Shaper Machine Process

The shaper process can be defined as a process for

removing metal from the surface in horizontal, vertical
and angular planes by the use of a single-point cutting
tool held in a ram that reciprocates the tool in a linear
direction across the workpiece held on the table of the
machine. The work is fed at right angles to the direction
of the ram in small increments, at the end of the return
stroke
 Roughing Process
• Roughing, the cornerstone of the manufacturing process, is frequently
termed as rough milling, shaper roughing, or the first step in the wild and
finish machining spectrum. It’s all about swiftly removing excess material
to approximate the workpiece’s ultimate design.
• Utilizing larger cutting tools, this stage delves deeper with broader cuts to
quickly get rid of unwanted material, typically resulting in a coarser
surface finish. While designed for efficiency and speed, roughing
transcends its moniker; it needs to be more robust.
• This pivotal phase bridges the gap between the raw stock and the
subsequent precision stages of machining. It primes the workpiece for the
detailed nuances of the finishing process, acting as the crucial
intermediary in the journey from raw material to a meticulously crafted
end product. The synergy of rapidity and calculated material elimination
underscores roughing’s indispensable role.
 Benefits Of Roughing
• Rapid Material Removal: One of the standout benefits of the roughing
process lies in its impressive material removal rate. It’s adept at swiftly
eliminating the majority of surplus material, streamlining the machining
process and optimizing time efficiency.
• Enhances Tool Life: Roughing protects the more delicate finishing tools from
excessive wear and tear. By removing most of the material, roughing ensures
that finishing tools are subjected to less strain, extending their lifespan.
• Creates a Base for Finishing: Roughing sets the groundwork for the finishing
process. Shaping the workpiece into an approximation of the final product
makes the task of finishing more accessible and more precise.
• Improves Efficiency: Roughing significantly reduces the time spent in
subsequent machining processes by quickly taking the workpiece closer to its
final form. This translates into reduced manufacturing times and potentially
lower costs.
• Facilitates Difficult Cuts: Roughing allows machinists to make deeper and
wider cuts that would be too aggressive or risky during the finishing phase.
This ability can be particularly beneficial when working with hard materials or
complex designs
 Purpose
Roughing:
• The primary purpose of roughing is to quickly remove the
maximum amount of material from the workpiece. It’s less
about precision and more about efficiency, transforming a
raw block of material closer to its final shape.

Rate of Material Removal

• Roughing involves a high rate of material removal. It’s
characterized by deep, wide cuts that quickly remove the
bulk of excess material.
 Surface finish
• The surface finish after roughing is typically
rough or ridged due to aggressive material
removal.

• Feed Rate and Cutting Depth

• Roughing operations have higher feed rates
and deeper cuts to facilitate rapid material
removal.