Shahjalal University of Science and Technology,

Sylhet
Department of Chemical Engineering & Polymer Science
Workshop Report
Experiment No: 04
Experiment Name: Study & Operation of Shaper Machine
Course Name: Workshop Practise
Course No: IPE -208
Submitted to: Submitted by:
Engr. Mohammed Abdul Karim
Registration no Name
Assistant Professor 2016332005 Sourav Sutradhar
Muhammad Abdus Samad 2016332008 Tamara Ferdous
Assistant Professor 2016332046 Shubhashes Paul
Group no: 01 Niloy
2015332049 Mohammad Farhan
Date of Experiment : 05-03-18
2015332057 Md. Razaul Karim
Date of Submission : 12-03-18

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Introduction:
The shaper is a reciprocating type of machine tool intended primarily to produce flat surfaces.
These surfaces may be horizontal, vertical, or inclined. In general the shaper can produce any
surface compost of straight line element. Modern shaper can generate contoured surface. Shapers
were very common in industrial production from the mid-19th century through the mid-20th. In
current industrial practice, shapers have been largely superseded by other machine tools (especially
of the CNC type), including milling machines, grinding machines, and broaching machines. But
the basic function of a shaper is still sound; tooling for them is minimal and very cheap to
reproduce; and they are simple and robust in construction, making their repair and upkeep easily
achievable. Thus they are still popular in many machine shops, from jobbing shops or repair shops
to tool and die shops, where only one or a few pieces are required to be produced and the alternative
methods are cost or tooling-intensive. A shaper is a type of machine tool that uses linear relative
motion between the work piece and a single-point cutting tool to machine a linear tool path. Its cut
is analogous to that of a lathe, except that it is (archetypal) linear instead of helical. (Adding axes
of motion can yield helical tool paths, as also done in helical planning.) A shaper is analogous to
a planer, but smaller, and with the cutter riding a ram that moves above a stationary work piece,
rather than the entire workpiece moving beneath the cutter. The ram is moved back and forth
typically by a crank inside the column; actuated shapers also exist.

Objective:
After completing this experiment, we will be able to:

(A) To understand basic concept of tools, requirement of shaper machine.

(B) To understand concept of working.

Operations:
Types of Shapers- There are different types of Shaper machines. We can classify them as given
below-

According to the position and travel of the arm

 Horizontal type
 Vertical type and
 Traveling-head type
According to the type of design of the table

 Standard shaper and

 Universal shaper

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According to the type of cutting stroke

 Push type and

 Pull \ Draw type

According to the type of mechanism used

 Crank type

 Geared type and

 Hydraulic type

Crank Shaper:
Among all the Shapers Crank shaper is the most common. This is the most common type of shaper
where a single point cutting tool is given a reciprocating motion equal to the length of the stroke
desired while the work is clamped in position on an adjustable table. In construction, the crank
shaper employs a crank mechanism to change circular motion of a larger gear called ‘bull gear’
incorporated in the machine to reciprocating motion of the ram. The bull gear receives power either
from an individual motor or from an overhead line shaft if it is a belt driven shaper.

The principle parts of shaper machine:

 Base:
The base is a heavy cast iron casting which is fixed to the shop floor. It supports the body
frame and the entire load of the machine. The base absorbs and withstands vibrations and
other forces which are likely to be induced during the shaping operations.
 Body (Pillar, Frame, and Column):
It is mounted on the base and houses the drive mechanism compressing the main drives,
the gear box and the quick return mechanism for the ram movement. The top of the body
provides guide ways for the ram and its front provides the guide ways for the cross rail.
 Cross rail:
The cross rail is mounted on the front of the body frame and can be moved up and down.
The vertical movement of the cross rail permits jobs of different heights to be
accommodated below the tool. Sliding along the cross rail is a saddle which carries the
work table.

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 Ram:
The ram is driven back and forth in its slides by the slotted link mechanism. The back and
forth movement of ram is called stroke and it can be adjusted according to the length of the
work piece to be-machined.
 Tool head:

It is situated at the front of the ram. Its main function is to hold the cutting tool.
The tool can be adjusted on it by some of clamps.

 Table:

It is the metal body attached over the frame. Its main function is to hold the work
piece and vice over it. It has two T slots which used to clamp vice and work piece
over it.

 Clapper box:

It carries the tool holder. The main function of clapper box is to provide clearance
for tool in return stock. It prevents the cutting edge dragging the work piece while
return stock and prevent tool wear.

