Types of shaper machine

Types of shaper machine:

1. According to the type of mechanism used  for giving reciprocating motion to the ram :

• Crank type
• Geared type
• Hydraulic type

2. According to the position and travel of ram :

• Horizontal type
• Vertical type
• Travelling head type

3. According to the type of design of the table :

• Standard shaper 
• Universal shaper 

4. According to the type of cutting stroke :

• Push type
• Draw type

Parts of shaper machine

Main parts of shaper machine :

Base :

The base is the main body of the machine. It consist of all elements of the machine. The bed may be rigidly bolted to the floor of the shop or on the bench according to the size of the machine.

The base is made of cast iron to resist vibration and take up high compression load.

Column :

The Column is a box it can be mounted upon the base.

It provides the housing for the crank slider mechanism and also encloses the ram driving mechanism.

Two accurately guideways are provided on the top of the column on which the ram reciprocates.

Crossrail :

The Crossrail is mounted on the front vertical guideways of the column.

A horizontal cross feed screw which is fitted within the Crossrail and parallel to the top guideways of the column.

It attaches with some cross-movement mechanism.

Saddle :

The saddle is mounted on the Crossrail which holds the table firmly on its top.

Crosswise movement of the saddle by rotating the crossfeed screw by hand or by the power to move sideways.

Clapper Box :

The Clapper box carries the tool holder.

It provides clearance for the tool in return stroke.

It also prevents the cutting edge dragging the work piece while return stroke and prevents tool wear.

Table :

The table is bolted to the saddle receives crosswise and vertical movements from the saddle and Crossrail. It is the metal body attached over the frame.

The main function of the table is to hold the work piece and vice over it.

T slots which used to clamp vice and work piece over it.

Ram :

Ram is the main part of shaper machine.

The ram is a reciprocating member of shaper machine.

Ram is semi-cylindrical in shape and heavily ribbed inside to make it more rigid.

Ram is made by cast iron and moves over ways on the column.

It attached by the rocker arm which provide it motion in the crank driven machine and if the machine is hydraulically driven it attached by hydraulic housing.

Toolhead :

Toolhead is situated at the front of the ram.

The main function of it is to hold the cutting tool.

The cutting tool can be adjusted on it by some of the clamps.

Stroke adjuster :

It is attached below the table.

It is used to control the stroke length which further controls the ram movement.

Table supports :

These are attached front side of the table and used to support the weight of the table during working.

Advantages of hydraulic shaper

Shaper is a type of machine which, using hydraulic power, provide linear relative motion between the workpiece and single-point cutting tool to a linear path. Under high pressure, oil is pumped into the piston-fitted operating cylinder. This machine gives the following advantages. 

Advantages of hydraulic shaper : 

• The cutting speed and return speed of this shaper is practically constant throughout the stroke thus work done is uniform during the cutting stroke.
• The reversal of the ram is obtained quickly without any shock as the oil on the other end of the cylinder provides cushioning effect.
• An infinite number of cutting speeds may be obtained and its control is also easier. speed range varies from zero to the maximum value.
• Because of the high rate of return speed, a greater number of cutting strokes may be available within the range of cutting speed.
• The relief valve ensures safety to the tool and the machine when the machine is overloaded.
• Wide range of speed can achieve by controlling the fluid flow rate to shaper ram. 
• Shock and vibration levels can reduce. 
• Higher load-carrying capacity. 
• Fluid on both sides of the ram provides a cushioning effect. 
• Highly efficient. 

Advantages of vertical boring machine over lathe machine

The vertical boring machine may be looked like a vertical lathe with its headstock resting on the floor and its large faceplate or chuck lying in a horizontal plane. This specified vertical boring machine design offers some advantages over a lathe machine. Let us have a deep insight into the advantages below. 

Advantages of a vertical boring machine :

• Large diameter and heavy workpiece may be set up more conveniently and quickly than on lathe machine.
• The table and the work it carries rotate in a horizontal plane, and there is no overhang as in the lathe spindle, and any chance of bending the spindle which supports the heavy workpiece is eliminated.
• The diameter of the table may be designed as large as possible to support large workpieces.
• Multiple tooling may be adapted in case of a vertical boring machine with its turret type tool post, as a result, increasing the rate of production.

