Shaping Machines

Shaping is a machining process of removing the excess material from the workpiece
by means of a single-point cutting tool held in a reciprocating ram. The process is
employed to produce flat surfaces (horizontal, vertical or inclined), grooves, T-slots,
dovetail slot etc. The machine used for performing the operation is called shaping
machine or shaper.

Principle of shaping:

In operation, the workpiece is clamped rigidly on the machine table and a single-
point cutting tool is held in the tool post mounted on the ram of the shaping machine.
The ram reciprocates the tool to and fro across the workpiece as shown in figure
3.10(a). Hence, the ram makes two strokes during the cutting process. These two
strokes are called cutting stroke and return stroke as shown in figure 3.10 (b) and
3.10 (c).

During cutting stroke, each time the tool moves forward, it cuts a small thin strip of
a metal from the workpiece as shown in figure 3.10(b). No cutting of material takes
place during the return stroke of the ram and hence, this stroke is called idle stroke.
During return stroke, the tool is lifted clear of the workpiece, reducing the cutting
action to one direction only. Refer figure 3.10(c).

The workpiece is given an indexed feed (equal amount after each cut) in a direction
perpendicular to the line of action of the cutting tool. Shaping is a relatively simple
process used often in the tool room. Tooling is simple, and the machine does not
always require operator attention while cutting.

Classification of shaping machines (Shaper):

Shapers may be classified according to:
a) Design of work table
• Standard shaper
• Universal shaper
b) Driving mechanism
• Crank shaper
• Geared shaper
• Hydraulic shaper
c) Design of travel of ram
• Horizontal shaper
• Vertical shaper
• Traveling head shaper
d) Nature of cutting stroke
• Push cut shaper
• Draw cut (pull type) shaper

Based on Design of Worktable

Standard Shaper
In a standard shaper, the worktable is provided with only vertical and horizontal
movements. The table may or may not have the vertical supports at its front.
Standard shaper is also known as plain shaper, since it consists of a plain worktable.
Horizontal Shaper:

Figure 3.11 shows the principal parts of a horizontal shaper, It consists of the
following parts:
• Base
• Column or pillar
• Cross-rail and saddle
• Table
• Ram
• Tool head

a) Base
The base of the horizontal shaper is a heavy cast iron body that supports all the other
parts of the machine. The entire weight of the machine parts, and also the forces
generated during the cutting is taken by the base. The base is secured rigidly to the
floor with the help of foundation bolts and nuts.

b) Column
The column, also called pillar or body, is a rigid hollow casting mounted on the base.
It houses the driving motor, control devices, and the mechanism for driving the ram
and the worktable. At the top of the column, there are two machined guideways on
which the ram reciprocates. The front face of the column is also provided with two
guideways. The cross-rail slides vertically
along these guideways.

c) Cross-rail
The cross-rail is mounted on the front vertical guideways of the column. It can be
raised or lowered by means of an elevating screw to accommodate workpiece of
different heights. The cross-rail is provided with two horizontal guideways in its
front face perpendicular to the ram movement. Refer figure 3.12(a).The saddle,
which supports the worktable, is gibbed to the cross-rail on the horizontal
guideways. This enables the worktable to be moved along the horizontal guideways
of the cross-rail. The cross-rail also carries the table cross-feed screw, together with
the Pawl and Ratchet intermittent drive mechanism.

d) Worktable
The worktable is a box shaped casting bolted to the saddle. Refer figure 3.12(a). The
table is provided with two movements in the horizontal and vertical directions. The
table slides on the horizontal guideways of the cross-rail. This movement is obtained
by rotating the cross-feed screw, either manually or using power. Also, since the
cross-rail can slide vertically along the guideways on the front face of the column,
the saddle along with the table can also move vertically. The vertical movement of
the table is obtained by means of an elevating screw.

The worktable is provided with T-slots on its top, and on one side for clamping the
work. It also has a v-groove machined in the vertical side to carry cylindrical
workpieces. The front face of the table is supported by an adjustable table support
to withstand the weight of the workpiece and the cutting action during operation.

e) Ram
The ram is a rigidly braced casting, and of semi-cylindrical form located on the top
of the column. The ram reciprocates on the guideways provided on top of the column
by means of a slotted link mechanism. The starting point and the
length of the stroke can be adjusted by means of a reciprocating mechanism housed
in the column. The cutting tool is attached to the ram via a tool holder and head.

f) Tool head
The tool head is mounted at the front end of the ram. The tool head holds the tool
and imparts the necessary vertical and angular feed movements of the tool.
Vertical movement
The tool head consists of a vertical slide, which can be moved up and down by
means of a tool feed handle. Refer figure 3.12(b). The downward movement of the
slide gives the necessary vertical movement to the cutting tool (depth of cut). A
graduated collar provided on the top of the vertical slide helps for the accurate
movement of the vertical slide, and hence the cutting tool.