 Column:

Column is attached to the base. It provides the housing for the crank slider
mechanism. The slide ways are attached upper section of column which provide
path for ram motion.

 Cross ways:

It consist vertical and horizontal table sideways which allow the motion of table. It
is attach with some cross movement mechanism.

 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 table
during working.

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Shaper size :
Size and Specification of Shaper Machine Points : Size and Specification of Shaper Machine,
Size and Specification of shaping Machine Highest length of cut it can take gives the dimension
of shaper common size range as of 175 mm to 900 mm. In adding to this, extra details also
required to detail a shaper. Specification of a shaper as follows:

Ram cycles per minute or strokes per minute 15 to 90

Highest vertical travel of toot slide 150mm

Highest horizontal travel of table 450mm

Dimension of side table 473mm x 330mm

Floor space necessary 1981mm x 1067mm

Limit vertical travel of table 475m

Fairly accurate net weight 1750kg

Power of the motor 3 HP

Extent of stroke 610mm

Working condition of shaper machine:

A shaper operates by moving a hardened cutting tool backwards and forwards across the work
piece. On the return stroke of the ram the tool is lifted clear of the work piece, reducing the cutting
action to one direction only. The work piece mounts on a rigid, box-shaped table in front of the
machine. The height of the table can be adjusted to suit this work piece, and the table can traverse
sideways underneath the reciprocating tool, which is mounted on the ram. Table motion may be
controlled manually, but is usually advanced by an automatic feed mechanism acting on the feed
screw. The ram slides back and forth above the work. At the front end of the ram is a vertical tool
slide that may be adjusted to either side of the vertical plane along the stroke axis. This tool-slide
holds the clapper box and tool post, from which the tool can be positioned to cut a straight, flat
surface on the top of the work piece. The tool-slide permits feeding the tool downwards to deepen
a cut. This adjustability, coupled with the use of specialized cutters and tool holders, enable the
operator to cut internal and external gear tooth profiles, splines, dovetails, and keyways. The ram
is adjustable for stroke and, due to the geometry of the linkage, it moves faster on the return (non-
cutting) stroke than on the forward, cutting stroke. This action is via a slotted link or whit-worth
link.

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Cutting Time Calculation and Quick Return Mechanism:
Let L = the length of the stroke in mm

B = the breadth of the work material in mm

s = the feed expressed in mm / double stroke

m = the ratio of return time to cutting time

v = the cutting speed in meter / min

𝐿
Time taken to complete one double stroke = (l+m)
1000×𝑣

Total numbers of double strokes required to B/s complete the cut.

𝐿×𝐵(𝑙+𝑚)
 Total time taken to complete the cut, = where, m = (Return stock time) / (Cutting
1000×𝑣×𝑠
stroke time)

Shaper machine uses quick return mechanism to work more accurately. Here the ratio of cutting
stroke and return stroke is 3:2.

Cutting stroke : return stroke = 3 : 2

Discussion:
We learned a lot of things from today’s experiment. Such as- Clapper box is hinged at the top to
permit the tool to ride over the work on the return stroke. The cutting action of the shaper is
intermittent—the tool moves slowly on the cutting stroke and return quickly. It must be
remembered that the rpm of the crank gear is unchanging once it has been set. The ratio between
the forward and the return strokes is approximately 1 to 1.5 or 2 to 3, varying slightly with the
length of the stroke. To obtain the correct number of strokes per minute, multiply the cutting speed
by 7 and divided the product by the length of the stroke in inches. Also the tool head of the shaper
should be set at the same angle as that of the dovetail to be cut. When dovetail bearing such as
those shown in fig (Dovetail bearing) are to be cut, the work should not be distributed in shaping
the angular and flat surfaces of the dovetail. The horizontal surfaces should be machined before
completing the angular surface. A right-hand tool and left-hand tool are used to machine the
angular sides, one at a time, as shown in fig (Shaping a dovetail with a right-hand and left-hand
tool holder). Both a roughing and finishing tool should be used if considerable stroke is to be

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removed. In using two tools and moving the tool head from one side of the centre line to the other,
great care must be exercised; if there is any variation in the angular setting of the head, a variation
in the angular sides of the dovetail will result. In overall appearance there is very little difference
between the hydraulic and crank shaper. The ram of the crank shaper gets its movement from the
rocker arm, which is caused to move by the crank pin attached to the bull gear. The ram of the
hydraulic shaper is moved by oil pressure, which is developed by a pump driven by an electric
motor. And a planer is designed with a stationary housing for holding tool head and a table with
a reciprocating movement for holding the work; thus the work is moved against the cutting tool.
With the shaper, the work is held stationary and the cutting tool is moved across the work.

