Shaper Machine

Introduction
• It is a reciprocating type of machine tool used for
producing flat surfaces by means of a cutting tool
which is moved backwards & forwards in a
straight line by means of a ram.
• Surfaces may be horizontal, vertical or inclined.
• Modern shapers can produce contoured surfaces.
• It uses reciprocating straight line motion of the
tool and a perpendicular feed of the job or the
tool.
• By moving the work piece across the path of the
reciprocating tool, a flat surface is generated
regardless of the shape of the tool.
 Working Principle
• The tool held in the tool holder mounted on the ram moves
forwards and backwards in a straight line over the work
piece rigidly held in a vice clamped over the work table.
• Each time the tool moves forward, it cuts a segment of
metal from the work piece.
• Each time the tool moves backward, the tool lifts clear of
the work piece.
• The feed is given to the workpiece and depth of cut is
adjusted by moving the tool downwards towards the
workpiece.
 L

• Less time taken during idle stroke is obtained by quick

return mechanism.
Forward & Return Strokes of Ram
Classification of Shaper
• According to the type of mechanism used for
giving reciprocating motion to the ram
a) Crank type – crank mechanism
b) Gear type – rack and pinion
c) Hydraulic type – hydraulic power using
pressurized oil.
• According to position & travel of ram
a) Horizontal – ram reciprocates horizontally.
b) Vertical - ram reciprocates vertically.
c) Traveling head type – additional crosswise
movement of ram to give required feed.
• According to the design of table
a) Standard shaper – horizontal & vertical table
movements.
b) Universal shaper – additionally table can be
swiveled about an axis parallel to the ram ways.
• According to the cutting stroke
a) Push type – metal removal takes place during
pushing of work.
b) Draw type - metal removal takes place during
drawing of work.
Principal parts of Shaper
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.
• It may be rigidly bolted directly to the floor of the
shop or on the bench according to the size of the
machine.
Body (Pillar, Frame, Column)
• It is mounted on the base and houses the drive
mechanism comprising of 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.
• The column supports the ram and the rails for
the saddle.
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 by rotating an elevating screw thus causing the
cross rail to slide up and down.
• Sliding along the cross rail is a saddle which carries
the work table.
• A horizontal cross feed screw fitted within the cross
rail actuates the table to move in a crosswise
direction.
Saddle & Clapper Box
• It is located on the cross rail and holds the table on
its top.
• Crosswise movement of the saddle due to rotation
of the cross feed screw by hand or power causes
the table to move sideways.
• It is bolted to the saddle and receives crosswise and
vertical movements from the saddle and cross rail.
• The clapper box is needed because the cutter drags
over the work on the return stroke. The clapper box
is hinged so that the cutting tool will not dig in. it is
automatically raised by mechanical, air or hydraulic
action.
Ram & Table
• The ram is driven back and forth in its slides
provided above the column 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.
• The table is moved left and right, usually by hand,
to position the work under the cutter when setting
up.
• Either by hand or more often automatically, the
table is moved sideways to feed the work under
the cutter at the end or beginning of each stroke.
Tool head
• It hold the tool rigidly.
• It provides vertical and angular feed movement of the
tool.
• It allows the tool to have an automatic relief during its
return stroke.
Specifications of Shaper Machine
• Adjustable stroke
• Length of Ram
• Max. & Min. distance from Table to Ram
• Max. table travel (Horizontal & Vertical)
• Angular movement of table
• Max. vertical travel of tool slide
• Max. swivel of tool slide
• No. of ram speeds & range of speeds
• Range of table feed per stroke of ram
• Overall dimensions (Length, Width, Height)
• Net weight
 Operations performed on Shaper
Machine
• The cutting tool
reciprocates in
horizontal direction
while the work is fed
towards the tool thus
removing material on
each stroke.
• In case of shaping, the
cutting force acts
parallel to the work
piece support.
• The tool post has been
turned at an angle so
that side of the
material can be
machined thus making
vertical shaping.
• The tool post is kept
vertical & the top slide
is slowly fed into the
material so that
a ‘rack’ can be
machined for a rack
and pinion gear
system.
• it calls for simultaneous
operation of horizontal
table feed as well as
vertical hand feed of the
cutting tool.
• It can be performed
only by a very skilled
operator.
Cutting Speed
• It is defined as the no. of cutting strokes,
which the ram makes per minute.
• In shaper, average cutting speed is
considered as no cutting takes place in
return stroke.
• Harder the metal or deeper the cut, slower
is the cutting speed.
• Softer the metal or lighter the cut, higher is
the cutting speed.
Process Capabilities
• Shaping process involves short setup time and
uses relatively inexpensive tools.
• Shaping is often used for emergency production
of gears, splined shafts, racks etc.
• It is often possible to produce one or two such
parts in a shaper in less time than is required
merely to set up for production on other
alternative equipment with a higher output rate.
• The cost per cubic cm of metal removed by
shaping may be as much as five times that for
removal by milling or broaching.
• This confines shaping to small quantity
production as in tool rooms or model shops.
 Shaper Mechanisms
1. Hydraulic Shaper
Mechanism
• This technique operates
by pumping hydraulic oil
from reservoir (K)
through the pump (P) to a
cylinder (C) from two
opposite sides (C1) or
(C2).
• The machine table is
connected to the rod of
the cylinder (R).
• To obtain the cutting
stroke, the valve (V1) is
opened while the other
valve (V2) is closed as
described by the dotted
position of the lower
piston.
• The pumped oil is fed to
the cylinder through its
right valve (V1).
• This pushes the piston (S)
causing the cutting action
in the direction described
by the figure.
• This motion continues until
socket (d1) hits the lever
(L) at the right position
making it to rotate around
its center (O).
• This pushes the piston rod
(r) to the new position
described in the figure by
the continuous line.
• This allows the oil to be
pumped through the valve
• (V2) through the other end
(C2) causing the return
stroke to start.
• This continues until
the lever (L) hits the
left socket (d2)
opening the right valve
(V1) and closing the
left one allowing
another cutting stroke.
• The rapid return
speed is obtained
since there is a
reduction in the
cylinder area due to
the existing of the
piston rod.
2. Crank & slotted link
quick return Mechanism
• The crank AB (of adjustable
length R) rotates with a
uniform angular speed.
• The crank pin B is in the
shape of a die block which
is free to slide inside the
slot in the slotted lever
OBC.
• This slotted lever is pivoted
at O and the other end C is
connected to the ram by a
short link arm.
• When the crank AB
rotates clockwise from
position AB1 to AB2, the
ram moves forward from
left to right and when it
rotates from position AB2
to AB1 the ram returns
back to its original
position.
• The further it is away from
the centre of bull wheel,
the longer is the stroke.
• The time taken to
complete forward stroke
is proportional to angle
α.
• The return stroke is
completed in less time
which is proportional to
angle β.
3. Whitworth Quick
Return Mechanism
• The crank OC is fixed
and OQ rotates about
O.
• The slider slides in the
slotted link and
generates a circle of
radius CP.
• Link 5 connects the
extension OQ provided
on the opposite side of
the link 1 to the ram
(link 6).
• The rotary motion of P
is taken to the ram R
which reciprocates.
• The angle covered
during cutting stroke
from P1 to P2 in
counter clockwise
direction is α or 360
-2θ.
• During the return
stroke, the angle
covered is 2θ or β.