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SHAPER MACHINE
INTRODUCTION
In a shaper, rotary movement of the drive is converted into reciprocating movement by
the mechanism contained within the column of the machine. The ram holding the tool
gets the reciprocating movement. Thus the shaper mechanism should be so designed that
it can allow the ram holding the tool to move at a comparatively slower speed during the
forward cutting stroke, the cutting speed depending upon the type of material and
machining condition, whereas during the return stroke it can allow the ram to move at a
faster rate to reduce the idle return time. This mechanism is known as quick return
mechanism. The reciprocating movement of the ram and the quick return mechanism of
the machine are usually obtained by any off of the following methods:
1. Crank and slotted link mechanism
2. Whitworth quick return mechanism
3. Hydraulic shaper mechanism
FEED MECHANISM: In a shaper both downfeed and crossfeed movements may be
obtained. Crossfeed movement is used to machine a flat horizontal surface. The rotation
of the bull gear causes the driving disc 8 to rotate in a particular direction. The driving
disc 8 is T-slotted and position of the crank pin 9 attached to the connecting rod may be
altered to give different throw of eccentricity. The other end of the connecting rod is
attached to the rocking any by a § § The rocking arm houses a spring loaded paw which
is straight on one side and bevel on the other side. As the driving disc rotates, the
connecting The amount of feed may be altered by shifted the position of crank pin with
respect to the centre. Greater the throw of eccentricity, more will be the rocking
movement of the arm and the pawl will pass through three or four teeth on the ratchet
wheel at a time imparting greater feed movement.
PLANER MACHINE
The planer like a shaper is a machine tool primarily intended to produce plane and fiat
surfaces by a single point cutting tool.
A planer is very large and massive compared to a shaper and capable of machining heavy
workpieces which cannot be accommodated on a shaper table. The fundamental
difference between a shaper and a planer is that in a planer the work which is supported
on the table reciprocates past the stationary cutting tool and the feed is supplied by the
lateral movement of the tool, whereas in a shaper the tool which is mounted upon the ram
reciprocates and the feed is given by the crosswise movement of the table.
EDGE OR PLATE PLANER: The design of a plate or edge planer is totally unlike that
of an ordinary planer. It is specially intended for squaring and beveling the edges of steel
plates used for different pressure vessels and ship-building works. One end of a long
plate which remains stationary is clamped with the machine frame by a large number of
air operated clamps. § § The cutting tool is attached to a carriage which is supported on
two horizontal ways of the planer on its front end. The operator can stand on a platform
extending from the carriage. The carriage holding the tool reciprocates past the edge of
the plate. The feed and depth of cut is adjusted by the tool holder which can be operated
from the platform.
DIVIDED TABLE PLANER: This type of planer has two tables on the bed which may
be reciprocated separately or together. This type of design saves much of idle time while
setting the work. The setting up of a large number of identical workpieces on the planing
machine table takes quite a long time. It may require as much time for setting up as may
be necessary for machining. To have a continuous production one of the table is used for
setting up the work, while the other reciprocates past the cutting tool finishing the work.
When the work on the second table is finished, it is stopped and finished jobs are
removed. Fresh jobs are now set up on this table while the first table holding the jobs now
reciprocates past the tool. § When a heavy and large job has to be machined, both the
tables are clamped together and are given reciprocating movement under the tool.
PLANER MECHANISMS
The two important mechanisms of a planer are: 1. Table drive mechanism. 2. Feeding
mechanism. The different mechanisms used to drive the table are:
I. Open and cross belt drive. 2. Reversible motor drive. 3. Hydraulic drive.
OPEN AND CROSS BELT DRIVE: The open and cross belt drive of the table is used in
a planer of smaller size where the table width is less than 900 mm
DRILLING MACHINE
INTRODUCTION:-
The drilling machine is one of the most important machine in workshop In a drilling
machine holes may be derived quickly and at a low cost. The hole is generated by the
rotating edge of a cutting tool known as the drill which exerts large force on the work
clamped on the table.
