LIST OF CONTENTS

CHAPTER 1

1.1Intorduction
1.1.1 Shaper Machine
1.1.2 Function of Shaper Machine
1.1.3 Types of Shaper Machine
1.1.4 Cranktypeshaper

CHAPTER 2

2.1 History
2.1.1Invention of Shaper Machine
2.2 Machine Tool
2.2.1 Usage

CHAPETR 3

3.1 Shaper Machine

3.1.1 Shaper Machine Components
3.1.2.1Types of Mechanism
3.1.2.1 With Worth QRM
3.1.2.2 Slotted QRM

CHAPTER 4

4.1 Rearanged Shaper Mechanism

4.1.1 Introduction of Gears
4.1.2 Types of Gears
4.1.2.1 External vs. Internal Gears
 4.1.2.2 Helical Gear
4.1.2.3 Bevel Gear
4.1.2.4 Hypoid Gear
4.1.2.5 Crown Gear

CHAPTET 5

5.1 Spur Gear Designe

5.1.1 Gear Ratio
5.2 Nomenclature of Gear

CHAPTER 6

6.1 Belt Drive

6.1.1 Introduction Of Belts
6.1.1.2 Types of belts
6.1..1.2.1 Flat Belts
6.1.1.2.2 Round Belts
6.1.1.2.3 Ribbed Belts
6.1.1.2.4 Film Belts
6.1.1.2.5 Specialy Belts
6.2 Usages
6.3 Specifications

CONCLUSION

REFERENCE
 ABSTRACT

Shaper is a reciprocating type machine tool which is primarily intended to produce flat surfaces.
The surfaces may be horizontal, vertical on inclined. This machine involves the use of a single point
cutting tool similar to a tool used in lathe machine.

The intermediate gear unit may comprise either a spur gear and a planetary gear assembly, or a pair
of planetary gear assemblies. Change of rotation within the gear unit can be effected easily.
Spur gear drive comprising a driven gear and driving gear wherein the driving gear has double crowned
teeth defined as (i) an envelope to a family of surfaces generated by a skew or straight rack-cutter having
a parabolic tooth profile in normal section and then (ii) as an envelope to a family of tool surfaces that are
generated while the tool performs a plunging motion with respect to the driving gear in the direction of
the shortest distance between the axes of rotation of the tool and the driving gear and tool plunging motion
is varied by a parabolic function, whose variable is displacement of the tool in a direction parallel to the
rotational axis of the driving gear.

The dual direction gear mechanism implemented in shaper machine in thispaper. There is used sun
gear, ring gear and plant gear. Ring gear and sun gearis meshed and the plant gear is meshed in sun gear.
The plant and sun gear is connected with electrical motor. The motor is rotating at clock wise direction the
ring and sun gear also rotating clock wise direction. The ring gear is having 50 teeth in 1800 and sun gear
is having 14 teeth in 1450 but plant gear is having 28 teeth in 3600.This plant gear is rotated by ring and
plant gear at so we get front and backward direction and also we get dual direction ram of the shaper
machine.
 CHAPTER 1

1.1 INTRODUCTION

1.1.1 SHAPER MACHINE

A shaper is machine used for producing flat surfaces on the given work piece. It can also be used
for doing any type of machining operations but with little difficulty. The shaper cuts the metal by
reciprocating motion of the tool carrying ram. The first metal working shaper was developed by James
Nasmyth in the year 1936

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 linear instead of helical. 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 work piece moving beneath the cutter.
The ram is moved back and forth typically by a crank inside the column; hydraulically actuated shapers
also exist.

1.1.2 FOUNTION 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 mountedon the ram

1.1.3 TYPES OF SHAPER MACHINE

Based on type of mechanism employed for the movement of the cutting tool i.e. tool carrying ram
the shapers are classified in to three types.
a .Crank type
b. Gear type
c. Hydraulic type

According to position and movement of ram the shapers are classifiedin to three types
Horizontal type
Vertical type
Travelling head type

Shapers are classified in to two types based on design of the work table
Standard shaper
Universal shaper

Based on type of cutting stroke employed these are classified in to

Push type
Draw type

1.1.4 CRANKTYPESHAPER

In these shapers the reciprocating ram is driven by crank mechanism. In this a single point cutting
tool is employed to do the operation. A crank is connected to the ram and the bull gear to which the
power is given through an individual motor. These are most common type of shapers being used. The
reciprocating length of tool will be always is equal to the length of stroke.
 CHAPTER 2

2.1 HISTORY

2.1 .1 INVENTION OF SHAPER MACHINE

Roe (1916) credits James Nasmyth with the invention of the shaper in 1836. 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. They also
have considerable retro appeal too many hobbyist machinists, who are happy to obtain a used shaper or, in
some cases, even to builda new one from scratch.