Angular movement
At the back of the vertical slide, is provided a graduated plate, called swivel plate,
which is bolted to the front of the ram. The swivel plate can be unbolted and tilted
to the desired angle to make the tool head inclined with the vertical axis to machine
angular surfaces.
In front of the vertical slide, is the apron, which carries the clapper box. The apron
can be swiveled to either side of the vertical and this is required during machining
of angular surfaces. The clapper box carries the tool holder in which the tool is held
vertically by means of a tightening screw. The clapper box allows the cutting tool to
lift during the return stroke thereby preventing the scratching of the tool on the job.

OPERATIONS ON A SHAPER
A few of the various operations that can be performed on a shaper are discussed
briefly below.

a) Horizontal shaping or cutting

Horizontal cutting is the most common operation carried out on a shaper to obtain
flat surfaces. Refer figure 3.35. The job is held rigidly on the worktable and an
appropriate tool is held in the tool head of the shaper. The length and position of the
stroke are adjusted to machine the entire length of the workpiece. Normally, the
stroke is adjusted in such a way that the tool begins the forward stroke from a
distance of around 15 mm from the beginning of the cut and end the stroke at a
distance of 5 mm after the end of the cut. The cutting feed and speed are adjusted
depending on the rough-cut or finish-cut desired. Cross-feed to the table, before the
cut is given manually by hand, and once the cut starts, power feed can be employed.
The depth of cut is given by the down feed screw of the tool head.
b) Vertical shaping
Vertical shaping is done on the vertical sides of the workpiece by feeding the tool in
the downward direction as shown in figure 3.36. In operation, the vertical surface of
the workpiece is set parallel with the ram movement. A
side-cutting tool is held rigidly in the tool head of the shaper, and the stroke length
and position is adjusted suitably. The vertical slide of the tool head is set at zero
position of the swivel base. The apron is tilted in a direction away from the surface
of the workpiece being cut. This prevents the rubbing of the tool with the machined
surface during the return stroke. The vertical downward motion of the tool at the
end of each stroke is given by rotating the down feed screw of the tool head.

c) Angular shaping
.
Angular shaping is employed for machining inclined surfaces, beveled surfaces,
dovetails etc. Figure 3.37 shows the angular shaping operation for cutting dovetails
in workpieces. The vertical surface of the workpiece is set parallel with the ram
movement. A dovetail cutting tool is held rigidly in the tool head of the shaper. The
vertical slide of the tool head is swiveled to the required angle. The apron is tilted in
a direction away from the surface of the workpiece being cut. Down feed to the tool
is obtained by rotating the down feed screw handle.
d) Shaping of slots and keyways

Figure3.38 and 3.39 shows the operation of slotting, cutting steps and keyways on
workpieces.
 PLANING MACHINE (PLANER)
Planing is a machining operation of removing the excess material from the
workpiece by means of a single-point cutting tool, which is held stationary' while
the worktable carrying the workpiece is being reciprocated beneath the cutting tool.
Planing is preferred primarily for large and heavy workpieces that cannot be worked
by shaping operation. The type of surface machined by planning may be horizontal,
vertical or inclined. The machine used for planing operation is called a planing
machine or a planer. Figure 3.13 shows the principle of operation of a planer.

In operation, the workpiece is clamped on the worktable, and a single-point cutting

tool is secured rigidly in the tool head of the machine. The table carrying the
workpiece is reciprocated beneath the stationary cutting tool. The tool is given feed
in the transverse direction, i.e., perpendicular to the direction of motion of the table,
and also in the vertical direction for obtaining the required depth of cut.The tool is
fed only when the workpiece is moving in the return stroke.

CLASSIFICATION OF PLANER
According to the general construction of the machine, planers are classified into the
following types:
• Standard or Double housing planer
• Open side planer
• Pit type planer
• Divided table planer
• Edge or plate type planer
a) Standard or Double housing planer
It is the commonly used type of planer. It consists of mainly a massive bed on which
the worktable reciprocates, and two vertical columns or housings: one on each side
of the bed as shown in figure 3.14. Each column carries a tool head that can slide up
and down on the column. A cross-rail fitted between the two columns may carry one
or two tool heads that can slide horizontally on the cross-rail. All the tool heads can
be clamped in position, and can be used collectively or individually depending on
the requirements.

DOUBLE HOUSING PLANER

Figure 3.17 shows the simplified diagram of a double housing planer. The machine
consists of the following parts:
• Bed
• Worktable
• Column or housing
• Cross-rail
• Tool head
a) Bed
The bed is a large cast iron casting. It forms the foundation of the machine, wherein
other parts are attached to, or supported by the bed. For very large machines, the bed
may sometimes be made in two parts and then bolted to form a single structure. The
bed carries either V-ways or flat ways to support and guide the worktable. Normally,
the length of the bed will be twice as long as the table.

b) Worktable
The worktable is a heavy rectangular casting, which carries the workpiece past the
cutting heads. It travels on the guideways of the bed. The top surface of the table is
provided with T-slots to facilitate clamping of workpiece or vices and special
fixtures. The side of the table has a groove to carry adjustable stops to reverse the
motion at the end of each stroke.

