Machining (2) Part Two

Notes On
“Machining (2) Course 231/64”

(Part Two: Shapers, Planers & Processes)
Prepared By:
Dr. Samy Oraby
(Associate Professor)
Feb 2009
Department of Mechanical Production Technology

Web: www.mpt-cts.com Email: se.oraby@paaet.edu.kw
Part One: Metal Cutting Principles
1. Introduction.
2. Shapers:
i. Classification of Shapers.
3. Planers.
4. Differences between Planers and Shapers.
5. Quick-Return Techniques.
i. Straight Gears and Rack.
ii. Hydraulic Systems.
6. Questions and Problems.
Dept. Mech. Prod. Tech.,
Machining 2 Course [231/64] –
Dr. Samy Oraby
2/28/2009 www.mpt-cts.com 2
1. INTRODUCTION
Metals are planed by single point tools similar in shape to lathe tools. A similarity also
exists in chip formation in the two processes. At the same time, planing differs from
turning in that planing is an intermittent process and chips are usually removed only during
the straight forward movement of the tool or work.
The conditions under which planing tools work are less favorable than in turning,
(even though the tool has an opportunity to cool on the idle stroke when no cutting takes
place) because a planing tool operates with impacts.
Work are planed on planers and shapers. In the first case, the primary cutting motion is
obtained by the reciprocating movement of the work while, in the second case by the
movement of the tool. On a planer, the tool is fed across the work while on a shaper the
work is fed crosswise in reference to tool travel. Feed in planing is intermittent; the tool or
work is fed at the end of each work stroke.
Each work stroke, during which the tool removes chips, is followed by an idle or
return stroke whose speed is 2 to 3 times greater than the work stroke speed.

Dr. Samy Oraby
Dr. Samy Oraby
2. SHAPERS
A shaper is a machine with a reciprocating tool that takes a straight line cut. By
successive movement of the work across the path of this tool, a plane surface is
generated. Power is applied to the machine by motor, either through gears or belt or by
the employment of a hydraulic system. As shown in Fig. 1, a horizontal shaper
consisting of a base and a frame that support a horizontal ram. The ram that carries the
tool is given a reciprocating motion equal to the length of the stroke desired. The
quick-return mechanism driving the ram is designed so that the return stroke of the
shaper is faster than the cutting stroke. A claper box toolholder attached to the ram
pivots at the upper end.
The shaper can be driven by a mechanical quick-return mechanism, Fig. 2. It consists

of a rotating crank driven at a uniform speed connected to an oscillating arm by a
sliding block that works in the center of the rather massive oscillating arm. The crank
is contained in the large gear and can be varied by a screw mechanism. The stroke
length is varied by changing the length of the crank. The ratio of return to cutting
speed is about 3:2.

Dr. Samy Oraby
Dr. Samy Oraby
Cutting Speed and Machining Time in Horizontal Shapers
Cutting speed on horizontal shapers is defined as the average

speed of the tool during the cutting stroke and depends primarily
on the number of ram strokes per minutes (N) and the length of
the stroke (L), Fig. 3. The average cutting speed may be
determined by the following formula:
2LN
Average Cutting Speed (V a) =
C
where;
N = strokes per minutes
L = stroke length
cutting time 3 Vc 2
C = cutting time ratio = = (when R= = )
total time 5 Vr 3
Therefore; the average cutting speed is:
10 L N
V a=
3
Dr. Samy Oraby
Dr. Samy Oraby
The number of strokes per minute for a desired cutting speed is then:
3 Va
N=
10 L
To determine the number of strokes required to complete a job;
Width of the work b

S= =
feed per stroke f

Dr. Samy Oraby
The total machining time is then:
1
Total Time (T) = Time per stroke × Number of strokes = ×S
N
A general expression, therefore to determine the cutting time

knowing the desired speed and the length of stroke is:
10 . b . L
T otal T ime (T ) =
3 . f . Va

Dr. Samy Oraby
Example (1)
Determine the cutting time to shaper machine a workpiece of

dimensions 300 × 100 × 60 mm if the cutting speed is 30 m/min
and the feed per stroke is 2 mm.
Solution:
10 . b . L
Machining Time (T) =
3 . f . Va
10 . 100 . 300
= = 1.67 min.
3 . 2 . 30 . 1000

Dr. Samy Oraby
3. PLANERS
Planers may be classified in a number of ways, but according to
general construction there are three types:
Double-Housing Planers, Fig. 4.

