UNIT 1 SHAPING MACHINE

Shaper Machine Definition:

The Shaper Machine is a reciprocating machine tool used to produce Horizontal, Vertical, or Inclined flat surfaces
using straight-line reciprocating single-point cutting tools similar to those which are used in wood lathe machines.
The flat surface produced may be horizontal, vertical, or inclined at an angle.

Working Principle of Shaper Machine:

A shaper machine is working on the following principle
 A shaper machine holds the Single point cutting tool in ram and the workpiece is fixed over the table.
 The ram holding the tool reciprocates over the workpiece and metal is cut during the forward stroke called a cutting
stroke
 No metal is cut during its return stroke is called an Idle stroke.
 The feed is given at the end of the cutting stroke.
 Generally, the cutting stroke is carried out at a slow speed and the idle stroke is carried out at a high speed with the
help of a quick return mechanism.
 In the shaper machine, there is another mechanism called the Quick return Motion Mechanism.

Parts of shaper machine

Base: The base is hollow and is made of cast iron. It provides the necessary support for all the other parts
of the machine. It is rigidly bolted to the floor of the workshop.
Column: It is a box like casting mounted vertically on top of the base. Two accurate guide ways are
machined on the top of the column. The ram reciprocates on these guide ways. The front face of the column
is provided with two vertical guide ways. They act as guide ways for the cross rail. Cross rail moves
vertically along these guide ways. The column encloses the ram reciprocating mechanism and the
mechanism for stroke length adjustment.
Cross rail: It is mounted on the front vertical guide ways of the column. The table may be raised or lowered
by adjusting the cross rail vertically. A horizontal cross feed screw is fitted within the cross rail.
Table: It is an important part useful in holding the work firmly on it. It is mounted on the saddle which is
located above the cross rail. The top and sides of the table are accurately machined and have T-slots. Work
pieces are held on the table with the help of shaper vise, clamps and straps.
Ram: Ram supports the tool head on its front. It reciprocates on the accurately machined guide ways on
the top of the column. It is connected to the reciprocating mechanism placed inside the column. The position
of ram reciprocation may be adjusted according to the location of the work on the table
Tool head: The tool head is fitted on the face of the ram and holds the tool rigidly. It provides vertical and
angular feed movement of the tool. The swivel tool head can be positioned at any required angle and the
vertical slide can be moved vertically or at any desired angle to machine vertical or inclined surfaces.
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Advantages of shaper
 The single point cutting tool used in shapers is inexpensive.
 Single point cutting tool can be easily grounded to any desirable shape.
 The simplicity and ease of holding work.
 Easy adjustment and the simple tool give the shaper its great flexibility.
 Shaper set up is very quick and easy and can be readily changed from one job to another.
 Lower cost.
 Thin and fragile jobs can be conveniently machined on shaper because of lower cutting forces.
Disadvantages of shaper
 Due to simple point tooling shaper is not suited for production work.
 Slower machining process compare to other machining process due to single point cutting tool is used.
 Slower machining process compare to other machining process due to lesser cutting speed.
 Shaper is limited in holding close tolerance because of the long unsupported overhang of the arm at the
end of each stroke.

Application of shaper
 Machining horizontal surface
 Machining vertical surface
 Machining angular surface
 Machining irregular surface
 Machining splines & Machining a “V” block
 Cutting external & internal gears.
 Cutting slots, T-slots & grooves, etc.
 Cutting external & internal keyways
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1.Bases on the Type of Driving Mechanism
1.1 Crank type shaper
Crank and slotted link mechanism of a crank type shaper converts the rotation of an electric motor into
reciprocating movement of the ram. Though the lengths of both the forward and return strokes are equal,
the ram travels at a faster speed during return stroke. This quick return is incorporated in almost all types
of shaper. In construction, the crank shaper employs a crank mechanism to change the circular motion of a
large gear called "bull gear" incorporated in the machine to reciprocation motion of the ram. It uses a crank
mechanism to convert the circular motion of the bull gear into reciprocating motion of the ram. The ram
carries a tool head at its end & provides the cutting action.

1.2 Hydraulic shaper

The ram of a hydraulic shaper is connected to a piston. Oil at high pressure is pumped to the cylinder of
the hydraulic system. As the oil pushes the the piston, the ram reciprocates. Hydraulic shapers are high
power machines and are used for heavy duty work.

The high-pressure oil first acts on one side of the piston and then on the other causing the piston to
reciprocating and the motion is transmitted to the ram. The main advantages of this type of shaper machine
are that the cutting speed and force of the ram drive are constant. From start to end of the cut without
making noise and operates quietly.

