DEPARTMENT OF MECHANICAL AND MANUFACTURING ENGINEERING

FACULTY OF ENGINEERING
UNIVERSITY OF RUHUNA

ENGINEERING WORKSHOP
ME 2302 – INTRODUCTION TO MATERIAL SCIENCE AND MANUFACTURING
ENGINEERING
TITLE: FAMILIARIZATION OF WORKSHOP MACHINERY (M 2.2)
ACADEMIC YEAR: 2022

Laboratory Seal and Signature of the Instructor

EG/2021/
Student Number

Lab Conducted Date 22/12/2022

Completion of Lab
05/01/2023
Report

Evaluation(Instructor Use Only)

Allocated Marks
Evaluation Component Student Achieved Marks
Out of 10.0
1 Viva 4.0
2 Discussion 6.0
Total 10.0

Signature of the Evaluator

Evaluator’s Comments:
Table of Contents
Discussion..............................................................................................................................1
Q1 Name the parts A to J in figure below.......................................................................1
Q2 Briefly explain the cutting action of the shaping machine........................................2
Q3 What is the advantage of quick return motion of the shaping machine?...................5
References..............................................................................................................................6

ii
List of figures
Figure 1-Shaper / Shaping Machine...............................................................................................................1
Figure 2 -Horizontal cutting. Available at: https://learnmech.com/...............................................................2
Figure 3-Vertical cutting. Available at: https://learnmech.com/....................................................................2
Figure 4-Angular cutting. Available at: https://learnmech.com/....................................................................3
Figure 5-Irregular cutting. Available at: https://learnmech.com/...................................................................3
Figure 6-Slot and Keyway cutting. Available at: https://learnmech.com/.....................................................4
Figure 7-Cutting Tools. Available at: https://learnmech.com/.......................................................................4
Figure 8-Quick Return Mechanism. Available at: https://learnmech.com/....................................................5

iii
Discussion

Q1 Name the parts A to J in figure below.

Figure 1-Shaper / Shaping Machine

A: Headstock
B: Cross Slide
C: Tool Post Slide
D: Tail stock
E: Lead Screw
F: Leg
G: Bed
H: Carriage
I: Feed Rod
J: Feed Box

1
Q2 Briefly explain the cutting action of the shaping machine

The shaping/ shaper machine produces horizontal or vertical flat surfaces in different sizes using a single
point cutting tool that moves forwards and backwards to remove extra material from the fixed work piece.
(E.A.Kumar, 2022)

This stroke mechanism is performed like this: the forward stroke of the cutting tool removes extra
material forming the surface or does the cutting action while the backward stroke brings back the cutting
tool to its initial position to repeat the action again. For the cutting action to take place rightfully, placing
the work piece on the table and cutting tool in the tool holder that is mounted on the RAM is fundamental.
(Admin, 2019)
There are various cutting operations that can be performed in this manner. The four main types are,

1 Horizontal cutting operation

Figure 2 -Horizontal cutting. Available at: https://learnmech.com/

The most common way of the cutting action. The work piece is fed in a horizontal direction
and the surface created is also horizontal. After placing the work piece and the cutting tool, the
depth of the cut is adjusted for requirements. The vertical cutting tool’s edge should be
pointing slightly away from the work piece thus it will not dig in to the work piece while
operating. The vertical slide of the cutting tool should not be far away from the ram as it will
be much weaker in a position that is too far away from the force transferring point which will
create deformation in the tool. (M., 2021)

2 Vertical cutting operation

Figure 3-Vertical cutting. Available at: https://learnmech.com/

The operation takes place at the end of a work piece: making a square from a block, cutting a
shoulder. The surface aimed is aligned with the ram before the operation. The tool post is
adjusted to move upwards away from the piece. This prevents any unnecessary dragging.
Bothe roughing and finishing work is done. (M., 2021)

