SHAPING AND PLANING

Shaping and planing the simplest of all machine operations

Straight line cutting motion with single-point cutting tool creates smooth flat surfaces.
Mainly plain surfaces are machined

GROOVES DOVE TAILS

T.SLOTS
FLATS & ANGLES

Shaping and planing operations are not production effective

They are used mainly in tool and die work
SHAPERS - The machine tool
reciprocating for single point cutting tool a cycle
feed across the line of reciprocating of the tool, between
strokes to produce a flat horizontal surface
 HORIZONTAL TYPE SHAPERS
BASE supports a HORIZONTAL RAM that will
COLUMN carry the tool
A QUICK RETURN MECHANISM
The tool is held in RAM in a clapper box
Tool holder the tool firm on the cutting route
The return stroke releases the tool so as not to dig into the
work. ( a swivel mounting)

QUICK RETURN MECHANISM

Crank and shaft are oscillating type
Crank length can be varied by a screw mechanism the stroke is changed
W W is width of the work piece
Cutting time CT
N s fc
Ns is the bull wheel rpm
Fc is the feed rate per stroke
 2 L Ns
Cutting speed CS L is stroke length, Rs is the stroke ratio
Rs
cutting _ stroke _ angle
Rs
360o
L W t t is the chip thickness
Material removing rate MRR
CT

SHAPERS: Horizontal Push cut, Pull cut or draw cut shapers

Vertical Regular (slotters), keyseaters
Special
Disadvantages - cutting speed is not constant
- force of cutting varies with the position of the crank
Advantages - return of the tool faster
- tool hits the work at lower speed
Hydraulic Shaper - Ram driven by hydraulic cylinder
- cutting speed and the force on the ram are constant
- return speed
- cutting speed
VERTICAL SHAPER
- Used mainly for machining of circular and internal surfaces
- The ram reciprocates vertically ; the table has a rotary movement angular
feed, circular surfaces can be processed.

WORK SET-UP IN SHAPERS

- Heavy vices are used; can be rotated and clamped about vertical axis ( and a
horizontal axis sometimes).
- Work-piece must be clamped solidly against the bottom of the vice.
- At the beginning of the stroke a dynamic force trying to dislodge the work-
piece
 The tool can be also fed across the work piece (planing)

tool cuts only in one direction during one stroke.

a slow process with no reverse cutting action
it is difficult to generate curvilinear surfaces by shaping
it is still used despite all these disadvantages ( is very cheap)
Low qualification of the machinist
low cost tools
 PLANING on planers
The work-piece is moved in a straight line against a single edge tool
adopted to much larger work-pieces than the shaper also suitable to machine multiple small
parts held in line or in matrix on the table
Less in use there are more effective milling processes
Some of the places leave the tool heads arranged so that cut can be carried in both directions.
For multiple pieces multiple tools

Drivers for Planers

Gear drive
Screw drive uniform cutting
Belt drive smaller inertia forces
Crank drive uniform cutting forces
Variable speed motor drive less noised in operation
Hydraulic devices less power consumption

Open side planers for wide work-pieces

Double Housing Planers

BEDS
- are providing parallel motion of table in machine tools
- Planners which have very long table need accuracy in moving the work-piece
- material stabilized cast iron
- narrow tables
- For wider table two V ees and a support ( for temperature compensation)

PIT TYPE PLANER

-Workpiece is fixed very large in size the tool is moved over the workpiece
-Tow Ramtype heads are mounted on a cross rail
-Each is furnished with double clapper box for two way planning.
-The reversing housings, which support the cross rail slide on ways
Feeds at the both ends of the planing stroke or at one end only
Plate Planer or Edge Planer
- For machining the edges of heavy steel plates.

- Carriage with the cutting tool as moved back and forth along the edge.
- Most edge planers use milling cutters for greater speed and accuracy

TOOLS - heavier in construction they face impact

- tool holders with removable lid are more used than forged tools
- the tip of the tool is backed to avoid digging into metal and to reduce chatter
Issues: blocking of tool.
 DRILLING AND REAMING

Drilling : Operations that creates internal cylindrical surfaces

DRILLING
HOLES - blind hole

- through hole
DRILLING AND REAMING
 Introduction
Drilling about 25 % of all
Looks simple but complex (two cutting edges or
lips)
Flexible tool and the cutting edges at the end
Cutting takes place inside the workpiece chip
removal
Additional friction to that of chip formation
additional heat
Counterflow of the chips
lubrication and cooling difficulties

At the tool tip V=0

high difficulties of engagement (starting the hole)
Twist drill
250 M pieces/year!!!
Introduction 2

