work may be fixed in the vice Operated manually or by power Saddle It is mounted on guide ways of bed It can be moved towards or away from bed Using saddle longitudinal feed is given Top is accurately finished to provide guide ways for cross slide These guide ways are perpendicular to the guide on the base Operated either manually or by power Cross slide Circular work-table is mounted on the top. Mounted on guide ways of saddle Moves parallel to the face of the column

 Using cross slide cross feed is given Operated either manually or by power Tool head It is attached to the bottom end of Ram Carries Tool post on it Tool is fixed in position No swiveling along verticle axis or horizontal axis Specifications of Slotting machine Max. length of Ram Stroke Diameter of work table in mm. Type of Drive Maximum table travel. Power input Floor Space required Specifications Contd.. Amount of longitudinal travel in mm No. of speeds available No. of feeds available Table feed. Slotter driving mechanism A Slotting machine produces flat surfaces The Ram holding the Tool reciprocates vertically up and down Cuts the material only in down stroke There should be some mechanism to move the ram in reciprocating motion It is called as slotter driving mechanism The mechanism commonly used is slotted disc mechanism Quick return mechanism (QRM) A Mechanism makes the ram to move slowly during cutting stroke. During return stroke ram moves at a faster rate. To reduce the idle time,It Should return quickly . The mechanism adopted is known as QRM Methods to obtain Q.R.M. in slotter . Whitworth Q.R.M. Mechanism 2. Variable speed reversible motor drive mechanism 3. Hydraulic drive Mechanism The mechanisms for QRM in slotter are similar to QRM in shaper Feed in Slotter In Slotter feed is given by table Feed movement is intermittent Feed is given at the beginning of the cutting stroke Feed may be given either manually or by power Table will have three types of feed movements a. longitudinal b. cross and c. circular feeds. Types of feed in Slotter Longitudinal feed: Table is fed perpendicular to the column Table moves towards or away from the column Cross feed: Table is fed parallel to the face of the column Circular feed: table is rotated with respect to verticle axis Feed mechanism of a Slotter Uses a ratchet and pawl mechanism

 Feed shaft engaged with cross, longitudinal / rotary feed screws has the ratchet mounted on it. Ratchet is moved by small amount in one direction only with the help of a connecting rod, lever. The roller moves in the cam groove cut on the face of the bull gear of slotting machine. Operations on slotter 1. Machining flat surfaces 2. Machining Circular Surfaces 3. Machining internal surfaces 4. Machining grooves or key ways Setup for Machining Work is properly held in a vice Table is raised to a gap of 25 to 30 mm between tool & work The length & position of stroke are adjusted The length of stroke should be nearly 20 mm longer than the work The approach & over run should be 10 & 5 mm respectively. Depth of cut is adjusted by rotating down the feed screw of tool head Feed is adjusted about half the width of cutting edge of tool Machining Flat Surfaces Fix the work properly on the table Adjust the length of stroke Set the required cutting speed Give required feed of the table Tool is held in the tool head of ram Ram reciprocates up and down Feed has to be given at the beginning of cutting stroke Both internal and external surfaces can be machined Give suitable depth of cut for rough cuts Finishing the job by giving less depth of cut Machining circular surfaces Tool is set radially on the work Work piece is placed centrally on the rotary table Feed is given by the rotary table feed screw Feed screw rotates the table through an arc Adjust the length of stroke Set the required cutting speed Finishing the job by giving less depth of cut Machining internal surfaces Fix up a tool in tool post Cross, longitudinal and rotary feed are combined Any contoured surface can be machined Mostly done manually Good skill is required from operator Machining grooves or key ways Slotter is specially intended for cutting internal grooves External or internal gar teeth can be machined Fix up the job between two centers Cut first a key way Move / Rotate work by the required amount Indexing can be done by using graduations on rotary table Cutting Key ways Fix up the job between two centres Cut first spline similar to a key way Move / Rotate work by the required amount Use index plate for this purpose Work holding devices Work should be properly & firmly fixed on the Slotter table