TYPES OF DRILLING MACHINE: - Drilling machines are made in many different
types and sizes, each designed to handle a class of work or specific job to the best
advantage. The different types of drilling machines are
1. Portable drilling machine.
2. Sensitive drilling machine. (a) Bench mounting, 3. Upright drilling machine. (a) Round
column section,
4. Radial drilling machine. (a) Plain (c) Universal
5. Gang drilling machine.
6. Multiple spindle drilling machine.
7. Automatic drilling machine.
8. Deep hole drilling machine. (a) Vertical (b) Flour mounting
GANG DRILLING MACHINE:-When a number of single spindle drilling machine
columns are placed side by side on a common base and have a common worktable, the
machine is known as the gang drilling machine. In a gang drilling machine four to six
spindles may be mounted side by side.
MULTIPLE SPINDLE DRILLING MACHINE:-The function of a multiple spindle
drilling machine is to drill a number of holes in a piece of work simultaneously and to
reproduce the same pattern of holes in a number of identical pieces in a mass production
work. Once the work is loaded at the first machine, the work will move from one
machine to the other where different operations can be performed and the finished work
comes out from the last unit without any manual handling. § This type of machine is
intended purely for production purposes and may be used for milling, honing and similar
operations in addition to drilling and tapping.
DEEP HOLE DRILLING MACHI:-The machine is operated at high speed and low feed.
Sufficient quantity of lubricant is pumped to the cutting points for removal of chips and
cooling the cutting edges of the drill. A long job is usually supported at several points to
prevent any deflection. The work is usually rotated while the drill is fed into the work.
This helps in feeding the drill in a straight path. In some machines both the work and the
drill are rotated for accurate location. § The machine may be horizontal or vertical type.
In some machines step feed is applied. The drill is withdrawn automatically each time
when it penetrates into the work to a depth equal to its diameter. This process permits the
chip to clear out from the work.
FEED MECHANISM
§ § In a drilling machine, the feed is effected by the vertical movement of the drill into
the work. The feed movement of the drill may be controlled by hand or power. The hand
feed may be applied by two methods: I. Quick traverse hand feed 2. Sensitive hand feed
BASE: The base of a radial drilling machine is a large rectangular casting that is finished
on its top to support a column on its one end and to hold the work table at the other end
COLUMN : The column is a cylindrical casting that is mounted vertically at one end of
the base RADIAL ARM : The radial arm that is mounted on the column extends
horizontally over the base. ]DRILL HEAD : The drill head is mounted on the radial arm
and drives the drill spindle. It encloses all the mechanism for driving the drill at multiple
speed and at different feed. SPINDLE DRIVE AND FEED MECHANISM: There are
two common methods of driving the spindle. A constant speed motor is mounted at the
extreme end of the radial arm which balances partially the weight of the overhanging
arm.
DRILL MATERIAL
The materials for the manufacture of twist drills are as follows 1. One piece construction’
: High speed steel or carbon steel. 2. Two piece construction: Cutting portion —High
speed steel. Shank portion — Carbon steel with a minimum tensile strength of 70 kg per
sq mm.
High speed drills are more widely used due to its greater cutting efficiency. Cemented
carbide tipped drills are also used in mass production work.
BORING MACHINES
The boring machine is one of the most versatile machine tools used to bore holes in large
and heavy parts such as engine frames, steam engine cylinders, machine housings, etc.
which are practically impossible to hold and rotate in an engine lathe or a drilling
machine. Boring machines have, therefore, been developed primarily to do this. In
addition to its primary purpose of boring the range of speeds and feeds provided to the
various traversing components allow drilling, milling and facing to be performed with
equal facility. § By the fitting of simple attachments, the use of the machine can be
extended still further to include screw cutting, turning, planetary grinding, or gear cutting.
Saddle and table : The table supports the work and is therefore provided with T-slots for
clamping the work or for holding various devices. The saddle permits the work to be
moved longitudinally on the bed. The table may be moved crosswise on the saddle. These
movements may be slow or rapid and is performed by hand or power. Boring bars: The
boring bar supports the cutter for boring operations on jobs having large bore diameters.
For short holes the bar may be supported on the headstock spindle end only, whereas for
long work the bar is supported on the spindle end and on the column bearing block.
Planer type:
It consists of two vertical columns at the two sides of the table and is mounted on the
base. The table has reciprocating movement for adjustment of the work. § The spindle is
mounted on the crossrail bridging the two vertical columns. In a planer type jig borer,
two co-ordinate movements for hole location are provided by the longitudinal movement
of the table and the cross movement of the spindle along the crossrail.