Leading edge of the land (terminating in

the point) forms the cutting edge
COUNTERBORING - to seat bold heads or sockets

COUNTERSINK

SPOT FACING
BORING - enlarging an already existent hole
- better tolerance control
- deeper holes
- surface finish

REAMING
- enlarges to proper size
- smooth finish
- finishing of the hole surface
DRILLING
Problems FLEXIBILITY AND LENGTH OF THE DRILL
DIFFICULT CHIPS RELEASE
Chips counter flow difficult COOLING & LUBRICATION
at the tip V=0 high difficulties of engagement
 TOOLS- TWIST DRILLS
Two flutes two chips
Two cutting edges
Cylinder or tapered shank
Why Land?
Cone angle affects the chip flow
High cone angles, 118-135o ductile
Small cone angles, 90-118o brittle

What to know
To draw the drill
Names of the basic parts of the drill
Helix (Rake)- angle 24o cannot be changed
Point angle (118o) can be different
 The cone-shaped point: cutting edges + various
clearance angles
Cone angle direction of the chip flow into the flute
118 cone angle mild steels, general purpose
drilling
Cone angles 90-118 brittle materials (gray cast
iron, magnesium alloys)
Cone angles 118-135 more ductile materials
(aluminum alloys)
Cone angles < 90 drilling plastics
Drills can be ground to produce various cone angles
Drilling

v DN , m / min, Din m
MRR (D 2 / 4) f r N , m3 / min
 DRILLING OPERATION
Is efficient to remove metal in thick chips than to increase the RPM
Feed recommended fa = 0.005 0.01 in/rev
0.1 0.2 mm/rev
Cutting liquid helps in chip removal
For chip evacuation periodic removal of drill recommended
Drilling horizontally more advantageous for deep hole drilling

DRILLING TIME ESTIMATION (F = 0.1/0.2 mm/rev)

(v 30m/min)

L A d L2
CT
fr RPM Vol
4
MRR Volume / CT
Torque increases with feed and dia.
Thrust influenced by chisel and web end design
Fundamentals 2
The chip depends on the point angle
Thick chips less energy per unit volume than thin chips
Drill Point : -chisel edge at the end of the web that connects the two cutting edges
-This edge DOES NOT CUT EFFECTIVELY
-large negative rake angle
-high axial forces and excessive heat at the point speed is ~O here
-buckling static instability
FAILURES -
Tendency - to try to engage a cutting edge when a drill engages in
metal
SOLUTIONS
1. Spiral point drill - - Spiral edge much better provides cutting action
- Difficult to grind it?
2. Spilt point drill - - has a spilt point and thinned web
- used to drill hard materials
- it has secondary cutting edges
3. Drills with chip breakers - to increase the efficiency of the drilling process.
DRILL SIZES
Three size series:
Millimeters series: 0.01 0.5 mm, increments starting from .015 mm

Numerical series: No. 80 to No. 1 (0.0135 to 0.228 )

Fractional series: 1/64 to 4 + increments (LARGE)

TiN coating of drill increases the life by 200-1000%

Angle Length Holes
Unequal Unequal Oversize
High speed, long flute tool support centering, tool change
THIS CHISEL HAS THE TEDENCY TO WALK AWAY

- a center drill is used prior to a regular drill

- drill combined with a countersink
OLD NEW
 DEEP HOLE DRILLS or GUN DRILLS
Very long holes compared to diameter!
Eg. Gun barrel
What could be the problems, if long drill is used?

Removal of chip
Cooling of the tool, Coolant can not reach
Tool drifting and bending
Increase of side friction and heating
COOLING, LUBRICATION, CHIP EVACUATION

SOLUTIONS
Different cutting mechanism
Include passages through which the coolant can be delivered to the cutting edge
Enlarged flute section to evacuate the chips
Straight Flute
 Deep hole drilling machines
Special machines for rifle barrels, connecting rods for engines, etc.
REQUIREMENTS: * high cutting speed * small feeds
* intensive reverse flow of cooling liquid to ease chip removal
* adequate support for the long drill
Special horizontal machines: the piece is rotating One single flute drill is used
- high pressure oil is brought through hole.
LARGE HOLE DRILLS
1. Saw cutting
or 2. Two single point tools (fly-cutter) pilot at the
center
Tendency to walk away is eliminated
Double margin drills - made to better lead the drill ?
Step drills - combinations of drills different diameters,
difficult to sharpen
 Spade drills: for making holes with 1 in or larger
Low speeds and high feed
Deep holes in solid or stacked materials (over an existing hole)
Drilling end mounted on a long supporting bar (ordinary steel)
Drill point can be ground with a minimum chisel edge
No flutes more rigid body (maybe a central hole for cooling
and chip removal)
TiN coated blades
 Carbide-tipped drills
Drills with indexable inserts (w/one or two-piece inserts)
Four times faster than a spade drill shallow holes
high speed/low feed roughing tools more closer to boring
process
Requirements: extremely rigid machine tool, enough horsepower,
cutting fluids
Effect of L/D ratio on tool Selection
 JIGS AND FIXTURES