1.3 Gear Type Shaper Machine

In these types of shaper machines, the ram is reciprocating. The ram is affecting due to reciprocating motion
with the rack and pinion. The rack teeth are cut directly below the ram mesh with the spur gear. The speed
and the direction in which the machine will traverse depend on the number of gears in the gear train. This
type of shaper machines is not widely using in any industry.
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2. Based on Ram Travel

2.1Horizontal Shaper Machine

In these types of shaper machines, the ram is reciprocating. The ram holding the tool in a horizontal axis
and reciprocate. This type of shaper is using for the production of flat surfaces, external grooves, keyways
etc.

2.2Vertical Shaper Machine

In these types of shaper machines, the ram reciprocating in the verticle plane. In this, the table holds the
workpiece. Verticle shapers maybe crank driven, rack-driven, screw-driven, or hydraulic power-driven.
The vertical shaper is very convenient for machining internal surfaces, keyways, slots, or grooves. The
workpiece can move in any given direction such as the cross, longitudinal or rotary movements. This type
of shaper is suitable for machining internal surfaces, slots & keyways
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3.Based on The Table Design

Following are the different types of shaper machine based on the table design.
3.1 Standard Shaper Machine
In this types of shaper machines, the table has only two movements, vertical and horizontal, to give the
feed. That's why it known as standard shaper machine. Here the table is not supporting at the outer end.
3.2 Universal Shaper Machine
In this types of shaper machines, in addition to the two moments i.e. vertical and horizontal, the table can
be moving in an inclined axis and also it can swivel on its own axis. Since the workpiece mounted on the
can be adjusted in different planes, the shaper os suitable for a different type of operations and is given the
name "Universal". This type of shaper is commonly using the tool room works.

4.Based on Cutting Stroke

4.1 Push cut Shaper Machine
In these types of shaper machines, the metal is removed in the forward motion of the ram. This is commonly
used types of shaper machines.
4.2 Draw cut Shaper Machine
In these types of shaper machines, the metal is removed in the backward motion of the ram. In this shaper,
the tool is fixed in the tool head in the reverse direction so that it provides the cutting action in the reverse
stroke of the ram.

Quick return mechanism

For the Quick return mechanism, In the forward stroke, the Slider moves fast and removes the material from the
workpiece. Whereas in the return stroke, the Slider moves faster than the forward stroke which means Quick return,
it takes less time to return, called a return stroke.
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Components of a Quick Return Mechanism

The various components of a Quick Return Mechanism are:

Crank - The crank is connected to the pinion wheel or motor and rotates with a uniform angularvelocity.

Slider & Slotted Bar - The slider is pivoted at the end of the crank, allowing free movement into the slotted
bar. Its function is to convert the circular motion of the crank into the oscillatingmotion of the slotted bar.

Connecting Rod - The connecting rod is responsible for converting the oscillating motion of the slotted bar
into reciprocating motion.

Ram - The ram moves back and forth in the horizontal direction along the line of stroke, completing the
reciprocating motion.

Types of Quick Return Mechanism

Whitworth Quick Return Mechanism

Fig 2: Whitworth Quick Return Mechanism

The Whitworth Quick Return Mechanism converts rotating motion into oscillatory motion using a bull gear with a
crank pinion. An electric motor shaft drives the crank pinion, and the bull gear rotates in synchronisation with the
crankpin. The connecting rod is connected to the ram on one end and slides over the crankpin and into the slot of
a crank plate on the other end. This arrangement causes the connecting rod to move the ram up and down during
operation.
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Crank and Slotted Link Mechanism

Fig 3: Crank and Slotted Link Mechanism

The Crank and Slotted Link Mechanism, devised by Whitworth in the 1800s, consists of a slider, crank,
fixed link, slotted lever, connecting rod, and ram. The crank is connected to the slider and fixed link. When
the cranks start to rotate, the connecting rod drives the ram forward and backwards. This mechanism
translates rotational motion into linear motion and is commonly used in shaping machines such as slotters
and shapers to produce flat surfaces on workpieces. Notably, the return stroke is significantly faster than
the forward stroke in this mechanism.

Hydraulic Drive

Fig 4: Hydraulic Drive

The Hydraulic Drive features a reciprocating piston inside a hydraulic cylinder, with the piston rod positioned
between the ram and the piston. As a result, the piston reciprocates along with the ram. The hydraulic cylinder has
two entries at its end, connected to a control valve with four passages located below it. The remaining two entries
from the cylinder to the control valve are linked through a reservoir. This mechanism utilises hydraulic pressure to
drive the reciprocating motion of the ram.