Work is fixed on the table by 3 methods. 1. Using a Swivel Vice 2. Using T bolts & Clamps 3. Using Angle plate & C Clamps What is a planer ? A Machine which produces flat surfaces Consists a stationary housing for holding the tools A table holding the work reciprocates Large works, that con not be accommodate on shapers The tool is stationary but the work moves Planer - working principle The table on which work is clamped is imparted a reciprocating movement Cutting takes place during the forward stroke of table During return stroke the cutting tool is slightly lifted Tool is fed for each forward stroke Table is driven by an electric motor Length of table stroke can be adjusted Speed of return stroke is also regulated Classification of planers Double housing Planer 2. Open side Planer 3. Pit type Planer 4. Edge Planer or Plate Planer 5. Divided Table Planer Double housing planer: It is the Standard model & most widely used Very heavy and robust Has a bed and two vertical housings are fixed Table moves along the guide ways of the bed Housing supports cross rail & tool heads. Cross rail carries two tool heads Tool head carries tools Open side planer It has only one supporting column (housing) Area larger than the table can be planed Cross rail is mounted as a Cantilever Tool holders ( max.3) are mounted on Cross rail Stroke length of bed is controled by adjustable dogs PIT Planer Columns and cross rail carrying tool head move longitudinally on massive rail above the work table Bed is recessed in the floor Loading and unloading of jobs is easy Used for Planing heavy & large jobs Table and work piece resting on it are stationary and the tool reciprocates Edge / plate planer Specially designed for squaring or beveling the edges of heavy steel plates for pressure vessels Carriage supporting the tool is moved back and front direction Cutting can take place during both directions of carriage travel Operator stands on the platform & operates Divided table planer Also known as Tandem planer Planer has two tables on the bed Table may be reciprocated together or separately Each table reciprocates under different tool head For continuous production, small work pieces clamped on one table are being machined, another is

stationary and can be used for setting up fresh works Used for quick & continuous production Main Parts of Planing machine 1. Bed 2. Table 3. Housing or Column 4. Cross rail 5. Tool heads 6. Driving Mechanism 7. Feed Mechanism 1. Bed Large box like casting Length is nearly twice the table length Consists guide ways on which table moves Houses the driving mechanism of table Made of Cast Iron 2.Table Also called Platen Large rectangular casting mounted on bed ways Holds the work & reciprocates along bed ways Top surface has T slots Work is clamped on T slots 3.Housing or Column Large vertical structures on each side of the bed Supports cross rail on which tool heads are mounted Also supports the mechanism for operating the tool heads Made of Cast Iron 4. Cross rail A rigid casting mounted horizontally on the column Can be moved up & down by elevating screw Carries two slides with tool heads Tool heads can be moved horizontally on the guide ways of cross rail 5. Tool heads Contains tool posts for holding the tools Tool post (clapper block) is hinged to the head During return stroke cutting tool will be lifted Tool heads can be swiveled through 60 on either side of its vertical position Specifications of a Planer . Distance between the two housings 2. Height between Table & cross rail at its uppermost position 3. Maximum length of table travel 4. Number of Speeds & feeds available 5. Power input 6. Floor space required 7. Type of Drive 8. Net weight of the Machine Mechanisms used to drive the table A Planing Machine produces flat surfaces The Table holding the Work reciprocates There should be some mechanism to move the Table in reciprocating motion, and Table to move quick during idle stroke Mechanisms to drive the Table (QRM) . Open & Cross belt drive 2. Reversible motor drive