Vertical boring machine

A vertical boring machine is particularly adapted for holding and machining the large, heavy workpiece.
On vertical boring machine following work are done :

• Large gear blanks
• Locomotive and rolling stock tires
• Steam and water turbine castings
• Flywheels
• Large flanges and number of circular-shaped parts

A vertical boring machine can take an only a circular cut.

The vertical boring machine is of two types :

• Vertical turret lathe
• Standard vertical boring machine

Vertical boring machine parts :

1. Bed
2. Table
3. Housing
4. Crossrail
5. Tool-head assembly

Size of vertical boring machine :

Its size is specified by the diameter of its table or chuck expressed in mm.

The size of vertical turret lathe varies from 600 to 2000 mm. 

The size of a standard vertical boring machine is as high as 6000 mm.

Vertical boring machine tools :

The vertical boring machine tools are similar to lathe tools.

For boring operation, the clearance angle of the tool is greater than in turning or facing tool.

Vertical boring machine operation :

A vertical boring machine may generate a horizontal flat surface.

It can also produce cylindrical turned surface, bore internal hole, perform cutting off, necking or forming operation, and generate internal or external taper surface.

Difference between reaming and boring

Reaming and boring is a similar process and use for the same purpose but just a minor difference between them. Reaming used to finish the hole previously drill whereas boring used to enlarge the hole previously drilled. 

Let us have a deep insight into the comparison between those two similar processes and also check the difference between them. 


Difference between reaming and boring : 

• Reaming is a process of sizing and finishing the already drilled holes while boring processes for producing holes of larger diameter compared to drilling.
• When compared to boring, a reamer holds tighter tolerances for longer periods of time because the cutting is generally spread out over multiple flutes.
• Boring operation is done on lathe or milling machine also whereas reaming operation on the same types of machines as drilling.
• In boring every time a hole has increased the size of a hole is not necessarily the same but in reaming also every time the hole is increased but the size of the hole is the same.
• In reaming, machinists may use hand or machine reamers depending on the job they are performing while boring a workpiece may be held in a 3, 4, or 6 jaw chuck and collets.
• Reaming uses multi teeth cutter while boring uses a single tooth cutter.
• Reaming process MRR is comparatively lower than boring. 
• Reaming produced a highly finished surface than boring. 
• The cutting tool used for boring is boring bar while reamer is used for reaming. 

Jig boring machine

The jig boring machine is the most accurate in all type of boring machine. Jig boring machine first developed in the year 1910 in Switzerland. The real jig borer was first built in the year 1917 by Pratt and Whitney.

Jig boring machine is now used for the production of jigs, fixtures, tools and other precision parts which require a high degree of accuracy.
They have the highest accuracy through rigidity, low thermal expansion and measuring distance for accurately locating and spacing holes.

Jig boring machine is a metal cutting machine for finishing holes, planes and slots with a highly precise location of centres or surfaces without the use of special attachments for tool alignment.

In jig boring machine machining accuracy is very high within a range of 0.0025 mm. 

The spindle and other parts of the machine are extremely rigid to resist deflection and the vibration is minimum.
The spindle runs in preloaded antifriction bearings.
The jig boring machine requires temperature-controlled rooms for operation where temperature can be maintained constant.

Types of jig boring machine :

There are two types of jig boring machine :

1. Vertical milling machine type
2. Planer type

Methods of locating holes in the jig boring machine :

Accurate positioning is essential for producing accurate jigs, fixture, dies etc.

The most important operation in a jig boring machine is the accurate way of positioning a hole that can be done by one of the following methods :

1. Lead screw method
2. Mechanical and electrical gauging method
3. Optical measuring method

Jig boring machine operations :

• The jig boring machine primarily designed to produce precision dies, jigs and gauges.
• They also used as measuring machine to check up a job already manufactured in other machines.
• Also used in enlarging holes.
• Single point tools enables maximum accuracy in locating holes and give a better surface finish.
• Jig boring machine operated by highly skilled workers.

Multiple head type horizontal boring machine

Multiple head type horizontal boring machine resembles a double housing planer or a Plano-miller.

The table is supported on a long bed on which it reciprocates.

In there two vertical columns at two sides of the bed, nearly at the middle of the bed.