Size of shaper machine

The size of a shaper The size of a shaper is determined by the maximum length of stroke it can make.
Shapers with maximum stroke length of 175mm to 900mm are available. Machines with maximum stroke
length of 300mm, 450mm and 600mm are used widely.
 UNIT 1 SHAPING MACHINE
To specify the machine further, the following points are to be provided.

 The type of drive

a) Individual motor b) Belt driven
 The method of obtaining different speeds
a) Gear box b) Step cone pulley
 Horse power of the motor
 Cutting to return stroke ratio
 Number and range of speed arrangement
 The type of the table

Stroke length calculation and adjustment

The length of the stroke is calculated to be nearly 30mm longer than the work. The position of stroke is so
adjusted that the tool starts to move from a distance of 25mm before the beginning of the cut and continues
to move 5mm after the end of the cut. For example, as shown in Fig. 3.5, the length of the work is 100mm.
The stroke length of the ram is calculated to be 130mm. (25+100+5). Fig. illustrates the calculation of
stroke length.

Adjusting the stroke length

The crank pin fastened to the sliding block can be adjusted by a lever placed outside the column. Through
the bevel gears placed at the centre of the bull gear, the radial slide lead screw can be rotated. This rotation
of lead screw changes the position of the sliding block to move towards or away from the bull gear centre.
The stroke length of the ram is adjusted by placing the sliding block at a required position from the centre
of the bull gear.
Note: The stroke length of the ram and its position should not be adjusted when the machine is in operation.
The machine should be stopped before these adjustments are made.

Method of table movement

o The table moves in a cross direction when the cross feed screw is rotated.  A crank handle is provided
to rotate the cross feed screw manually.
o When the cross feed screw is rotated in clockwise direction, the table will move towards left.
o When the elevating screw is rotated, the table slides up and down on the face of the column.
o As the handles meant for cross feed screw rotation and elevating screw rotation are placed side by side,
it is not possible to operate both of them at the same time.
o The work mounted on the table is provided with required feed only during the end of the return stroke.

Ratchet and Pawl mechanism (Automatic feed mechanism for the table)
The table of a shaping machine travels in a cross direction when the cross feed screw is rotated. The cross
feed screw is attached to the ratchet wheel. A spring loaded pawl‘ is positioned to be placed between the
teeth of the ratchet wheel. The pawl is housed within a frame known as rocker arm. The bull gear placed
inside the column of the shaping machine drives the gear B through the gear A. There is a diametric slot
provided on the face of the gear B. A crank pin is attached to a slider placed in the slot. The bottom of the
rocker arm and the crank pin are connected by a connecting rod. The rotation of the gear B makes the crank
pin to rotate. This movement makes the rocker arm to rock about the center of the ratchet wheel. The pawl
makes the ratchet to rotate by a small amount in one direction only. As the cross feed screw is attached to
 UNIT 1 SHAPING MACHINE
the ratchet wheel, the rotation of the ratchet wheel will make the table to move in a cross direction. If the
direction of the table feed is to be reversed, the pawl is turned about 180° from its position. The ratchet
wheel and the cross feed screw will rotate in the opposite direction resulting in the table movement in the
opposite direction. When power feed is not necessary for the table, the pawl is disengaged from the ratchet
wheel.

Swivel tool head

The tool head of a shaper holds the cutting tool rigidly. It is fitted on the face of the ram. The vertical slide
of the tool head can be moved vertically or at a particular angle to provide vertical and angular feed
movement to the tool. It allows the tool to have an automatic relief during the return stroke of the ram.
The tool head has a swivel base attached to the circular seat on the ram. The swivel base has angular
graduations marked on it. As the vertical slide is mounted on the swivel base of the tool head, it may be set
and moved at any desired angle to machine angular surfaces like V grooves and dove tail grooves. The
down feed screw handle is rotated to move the vertical slide up and down. A graduated dial is placed on
the top of down feed screw to control the amount of depth of cut or feed accurately. Apron consisting of
clapper box, clapper block and tool post is clamped on the vertical slide by a screw. By releasing the
clamping screw, the apron can be swivelled either towards left or towards right with respect to the vertical
slide. The clapper box has two vertical walls within which the clapper block is housed. It is connected to
the clapper box with the help of a hinge pin. This arrangement provides relief to the tool while machining
vertical or angular surfaces. The tool post is mounted upon the clapper block. The tool post is provided
with a slot to accommodate the tool and a screw to hold the tool rigidly on the tool post. The clapper block
fits securely inside the clapper box to provide a rigid tool support during forward stroke. On the return
stroke, a slight frictional drag of the tool on the work lifts the block out of the clapper box and prevents the
tool cutting edge from dragging on the work surface. Fig. illustrates the swivel tool head of a shaper.