UNIT - III RECIPROCATING AND MILLING MACHINES

3.3.4 Table drive mechanism of a planer

3.3.4.1 Open and cross belt drive quick return mechanism
In this mechanism the movement of the table is effect by an open belt and a cross belt drive. It is
an old method of quick return drive used in planers of smaller size where the table width is less than 900
mm. Fig. 3.37 schematically shows the open and cross
cr belt drive quick return mechanism of a planer.

Fig. 3.37 Open and cross belt drive quick return mechanism
It has a counter shaft mounted upon the housings receives its motion from an overhead line shaft.
Two wide faced pulleys of different diameters are keyed to the counter shaft. The main shaft is placed
under the bed. One end of the shaft carries a set of two
two larger diameter pulleys and two smaller diameter
pulleys. The outer pulleys are rotate freely on the main shaft and they are called loose pulleys. The inner
pulleys are keyed tightly to the main shaft and they are called fast pulleys. The open belt connects
conn the
larger diameter pulley on the countershaft with the smaller diameter pulley on the main shaft. The cross
belt connects the smaller diameter pulley on the counter shaft with the larger diameter pulley on the
main shaft. The speed of the main shaft is reduced through a speed reduction gear box. From this gear
box, the motion is transmitted to the bull gear shaft. The bull gear meshes with a rack cut at the
underside of the table and the table will receive a linear movement.

Referring to the Fig. 3.337, the open belt connects the smaller loose pulley, so no motion is
transmitted by the open belt to the main shaft. But the cross belt connects the larger fast pulley, so the
motion is transmitted by the cross belt to the main shaft. The forward stroke of o the table takes place.
During the cutting stroke, greater power and less speed is required. The cross belt giving a greater arc of
contact on the pulleys is used to drive the table during the cutting stroke. The greater arc of contact of
the belt gives greater
reater power and the speed is reduced as the belt connects smaller diameter pulley on the
counter shaft and larger diameter pulley on the main shaft. At the end of the forward stroke a trip dog
pushes the belt shifter through a lever arrangement. The belt shifter shifts both the belts to the right side.

The open belt is shifted to the smaller fast pulley and the cross belt is shifted to the larger loose
pulley. Now the motion is transmitted to the main shaft through the open belt and no motion is
transmitted
tted to the main shaft by the cross belt. The direction of rotation of the main shaft is reversed.
The return stroke of the table takes place. The speed during return stroke is increased as the open belt
connects the larger diameter pulley on the counter shaft
shaft with the smaller diameter pulley on the main
shaft. Thus a quick return motion is obtained by the mechanism. At the end of the return stroke, the belts
are shifted to the left side by another trip dog. So the cycle is repeated. The length and position of the
stroke may be adjusted by shifting the position of trip dogs.

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3.3.4.2 Reversible motor drive quick return mechanism

All modern planers are equipped with variable speed electric motor which drives the bull gear
through a gear train. The most efficient method of an electrical drive is based on Ward Leonard system.
Fig. 3.38 schematically shows the reversible
eversible motor drive quick return mechanism of a planer.

Fig. 3.38 Reversible motor drive quick return mechanism

This system was introduced by Harry Ward Leonard in 1891. This system consists of an AC
motor which is coupled with a DC generator, a DC motor and a reversing switch. When the AC motor
runs, the DC motor will receive power from the DC generator. At that time, the table moves in forward
direction. At the end of this stroke, a trip dog actuates an electrical reversing switch. Due to this action, it
reverses the direction of current in DC generator with increased current strength. Now, the motor rotates
in reverse direction with higher speed.
spe So, the table
able moves in the reverse direction to take the return
stroke with comparatively high speed.
speed Thus the quick return motion is obtained by the mechanism.
The distinct advantages
dvantages of electrical drive over a belt drive are:

Cutting speed, stroke length
ngth and stroke position can be adjusted without stopping the machine.

Large number of cutting speeds and return speeds are available.

Quick and accurate control.
control Push button controls the start, stop and fine movement of the table.

Return speed can be greatly tly increased reducing idle time.

3.3.4.3 Hydraulic drive quick return mechanism

The hydraulic drive is quite similar to that used for a horizontal shaper. More than one hydraulic
cylinder may be used to give a wide range of speeds. The main drawback of the hydraulic drive on long
planers is irregular movement of the table due to the compressibility of the hydraulic fluid. The
hydraulic drive has been described in Article 3.2.4.3, Page
age 107 and illustrated in Fig. 3.8.