3. Hydraulic drive Open & Cross belt drive Mechanism Used for smaller capacity machines Table is moved by gears & rack attached under the table Counter shaft at the top of housing has 2 pulleys Pulleys transfer power to main shaft Main shaft drives the table by rack & pinion 2 Sets of fast & loose pulleys are mounted on driving shaft Smaller fast pulley is used for backward motion of table (Quick motion) It is connected by open belt drive Bigger fast pulley is driven by cross belt drive It is used to drive the table during forward stroke At the end of cutting stroke, cross belt is shifted from fast pulley to loose pulley Simultaneously open belt is shifted from loose pulley to fast pulley This is achieved by trip dog which operates belt shifting lever Thus the direction of movement is automatically reversed 2. Reversible Motor Drive Mechanism Electric motor drives the bull gear through gear trains Motor is coupled to D.C. generator When motor is started, generator supplies power to reversible motor Reversible motor causes the planer table to move At the end of stroke, trip dog operates the switch which reverses the direction of table Speed of cutting stroke is reduced by regulating the field current of the generator 3.Hydraulic Drive of Planer Forward Stroke of Table During cutting stroke, oil is pumped into LHS of cylinder As the area is less due to presence of piston rod, less force acts So the table moves slowly in cutting stroke At the end of each stroke trip dog operates a lever Lever actuates the control valve of circuit Return Stroke of Table Oil is pumped into the Operating cylinder Cylinder contains piston & piston rod The other end of piston rod is connected to the Table During return stroke, oil is pumped into RHS of cylinder More force acts on the piston & it moves quickly Planer Operations 1.Planing Horizontal Surfaces 2. Planing Vertical Surfaces 3. Planing Angular Surfaces / Dovetails 4. Planing Curved surfaces 5. Planing Slots & Grooves Planing Horizontal Surfaces Fix the work properly on the table Set the required cutting speed Give required feed of the tool Give suitable depth of cut for rough cuts Finishing the job by giving less depth of cut Planing Vertical Surfaces Fix the job on the table firmly Align the surface to be machined properly Vertical slide is adjusted perpendicular to the table Swivel the apron away from the job Switch on the machine

 Rotate down feed screw by hand to give down feed Planing Angular Surfaces Main angular planing is to make dove tails & V grooves Set the work on the table Swivel the tool head to the required angle Set apron away from work Give down feed as per requirement Planing Formed Surfaces Fix up a square nose tool in tool head Required form is obtained by feeding the tool simultaneously in both hor. & ver. Directions Give suitable depth of cut This can also be done with the aid of a special fixture Planing Slots & Grooves Fix up the job on the table suitably Fix Slotter tools in tool heads Give feed using down feed screw Move the tool by the required amount to get uniform slots / grooves broach BROACHING OPERATION A method of metal removal with a special tool called Broach. Cutting tool called broach has three types of teeth, namely roughl y teeth, semi finishing teeth, finishing teeth Broach can be pulled or pushed in a fixed path Surfaces machined may be flat or contoured can be produced in a single pass or stroke of broach Both internal and external surfaces can be machined But limited to removal of 6 mm stock or less BROACHING OPERATION Surfaces machined may be flat or contoured can be produced in a work piece by a single pass or stroke of broach. Both internal and external surfaces can be machined But limited to removal of 6mm stock or less BROACH Tool used in broaching Broach is a multi-teeth cutter produced to close tolerances. It has successively higher cutting edges along length It has three types of teeth, is rough, semi finish, finish teeth. Available in different shapes and sizes For irregular shapes one broach for one contour or shape has to be developed High speed steel is the most widely used material for producing broach. Carbide tools are also used for machining steel castings CLASSIFICATION OF BROACHES Broaches may be classified on different criteria, some of them are According to type of operation i) internal broach ii) external broach According to method of operation i) push broach ii) pull broach According to type of construction i) solid broach ii) built-up broach iii) inserted tooth broach iv) progressive cut broach According to function i) surface broach

ii) key way broach iii) round hole broach iv) Spiral broach PUSH BROACH Designed to be pushed through a stationary work piece It has tendency to bend under compressive load It is short and stocky Fewer teeth on broach Less stock can be removed for each pass So production time will be more PULL BROACH Designed to pull through a stationary work piece Tool is in tension during cutting Pull broach is long and slender It has large number of teeth More stock can be removed Production time will be less BROACHING METHODS According to method of operation the broaching may be classified as pull broaching push broaching surface broaching continuous broaching PULL BROACHING Work is held stationary Broach is held in a special head Broach is pulled over or through the work Mostly used for internal broaching Surface broaching can also be done PUSH BROACHING Work is held stationary Broach is held in a special head Broach is pushed over or through the work Mostly used for i) sizing already drilled holes ii) cutting key ways Broach is operated by i) manually or ii) Hydraulic arbor press less metal is removed SURFACE BROACHING Work is held in a fixture and tool in tool head Either work or broach moves across each other Tools must be specially designed for each work piece Many irregular and intricate shapes can be broached Produces excellent surface finish Time required will be very low when compared to other machining processes. CONTINUOUS BROACHING Broach tool is held stationary Work pieces are moved continuously Path of work piece movement may be i. Straight horizontal or ii. Circular Suitable for producing similar work pieces Suitable for mass production

