MANUFACTURING PROCESS-II UNIT-3 SHAPER MACHINES

MANUFACTURING PROCESS-II UNIT-3 SHAPER MACHINES

1. UNIT 3 Shaper - Types of operations. Drilling, reaming, boring, Tapping. Milling operations-types of milling cutter. Gear cutting – forming and generation principle and construction of gear milling, hobbing and gear shaping processes –finishing of gears.

2. SHAPER Shaper, planner and slotter are used for machining flat surface which may be horizontal, vertical or inclined surfaces. Single point cutting tools are mainly used in these machines. Drilling, grinding, boring, milling and broaching machines are not used for machining flat surfaces but they are performing specific operations by using a multi point cutting tool

3. PRINCIPLE OF OPERATION The shaper having a reciprocating type of machine tool with single point cutting tool is used to produce flat surfaces. It has the three important parts such as Table Tool head Ram

4. MACHINING THE VARIOUS TYPE OF FLAT SURFACES The table is moved cross wise direction to machine the horizontal surfaces. The tool head is moved perpendicular to the table in downward direction to machine the vertical surfaces. The tool head is fed at an angle to produce inclined surfaces.

5. CLASSIFICATION OF SHAPER According to the type of driving mechanism Crank drive type Whit worth driving mechanism Hydraulic drive type According to the position of ram Horizontal shaper Vertical shaper Travelling head shaper According to the table design Plain shaper Universal shaper According to the type of cutting stroke Push out type Draw cut type

6. PRINCIPLE PARTS OF A SHAPER The different parts of a shaper are listed Base Column Cross rail Saddle Table Ram Tool head

7. TOOL HEAD

8. SHAPER SPECIFICATION Maximum length of stroke Maximum crosswise movement of the table Maximum vertical adjustment of the table Type of driving mechanism Power of the motor Available speed and feed Type of shaper-plain or universal Floor space required Total weight of the shaper Ratio of cutting stroke time and return stroke time

9. TYPE OF QUICK RETURN MECHANISM The following are three types of quick return mechanism Hydraulic drive Crank and slotted link mechanism Whit worth quick return mechanism

10. Hydraulic drive

11. Crank and slotted link mechanism

12. Quick return principle

13. Whit worth quick return mechanism

14. SHAPER OPERATIONS Machining horizontal surface Machining vertical surface Machining angular surface Machining slots, grooves and keyways Machining irregular surfaces

15. Machining horizontal surface

16. Machining vertical surface

17. Machining angular surface

18. Machining slots, grooves and keyways

19. Machining irregular surfaces

20. DRILLING Drilling is the process of producing hole on the work piece by using a rotating cutter called drill. The machine on which the drilling is carried out is called drilling machine. Drilling machine can also used for boring, counter boring, counter sinking, reaming, tapping and spot facing operations.

21. CLASSIFICATION OF DRILLING MACHINE Portable drilling machine Sensitive drilling machine Bench type Floor type Upright drilling machine Round column type or pillar type Box column type or square section type Radial drilling machine Plain type Semi-universal type Universal type Gang drilling machine Multiple spindle drilling machine Automatic drilling machine Deep hole drilling machine

22. PORTABLE DRILLING MACHINE

23. SENSITIVE DRILLING MACHINE

24. UPRIGHT DRILLING MACHINE

25. RADIAL DRILLING MACHINE

26. PLAIN TYPE The following adjustments are available in this type Vertical movement of the radial arm with respect to the column Circular movement of the radial arm about the column Horizontal movement of the tool along the arm ways

27. SEMI UNIVERSAL TYPE In addition to the above three movements as in the case of plain type, the fourth movement of the tool post can be swung about a horizontal axis perpendicular to the arm. This arrangement permits for drilling a hole inclined at any angle to the horizontal plane

28. UNIVERSAL TYPE In addition to the above fourth movement as in the case of semi universal type, the fifth movement of the radial arm is rotated on a horizontal axis. All these movements enable the universal drilling machine to drill on a job at any angle in either horizontal plane or vertical plane or in both the planes.

29. MULTIPLE SPINDLE DRILLING MACHINE This machine is more suitable for mass production. In this machine, several holes of different sizes can simultaneously be drilled. It has several spindles. They are driven by a single motor by using set of gears . All spindles holding the drills are fed into the work at the same time. The feed is given either by raising the table or lowering the spindle head.

30. GANG DRILLING MACHINE When a number of single spindles with essential speed and feed are mounted side by side on one base and have a common worktable known as gang drilling machine

31. AUTOMATIC DRILLING MACHINE A series of drilling machines are arranged to perform more than one operation at a time in sequence of successive work stations is called automatic drilling machine.