2.2 MACHIN TOOL

Before the Industrial Revolution of the 18th century, hand tools were used to cut and shape
materials for the production of goods such as cooking utensils, wagons, ships, furniture, and other products.
After the advent of the steam engine, material goods were produced by power-driven machines that could
only be manufacturedby machine tools. Machine tools (capable of producing dimensionally accurate parts
in large quantities) and jigs and fixtures (for holding the work and guiding the tool) were the
indispensable innovations that made mass production and interchangeable realities in the 19th century
2.2.1 USAGE

The most common use is to machine straight, flat surfaces but with ingenuity andsome accessories a
wide range of work can be done. Other examples of its use are:

Keyways in the boss of a pulley or gear can be machined without resortingto a dedicated broaching setup.

Dovetail slides.

Internal spines.

Keyway cutting in blind holes.

 CHAPTER 3

3.1 SHAPER MACHINE

3.1.1 BASIC SHAPER MACHINE COMPONENTS

It is consist of many components are,

Ram
Tool post (or) Tool head
Tool feed handle
Vice
Adjustable sliding support
Table
Clapper Box
Graduated collar
Ram clamping nut
Scale indictor
Clutch handle
Cross traverse handle

Fig:3.1.1.1: Full Shaper machine

 Fig:3.2 Shaper machine head

3.1.2 TYPES OF MECHANISM

Shaper machine is working at many mechanisms. It is classified 3 types.

3.1.2.1 Quick return mechanism (QRM)

3.1.2.2 Slotted QRM

While designing a mechanism either for function generation [1] or for path generation [2] or for
rigid-body guidance applications, it is necessary to take into account not only the structural error but also
the mechanical error resulting due to tolerances on link-lengths, clearances in link joints [3], and static
and dynamic deflection of links [4]. Various attempts have been made to analyze and synthesize the
mechanical error offunction and path generating linkages. There are two distinct approaches deterministic
and stochastic. The deterministic approaches are based on worst-case analysis of individual tolerances
[1], [2], [3], [5], [6]. On the other hand, Dhande, Mallik and Chakra borty [7], [8] have used a stochastic
model to allocate tolerance and clearance in four-bar function generators,
 while Shi [9] allocated them in spatial linkages. In this paper, the effect of practical manufacturing
tolerances is analyzed by using deterministic approach. It was observed on an example [2] (using a
approach based on the worst case analysis of the individual tolerances) that the mechanical error resulting
due to practical manufacturing tolerances is greater than themechanical error resulting due to clearances in
link joints.

Fig:3.1.2.1.1: Quick Return Mechanism

3.1.2.2 SLOTTED QRM

Slotted link mechanism is very common in mechanical shapers. The mechanism is simple and
compact. It converts the rotary motion of the electric motor and gearbox into the reciprocating motion of
the ram. The slotted link mechanism gives the rain a higher velocity during the return non cutting stroke
than during its forward cutting stroke thereby reducing the time wasted during the return stroke. The bull
gear is driven by a pinion which is connected to the motor shaft through a gearbox with four, eight or
more speeds available. The bull wheel has a slot. The crank pin A is secured into this slot; at the same
time it can slide in the slotted crank B.
 When the bull wheel rotates, the crank pin A also rotates and side by side slides through the slot
in the slotted crank B. This makes the slotted crank to oscillate about its one end C. This oscillating motion
of slotted crank (through thelink D) makes the ram to reciprocate. The intermediate link D is necessary to
accommodate the rise and fall of the crank. The position of the crank pin A in the slot in the bull wheel
decides the length of the stroke of the shaper. The further it is away from the centre of bull wheel, the
longer is the stroke.

Fig:3.1.2.2.1 Slotted Mechanism

The cutting stroke of the ram is completed while the crank pin moves from A to A1 and the slotted
link goes from left to right. Similarly, during return stroke
.
 CHAPTER 4

4.1 REARANGED SHAPER MECHANISM

4.1.1 INTRODUCTION OF GEARS

A gear is a rotating machine part having cut teeth, or cogs, which mesh with another toothed part
in order to transmit torque. Two or more gears working in tandem are called a transmission and can
produce a mechanical advantage through a gear ratio and thus may be considered a simple machine.
Geared devices can change the speed, magnitude, and direction of a power source. The most common
situation is for a gear to mesh with another gear , however a gear can also mesh a non-rotating toothed
part, called a rack, thereby producing translation instead of rotation. The gears in a transmission are
analogous to the wheels in a pulley. An advantage of gears is that the teeth of a gear prevent slipping.