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Assignment:
Question 1: What is the function of a clapper box in a shaper machine ?
Ans: The shaping machine usually cuts on the forward stroke and does not on the backward
stroke. So it’s not required for the tool to be in contact with the work piece when it’s on the
backward stroke. This is ensured by the Clapper box, a device which is hinged to the ram. The
lifting of the cutting tool by the clapper box ensures longer tool life and also accidental scratch or
other machining defects on the work piece/final product.

Question 2: Write briefly the quick return motion mechanism with a net sketch.

Ans: A quick return mechanism is an apparatus that converts circular motion (rotating motion
following a circular path) into reciprocating motion (repetitive back-and-forth linear motion)
in presses and shaping machines, which are utilized to shape stocks of metal into flat surfaces,
throughout mechanical engineering. The quick return mechanism is the foundation behind the
energy of these machines. The mechanism consists of an arm attached to a rotating disc that
moves at a controlled uniform speed. Unlike the crank, the arm of the mechanism runs at a
different rate than the disc. By having the disc run at a different rate than the attached arm,
productivity increases because the amount of time needed for a cut is reduced. The design of this
mechanism specializes in vector calculus and the physical aspects of kinematics (study of motion
without the effects of forces) and dynamics (study of forces that affect motion).

Fig no. : Quick return motion

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Question 3: Explain how a dovetail slide way may be cut on a shapper with a net sketch.

Ans: The tool in place on the shaper, ready to cut. In some cases it'll be tough to find room for
everything: For not being careful, the tool slide will stub its toe on the work. To avoid this, one
may have to raise the tool slide up away from the work surface, and then extend the tool a good
long distance to reach the cut. Times like that, flex and chatter could cause real problems. This is
why it is used such a heavy piece of HSS to make the cutter. It's a workable solution.

Fig no. : Dovetail slide way cut on a shapper

Question 4: How a hydraulic shaper different from the more common crank shaper?
Ans: The difference is in the way the ram is moved. A crank driven shaper has a bull gear that
has a movable pivot sticking out. This engages a slot in a long arm. The arm has a pivot at one
end, and a connection to the ram at the other. As the gear rotates, the lever drives the ram
forward slowly, then retracts it quickly. By adjusting how far from the center the pivot is, you
adjust the stroke. In the case of the hydraulic shaper all those bits are replaced by a hydraulic
cylinder that drives the ram. It would be a lot simpler system, except for the controls needed to
set the stroke length. They may not be as precise with stroke length as a crank operated shaper in
good tune. (But for a lot of shaper work, that isn’t a concern). While the return is faster than the
cutting stroke, it usually isn't as big a difference as with the crank driven. They usually are a lot
more compact, and can take quite heavy cuts.

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Question 5: Write down the difference between a shaper and a planer.
Ans:

S.no Shaper Planer

In a shaper machine work is held

stationary and the cutting tool on the In a planar machine, the tool is stationary and
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ram is moved back and forth across the work piece travels back and forth under the tool.
work.

A planer is meant for larger jobs than can be

Shaper can be used for shaping much undertaken on a shaper. Jobs as large as 6 meter
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smaller jobs. wide and twice as long can be machined on a
planer.

3 A shaper is a light machine. A planer is a heavy duty machine.

Shaper can employ light cuts and finer

4 Planer can employ heavier cuts and coarse feed.
feed.

5 Shaper uses one cutting tool at a time. Planer uses several tools to cut simultaneously.

The shaper is driven using quick return The drive on the planer table is either by gears or
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mechanism. by hydraulic means.

Due to better rigidity of planer machine,

7 It is less rigid and less robust. compared to that of a shaper, planer can give
more accuracy on machined surfaces.

Question 6: Briefly discuss on a single point cutting tool is used in shaper other than a
single point used in an engine lathe.
Ans: The single point cutting tool has only one cutting point or edge. These tools used for
turning, boring, shaping or planning operations. These tools used on lathe, boring and shaper
machines. It is simplest from of cutting tool & it have only one cutting edge. The single point
cutting tool mainly consist of tool shank & cutting part called point. The point of cutting tool is
bounded by cutting face, end flank, side/ main flank, & base. The chip slide along the face.

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