BROACHING MACHINE
Broaching is a method of removing metal by pushing or pulling a cutting tool called a
broach which cuts in fixed path. The tool may be pulled or pushed through the surfaces to
be finished. Surfaces finished by broaching may be flat or contoured and may be either
internal or external. Broaching is generally limited to the removal of about 6 mm of stock
or less. § The term broaching may have derived from an ancient Roman word braces,
which meant an object having projecting teeth. § The operation itself dates only to the
1850’ s when broaching tools, then called “drifts” were hammered in blacksmith shops
through the work or pushed through with an arbor press.
BROACHES A broach is a multiple-edges cutting tool that has successively higher
cutting edges along the length of the tool.
TYPES OF BROACHES : Broaches may be classified in various ways, according to: 1.
Type of operation: internal or external. 2. Method of operation: push or pull.
3. Type of construction: solid, built-up, inserted tooth, progressive cut, rotor cut, double
jump, or overlapping tooth.’ 4. Function : surface, keyway, round hole, splint, spiral,
burnishing, etc.
BROACH MATERIAL: Most broaches are made from 18-4-1 tungsten chromium
vanadium steel ground after hardening. Carbide broaches are. used extensively in the
broaching of cast iron in the automotive field. They are also used for surface broaches,
for high production and for finishing broaches.
BROACHING METHODS: Broaching, according to the method of operation, may be
classified as follows 1.Pull broaching: The work is held stationary and the broach is
pulled through the work. Broaches are usually long and are held in a special head. Pull
broaching is used mostly for internal. broaching but it can do some surface broaching.
2.Push broaching: The work is held stationary and the broach is pushed through the work.
Hand and hydraulic arbor presses are popular for push broaching, This method is used
mostly for sizing holes and cutting keyways. 3.Surface broaching: § Either the work or
the broaching tool moves across the other. This method has rapidly become as important
means of surface finishing. Fixtures are most important in broaching operations. § They
are used particularly for two reasons first, because of the high pressures used and because
of the manner in which the cutting is done ; second, broaching being essential a mass-
production operation, fixtures speed up the operation and help to keep it accurate.
BROACHING OPERATION § Broaching is applied for machining various internal and
external surfaces, for round or irregular shaped holes from 6 to 100 mm in diameter, for
external flat and contoured surfaces. Certain types of surfaces, for example, splint holes,
are machined at the present time only by broaching due to the exceptional difficulties in
machining such surfaces by other methods. § Most broaching operations are completed in
one pass, but some are arranged for repeated cuts to simplify the design of the broach. §
The teeth of a gear or splint may be broached altogether or one or a few at a time. A
comparatively simple broach can be made to cut one or a few tooth spaces, After one
pass, the gear blank is indexed, and more of its teeth are cut. Successive passes are made
until all the teeth are finished.
ADVANTAGES AND LIMITATIONS OF BROACHING:-
Broaching has been adopted for mass production work because of the following
outstanding features and advantages: 1. Rate of production is very high. With properly
applied broaches, fixtures, and machines, more pieces can be turned per hour by
broaching than by any other means, 2. Little skill is required to perform a broaching
operation. In most cases the operator merely loads and unloads the workpiece. 3. High
accuracy and a high class of surface finish is possible. A tolerance of ± 0.0075 mm and a
surface finish of about 0.8 microns (1 micron =0.001mm) can be easily obtained in
broaching. 4. Both roughing and finishing cuts are completed in one pass of the tool. 5.
The process can be used for either internal or external surface finishing. 6. Any form that
can be reproduced on a broaching can be machined. 7. Cutting fluid may be readily
applied where it is most effective because a broach tends to draw the fluid into the cut.
Certain reasons, however, limit the application of the broaching process. They are: 1.
High tool cost. A broach usually does only one job and is expensive to make and sharpen.
2. Very large workpieces cannot be broached. 3. The surfaces to be broached cannot have
an obstruction. 4. Broaching cannot be used for the removal of a large amount of stock. 5.
Parts to be broached must be capable of being rigidly supported and must be able to
withstand the forces that set up during V Cutting.