This planer consists of a long heavy base on which the table
reciprocates. The upright housing near the center on the sides of the
base supports the crossrail on which the tools are fed across the
work.
Open-side planers
This planer has the housing on one side only. The open side permits
machining the wide workpiece.
Pit-Type planers
A pit-Type planer is massive in construction and differs from an
ordinary planer in that the bed is stationary and the tool is moved
over the work. Dept. Mech. Prod. Tech.,
Dr. Samy Oraby
Fig. 4 Double-Sided Planer
Dr. Samy Oraby
4. Differences between Planers and Shapers
Although the planer and shaper are able to machine flat surfaces,
there is not much overlapping in their fields of usefulness. They
differ widely in construction and in the method of operation. When
two machines are compared the following differences may be
seen:
1. The planer is especially adapted to large work; the shaper can
do only small work.
2. On the planer the work is moved against a stingray tool; on the
shaper the tool moves across the work which is stationary.
3. On the planer the tool is fed into the work; on the shaper the
work is usually fed across the tool.
4. The drive on the planer table is either by gears or by hydraulic
means. The shaper ram can also be driven using a quick-return
mechanism.
5. Most planers differ from shapers in that they approach more
constant-velocity cutting Dept.
speeds.
Mech. Prod. Tech.,
Dr. Samy Oraby
4. Quick-Return TECHNIQUES
4.1 Using Straight Gears and Rack

As shown in Fig. 5, the motion is primarily supplied by the motor
to the loose pulley (b). This motion can be transferred either to the
pulley (c) or the pulley (a) using a special mechanical switch designed
according to the length of the machining stroke.
To obtain the cutting stroke, motion is transferred to pulley (a)
which it is moving on the shaft (c1) freely. Then motion is transferred
to gear (G2) across gear (G1) which is rigidly connected to pulley (a).
Since gear (G2) is bolted to axis (c2), motion is transferred to gear
(G6) and, then, to the machine table through the rack (R).
To obtain motion for the return stroke, the motion is shifted from
pulley (b) to pulley (c) which is bolted to the axis (c1). As axis (c1)
rotates, motion is transferred from gear (G3) to gear (G5) through an
intermediate gear (G1). The motion then is transferred to gear (G6)
and then to the machine table.
The ratio (R) may be determined as the inverse ratio between the
teeth of gears (G2) and Dept.
(G5).
Mech. Prod. Tech.,
Dr. Samy Oraby
Fig. 5 Rapid Return Speed using
Straight Gears and Rack

Dr. Samy Oraby
Example (2)
Determine the cutting speed in a planer working using rack and

gears combination if motor speed is 1000 rpm and a reduction
ratio of 4. Assume suitable number of gear teeth.
Solution
Speed on axis (c1) = 1000/4 = 250 rpm.
Assume that:
Z for G1 = 30 teeth Z for G2 = 68 teeth
D for G6 = 100 mm.
Cutting Speed (Vc) =π × 100 × (1000/4) (30/68) = 34.65 m/min.
Return Speed (Vr)= π × 100 ×(1000/4)(30/20)(20/30)=78.54
m/min.
R = Vc / Vr = 0.44.
Dr. Samy Oraby
4.2 Hydraulic System
As shown in Fig. 6, this technique operates by pumping hydraulic oil from

