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General-Purpose Metal-Cutting Machine Tools
Published in Helmi Youssef, Hassan El-Hofy, Traditional Machining Technology, 2020
A shaper machine is commonly used in single-piece and small-lot production as well as in repair shops and tool rooms. Due to its limited stroke length, it is conveniently adapted to small jobs and best suited to surfaces comprising straight-line elements and contoured surfaces when the shaper is equipped with a tracing attachment. It is also applicable for cutting keyways and splines on shafts. Although the shaping process is inherently slow, it is quite popular because of its short setup time, inexpensive tooling, and ease of operation. In comparison to a planer, it occupies less floor space, consumes less power, costs less, is easier to operate, and is about three times quicker in action, as stroke length and inertia forces are lower. Its stroke length is limited to 750 mm, as the accuracy decreases for longer strokes due to ram overhanging. Figure 3.68 shows a typical shaper. The column (1) houses the speed gearbox, the crank, and the slotted arm mechanism. The power is, therefore, transmitted from the motor (2) to the ram (3). Ram travel is the primary reciprocating motion, while the intermittent cross travel of the table is the feed motion. The tool head (5), carrying the clapper box and the tool holder (6), is mounted at the front end of the ram and is fed manually or automatically. The slot with the clamp (7) serves to position the ram in setting up the shaper.
Fitting using hand skills
Published in David Salmon, Penny Powdrill, Mechanical Engineering Level 2 NVQ, 2012
A shaping machine is a machine tool that is sometimes available to fitters in engineering workshops. Shapers, as they are commonly known, are simple machines to operate and quick to set up. They can be used to produce flat surfaces in either horizontal, vertical or angular planes on workpieces. The Ram carries a cutting tool to and fro over the work and the cutting tool removes material from the work's surface as it traverses forward over the work, hinging away from the work on the return stroke. For each cutting stroke, the work can be automatically fed across the tool's path so that the next stroke will remove more material. The stroke length and the feedrate can be adjusted to suit the workpiece's dimensions and the required surface finish.
Shaping/Planing Operations and Machines
Published in Zainul Huda, Machining Processes and Machines, 2020
The shaper is a machine tool that is used to produce flat surface by means of a straight line reciprocating single-point cutting tool. The flat surface so produced may be horizontal, vertical, or inclined at an angle. Based on the ram position and its travel, shapers may be horizontal, vertical, or travelling-head type shapers (Bradley, 1973). The horizontal shaper is the most commonly used shaping machine tool (see Figure 8.3). The principal components of a horizontal shaper are illustrated in the following paragraph.
Numerical analysis on heat-flow-coupled temperature field for orthogonal face gears with oil–jet lubrication
Published in Engineering Applications of Computational Fluid Mechanics, 2021
Bin Ouyang, Feiyue Ma, Yu Dai, Yanyang Zhang
where is the base circle radius of the shaper cutter, , in which m is the module, z denotes the gear number, and represents the pressure angle; is the transmission ratio; is the rotating angle of the shaper cutter; and are the angle parameters of the involute; additional details can be obtained from (Litvin et al., 1998, 2001, 2008).
Modeling and verification of temperature rise during machining
Published in Journal of the Chinese Advanced Materials Society, 2018
Prabhat Chand Yadav, Sandeep Sahu, Shashank Shekhar
The machining was performed on rigid instrumented shaper machine with power 2 kW and constant machining speed of 250 mm/s. The schematics of machining setup with thermomicrograph in grayscale is shown in Figure 1. Machining parameters like feed (0.275 mm/rev), depth of cut (1.0 mm), and rake angle of the tool (−20°) were kept constant throughout the process to get constant strain and strain rate, which were found to be ∼3.0 and ∼940/s, respectively. The heat capacity of aluminum was taken as 2.40 MJ/m3 °C.[16] After machining with constant parameters, aluminum chips having average final thickness ∼0.40 mm were obtained in one complete run of the tool. The hardness of the starting aluminum block and machined chips was found to be ∼23.2 VHN and ∼71.54 VHN, respectively. The drastic enhancement in hardness value ensures that the process is severe plastic deformation and hence, large microstructural transformation takes place during the process. Similar results in hardness were also observed in our previous research work.[17,18] Simultaneously, thermomicrograph of chips along with machining tool at particular instants was recorded frame by frame using thermal imagining technique by infrared camera (model no. FLIR X6540SC). Details of the infrared camera used in the current study are shown in Table 2. After calculation, it was found that the size of each pixel was ∼32 μm. The camera was focused on the zone considering tool tip and workpiece contact in the machining configuration. For better visibility, the rainbow color scale was used during recording of the image. Proper estimation of emissivity is important in determining the temperature rise accurately. Emissivity measures an object’s ability to emit radiation, and its value can vary between 0 and 1.0 (for blackbody). After careful study of the literature about our work material, we used an emissivity of 0.18 for our workpiece.[19] The frame by frame movement of the High-speed steel (HSS) tool on the aluminum workpiece during machining is shown in Figure 2.
Benefits of adopting lean production on green performance of SMEs: a case study
Published in Production Planning & Control, 2018
Amine Belhadi, Fatima Ezahra Touriki, Said El Fezazi
Foundary cell: produces metal castings. Metals are casted into shapes by melting them into a liquid, pouring the metal in a mould and removing the mould material or casting after the metal has solidified as it cools. The most common metals processed are aluminium and cast iron. However, other metals, such as bronze, brass, steel, magnesium and zinc, are also used to produce castings in foundries. In this process, parts of desired shapes and sizes can be formed.Foundary cell: produces metal castings. Metals are casted into shapes by melting them into a liquid, pouring the metal in a mould and removing the mould material or casting after the metal has solidified as it cools. The most common metals processed are aluminium and cast iron. However, other metals, such as bronze, brass, steel, magnesium and zinc, are also used to produce castings in foundries. In this process, parts of desired shapes and sizes can be formed.Machining cell: is the process to achieve desire shape of the material by different types of machining work. The company has different types of machines to do this task such as lathe machine, milling machine, shaper machine, grinding machine and drill machine.Assembly and painting cell: is the last part of the manufacturing process. It includes installation of mechanical (bearing, shaft, mechanical seal, flange coupling) and hydraulic (impeller, volute) components and then putting and tightening the bolts. Sometimes maintenance work is also occurring in assembly cell.Testing and quality control cell: After assembly, a pump passes through the testing and QC cell to confirm its readiness for expedition to the final customer. Otherwise, the pump is returned to assembly cell in order to make the necessary adjustments.