GRINDING MACHINES
INTRODUCTION § Grinding is metal cutting operation performed by means of a
rotating abrasive wheel that acts as a tool. This is used to finish workpieces which must
show a high surface quality, accuracy of shape and dimension. § Mostly grinding is the
finishing operation because it removes comparatively little metal, 0.25 to 0.50mm in
most operations and the accuracy in dimensions is in the order of 0.000025 mm. KINDS
OF GRINDING Grinding is done on surfaces of almost all conceivable shapes and
materials of all kinds. Grinding may be classified broadly into two groups I. Rough or
non-precision grinding. 2. Precision grinding.
Rough grinding: § The common forms of rough grinding are snagging and off-hand
grinding where the work is held in the operator’ s hand. The work is pressed hard against
the wheel, or vice -versa. The accuracy and surface finish obtained are of secondary
importance. § Snagging is done where a considerable amount of metal is removed
without regard to the accuracy of the finished surface. Examples of snag grinding are
trimming the surface left by sprues and risers on castings, grinding the parting line left on
castings, removing flash on forgings, the excess metal on welds, cracks, and
imperfections on alloy steel billets.
Precision grinding: This is concerned with producing good surface finish and high degree
of accuracy. The wheel or work both are guided in precise paths. Grinding, in accordance
with the type of surface to be ground, is classified as 1. External cylindrical grinding. 3.
Surface grinding.
The simplest type of grinder is the floor-stand grinder. A floor-stand grinder has a
horizontal spindle with wheels usually at both ends and is mounted on a base or pedestal.
1.There is provision for driving the wheel spindle by belt from motor at the rear, at floor
level. 2. The headstock can be swiveled at an angle in a horizontal plane. 3. The wheel
head and slide can be swivelled and traversed at any angle. The wheelhead can also be
arranged for internal grinding by the addition of an auxiliary wheelhead to revolve small
wheels at high speeds.
CENTRELESSS GRINDERS
Centreless grinding is a method of grinding exterior cylindrical, tapered, and formed
surfaces on workpieces that are not held and rotated on centres. The principal elements of
an external centreless grinder are the grinding wheel, regulating or back up wheel, and
the work rest. Both wheels are rotated in the same direction. The work rest is located
between the wheels. The work is placed upon the work rest, and the latter, together with
the regulating wheel, is fed forward, forcing the work against the grinding wheel. § The
axial movement of the work past the grinding wheel is obtained by tilting the regulating
wheel at a slight angle from horizontal.
Centreless grinding may be done in one of the three ways :
(a) through feed,
(b) infeed and
(c) end feed. Internal grinders of chucking type may be classified as plain and universal
grinders. In a plain internal grinder, the workhead can be swivelled to grind a straight
hole tapers upto 450 included angle. The wheel head is moved into and away from the
bole and can be cross fed into the work. § In a universal grinder, which is basically the
same as a plain internal grinder, the workhead is mounted on a cross-slide as in the wheel
head, and can be swivelled through a 9O0angle
SURFACE GRINDERS
Surface grinding machines are employed to finish plane or flat surfaces. They are also
capable of grinding irregular, curved, convex, and concave surfaces. § Conventional
surface grinders may be divided into two classes One class has reciprocating tables for
work ground along straight lines, while the other covers the machines with rotating work
tables for § The first two are most commonly used for repetitive work by hand operation
or with simple fixtures. The third type is widely used for production operations where
parallel surfaces are ground simultaneously.
TOOL AND CUTTER GRINDERS
Tool and cutter grinders are used mainly to sharpen and recondition multiple tooth
cutters like reamers, milling cutters, drills, taps, hobs and other types of tools used in the
shop.
With various attachments they can also do light surface, cylindrical, and internal grinding
to finish such items as jig, fxture, die and gauge details and sharpen single point tools.
They are classified according to the purpose of grinding, into two groups:
Universal tool and cutter grinders. purpose tool and cutter grinders.