2
3 Angular or Inclined cutting operation

Figure 4-Angular cutting. Available at: https://learnmech.com/

The operation is performed by tilting the vertical slide of the cutting tool to the required angle
to clock wise or anti clock wise direction. The apron is moved even further from the piece to
give the tool a clear path of work. The act of swiveling or tilting the tool head can be replaced
by using a universal shaper or a universal vice. (M., 2021)

4 Irregular cutting operation

Figure 5-Irregular cutting. Available at: https://learnmech.com/

The shaper can manufacture concave or convex surfaces or the combination of both using a
forming tool. If there are too many fluctuations in the surface of the work piece, the feed is
given by hand. The round nose tool is often used and the apron is desired to be slightly tilted
away from the work piece if the cut surface is sharp. (M., 2021)

3
Except the main cutting operations, the shaper machine can also perform other two different type of
operations

5 Cutting slots and Keyways

Figure 6-Slot and Keyway cutting. Available at: https://learnmech.com/

A square nose tool that is similar to a parting tool is used in the operation. External key ways
are made on a shaft. Leaving behind a clearance at the end of the stroke is important and the
position of the tool will be adjusted to end the stroke at the clearance hole. The operation is
done in low speeds. Internal keyways are cut by keeping the tool on a special tool holder to let
the tool post have space. The clapper block is locked in the box to terminate the possibility of
cutting tool lifting during the operation. (M., 2021)

6 Machine splines or Cutting Gears

Operation is done using an index center which may be in a gear. The work piece is held
between the two centers and rotated in a fixed angle using the index pin. A forming tool is used
while cutting gear. (M., 2021)

The above operations require the cutting tool to function properly as needed. The single pointed cutting
tool of the shaping machine is more rigid and heavier to perform heavy duty strokes of removing extra
material in every forward stroke. Smaller clearance angles deliver stronger performance. Both right and
left hand tools can be used in the shaper. High speed steel very commonly used in manufacturing cutting
tools. Shock resistant carbide tipped tools are sometimes used when machining harder surfaces. Some of
the commonly used cutting tools are shown below. (S.Thorat, 2020)

Figure 7-Cutting Tools. Available at: https://learnmech.com/

4
Q3 What is the advantage of quick return motion of the shaping machine?

Figure 8-Quick Return Mechanism. Available at: https://learnmech.com/

The shaper machine’s cutting tool has a forward and back ward motion where forward motion is the only
stroke of motion that put on the work on the piece by removing material while the back ward stroke only
brings the cutting tool to its initial position. This is backward motion is done much more quickly than the
forward motion. That is the quick return method of the shaper machine.

The cutting tool in backward motion, does not perform any work within the returning time and is only
useful when it is at its initial position. So this transient period of the cutting tool from forward to
backward is done with high speed to avoid wastage of time. This saves up a lot of time which will be
latterly useful to machine even more work pieces. This increases the efficiency of the shaper tool as time
is often regard as money within the manufacturing industry.

5
References
Admin, 2019. Esskay International Machine Tools Blog. [Online]
Available at: https://esskaymachines.com/blog/shaping-machine-its-mechanism-parts-and-respective-functions/
[Accessed 05 01 2023].
E.A.Kumar, 2022. Shaper Machine: Definition, Parts, Working Principle, Types, Operation, Advantages,
Application [Notes & PDF. [Online]
Available at: https://themechanicalengineering.com/shaper-machine/#:~:text=A%20shaper%20Machine%20is
%20a,is%20fixed%20on%20a%20table
[Accessed 04 01 2023].
M., S., 2021. The Engineers Post. [Online]
Available at: https://www.theengineerspost.com/shaper-machine-operations/
[Accessed 05 01 2023].
S.Thorat, 2020. Learn Mechanical Engineering. [Online]
Available at: https://learnmech.com/shaper-tools-types-of-shaper-tools-classification-of-shaper-tools/#:~:text=The
%20cutting%20tool%20used%20in,commencement%20of%20each%20cutting%20stroke
[Accessed 05 01 2023].