UNIT II - SPECIAL MACHINES AND GEAR MANUFACTURING PROCESSES

2. RECIPROCATING MACHINES

Reciprocating Machines classification

a) SHAPER b) PLANER c) SLOTTER

2.1 SHAPER - PRINCIPLE OF OPERATION

The shaper which is having a reciprocating type of machine tool with single
point cutting tool used to produce flat surface. The flat surface may be
horizontal, vertical or inclined.

It has the three important parts such as

1. Table

2. Tool head

3. Ram

2.2 SHAPER – CONSTRUCTIONAL DETAILS

1. Base

The base is a heavy and robust in construction which is made of cast iron by
casting process. It is the only part to support all other parts because all parts
are mounted on the top of this base. So, it should be made to absorb
vibrations due to load and cutting forces while machining.

2. Column

The column has a box type structure which is made of cast iron. The inside
surface is made as hollow to reduce the total weight of the shaper. It is
mounted on the base. The ram driving (Quick return) mechanism is housed.
The two guide ways are provided on the top. The ram reciprocates on this
guide ways. Similarly, there are two guide ways at the front vertical face of
the column to move the cross rail along these guide ways

3. Cross rail

It is also a heavy cast iron construction. It slides on the front vertical ways of
the column with two mechanisms. One is for elevating the table and the
other one is for cross travel of the table. A saddle slides over two guide ways
already provided in the front face of the cross slide. The crosswise movement
of the table is obtained by cross feed screw and the vertical movement of the
cross rail is obtained by an elevating screw.

4. Saddle

It is mounted on the cross rail which holds the table in position on its top
without any shake.

5. Table

It is also a box type rectangular hollow cast iron block. This table slides along
the horizontal guide ways of the cross rail. The work is held in the table. The
table has machined surfaces on the top and sides of T- slots for clamping
work. It can be moved vertically by the elevating screw. An adjustable table
support supports the front face of the table.

6. Ram

Ram of cast iron has cross ribs for rigidity. Generally, it is a reciprocating
type which slides over the guide ways on the top of the column. It is
connected to driving mechanism of any one and also it carries the tool head
at the front end.
7. Tool head

It holds the tool rigidly having swivel base with degree graduation. So, the
tool head can be swivelled to any angle as required. The tool head has a
vertical slide and apron to provide vertical and angular feed to the tool. A
feed screw with graduated dial moves the vertical slide vertically to set the
accurate movement.

2.3 SHAPER SPECIFICATIONS

Generally, the specifications of a typical shaper are listed below:

1. Maximum length of stroke.

2. Maximum crosswise movement of the table.
3. Maximum vertical adjustment of the table.
4. Type of driving mechanism.
5. Power of the motor.
6. Speed and feed available.
7. Type of shaper-plain or universal.
8. Floor space required.
9. Total weight of the shaper.
10. Ratio of cutting stroke time to return stroke time.

2.4 SHAPER MECHANISMS

2.4.1 Crank and Slotter Mechanism

The below figure shows the crank and slotted link mechanism. An electric
motor drives the pinion. The pinion drives the bull gear. The bull gear has a
radial slide. In this radial slide, a bull gear sliding block is assembled. This
block can be adjusted in radial direction, by rotating the stroke adjustment
screw. This screw receives motion through bevel gears by rotating the
handle from outside.

The sliding block carries a crank pin. A rocker arm sliding block is freely
fitted to this crank pin. The rocker arm sliding block fits into the slot
provided in the rocker arm. This rocker arm is called slotted link. It is
pivoted at the bottom end. Its upper end has fork. It is freely connected to the
ram block by a pin.

The rotation of bull gear makes the crank pin to rotate in a circle The rocker
arm sliding block also rotates in the same circle. At the same time, this sliding
block also moves up and down in the slot of rocker arm. This gives oscillation
(rocking motion) to the rocker arm. The rocking movement is transmitted to
the ram. The ram reciprocates. Thus the rotary motion is converted into
reciprocating motion by this mechanism.

Crank and Slotter Mechanism

2.4.2 Hydraulic Drive

Below Fig illustrates the hydraulic drive in shaper. In this, there’s a hydraulic
cylinder. A piston reciprocates inside the cylinder. A piston rod connects the
piston and ram. Therefore, when the piston reciprocates, the ram also
reciprocates
The cylinder has two entries, one on right and other on left side These are
connected to the reservoir through a 4 way valve The valve is connected to
the reservoir through a drain pipe ant a supply pipe. A pump and relief valve
is fitted on the supply line. The valve is controlled by the lever and trip dig
attachment to the ram.