Single -Universal tool and cutter grinders are particularly intended for sharpening of
miscellaneous cutters. Single-purpose grinders are used for grinding tools such as drills,
tool-bits etc in large production plants where large amount of grinding work is necessary
to keep production tools in cutting condition. In addition, tools can be ground uniformly
and with accurate cutting angles proper
Universal tool and cutter grinders The universal tool and cutter grinders made by
different manufacturers vary more or less as to details, but they are similar in their
general arrangement and operate on the same general principle. The grinder has the
following principal parts. Base: The base 4 gives rigidity and stability to the machine. It
is heavy, rugged and box-type. Tapered face straight wheels primarily used for grindiag
thread, gear teeth, etc. Cylinder or wheel ring is used for producing flat surfaces, the
grinding being done with the end face of the wheel. Cup wheel No. 6 is used for grinding
flat surfaces by traversing the work past the end or face of the wheel. Flaring cup wheel
No.11 is used for grinding in tool room. Dish wheel No. 12 is also used for tool room
work. The thinness of the wheel permits it grind the surface at narrow places. Saucer
wheel No. 13 is generally used for sharpening of circular or band saws. The principal
dimensions of a grinding wheel are the outside diameter, bore diameter, and the width.
Segmented wheels are used chiefly on vertical spindle, rotary, and reciprocating-table
surface grinders and way grinders. Grinding wheels of the straight wheel type can be
supplied with a large variety of face : flat, pointed, concave, convex, etc. These faces are
used for grinding special contours and sharpening saws.
MOUNTED WHEELS Mounted wheels are small shaped wheels (50 mm dia and below)
mounted securely and permanently to steel spindle or mandrel by cementing or other
means. Mounted wheels and points are shown Great care should be taken in using
mounted wheels and points.
Pressure between wheel and work small at no time be so heavy that any considerable
springing of the spindle will result. It is particularly important to observe this rule in
connection with small wheels and points where the end of the mandrel entering the wheel
is of reduced diameter.
STANDARD MARKING SYSTEM The Indian standard marking system for grinding
wheels (IS: 551-1954) has been prepared with a view to establishing a uniform system of
marking of grinding wheels to designate their various characteristics, to give a general
indication of the hardness and grit size of any wheel as compared with another. Each
marking shall consist of six symbols, 1. Abrasive type 2. Grade 3. Grain size 4. Structure
5. Bond type 6. Manufacturer’ s record
SELECTION OF GRINDING WHEELS § It is customary for grinding wheel
manufactures to provide, through their published literature, information on the selection
and use of grinding wheels, but it may not always be possible or convenient for users to
take advantage of such consultative service. § The need for ready to use general guide on
grinding wheels hp been keenly felt and the Indian Standard (IS:1249-1958) gives
recommendations on the general considerations which should guide the selection of
grinding wheels for different applications. In selecting a grinding wheel there are four
constant factors and four variables given in table grinding wheel selection factors
1. The material to be ground This influences the selection of (a) abrasive, (b) grain size,
(c) grade, (d) structure, and (e) bond.
As general guide the grit and grade ranges given in Table would be suitable for the class
of work shown against each (a) Aluminum Oxide abrasive is recommended for materials
of high tensile strength and silicon carbide for low tensile strength. (b) Fine grain is used
for hard and brittle materials and coarse grain for soft ductile metals. (c) Hard wheel is
used for soft materials and soft wheel for hard materials. (d) Generally, close spacing is
required for hard and brittle materials and wide for soft and ductile. (e) The class of work
usually dictates the bond to be used. Bond selection, of course, can be safely left to the
manufacturers, if the class of work for which the wheel is required is clearly stated.
However, majority of wheels are manufactured with vitrified bonds.
2. Amount of stock to be removed: This involves accuracy and finish. Coarse grain is
used for fast cutting and fine grain for fine finish; wide spacing for rapid removal and
close for fine finish; resinoid, rubber, and shellac bond for high finish.
3. Area of contact: Area of contact influences the selection of (a) grit size, (b) grade, and
(c) structure number. Fine grain and close grain spacing are useful where the area of
contact involved is small, and coarse grain and spacing are employed where a large area
of contact is concerned.