 Suitable for small size work pieces only BROACHING MACHINES Simplest of all machine tools Have less components Broaching machines consist of : work holding fixture broaching tool drive mechanism suitable supporting frame Most machines are hydraulically operated Has smooth and uniform cutting action Used for low or high production quantities. CLASSIFICATION OF BROACHING MACHINES Broaching machines are mainly classified as Horizontal broaching machines (push or pull type) Vertical broaching machines Special design continuous broaching machine Rotary table continuous broaching machine horizontal continuous broaching machine HORIZONTAL BROACHING MACHINE Main parts of the broaching machine are Bed Housing Drive mechanism Broach pilot Fixture BED: Bottom most part Supports other parts of the machine Made of Cast Iron HOUSING: houses the driving mechanism houes the pulling head DRIVE MECHANISM drives the pulling head cutting stroke speed is less return stroke speed is more Broach pilot holds the broach rigidly Fixture holds the work piece rigidly HORIZONTAL BROACHING MACHINE Both surface and internal broaching can be done Broach is securely held in a pulling head In surface broaching broach is pulled over the surface For internal broaching broach is pulled through work Mainly used for internal broaching Operated at cutting speed of 3 to 5 m/min Speed of return stroke is 30 m/min Hydraulic drive is used for pulling head Operated at infinitely variable range of cutting speeds Hydraulic cylinder is housed on right side of the machine Long broaches are easily handled heavy work pieces are easily handled occupies more space than vertical machine Uses It is used to machine Keyways

 Splines Slots Round holes Other internal shapes These are further classified as Surface broaching machines internal broaching machines VERTICAL BROACHING MACHINE it may either push type or pull type pull type is popular Main parts of vertical broaching machines are Base Column Ram and broach Fixture and table Drive mechanism Three models are available in vertical type pull up pull down push down Pull up model is most popular Broach is securely held in ram Occupy less floor space Modern vertical machines are available with Hydraulic drive Electro-mechanical drive Hydraulic drive machines cost less Require plat form or pit for the operator Convenient to pass work from one machine to other Employed in multiple operations Two rams will be provided on some machines Such machines are called duplex head machines DUPLEX HEAD BROACHING MACHINE Machine with two heads Simultaneously two surfaces can be machined Mostly push type machines Commonly employed for surface broaching Rate of production is high CONTINUOUS BROACHING MACHINES used for mass production of small parts they are of two types Rotary continuous broaching machine Horizontal continuous broaching machine In both machines Broach is stationary Work pieces move across broach ROTARY CONTINUOUS BROACHING MACHINES Work pieces are loaded on the table Table rotates continuously During broaching broach is stationary Work pieces are held in fixtures Work pieces come into contact with broach during table rotation Loading and unloading done on the table It is a surface machining operation

 Heavy production rate Chain carries work holding fixtures Work pieces are placed in fixtures Broach is held stationary When chain rotates the work pieces move against stationary broach It is a surface broaching operation Heavy production rate SPECIFICATION OF BROACHING MACHINE Main specification Length of stroke in mm. Force that can be applied to broach in tones i.e., broaching machine with specification 1000-10 means Machine has 1000 mm stroke length and 10 tones broach driving force Other parameters to be specified are Broaching speed Return speed Machine horse power Floor space required H.P of the motor BROACHING OPERATIONS Broaching is applied for various internal and external surfaces round and irregular shaped holes of 6 to 100 mm diameter Flat and contoured surfaces Most operations are completed with one pass of the broach In all broaching operations Work is held in a fixture Tool is held in tool head (pulling or pushing head) Either work or tool move across each other Various broaching operations are as shown in following slides Nomenclature of broach tooth Pitch: linear distance between cutting edge of one tooth and corresponding edge on next tooth Land: top portion of tool ground to provide a slight clearance Back off: it is the clearance angle of broach its value vary from 0.50 to 200 Rake angle: it corresponds to rake angle of lathe tool its value increases as ductility increases ADVANTAGES OF BROACHING rate of production is high Less skilled worker can be employed High accuracy can be obtained High surface finish can be obtained Rough and finish cut both are completed in one pass both internal and external surfaces can be machined Any form that can be reproduced on broach can be machined