The two columns are bridged by a Crossrail.

This machine has two, three or four headstock.

This type of machine may be used as both a horizontal and vertical boring machine.

The machining operations can be performed simultaneously at different work surfaces.

Planer type horizontal boring machine

Planer type horizontal boring machine the table type but table slide directly on the bed instead of on a saddle and reciprocates at right angles to the spindle similar to a planer.

The end supporting column may be adjusted towards or away from the table for accommodating different widths of work.

This types of boring machine suitable for supporting a long work.

Floor type horizontal boring machine

The floor type horizontal boring machine having no table uses a stationary floor-plate on which T-slots are provided to hold the work.

The headstock supporting column and the end supporting column are mounted on the runways which are placed at right angles to the spindle axis.

Any crosswise adjustment or cross-feed movement is provided by the spindle itself and not by the work.

Table type horizontal boring machine

This is the most common type of all horizontal boring machines because the work is mounted on the table which is adjustable and feed is given by hand or power lengthwise or crosswise with respect to the bed of the machine.

The head stock may be adjusted vertically on the column and the spindle has a horizontal feed motion.

The machine consists of bed, head stock supporting column, end supporting column, head stock, saddle and table and boring bar.

This type of machine is suitable for general purpose work where other operations in addition to boring are required to be performed.

 

Horizontal boring machine

In a horizontal boring machine, the work is supported on a table which is stationary and the tool revolves in a horizontal axis.
A horizontal boring machine can perform boring, reaming, turning, threading, facing, milling, grooving and many other operations with suitable tools.
Different types of horizontal boring machines have been designed to suit different purposes.

Parts of Horizontal boring machine :

Bed :
The bed is fitted on the floor of the shop and has a box-like casting.
The bed supports the columns, tables and other parts of the machine.

Headstock supporting column :
The column provides supports to the headstock and guides it up and down accurately by the guideways provided on the face of the column.

End supporting column :
The end supporting column situated at the other end of the bed houses the bearing block for supporting a long boring bar.

Headstock :
The headstock mounted on the column supports, drives, and feed the tool.
The headstock may be moved up and down on the column for setting the tool for different heights of the work.

Saddle and table :
The table supports the work and provided with T-slots for clamping the work or for holding devices.
The saddle allows the work to be moved longitudinally on the bed.
The table may be moved crosswise on the saddle.

Boring bars :
The boring bar supports the cutter for boring operations on jobs having large bore diameters. 

Size of horizontal boring machine :

The size of that is specified by the diameter of its spindle in mm.
Spindle diameter varies from 75 to 355 mm.
Other important dimensions such as spindle motor horsepower, column heights, size of the table or size of the floor plate, spindle speed, feed and length of feeds, floor space required, the weight of the machine should be stated.

Boring machine mechanism :

The boring machine has different controls for movements of the different parts of the machine. A table type machine has movements mentioned below :

1. The headstock and the end supporting block may be moved up and down.
2. The spindle may be rotated with different speeds.
3. The spindle may be moved in or out by hand or power for feeding.
4. The saddle or table may be moved by hand pr power.
5. The columns may be moved by hand or power.

As all the controls are housed in a particular position of the machine the operator may give closed attention on the work while controlling the machine.

Work holding device for horizontal boring machine :

• Conventional work holding devices comprise of T-bolts and clamps, angle plates, step blocks etc.
• Special jigs are used in mass production work.

Horizontal boring machine operations :

In boring machine used for milling operation and the milling cutter may be fitted to the spindle. 

Facing cutter is used for machining flat vertical surfaces for face milling operation.

End mills are used to produce grooves and slots.

Other operations such as following below :

• Drilling 
• Reaming
• Counter boring
• Tapping
• Spot facing

Boring tool mountings for horizontal boring machine :

The different equipment for mounting cutters in horizontal boring machine are :

• Boring bar
• Boring head or cutter head
• Facing head

There are different boring tool used in boring bars are of different shapes and sizes for different types of operation.

Types of Boring Machine

The boring machine may be classified into four types. we can check it our below :

1. Horizontal boring machine 

• Table type
• Floor-type
• Planer type
• Multiple head type

2. Vertical boring machine

• Vertical turret lathe
• Standard vertical boring machine

3. Precision boring machine

4. Jig boring machine

• Vertical milling machine type
• Planer type

Boring machine introduction

The first boring machine tool was invented by John Wilkinson in 1775.