4. Type of grinding machine: Type of grinding machine determines to an extent the grade
of the wheel. Heavy rigidly constructed machines take softer wheels than the lighter more
flexible types. The combination of speeds and feeds on some precision machines may
affect the grade of wheel desirable for best results. (i) Wheel speed : The wheel speed
influences the selection of grade and bond. The higher the wheel speed with relation to
work speed, the softer the wheel should be. Vitrified bond is usually specified for speeds
upto 2000 s.m.p.m. (or 6~00 s.f.p.m.) and rubber, shellac or resinoid bonds for speed
over 2000 s.m.p.m. (or 6500 s.f.p.m.). (ii) Work speed: The work speed with relation to
the wheel speed determines the hardness of the wheel. The higher the work speed with
relation to the wheel speed, the harder the wheel should be. Variable work speed are
often provided on grinding machines to preserve the proper relative surface speeds
between the work and wheel as the wheel diameter decreases because of wear.
MOUNTING THE GRINDING WHEELS
Great care must taken in mounting the grinding wheels on the spindle because of the high
cutting speeds of the grinding wheel.. The following points are important in connection
with mounting the wheel. I. All wheels should be closely inspected just before mounting
to make sure that they have not been damaged in transit, storage, or otherwise. The wheel
must first be subjected to the ringing test. For this purpose, the grinding wheel is put on
an arbor while it is subjected to slight hammer blows. A clear, ringing, vibrating sound
must be heard. If a grinding wheel contains fine cracks, discordant sound that fail to
vibrate will be emitted. This test is applicable to vitrified and silicate wheels. Shellac,
resinoid or Rubber loaded wheels will not ring distinctly. 2. The abrasive wheels should
have an easy fit on their spindles or locating spigots. They should not be forced on.
BALANCING GRINDING WHEELS
If wheels become out of balance through wear and cannot be balanced by truing or
dressing, they should be removed from the machine and discarded. Wheels should be
tested for balance occasionally and rebalanced if necessary. Wheels that are out of
balance not only produce poor work but may put undue strains on the machine. Small
wheels may be balanced by milling a short recess on the inside of the flanges and filling
with lead. Large wheels should be placed on a balancing stand and balanced by moving
weights around a recessed flange. Now-a-days, grinding wheel mounts are provided with
devices to enable balancing to be done whilst the wheel is running and between grinding
operations.
LAPPING
Lapping is an abrading process that is used to produce geometrically true surfaces,
correct minor surface imperfections, improve dimensional accuracy, or provide a very
close fit between two contact surfaces. Very thin layers of metal (0.005 to 0.01 mm) are
removed in lapping and it is, therefore, evident that lapping is unable to correct
substantial errors in the form and sizes of surfaces.
It is, however, low efficiency process and is used only when specified accuracy and
surface finish cannot 1e obtained by other methods.
Small flat surfaces may be lapped by holding the work against a rotating disc, or the
work may be moved by hand in an irregular path over a stationary faceplate lap. In
equalizing lapping the work and lap mutually improve each others surface as they slide
on each other. § There are three important types of lapping machines. The vertical axis
lapping machine laps flat or round surfaces between two opposed laps on vertical
spindles. The centreless lapping machine is designed for continuous production of round
parts such as piston pins, bearing races and cups, valve tappets and shafts. The centreless
lapping machine operates on the same principle as centreless grinding. The abrasive belt
lapping machine laps bearings and cam surfaces by means of abrasive coated clothes.
HONING
Honing is grinding or a abrading process mostly for finishing round holes by means of
bonded abrasive stones, called hones. Honing is therefore a cutting operation and has
been used to remove as much as 3 mm of stock but -is normally confined to amounts less
than 0.25 mm. § Honing is done on general purpose machines, such as the lathe, drill
press, and portable drills, as an expedient. But more economical results can be obtained
by honing machines for production work. There are two general types of honing
machines Horizontal and vertical. A honing machine rotates and reciprocates the hone
inside holes being finished. The two motions produce round and straight holes that have a
very fine surface finish of random scratches. Vertical honing machines are probably more
common. Horizontal honing machines are often used for guns and large bores.