3.3.5 Feed mechanism of a planer

In a planer the feed is provided intermittently and at the end of the return stroke similar to a
shaper. The feed of a planer, both down feed and cross feed, is given by the tool head. The down feed is
applied while machining a vertical or angular
angular surface by rotating the down feed screw of the tool head.
The cross feed is given while machining horizontal surface by rotating the cross feed screw
passes through a nut in the tool head. Both the down feed and cross feed may be provided either by hand
or power by rotating two feed screws, contained within the cross rail.
If the two feed screws are rotated manually by a handle, then it called hand feed. If the two feed
screws are rotated by power, then it is called automatic feed.

3.3.5.1 Automaticc feed mechanism of a planer

Fig. 3.39 illustrates the front and top view of the automatic feed mechanism of a planer.planer A trip
dog is fitted to the planer table. At the end of the return stroke, the trip dog strikes a lever. A pawl
attached to this lever rotates a ratchet. So a splined shaft attached to the ratchet rotates. A bevel gear cast
integral with a spur gear is fitted
ted freely on the down feed screw. This bevel gear meshes with other bevel
gear slides on the splined shaft.

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Fig. 3.39 Front and top view of the automatic feed mechanism of a planer

The spur gear meshes with another spur gear which is keyed to the cross cr feed screw. So the
power from the splined shaft is transmitted to the cross feed screw. Then the rotation is transmitted to the
tool head through a nut. The tool head moves horizontally. It is known a cross feed. At the end of the
forward stroke, another trip dog strikes the lever. The lever comes to its original position. During this
time, the pawl slips over the ratchet. The ratchet wheel does not rotate.
For giving automatic down feed, the spur gear keyed to the the cross feed screw is disengaged. The
bevel gear freely fitted to the down feed rod is keyed to the down feed rod. At the end of return stroke,
the power is transmitted to the down feed rod through the lever, ratchet and bevel gears. Then the
rotation is transmitted to the tool head though the bevel gears. The tool moves downward.

3.3.6 Work holding devices used in a planer

A planer table is used to hold very large, heavy and intricate work pieces, and in many cases,
large number of identical work pieces together.. Setting up of the work pieces on a planer table requires
sufficient amount of skill. The work piece may be held on a planer table by the following methods:

By standard clamping.

By special fixtures.

3.3.6.1 Standard clamping devices

The standard clamping devices are used for holding most of the work pieces on a planer table.
The standard clamping devices are as follows:

Heavy duty vises.

T-bolts, step blocks and clamps.

Stop pins and toe dogs.

Angle plates.

Planer jacks.

Planer centres (similar to shaper centre).

V-blocks.
Most of them have been described
cribed in Article 3.2.6 and Page 110.

A planer vise is much more robust in construction than a shaper vise as it is used for holding
comparatively larger size of work. The vise may be plain or swiveled base type.
Large work piecess are clamped directly on the table by T- T bolts and clamps. Different types of
clamps are used for different types of work. Fig. 3.40 illustrates the method of clamping a large work
piece on a planer table. Step blocks are used to lend support to the other end of the clamp.
Planer jacks are used for supporting the overhanging part of a work to prevent it from bending.
Fig. 3.41 illustrates the use of a planer jack.

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Fig. 3.40
40 Clamping a large work piece on a planer table

Fig. 3.41 Use of planer jack

3.3.6.2 Special fixtures
These are used for holding a large number of identical pieces of work on a planer table. Fixtures
are specially designed for holding a particular type of work. By using a fixture the setting time may be
reduced considerably compared to the individual setting of work by conventional clamping devices.
Fig. 3.42 illustrates
llustrates the use of a fixture.

Fig. 3.42 Use of a fixture

3.3.7 Planer tools
The cutting tools used on planers are all single point cutting tools. They are in general similar in
shapes and tool angles to those used on a lathe and shaper. As a planer tool has to take up heavy cut and
coarse feed during a long cutting stroke, the tools
tools are made heavier and larger in cross-section.
cross Planer
tools may be solid, forged type or bit type. Bits are made of HSS, stellite or cemented carbide and they
may be brazed, welded or clamped on a mild steel shank. Cemented carbide tipped tool is used for fo
production work. Fig. 3.43 shows the typical tools used in a planer.