JIGS: are used in production like drilling, tapping and reaming operations
HELP DRILLING THE PART (QUICK LOADING AND UNLOADING) MUST GUIDE
CUTTING TOOL
Advantages - the operations can be performed by unskilled operators
- bushing to pilot (guide) the drill
CLEARANCE - under drill clearance for chips escaping
- cleaning of the jig from chips
BUILT OF STANDARD PARTS to reduce the COST

FIXTURES - Work holding and work supporting devices

- THEY DO NOT GUIDE THE TOOL
- Jigs perform the junction of a fixture (not vice - versa)
Machine Tools for Drilling
 DRILLING MACHINES

Early drills : 3rd century BC - 19th Century

Portable drills for field operations up to 3/8 in dia

Bench type drilling machine
Hand moved to provide feed. (Rack and
pinion is operated by hand)
Spindle driven by step cone pulley
shaft, 6-8 speeds.
Sensitive drilling machines
similar to the bench type drilling machines
- high speeds 30,000 1,000,000 RPM
- high skilled operators
Upright drilling machines Production machines
- stay on the floor
- single spindle and power feeding mechanism
- speeds 60 3500 RPM
- feed 4 - 12 steps 0.1/0.6 mm/rev
- feed clutch - disengages automatically at the preset depth of drilling
- Coolant supply system and a collecting system.
- Vertical movement of the table

Gang drilling machines

- several drilling spindles mounted on a
single table
- for production when many operations are
required
- holes of several sizes
- boring, counterboring, reaming etc
mobile jigs one operator
Radial Drilling Machines:
- large work-pieces several holes are drilled
- vertical arm that carries a drilling head
- the arm can be swung around to any position over the work.
- the drilling head radial adjustment along the arm
PLAIN MACHINES - vertical holes
SEMI-UNIVERSAL MACHINES head swiveled on the arm to drill holes at various
angles
 Multi-spindle drilling machines
-Can drill several holes simultaneously
-Production machines with high accuracy for cylinder blocks
-Guiding plates are used to guide the drills accurately
Design: a central gear + an assembly of gear boxes and universal joints the spindles can be
adjusted over a large area (each spindle can bore its own RPM)
 UNIVERSAL MACHINES additional swiveling adjustment for the arm
and can drill holes at any angle.
Sizes 3 20ft available
Speed 20 1600 RPM
Feeds 0.075 3 mm/rev

Turret type drilling machines

Substitutes the gang drill press when there is space restriction.
Used when series of operations are required.
A turret feeds the spindle with the required tool.
Counterboring, Countersinking & Spot Facing
 REAMING
-To finish the existing hole - IMPROVEMENT OF SURFACE QUALITY
- geometry many teeth

SURPLUS OF MATERIAL 0.005 0.030 in

0.15 0.75 mm
If surplus is not enough the cutting hole Reamer has to float when the hole is trimmed.
Reamer cannot improve the position of the hole
Reaming
 TYPE OF REAMERS
HAND REAMERS - straight flutes
- shank ended with a square tang for handle
- different starting taper available
CHUCKING REAMERS - for machine use
Straight flute, Rose reamer soft materials
Helical flute hard materials

Taper reamer-for finishing hole

to produce exact taper (Morse
taper)

EXPANSION REAMERS - can be adjusted in

size (few thous) to fit the hole size after regrinding

SHELL REAMERS
- > dia
- mounted on a tapered holder
- is saving expensive tool material

ADJUSTABLE REAMERS adjustable blades

can be adjusted in size (few thous) to fit the
hole size after regrinding
 Types of Drills 9

Toolholders for drills

Toolholders for drills 2

Workholding for Drilling:

vise or specially designed
workholders (jigs)
Chapter 29
for too large workpieces
clamping directly on to
the machine tool table
 Machine Tools for Drilling
Rotation + feed drilling can be done on a
variety of machine tools lathes, vertical
milling machines, boring machines and
machining centers
Power (in the form of torque) + thrust
Rigidity is essential machine tool
dynamics chatter & form errors
 Transfer Type Production drilling machines
- automated machines on a synchronized line
- the work piece is loaded at the front work station
is transferred and completed.

Types
A. Indexing Table Type
B. Transfer Type
C. Manipulators (robots)