Working Principle of Shaper & Planner

Introduction

In the manufacturing process, Shaper and Planner are two important machines used for shaping and machining various workpieces. These machines play a crucial role in achieving accurate dimensions and desired surface finishes. In this article, we will explore the working principles of Shaper and Planner, their components, mechanisms, advantages, disadvantages, and real-world applications.

Working Principle of Shaper

A Shaper is a reciprocating type of machine tool used for producing flat surfaces on a workpiece. It operates on the principle of cutting metal using a single-point cutting tool.

Components of a Shaper

A typical Shaper consists of the following components:

1. Base: It provides support and stability to the machine.
2. Column: It houses the reciprocating mechanism.
3. Table: It holds the workpiece and can be moved horizontally.
4. Ram: It carries the cutting tool and reciprocates.

Working Mechanism of a Shaper

The working mechanism of a Shaper involves the following steps:

1. Cutting Tool and Workpiece Arrangement: The cutting tool is mounted on the ram, and the workpiece is fixed on the table.
2. Stroke and Feed Mechanisms: The ram moves back and forth, creating a cutting stroke. The table can be moved horizontally to provide the required feed.
3. Cutting Action and Chip Formation: During the cutting stroke, the tool removes material from the workpiece, creating chips.

Advantages and Disadvantages of Using a Shaper

Advantages of using a Shaper:

• Suitable for machining flat surfaces
• Can produce both internal and external shapes

Disadvantages of using a Shaper:

• Limited cutting speed
• Not suitable for complex shapes

Working Principle of Planner

A Planner is a machine tool used for machining large workpieces and producing flat surfaces. It operates on the same principle as a Shaper but is designed for heavier and larger workpieces.

Components of a Planner

A typical Planner consists of the following components:

1. Bed: It provides support and stability to the machine.
2. Tool Head: It carries the cutting tool and reciprocates.
3. Worktable: It holds the workpiece and can be moved horizontally.

Working Mechanism of a Planner

The working mechanism of a Planner involves the following steps:

1. Tool Head and Worktable Arrangement: The tool head is mounted on the cross-rail, and the worktable is fixed on the bed.
2. Reciprocating Motion and Feed Mechanisms: The tool head moves back and forth, creating a cutting stroke. The worktable can be moved horizontally to provide the required feed.
3. Cutting Action and Chip Formation: During the cutting stroke, the tool removes material from the workpiece, creating chips.

Advantages and Disadvantages of Using a Planner

Advantages of using a Planner:

• Suitable for machining large workpieces
• Can produce flat surfaces with high accuracy

Disadvantages of using a Planner:

• Requires a larger workspace
• Limited to machining flat surfaces

Comparison between Shaper and Planner

While both Shaper and Planner operate on similar principles, there are some key differences between them:

1. Working Principles: A Shaper uses a reciprocating motion to cut the workpiece, while a Planner uses a reciprocating tool head.
2. Applications and Capabilities: Shapers are suitable for smaller workpieces and can produce both internal and external shapes. Planners are designed for larger workpieces and are primarily used for machining flat surfaces.
3. Factors to Consider: When choosing between a Shaper and Planner, factors such as workpiece size, shape complexity, and required surface finish need to be considered.

Real-world Applications and Examples

Shapers are commonly used in industries such as automotive, aerospace, and tool manufacturing. They are used for shaping components like gears, keyways, and slots.

Planners find applications in industries such as shipbuilding, construction, and metal fabrication. They are used for machining large surfaces, such as ship decks and building panels.

Typical Problems and Solutions

While using a Shaper, some common issues that may arise include:

1. Uneven Cutting or Surface Finish: This can be caused by incorrect tool alignment or improper feed rate. Adjusting the tool position and feed rate can help resolve this issue.
2. Tool Wear and Breakage: Continuous cutting can lead to tool wear or breakage. Regular tool inspection and replacement can help prevent this problem.
3. Vibration and Noise: Excessive vibration and noise can be caused by worn-out machine parts or improper cutting conditions. Replacing worn-out parts and optimizing cutting parameters can help reduce vibration and noise.

When using a Planner, some common issues that may occur are:

1. Inaccurate Cutting Dimensions: This can be caused by incorrect tool alignment or worn-out machine parts. Adjusting the tool position and replacing worn-out parts can help achieve accurate cutting dimensions.
2. Poor Surface Finish: Improper feed rate or worn-out cutting tools can result in a poor surface finish. Adjusting the feed rate and replacing cutting tools can improve the surface finish.
3. Tool Misalignment: Improper alignment of the tool head can lead to inaccurate machining. Ensuring proper alignment of the tool head can help avoid this problem.

Conclusion

In conclusion, understanding the working principles of Shaper and Planner is essential in the manufacturing process. Shapers are suitable for smaller workpieces and can produce both internal and external shapes, while Planners are designed for larger workpieces and are primarily used for machining flat surfaces. By considering factors such as workpiece size, shape complexity, and required surface finish, manufacturers can choose the appropriate machine for their specific needs. Regular maintenance and troubleshooting can help overcome common issues and ensure optimal performance of these machines.

Summary

Shaper and Planner are two important machines used in the manufacturing process. A Shaper operates on the principle of cutting metal using a single-point cutting tool, while a Planner is designed for heavier and larger workpieces. Both machines have their advantages and disadvantages, and understanding their working principles is crucial for achieving accurate dimensions and desired surface finishes. Shapers are commonly used in industries such as automotive and tool manufacturing, while Planners find applications in shipbuilding and construction. Common issues faced while using these machines include uneven cutting, tool wear, vibration, inaccurate cutting dimensions, poor surface finish, and tool misalignment. By addressing these issues and considering factors such as workpiece size and shape complexity, manufacturers can choose the appropriate machine for their specific needs.

Analogy

Imagine a Shaper as a small precision knife that delicately carves intricate designs on a piece of wood, while a Planner is like a heavy-duty saw that cuts through thick logs to create flat surfaces. Just as the knife and saw have different purposes and capabilities, Shapers and Planners are designed for different workpieces and machining requirements.