32. DEEP HOLE DRILLING MACHINE Deep hole drilling machines are used when the drill hole depth exceeds the normal drill hole depth.

33. SPECIFICATION OF DRILLING MACHINE Maximum size of the drill in mm that the machine can be operated Table size of maximum dimensions of a job can mount on a table in square metre. Maximum spindle travel in mm The number of spindle speed and range of spindle speeds are in rpm Power input of the machine is in HP Floor space required Net weight of the machine

34. DRILLING OPERATIONS Drilling Reaming Boring Counter boring Counter sinking Spot facing Tapping Trepanning Undercutting Grinding Lapping honing

35. MOUNTING THE DRILL TOOL Both taper shank and straight shank drills can be mounted on the drilling machine spindle in a number of ways. Fitting directly in the spindle By using a sleeve By using a socket By means of chucks

36. BORING Boring is the process of enlarging and locating previously drilled holes with a single point cutting tool.

37. TYPE OF BORING MACHINE Horizontal boring machine Table type Floor type Planer type Multiple head type Vertical boring machine Precision boring machine Jig boring machine

38. Horizontal boring machine

39. Floor type

40. Planer type

41. Multiple head type

42. Vertical boring machine

43. OPERATIONS IN HORIZONTAL BORING MACHINE Boring Face milling Drilling Reaming

44. OPERATIONS IN VERTICAL BORING MACHINE Cylindrical turning Taper turning Boring Turning plain surface Necking

45. JIG BORING MACHINE A jig boring machine is a precision boring machine used for boring accurate holes at centre to centre distances. There are mainly two types of jig boring machines Single vertical column type Planer type

46. MILLING Milling is the process of removing metal by feeding the work past against a rotating multipoint cutter. The metal is removed in the form of small chips .

47. SPECIFICATION OF MILLING MACHINE The table length and width Maximum longitudinal cross and vertical travel of the table Number of spindle speeds and feeds Power of driving motor Floor space required Type of milling machine

48. CLASSIFICATION OF MILLING MACHINE Column and knee types Plain milling machine vertical milling machine Universal milling machine Ram type milling machine omniversal milling machine Bed type milling machine Simplex milling machine Duplex milling machine Triplex milling machine Plano-type milling machine Special purpose milling machine Rotary table milling machine Drum milling machine Profile milling machine

49. WORK HOLDING DEVICES The following work holding devices are used for clamping the work in the milling machine. Swivel vice Universal vice Indexing head

50. TOOL HOLDING DEVICES The following tool holding devices are used in milling machines. Arbors Adaptors Collets

51. MILLING CUTTERS Classification of cutters According to the shape of the tooth Milled tooth cutters Form relieved cutters

52. According to the type of operation Plain milling cutter Side milling cutters End milling cutters Angle milling cutters T slot milling cutter Slitting saws Form milling cutter Fly cutters

53. MILLING OPERATIONS Plain or slab milling Face milling Angular milling Straddle milling Gang milling Form milling End milling T slot milling Gear cutting

54. DIVIDING HEADS These are the following types of dividing heads Plain or simple dividing head Universal dividing head Optical dividing head

55. INDEXING METHODS Direct or rapid indexing Plain or simple indexing Differential indexing Compound indexing Angular indexing

56. GEAR CUTTING Gear cutting by single point form tool Gear cutting by shear speed shaping process Gear milling using a formed end mill Gear broaching Template method

57. Gear cutting by single point form tool

58. Gear cutting by shear speed shaping process

59. Gear milling using a formed end mill

60. Gear broaching

61. Template method

62. GEAR GENERATION PRINCIPLE AND CONSTRUCTION OF GEAR MILLING The common gear generation processes are given below Gear shaping process Gear planning process Gear hobbing process

63. GEAR SHAPING PROCESS

64. APPLICATIONS Gear shaping is used for generating both internal and external spur gears. Helical gears can also be generated using special attachments.

65. GEAR PLANNING PROCESS

66. GEAR HOBBING PROCESS

67. FINISHING OF GEARS Generally the gear teeth are produced by any one of the generating processes, but the gear does not be more accurate with good quality surface. The rough surface gear teeth occur due to vibrations causing noise, excessive wear, play and backlash between meshing pair of gears. Therefore, the gear finishing is carried at last in gear manufacturing.

68. GEAR SHAVING

69. ROLL FINISHING OF GEAR TOOTH

70. GEAR BURNISHING

71. GEAR LAPPING

72. GEAR HONING