Fig. 3.43
3.4 Typical tools used in a planer

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3.3.8 Planer operations

All the operations done in a shaper can be done in a planer. But large size, stroke length and
higher rigidity enable the planers do more heavy duty work on large jobs and their long surfaces.
Simultaneous use of number of tools further enhances the production capacity of planers. The common
types of work machined in a planer are: Beds and tables of various machine tools,
tools large structures, long
parallel T-slots,
slots, V and inverted V type guide ways,
ways frames of different engines and identical pieces of
work which may be small in size but large in number.
Machining the major surfaces and guide ways of beds and tables ofof various machines like lathes,
drilling machines, milling machines, grinding machines,
machines broaching machines and planers itself are the
common applications of a planer as illustrated in Fig. 3.44. Where
here the several parallel surfaces of typical
machine bed and guide way are machined by a number of single point HSS or carbide tools.

Fig. 3.44
3.4 Machining of a machine bed in a planer
Besides the general machining work, some other critical work like helical
helical grooving on large rods,
long and wide 2-D D curved surfaces, repetitive oil grooves etc. can also be made, if needed, by using
suitable special attachments.

3.3.9 Special attachments

ttachments used in a planer
3.3.9.1 Contour forming attachment
Fig. 3.45 illustrates
ates the contour forming attachment used in a planer. The machining operation is
performed by using the attachment which consists of a radius arm and a bracket. The bracket is
connected to the cross member attached to the two housings. One end of thethe radius arm is pivoted on the
bracket and the other end to the vertical slide of the tool head. The down feed crew of the tool head is
removed. The horizontal rail is kept delinked from the vertical lead screws. The tool which is guided by
the radius arm planes a convex or a concave surface. The radius of convex or concave surface produced
is dependent upon the length of the radius arm.

Fig. 3.45 Contour forming attachment used in a planer

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3.3.10 Specifications of a planer

The planer is specified by the following parameters:

Radial distance between the top of the table and the bottom most position of the cross rail.

Maximum length of the table and maximum stroke length of table.

Power of the motor.

Range of speeds and feeds available.

Type of feed and type of drives required.

Horizontal distance between two vertical housings.

Net weight of machine and Floor area required.

3.3.11 Difference between shaper and planer

Sl. No. Shaper Planer
The tool reciprocates and the work is The work reciprocates and the tool is
1
stationary. stationary.
Feed is given to the work during the idle Feed is given to the tool during the idle
2
stroke of the ram. stroke of the work table.
It gives more accuracy as the tool is rigidly Less accuracy due to the over hanging of the
3
supported during cutting. ram.
4 Suitable for machining small work pieces. Suitable for machining large work pieces.
5 Only light cuts can be applied. Heavy cuts can be applied.
Only one tool can be used at a time. So Vertical and side tool heads can be used at a
6
machining takes longer time. time. So machining is quicker.
7 Setting the work piece is easy. Setting the work piece is difficult.
Only one work piece can be machined at a Several work pieces can be machined at a
8
time. time.
9 Tools are smaller in size. They are larger in size.
10 Shapers are lighter and smaller. Planers are heavier and larger.

3.4 SLOTTER
Slotter can simply be considered as vertical shaper where the single point (straight or formed)
cutting tool reciprocates vertically and the work piece, being mounted on the table, is given slow
longitudinal and / or rotary feed. The slotter is used for cutting grooves, keyways, internal and external
gears and slots of various shapes. The slotter was first developed in the year 1800 by Brunel.

3.4.1 Types of slotter

The different types of slotter which are most commonly used are:

Puncher slotter.

Precision slotter.

3.4.1.1 Puncher slotter

It is a heavy, rigid machine designed for removal of a large amount of metal from large forging
or castings. The length of a puncher slotter is sufficiently large. It may be as long as 1800 to 2000 mm.
The ram is usually driven by a spiral pinion meshing with the rack teeth cut on the underside of the ram.
The pinion is driven by a variable speed reversible electric motor similar to that of a planer. The feed is
also controlled by electrical gears.

3.4.1.2 Precision slotter

It is a lighter machine and is operated at high speeds. The machine is designed to take light cuts
giving accurate finish. Using special jigs, the machine can handle a number of identical works on a
production basis. The precision machines are also used for general purpose work and are usually fitted
with Whitworth quick return mechanism.

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