c) Column or housing
The machine consists of two vertical columns or housings, one on each side of the
bed. The columns are fastened together at the top with a large bracing section, and
fastened at the bottom to the machine bed. This arrangement creates a very strong
and a rigid structure capable of machining large and heavy workpieces. The front
face of the column is provided with guideways for the cross-rail to slide up and down
on the two columns. Two side tool heads, holding the cutting tools are mounted on
each of the vertical column. The side tools can move up and down
on the vertical column ways, and also can be fed horizontally onto the job or at any
desired inclination for machining angular surfaces. The column houses different
mechanisms for transmitting power from the main drive to the upper parts of the
machine like cross-rail, elevating screws etc.

d) Cross-rail
The cross-rail is a horizontal member connecting the two vertical columns of the
machine. The cross-rail slides up and down on the vertical guideways of the two
columns by means of elevating screws and can be clamped to any desired position.
The cross-rail is provided with guideways at its front for the two vertical heads to
move towards the left or right end of the machine. The two vertical heads can be
rotated and adjusted for depth of cut. They also have a clapper box that allows the
cutting tool to lift during the return stroke thereby preventing the scratching of the
tool on the job. Either both the vertical heads can be used simultaneously, and
anyone of them can be used depending on the requirements. In such situations, one
of the vertical head is pushed to the extreme end of the cross-rail to enable the other
vertical head to cover the entire surface of the workpiece.
e) Tool head
The tool head of a planer is similar to that of a shaper in both construction and
operation. The machine has four tool heads: two heads in vertical position on the
cross-rail, and the other two heads mounted on each of the two columns below the
cross-rail. All the four tool heads can be operated at a time or individually depending
on the needs, and also can be swiveled for making angular cuts.

SPECIFICATION OF PLANER:

• Horizontal distance between two housings.

• Maximum vertical distance between the cross rail and the table

• Maximum length of table travel or length of stroke

• Length of bed

• Size of table

• Method of table driving mechanism.

• Number of tool heads used.

COMPARISON BETWEEN SHAPER & PLANER

Both shaper and planer use single point cutting tools and cut only in straight lines.
Also, both the machines make the same type of cuts. However, a few features
distinguish both the machines in terms of construction and operation. Table 3.3 gives
a brief comparison between the two machines.
DRIVING MECHANISM OF A PLANER

A planer driving mechanism provides the longitudinal reciprocating motion-to the

worktable. The following methods are employed for the said purpose:
• Open and cross belt drive mechanism
• Hydraulic drive mechanism.
• Reversible motor drive mechanism
Open & Cross Belt Drive Mechanism

In this mechanism, open and cross belt drive is used to transfer motion from the
countershaft (or electric motor) to the pinion, which moves the rack fitted under the
worktable thereby making the worktable to reciprocate. Figure 3.21 shows the
simplified arrangement of the drive mechanism for a double housing planer.
The open and cross belt driving mechanism consists of a main driving motor situated
over the housings of the machine (not shown in figure). The motor drives the
countershaft through an open V-belt. The countershaft at its extreme end carries two
driving pulleys: one for open belt drive and the other for cross belt drive. The main
driving shaft provided below the bed of the machine carries a pinion, which meshes
with the rack fitter under the worktable. The extreme
end of the driving shaft carries two pairs of pulleys: each pair consisting of a fast
pulley (tight pulley) and a loose pulley. The larger tight pulley is used for the slower
forward or cutting stroke, while the smaller tight pulley is used for the quicker return
stroke. When the belt is on the loose pulleys, no power drive is transmitted.
To obtain return and forward stroke

To obtain the return stroke, the cross belt should be on the loose pulley, and the open
belt on Tight pulley. In this position, no drive is transmitted by the cross belt to the
main shaft, instead, the drive is obtained by the open belt, as it is mounted on the
tight pulley. The backward motion (return stroke) of the worktable takes place with
this arrangement. At the end of the return stroke, the trip dog (trip dog is mounted at
both the ends of the worktable) pushes the belt shifter causing the belt to shift to the
right side. In other words, the open belt which was on the tight pulley shifts on the
loose pulley, while the cross belt which was on the loose pulley shifts on the tight
pulley. The cross belt, which is now on the tight pulley drives the shaft causing the
worktable to move forward, and hence the cutting stroke to take place. Due to the
cross belt drive arrangement, the direction of rotation of the main shaft, and hence
the worktable is reversed. At the end of cutting stroke, the trip dog activates the belt
shifter to move the belts towards the left side, and thus the table movement is
reversed. Thus the continuous forward and return motion of the worktable takes
place by shifting the belt back and forth on the tight and loose pulleys. The length
and position of the stroke may be adjusted by adjusting the position of the trip dogs
on the worktable.

The cross belt is mounted on a larger diameter tight pulley, which causes the shaft
to rotate at slow speeds. Hence the forward motion (cutting stroke) of the worktable
takes place at slow speeds. On the other hand, the open belt drive is mounted on the
smaller diameter tight pulley, which cause the shaft to rotate at high speeds. Hence,
the backward motion (return stroke) of the worktable takes place at a faster rate
thereby achieving the quick return motion mechanism.