A gear pump sucks oil from the reservoir and develop pressure The high
pressure oil flows to the cylinder through 4 way valve When the lever of
valve is on one position, it allows the oil from pump to left side of the piston.
The oil forces piston and hence the ram moves towards right. It is forward
stroke or cutting stroke.

During this stroke, oil on the right side of piston flows out and goes to
reservoir through 4 way valve and drain pipe as shown in the figure. At the
end of that stroke, the lever hits one trip dog. Hence, the position of lever is
changed.

In this position, the supply pipe is connected to the right side of cylinder and
left side is connected to drain pipe. The high pressure oil enters on right side
of piston and moves the ram backward. It is return stroke.

During this stroke, high pressure oil acts on lesser area on the piston.
Because of the piston rod, the area on right of piston is less. So the pressure
force will be more. Hence, this return stroke is faster.
 Hydraulic Drive
Advantages of hydraulic drive
1. Uniform cutting speed
2. Smooth and noiseless operation
3. Changing of cutting speed is easier
4. Higher ratios on quick return can be obtained
5. Infinite number of cutting speeds can be obtained
6. More safety as the relief valve is provided
7. Stroke adjustment can be done without stopping the machined

2.4.3 Whitworth Quick return Mechanism

 Whitworth Quick return Mechanism

The mechanism consists of a pinion, bull gear and a crank plate as shown in
Fig above. An electric motor drives the pinion. The pinion rotates the bull
gear. The bull gear has a crank pin. A sliding block is fitted freely over the
crank pin. It also slides in the slot of a crank plate. This crank plate is pivoted
eccentrically on a pin 'O'. This pin is fixed to the body of the machine. The
crank plate is connected to the ram by a connecting rod through the pins P
and M.

The crank pin rotates about the centre of bull gear 'C'. At the same time, the
sliding block (fitted with the crank pin) slides along the slot of the crank
plate. This makes the crank plate to rotate about its centre 'O'. The crank pin
P will also rotate about the centre 'O'. Its rotary motion is converted into
reciprocating motion of ram by the connecting rod.
When the pin A is at X, the ram is at its starting position of forward stroke.
When the bull gear rotates in anticlockwise direction, the pin moves through
the angle L and reaches the point Y. It is the end position of cutting stroke.

When the bull gear rotates further, from Y to X, it makes angle of B. It is the
return stroke. The angle B is smaller than The angle B is smaller than Fig.
1.29 Width worth mechanism angle L. The speed of bull gear is uniform. So
the time taken for the return stroke is less than cutting stroke.

Cutting time Angle L = Return time Angle B

2.5 SHAPER OPERATIONS

1. Machining Horizontal surfaces

2. Machining Vertical Surfaces
3. Machining Angular surfaces
4. Machining V or Keyway Curved surfaces

2.6 SLOTTER MACHINE

The slotting machine is a reciprocating machine tool in which, the ram
holding the tool reciprocates in a vertical axis and the cutting action of the
tool is only during the downward stroke.
A slotter machine, also known as a slotting machine or vertical shaper, is a
type of reciprocating machine tool used for making vertical cuts, slots, and
keyways in metal work pieces. It operates similarly to a shaper but with the
cutting action in a vertical direction.

CONSTRUCTION OF SLOTTER :
The slotter can be considered as a vertical shaper and its main parts are:
1. Base, column and table
2. Ram and tool head assembly
3. Saddle and cross slide
4. Ram drive mechanism and feed mechanism
 SLOTTER MACHINE

Base
It is a heavy cast iron construction. It supports the column and the saddle. It
has horizontal guideways on its top. These guideways are perpendicular to
the column.
Column
It is cast integral with base. It houses driving mechanism of ram and
feeding mechanism. The top vertical front face has guideways. The ram
slides vertically in it

Saddle
It moves on the guideways provided on the base. It moves either towards
or away from the column. It is for longitudinal feed. The top face of saddle
has guideways. These guideways are perpendicular to the guideways on
the base. A cross slide moves on this guideways. It moves parallel to the
face of the column. It is for cross feed.

Rotary table
The rotary table is a circular table. It is mounted on the top of the cross
slide. It can be rotated about a vertical axis. It has T slots on the top. The T
slots are for holding the work. The table bottom is graduated in degrees.

Ram and tool head

Ram is a reciprocating member. It slides vertically on the guideways of the
column. It has tool head at its bottom end. The ram has a slot at the back
surface. It is for changing the position of ram. The tool is set in the tool
holder.