05/09/2019

SAFETY PRECAUTIONS
WHEN WORKING WITH SHAPING MACHINES
1. Wear approved goggles or face shield.
2. Select proper tool for the job.
3. Be sure that the tool, tool head, table, and table support are
secure before starting the machine.
4. Remove all wrenches before starting the machine.
5. Select the proper speed, feed, and depth of cut according to the
kind of material, type of tool, and method of holding the work.
6. Stand parallel to the direction of the stroke of the machine when
it is operating, and never reach across the table between strokes.
7. Do not touch the tool, clapper box, or w/p while the machine is
running.
8. Make adjustments on the work setup only when the machine is
stopped.
9. Turn off the machine before leaving it.

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SHAPER MACHINES
One of the most common and useful m/c found in the machine shop is
the shaper.

• The shaper is used primarily for machining flat surfaces with a single
point tool.

• Following type of the works we can perform on this machine.

Cutting external and internal key-way, dovetail, T-slots, gear racks,
grooves, and miscellaneous shapes can be machined on the
shaper.

• In this machine, the cutting tool reciprocates or moves backward and

forward.

• Cutting takes place only on the forward stroke.

TYPES OF SHAPER MACHINES

Three types of shapers commonly found in a machine shop are
1 . Crank 2. Gear 3. Hydraulic
The size of a shaper is determined by the largest cube which it can machine.
1.CRANK SHAPER
• Most commonly used.
• Its ram is given reciprocating motion by means of a rocker arm operated
by a crank pin from the main driving gear, or "bull wheel."
• The forward stroke of the shaper occurs when the crank pin is in the
upper portion of the rocker arm
• The return stroke occurs when the pin is in the lower portion .
• The return stroke to be faster than the forward stroke on a 3:2 ratio.

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CRANK MECHANISM
The shaping machine is used to machine flat metal surfaces especially where
a large amount of metal has to be removed. Other machines such as milling
machines are much more expensive and are more suited to removing smaller
amounts of metal, very accurately.

The reciprocating motion of

the mechanism inside the
shaping machine can be
seen in the diagram. As the
disc rotates the top of the
machine moves forwards
and backwards, pushing a
cutting tool. The cutting
tool removes the metal
from work which is
carefully bolted down.

CRANK SHAPER….

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MAIN PARTS OF CRANK SHAPER MACHINE

MAIN PARTS OF CRANK SHAPER MACHINE

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 RAM
 TOOL HEAD
 CROSSFEED TRAVERSE CRANK
 TABLE

Tool Head Assembly

TYPES OF SHAPER MACHINES

2. GEAR SHAPER

The gear shaper obtains

the drive for the ram
from a gear and a rack 3. HYDRAULIC SHAPER
connected to the ram.
The hydraulic shaper is
This shaper also has a
driven by the movement
mechanism that provides
of a piston in a cylinder
a quick return for the
of oil and is controlled
ram.
by a valve mechanism
connected with the oil
pump.

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VARIOUS OPERATION PERFORMED ON A SHAPING MACHINE

a. Horizontal shaping
b. Vertical shaping
c. Angular shaping
d. Irregular cutting
e. Slots & Keyways
f. Gear cutting, etc.

SHAPER TO BE USED FOR DIFFERENT TYPES OF WORK

f: The top slide is slowly

feed into the material so The tool post has been
that a ‘rack’ can be turned at an angle so that
machined for a rack and side of the material can be The tool post is not angled
machined so that the tool can be used
pinion gear system.
to level a surface.

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CALCULATIONS OF SHAPER CUTTING SPEEDS

Inch Speed Calculations

To obtain number of strokes per minute.

N = (CS *7)/ L
Where

N = number of strokes per minute

L = length of work plus 1 in. for tool clearance
CS = cutting speed of metal in feet per minute

CALCULATIONS OF SHAPER CUTTING SPEEDS

Metric Speed Calculations

Strokes per minute

N = (CS*0.6)/L
Where
N = number of strokes per minute
L = length of work plus 0.025 m for tool clearance
CS = cutting speed of metal in meter per minute

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CALCULATIONS OF SHAPER CUTTING SPEEDS

Example:
How many strokes per minute are required to machine a 330 mm-long piece
of tool steel (CS= 15m)
Length of stroke L = 330 + 25 mm clearance
Convert L to meters = 355/1000
= 0.36 m

= 25 strokes / min

SELECTING AND MOUNTING SHAPING TOOLS

CUTTING TOOLS USED IN SHAPING
Two basic kinds are used.

1. Forged tools:

These type of tools are heavy tools.

 Round Nose Tool

 Square Nose Tool
 Side Tool
 Goose Neck Tool
 Parting off

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CUTTING TOOLS USED IN SHAPING

2. Tool bits are more widely used than forged tools because of their lower cost.