When two gears of unequal number of teeth are combined a mechanical advantage is produced,
with both the rotational speeds and the torques of the two gears differing in a simple relationship. In
transmissions which offer multiple gear ratios, such as bicycles and cars, the term gear, as in first gear,
refers to a gear ratio rather than an actual physical gear. The term is used to describe similar devices even
when gear ratio is continuous rather than discrete, or when the device does not actually contain any gears,
as in a continuously variable transmission.

The earliest known reference to gears was circa 50 A.D. by Hero of Alexandria, but they can be
traced back to the Greek mechanics of the Alexandrian school in the 3rd century BC and were greatly
developed by the Greek polymath Archimedes.
4.1.2 TYPES OF GEARS

4.1.2.1 EXTERNAL VS INTERNAL GEARS

An external gear is one with the teeth formed on the outer surface of a cylinder or cone.
Conversely, an internal gear is one with the teeth formed on the inner surface of a cylinder or cone. For

bevel gears, an internal gear is one with the pitch angle exceeding 90 degrees. Internal gears do
not cause direction reversal.

Fig:4.1.2.1.1: External Vs Internal Gear

4.1.2.2 SPUR GEAR

Spur gears or straight-cut gears are the simplest type of gear. They consist of a cylinder or disk,
and with the teeth projecting radically, and although they are not straight-sided in form, the edge of each
tooth thus is straight and aligned parallel to the axis of rotation. These gears can be meshed together
correctly only if theyare fitted to parallel axles.

Fig:4.1.2.2.1: Spur Gear

4.1.2.3 HELICAL GEAR

Helical gears offer a refinement over spur gears. The leading edges of the teeth are not parallel to
the axis of rotation, but are set at an angle. Since the gear is curved, this angling causes the tooth shape to
be a segment of a helix. Helical gears can be meshed in a parallel or crossed orientations. The former
refers to when the shafts are parallel to each other; this is the most common orientation. In the latter, the
shafts are non-parallel. The angled teeth engage more gradually than do spur gear teeth causing them to
run more smoothly and quietly.

With parallel helical gears, each pair of teeth first make contact at a single point at one side of the
gear wheel; a moving curve of contact then grows gradually across the tooth face to a maximum then
recedes until the teeth break contact at a single point on the opposite side.

In spur gears teeth suddenly meet at a line contact across their entire width causing stress and noise.
Spur gears make a characteristic whine at high speeds and can not take as much torque as helical gears.
Whereas spur gears are used for low speed applications and those situations where noise control is not a
problem, the use of helical gears is indicated when the application involves high speeds, large power
transmission, or where noise abatement is important. The speed is considered to be high when the pitch line
velocity exceeds25 m/s

A disadvantage of helical gears is a resultant thrust along the axis of the gear, which needs to be
accommodated by appropriate thrust bearings, and a greater degree of sliding friction between the
meshing teeth, often addressed withadditives in the lubricant
4.1.2.4 HYPOID GEAR

Hypoid gears resemble spiral bevel gears except the shaft axes do not intersect. The pitch surfaces
appear conical but, to compensate for the offset shaft, are in fact hyperboloids of revolution. Hypoid
gears are almost always designed to

operate with shafts at 90 degrees. Depending on which side the shaft is offset to, relative to the
angling of the teeth, contact between hypoid gear teeth may be even smoother and more gradual than
with spiral bevel gear teeth

Fig:4..1.2.4.1: Hypoid Gear

4.1.2.5 CROWN GEAR

Crown gears or contrite gears are a particular form of bevel gear whose teeth project at right
angles to the plane of the wheel; in their orientation the teeth resemble the points on a crown. A crown
gear can only mesh accurately with another bevel gear, although crown gears are sometimes seen
meshing with spurgears. A crown gear is also sometimes meshed with an escapement such as foundin
mechanical clocks.

Fig:4.1.2.5.1: Crown Gear

 CHAPTER 5

5.1 SPUR GEAR DESIGNE

5.1.1 GEAR RATIO

The gear ratio is the relationship between the numbers of teeth on two gears thatare meshed or two
sprockets connected with a common roller chain, or the circumferences of two pulleys connected with a
drive belt.