 Cutting fluid may be readily applied

Life of broach tool is high

Cutting temperature and tool wear is low Cutting force acts in clamping direction Process can be semi or fully automised LIMITATIONS OF BROACHING High tool cost Economical only for mass production Sharpening is difficult and expensive Not suitable for very large work pieces Surfaces should not have obstructions Cannot remove large amount of stock Very light and delicate jobs cannot be broached

Planer

Planer
Types of planers-description of double housing planer-specifications-principles of operation-drivesquick return mechanism-feed mechanism- work holding devices and special fixtures-types of toolsvarious operation. What is planer? A planer is a type of metalworking machine tool that is analogous to a shaper, but larger, and with the entire workpiece moving beneath the cutter, instead of the cutter moving above a stationary workpiece. 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. Planer

Planing is used for large workpieces too big for shapers Planing machines have largely been replaced by planing mills In planing, large workpieces and their support tables are slowly moved against the tool head.

Shaper:

Shaper
Types of shapes-specifications-standard-plain-universal-principles of operations-drives-quick return mechanism-crank and slotted link-feed mechanism-work holding devices-Special fixture-various operations. Shaper: A shaper is a machine tool used for shaping or surfacing metal and other material. Shapers have been largely superseded by milling machines or grinding machines in modern industrial practice. The basic function of a shaper machine is still sound and tooling for them is minimal and very cheap to reproduce. They can be invaluable for jobbing or repair shops where only one or a few pieces

are required to be produced and the alternative methods are cost or tooling intensive. The mechanically operated machines are simple and robust in construction, making their repair and upkeep easily achievable.

A shaper operates by moving a hardened cutting tool backwards and forwards across the workpiece. On the return stroke of the ram the tool is lifted clear of the workpiece, reducing the cutting action to one direction only. The workpiece mounts on a rigid, box shaped table in front of the machine. The height of the table can be adjusted to suit this workpiece, and the table can traverse sideways underneath the reciprocating tool which is mounted on the ram, the table motion is usually under the control of an automatic feed mechanism which acts on the feedscrew. The ram slides back and forth above the work, at the front end of the ram is a vertical tool-slide that may be adjusted to either side of the vertical plane. This tool-slide holds the clapper box and toolpost from where the tool can be positioned to cut the straight, flat surface on the top of the workpiece. The tool-slide permits feeding the tool downwards to put on a cut it or may be set away from the vertical plane, as required. The ram is adjustable for stroke and, due to the geometry of the linkage, it moves faster on the return (non-cutting) stroke than on the forward, cutting stroke. This action is via a slotted link or whitworth link. Cutting fluid may be employed to improve the finish and prolong the tool's life.

Slotter
Types of slotters-specifications-method of operation-Whitworth quick return mechanism-feed mechanism-work holding devices-types of tools

Work Holding Device

Some work holding devices:

"M" Qwik-Change Face Plate "M" System Vise Fixturing "Tom Thumb" Flexible Cable Arm 6" or 9" "Tom Thumb" Flexible Indicator Holder ?C? Clamps 2-Way Cross Slide Machine Vise 3 Jaw Set-Tru Fine Adjustment Lathe Chucks 3" Pipe Vise 4 Pc. Die Holder Set 4" Cross Slide Vise 52 Piece Clamping Kit 5C Collet Block Set 5C Collets 5C Expanding Collet Kit 5C External Oversize Collet - Steel or Aluminum 5C Spin Index 6" Milling Machine Vise with Swivel Base 90 Holder Accurate Accessories Monorail Indicator Holder Adjustable Trolleys