SUPERFINISHING
Supervising is an operation using bonded abrasive stones in a particular way to produce
an extremely high quality of surface finish in conjunction with an almost complete
absence of defects in the surface layer. § A very thin layer of metal (0.005 to 0.02 mm) is
removed in super finishing. This operation may be applied for external and internal
surfaces of parts made of steel, cast iron and non-ferrous alloys, which have been
previously ground or precision turned. It is most frequently used to obtain very fine
surface finish. In super finishing, a very fine grit (grain size 400 to 600) abrasive stick is
retained in a suitable holder and applied to the surface of the work piece with a light
spring pressure. The stick is given a feeding and oscillating motion, and the work piece is
rotated or reciprocated according to the
requirements of the shape being super finished, In this process, the work rotational speed
is low (2 to 20 in/mm.) the longitudinal feed ranges from 0.1 to 0.15mm per work piece
revolution, the abrasive stick oscillates rapidly in short strokes (2 to 5mm) with a
frequency from 500 to 1,800 strokes per minute and the springs hold the stick against the
work with a force from 2 to 10 kg. A special lubricant, usually a mixture of kerosene and
oil, is used to obtain a high quality of surface finish, § Special general-purpose machine
tools are available for super finishing. Other types of ordinary machines, in particular,
lathes, are sometimes employed for this purpose. Single purpose machine tools for
example, for finishing crankshaft journals, camshafts, etc. are also used. PART-A 1. The
one and only basic machine is________ 2. State any two other basic machines. 3.
Mention the types of other basic machine, which are w 4. What is shaper? 5.List any four
important parts of a shaper. 6. Define one pass of the cutting tool 7. In which stroke, the
speed of the ram is faster? 8. Define cutting ratio of a shaper. 9. List any two types of
quick return mechanism. 10. How the feed and depth of cut is given to the shaper? 11.
State the various types of flat surface produced on a shaper. 12. What are the various
types of shaper according to various conditions? 13. What are the other types of shaper?
14. Mention any four-shaper speafications. 15. Why the apron is fitted away from the
machined surface machining? 16. State the important part to control and divert the flow
of oi4 17. State any two advantages of hydraulic drive?
18. State the type of mechanism followed on a shaper and how it works? 19. What are the
precautions to be carried out before machining anp surfaces? 20. State any two reasons
for making the stroke length greater than work length. 21. List any four types of work
holding devices? 22. What are the various types of tool? 23. How the tool is fitted on the
tool head for machining inclined surfaces? 24.How the dovetail is machined? 25. What
are the various types of recessing that can be made by 1h 26.How the fred and depth of
cut are given to the shaper while machining irregular surfaces? 27.Define feed and depth
of Cu I. 28. Write down the formula for calculating no. of strokes and passes required in a
shaper. 29.Define the metal removal rate. PART-B 1. Describe the principle of operation
of a shaper with a neat sketch. 2. Explain briefly the various parts of a shaper with neat
sketches. 3. Write short notes on a. Universal shaper b. Draw cut shaper 4. Describe the
working of a hydraulic drive quick return mechanism. 5. Explain crank and slotted link
mechanism and how quick return principle is achieved. 6. 1-low the stroke length and
position are adjusted? Explain briefly with a neat sketch. 7. Describe the automatic feed
of the shaper table with a suitable sketch. 8. List all work holding devices and explain any
two in detail. 9. Explain with neat sketches the machining of inclined and irregular
surfaces. 10. Write a short notes on machining shots, grooves and keyways.
11. A shaper is operated at 130 cutting strokes per minute and is used to machine a work
piece of 300mm in length and 122mm in widtlt Use a feed of 0.7mm per stroke and a
depth of cut of 5mm. Calculate the total machining time for machining the component
The forward stroke is completed in 220°. Calculate the percentage of the time when the
tool is not contacting the work piece. 12. Calculate the power required for shaping steel
with a depth of cut of 2.6mm, cutting speed 73 rn/mm and the work length 54 mm. The
feed rate is 0.6mm/rev. Take machining constant k as 79x 10 13. Estimate the shortest
machining time required in a shaper to machine a plate of 220 x 80mm under the
following conditions. Cutting speed = 13.3m/min Feed = 0.67mm/double stroke Ratio of
cutting speed to rapid return 14. The cross-feed on a shaper consists of a lead screw
having 0.25 threads per mm. A ratchet and pawl on the end of the lead screw is driven
from the shaper crank such that the pawl indexes the ratchet by one tooth during each
return stroke of he ram. Ratchet has 23 teeth. (a)Find the cross feed in mm. (b) If a plate
120mm wide has to be machined in 15 minutes. Find the cutting speed in rn/s. The ratio
of return to cutting speed is 2.5:1 and the length of the stroke is 130mm.