In other words, the gear ratio is proportional to ratio of the gear diameters and inversely
proportional to the ratio of gear speeds. Belts can have teeth in them also and be coupled to gear-like
pulleys. Special gears called sprockets can be coupled together with chains, as on bicycles and some
motorcycles. Again, exactaccounting of teeth and revolutions can be applied with these machines.

Gear Ratio (GR) = (No of teeth on Gear or driven) / (No of teeth on Pinion ordriver)

5.2 NAMUNCLATURE OF GEAR

Fig:5.2.1 Gear Namunclatur

NUMBER OF TEETH, N
How many teeth a gear has, an integer.

GEAR, WHEEL
The larger of two interacting gears.

PINION
The smaller of two interacting gears.

PATH OF CONTACT
Path followed by the point of contact between two meshing gear teeth.

LINE OF ACTION, PRESSURE LINE

Line along which the force between two meshing gear teeth is directed. It has the same direction
as the force vector. In general, the line of action changes from moment to moment during the period of
engagement of a pair of teeth. For involutes gears, however, the tooth-to-tooth force is always directed
along the same line—that is, the line of action is constant. This implies that for involutes gears the path of
contact is also a straight line, coincident with the line of action—as is indeed the case.

AXIS
Axis of revolution of the gear; center line of the shaft.

PITCH POINT, P
Point where the line of action crosses a line joining the two gear axes.

PITCH CIRCLE, PITCH LINE

Circle centered on and perpendicular to the axis, and passing through thepitch point.

PITCH DIAMETER, D
Diameter of a pitch circle. Equal to twice the perpendicular distance from the axis to the pitch
point. The nominal gear size is usually the pitch diameter.
MODULE, M
The pitch diameter divided by the number of teeth.

OPERATING PITCH DIAMETERS

Diameters determined from the number of teeth and the center distance atwhich gears operate.
Example for pinion:

PITCH SURFACE
In cylindrical gears, cylinder formed by projecting a pitch circle in the axial direction. More
generally, the surface formed by the sum of all the pitch circles as one moves along the axis. For bevel
gears it is a cone.

ANGLE OF ACTION
Angle with vertex at the gear center, one leg on the point where mating teeth first make contact,
the other leg on the point where they disengage.

ARC OF ACTION
Segment of a pitch circle subtended by the angle of action.

PRESSURE ANGLE, Θ
The complement of the angle between the direction that the teeth exert force on each other, and the
line joining the centers of the two gears. For involutes gears, the teeth always exert force along the line of
action, which, for involutes gears, is a straight line; and thus, for involutes gears, the pressure angle is
constant.

OUTSIDE DIAMETER, DO
Diameter of the gear, measured from the tops of the teeth.

ROOT DIAMETER
Diameter of the gear, measured at the base of the tooth.
 CHAPTER 6

6.1 BELT DRIVE

6.1.1 INTRODUCTION OF BELTS

A belt is a loop of flexible material used to link two or more rotating shafts mechanically. Belts
may be used as a source of motion, to transmit power efficiently, or to track relative movement. Belts are
looped over pulleys. In a two pulley system, the belt can either drive the pulleys in the same direction, or
the belt may be crossed, so that the direction of the shafts is opposite. As a source of motion, a conveyor
belt is one application where the belt is adapted to continuallycarry a load between two points.

6.1.1.2 TYPES OF BELTS

6.1.1.2.1 FLAT BELTS

Flat belts were used early in line shafting to transmit power in factories.[1] It is a
simple system of power transmission that was well suited to its day. It delivered high power for high
speeds (500 hp for 10,000 ft/min), in cases of wide belts andlarge pulleys. These drives are bulky, requiring
high tension leading to high loads,so vee belts have mainly replaced the flat-belts except when high speed is
neededover power.

Fig:6.1.1.2.1.1: Flat Belt

6.1.1.2.2 ROUND BELTS

Round belts are a circular cross section belt designed to run in a pulley with a circular (or near
circular) groove. They are for use in low torque situations and may be purchased in various lengths or cut
to length and joined, either by a staple, gluing or welding (in the case of polyurethane). Early sewing
machines utilized a leather belt, joined either by a metal staple or glued, to great effect.
VEE BELTS

“V” belts (also known as V-belt or wedge rope) solved the slippage and alignment problem. It is
now the basic belt for power transmission. They provide the best combination of traction, speed of
movement, load of the bearings, and long service life. The V-belt was developed in 1917 by John Gates
of the Gates Rubber Company. They are generally endless, and their general cross-section shape is
trapezoidal. The "V" shape of the belt tracks in a mating groove in the pulley (or sheave), with the result
that the belt cannot slip off. The belt also tends to wedge into the groove as the load increases — the
greater the load, the greater the wedging action — improving torque transmission and making the "V" belt
aneffective solution, needing less width and tension than flat belts.