reservoir (K) through the pump (P) to a cylinder (C) from two opposite
sides (C1) or, (C2). The machine table is connected to the rod of the
cylinder (R).
To obtain the cutting stroke, the valve (V1) is opened while the other
valve (V2) is closed as described by the dotted position of the lower
piston. The pumped oil is fed to the cylinder through its right valve (V1).
This pushes the piston (S) causing the cutting action in the direction
described by the figure. This motion continues until socket (d1) hits the
lever (L) at the right position making it to rotate around its center (O).
This pushes the piston rod (r) to the new position described in the figure
by the continuos line. This allows the oil to be pumped through the valve
(V2) through the other end (C2) causing the return stroke to start.
This continues until the lever (L) hits the left socket (d2) opening the right
valve (V1) and closing the left one allowing another cutting stroke.
The rapid return speed is obtained since there is a reduction in the
cylinder area due to the existing of the
Dept. Mech. Prod.piston
Tech., rod.
Dr. Samy Oraby
Fig. 6 Hydraulic Rapid Return
Speed Technique

Dr. Samy Oraby
Example (3)
Determine the speed ratio (q) in a planing operation using a hydraulic system.
The oil pressure is 1.1 kp/mm2 and flow of 0.1 m3/min. The piston diameter is
50 mm with a rod of a 30 mm diameter.
Solution
Flow (Q) = Flow Speed × Area
Cutting Speed (VC) = 0.1/[(π/4)(50/1000)2]= 50.93 m/min.
Return Speed (Vr) = 0.1/[(π/4)((50/1000)2)-(30/1000)2)]=79.58 m/min.
Speed Ratio (q) = (Vr) / (Vc) = 1.56

Dr. Samy Oraby
5 QUESTIONS AND PROBLEMS
1. In shaping process it is required to remove a 4 mm thickness from a 200
× 80 × 50 mm steel workpiece using average cutting speed of 60 m/min
and 0.1 mm feed and 2mm depth of cut. Calculate:
i) Number of strokes per minutes (N); ii) Number of strokes to
finish the job (S); iii) Time per stroke; and iv) Total time.
2. It is required to remove a 10 mm from a 300 × 110 × 40 mm steel
workpiece. Maximum depth of cut in one pass is 4 mm. Range of shaper
strokes/minutes is between 100 and 500, and range of machine traverse
feed is between 0.1 and 2.0 mm. Calculate the range of machining time.
3. Explain by a sketch the different parts of double sided planer?
4. What are the main differences between planers and shapers?
5. In a planer with a hydraulic driving system the oil pressure was 2.2
kp/mm2 with a flow rate of 0.15 m3/min. The piston and rod diameters
are 80 and 30 mm respectively. i) Draw a sketch indicating the case.
ii) Determine the speed ratio (q) and the system power.
6. In a planer with rack and gears driving system the motor rotates at 2000
rpm. Motion is transferred with (1:5) ratio.
i) Suggest a suitable gears size of the system and draw a sketch indicating
the main elements.Dept. Mech.
ii) Determine the speed ratio (q).
Prod. Tech.,
Dr. Samy Oraby
End of Part (Two)
BREAK

Dr. Samy Oraby

Machining (2) Part Two

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Notes On

“Machining (2) Course 231/64”

Department of Mechanical Production Technology

Dept. Mech. Prod. Tech.,

The shaper can be driven by a mechanical quick-return mechanism, Fig. 2. It consists

Dept. Mech. Prod. Tech.,

Cutting speed on horizontal shapers is defined as the average

To determine the number of strokes required to complete a job;

Width of the work b

Dept. Mech. Prod. Tech.,

A general expression, therefore to determine the cutting time

Dept. Mech. Prod. Tech.,

Determine the cutting time to shaper machine a workpiece of

Dept. Mech. Prod. Tech.,

Double-Housing Planers, Fig. 4.

4.1 Using Straight Gears and Rack

Dept. Mech. Prod. Tech.,

Determine the cutting speed in a planer working using rack and

As shown in Fig. 6, this technique operates by pumping hydraulic oil from

Dept. Mech. Prod. Tech.,

Dept. Mech. Prod. Tech.,

Dept. Mech. Prod. Tech.,

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