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.

By the use of the boring machine the range of speeds and feeds provided to various traversing components allow drilling, milling and facing operation with equal facility.

By the fitting of simple attachments, the use of the machine can be extended to include screw cutting, turning, planetary grinding or gear cutting.

What is polorization

Light is electromagnetic in nature. The light is transverse in nature. 

The vibration of the electric field and magnetic field are perpendicular to each other and they are also perpendicular to the direction of propagation of light.

The light in which electric field has the freedom to vibrate in all direction which is perpendicular to the propagation of light is known as unpolarised light.

Unpolorised means it has the freedom and it does not have any restrictions.

The light in which the electric field can vibrate only in one direction in another word there is restriction of vibration of an electric field such light is known as polarised light.
The phenomenon in which unpolarised light is converted into polarized light is known as polarization.

There are different method unpolarised light converted into polarised light :

• Using polarising materials.
• By reflection of light.
• By scattering of light. 
• By doable refraction of light.

What is diffraction

Diffraction :

Diffraction is the bonding of light around an edge of the obstacle such as the edge of the slit we can diffraction of light through the crack between two fingers at the distant source.

Diffraction of any kind of waves depends upon the wavelength and the size of the obstacle. 

For significant diffraction, the ratio of λ/d should be 1. 

There are two types of diffraction :

1. Fresnel diffraction
2. Fraunhofer diffraction

Optical wavelength

What is Optical Wavelength?

When there is a medium which has refractive index µ we have to use optical wavelength λ_µ.

The relation between optical wavelength and geometrical wavelength is given by 

λ_µ = λ / µ 

λ_µ = Optical wavelength

λ = Geometrical wavelength

µ = Refractive index of medium

Electromagnetic spectrum definition

The electromagnetic waves can be characterised by the parameters like wavelength, frequency, phase and state of polarization.

Wavelength :
The distance between two-crust or two throughs is known as wavelength. 
Wavelength denoted by λ.

Frequency : 
Frequency is the quantity that represents a number of oscillations that particle carries out in unit time.
Frequency denoted by ν.

Wavelength (λ) = c / Frequency (ν)

Where c = velocity of electromagnetic wave

Wavelength × Frequency = Velocity of the wave

The wavelength of the electromagnetic wave varies from 10^-12 meters to 10⁴ meters.

Phase :

The electromagnetic wave can be represented by a sine or cosine function.

E = E₀ Sin (wt + Φ )

Where E = Position of a wave at time t

E₀ = Maximum displacement of Amplitude

(wt + Φ ) = Phase of the wave

Φ = Initial phase or phase difference

Phase difference :

The difference between the phase if the two waves or phase of two position of a single wave is known as phase difference.

Wave optics Introduction

In a one-word optics can define that science of light.
Light has dual nature sometimes it behaves like a wave and sometimes it behaves like a particle.
In other word deal with optics is the branch of physics dealing with the study of optical phenomena.
The phenomena like reflection and refraction are explained by corpuscular theory. but the phenomena like interference, diffraction and polarisation can not explain the particle nature of light.
In optics, we consider the light as a wave.

We have also seen terms in optics are following below :

• Light 
• Electromagnetic Spectrum
• Wavelength
• Frequency
• Phase
• Phase difference
• Coherence
• Interference 

Coherence definition in physics

Coherence :

If the phase difference between two waves or phase difference between two positions of the single wave remains constant, such waves are known as coherent waves and phenomenon is called coherence.

If the phase difference between two sources changes then sources are known as incoherent. Sunlight, incandescent lamp. tube light etc is an example of the incoherent source.

There are two methods by which we can produce a coherent source :

• Division of wavefront
• Division of amplitude

Types of coherence :

• Temporal coherence
• Spatial coherence

Measurement of coherence :

The coherence of any source can be measured by the visibility of contrast of the fringe system produced by the source. It is given by 

V = I_max - I_min / I_max + I_min 

Where I_max = Maximum Intensity of bright fringe

I_min = Minimum Intensity of dark fringe