Fig:6.1.1.2.2.1: V Belt
6.1.1.2.3 RIBBED BELT

A ribbed belt is a power transmission belt featuring lengthwise grooves. It operates from contact
between the ribs of the belt and the grooves in the pulley. Its single-piece structure it reported to offer an
even distribution of tension acrossthe width of the pulley where the belt is in contact, a power range up to
600 kw,a high speed ratio, serpentine drives (possibility to drive off the back of the belt),long life, stability
and homogeneity of the drive tension, and reduced vibration. The ribbed belt may be fitted on various
applications : compressors, fitness bikes, agricultural machinery, food mixers, washing machines, lawn
mowers, etc..,

6.1.1.2.4 FILM BELTS

Hough often grouped with flat belts; they are actually a different kind. They consist of a very thin
belt (0.5-15 millimeters or 100-4000 micrometers) strip of plastic and occasionally rubber. They are
generally intended for low-power (10 hp or 7 kw), high-speed uses, allowing high efficiency (up to 98%)
and long life.These are seen in business machines, printers, tape recorders, and other light-dutyoperations.
TIMING BELTS

Timing belts, (also known as Toothed, Notch, Cog, or Synchronous belts) are a positive transfer
belt and can track relative movement. These belts have teeth that fit into a matching toothed pulley. When
correctly tensioned, they have no slippage, run at constant speed, and are often used to transfer direct
motion for indexing or timing purposes (hence their name). They are often used in lieu of chains or gears,
so there is less noise and a lubrication bath is not necessary. Camshafts of automobiles, miniature timing
systems, and stepper motors often utilize these belts. Timing belts need the least tension of all belts, and
are amongthe most efficient. They can bear up to 200 hp (150 kw) at speeds of 16,000 ft/min.
 Fig:6.1.1.2.4.1: Timing Belt

6.1.1.2.5 : SPECIALTY BELTS

Belts normally transmit power on the tension side of the loop. However, designs for continuously
variable transmissions exist that use belts that are a series of solid metal blocks, linked together as in a
chain, transmitting power on the compression side of the loop.
HISTORY OF BELTS

Belts used for rolling roads for wind tunnels can be capable of 250 km/h.

6.2 USAGE

The open belt drive has parallel shafts rotating in the same direction, whereas the cross-belt drive
also bears parallel shafts but rotate in opposite direction. The former is far more common, and the latter
not appropriate for timing and standard V-belts, because the pulleys contact both the both inner and outer
belt surfaces. Nonparallel shafts can be connected if the belt's center line is aligned with the center plane
of the pulley. Industrial belts are usually reinforced rubber but sometimes leather types, non-leather non-
reinforced belts, can only be used in light applications.
The pitch line is the neither line between the inner and outer surfaces that is neither subject to tension (like
the outer surface) nor compression (like the inner).
.

6.3 SPECIFICATIONS

To fully specify a belt, the material, length, and cross-section size and shape are required. Timing
belts, in addition, require that the size of the teeth be given. The length of the belt is the sum of the central
length of the system on both sides, half the circumference of both pulleys, and the square of the sum (if
crossed) or the difference (if open) of the radii. Thus, when dividing by the central distance, it can be
visualized as the central distance times the height that gives the same squared value of the radius
difference on, of course, both sides. When adding to the length of either side, the length of the belt
increases, in a similar manner to the Pythagorean theorem. One important concept to remember is that as
D1 gets closer to D2 there is less of a distance (and therefore less addition of length) until its approaches
zero.

On the other hand, in a crossed belt drive the sum rather than the difference of radii is the basis
for computation for length. So the wider the small drive increases, the belt length is higher.
 CONCLUSION

The project performs well under all conditions and enables to improve the operational efficiency.
It also meets all the reqirements specified by the user.

This project has been a great learning process for us to climb the greater heights of mechanical
world. The experience that we have earned from this project will surely stand in good stead in my future.
Once again we thank whole – heartedly all those who helped to complete the project work.
 REFERENCE

Design data book

Machine design – R.S. Khurmi
Automobile engineering vol&2 - Kripal singh
Automobile repair guide 1&2 – Lucas peterson.
http://encyclopedia.org
http://en.wikipedia.org
www.tpup.com