Shaper Machine
A shaper is a reciprocating-type machine tool used for producing small flat surfaces in
horizontal, vertical, or angular planes by removing metal with a single-point cutting tool
mounted on a reciprocating ram.
Applications:
Machining flat, angular, concave, or convex surfaces
Cutting slots, grooves, and keyways
Rough machining of blanks before precision finishing
Working Principle:
The cutting tool is clamped in a tool post on a clapper box, mounted to the ram.
During the forward stroke, the tool cuts the metal; during the return stroke, no cutting
occurs.
Between strokes, the work table feeds horizontally (perpendicular to cutting
direction).
Notes:
Shapers are slow with low material removal rates.
Mostly replaced by milling machines in production but still used for low-cost, rough
machining jobs.
Stroke (Shaper Machine)
The stroke is the distance traveled by the ram in one complete cutting and return cycle.
The size of a shaper is determined by the
length of its stroke, which equals the
largest cube it can machine.
The stroke length is controlled by the
position of the sliding block in the slide.
Changing the radius of the circle in which
the bull gear pin rotates adjusts the stroke
length.
Feed (Shaper Machine)
The feed is the horizontal movement of the table
perpendicular to the cutting direction (cross
feed).
Automatic feed across the tool is provided when the table is equipped with a ratchet
mechanism.
Feed moves the workpiece to present a new cutting path for each stroke.
Types of Shapers
A. Based on Drive Mechanism:
1. Crank Shaper – Ram movement obtained by a crank pin and rocker arm from the
main driving gear.
2. Gear Shaper – Ram driven by a gear and rack assembly; has a reversible motor or
quick-return mechanism for faster return stroke.
3. Hydraulic Shaper – Ram driven by a piston moving in an oil-filled cylinder;
mechanically similar to crank shapers.
B. Based on Ram & Tool Reciprocation Direction:
1. Horizontal Shaper – Ram moves in a horizontal direction.
o Plain Shaper: Fixed table (no rotation/swivel).
o Universal Shaper: Table can swivel left/right and rotate 360°.
2. Vertical Shaper – Ram moves in a vertical direction.
Major parts of a Shaper Machine
Base- The base is the necessary bed or support required for all machine tools. All other
parts are mounted on and above the base. The bed takes up the total dead weight of the
machine as well as the dynamic load during machining operations.
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. Sliding along the cross rail is a saddle that carries the work
table.
Column-The column of the shaper is a hollow casting and is mounted on the base. It
houses the drive mechanism for the ram and the table.
Table- The worktable of a shaper is fastened to the front of the column. The table moves
across the column on cross rails to give the feed motion to the job.
Ram- The ram carries the tool head at its front end and travels in “guide ways” to give
straight-line reciprocating motion to the tool. The ram is either mechanically driven or
hydraulically operated. A single-point tool is fastened in the tool post.
Tool Head- It holds the cutting tool and is fastened to the front of the ram. The tool is
held in a tool holder/tool post similar to the lathe tool post. The tool post and the tool
block fit snugly in the clapper box and is hinged at the upper edge.
ClapperBox
The clapper box houses the clapper block, which is connected to it by means of a
hinge pin
The tool post is mounted upon the clapper block to prevent interference between the
tools and workpiece on the return stroke
On the forward cutting stroke, the clapper block fits securely to the clapper box to
make a rigid tool on the work
It prevents the tool cutting edge from dragging and wear
The work surface is also prevented from any damage due to dragging
Mechanism of Motion in a Shaper
The shaper converts the rotary motion of the motor into the reciprocating motion of the ram
using the following components:
1. Motor and Driving Gear (Pinion):
o The motor drives a small pinion gear or driving pulley.
2. Bull Gear:
o The pinion turns a large bull gear, which rotates clockwise at a uniform speed.
o A crankpin attached to the bull gear drives the next mechanism.
3. Sliding Block:
o Fits into a slide on the rocker arm.
o The crankpin passes through a hole in the sliding block.
o The radial position of the crankpin can be adjusted externally to change the
length of the stroke.
4. Rocker Arm and Linkage:
o One end of the rocker arm is pivoted at the base, the other end is connected to
the ram via a link arm.
o As the crankpin rotates with the bull gear, the sliding block moves up and
down, causing the rocker arm to swing back and forth.
5. Ram Motion:
o The swinging motion of the rocker arm is transferred to the ram, producing
straight-line reciprocating motion for the cutting stroke.
Summary: The motor → pinion → bull gear → crankpin → sliding block → rocker arm →
ram sequence transforms rotary motion into the reciprocating cutting stroke.
Quick Return Motion in a Shaper
In a shaper, the cutting stroke (forward stroke) removes material, while the return
stroke is idle.
To reduce idle time, a quick return mechanism is used to make the return stroke
faster than the forward stroke.
How It Works (Crank Shaper):
1. The motor drives the bull gear, which rotates a pin in a circular path.
2. The pin fits into the slot of the rocker
arm and slides freely in a straight path.
3. As the bull gear rotates, the rocker arm
oscillates, moving the ram via a link
arm.
4. The stroke length is adjusted by
changing the radius of the circle traced
by the pin.
5. During the forward cutting stroke, the
pin moves through about 220°, while in the return stroke, it moves only 140°, giving
a faster return.
6. The velocity of the forward stroke
is lower for accurate cutting, while
the return stroke has a higher
velocity to save time.
Alternative (Geared Shaper):
Uses rack-pinion and belt
arrangements to convert rotary
motion to reciprocating motion.
Adjustable dogs shift belts to engage
forward or return stroke
automatically.
Key Points:
The forward stroke removes
material; the return stroke is idle.
Quick return increases efficiency by reducing non-cutting time.
The mechanism ensures the clapper box swings back and is ready for the next
cutting stroke.
Planer (Planning Machine)
A planer is a machine tool used for producing flat surfaces on large workpieces.
Unlike a shaper, the workpiece is mounted on a table, which moves past a
stationary single-point cutting tool.
The table slides on ways over a heavy, rigid bed capable of sustaining heavy loads.
Most planers cut in one direction only, but some are capable of cutting in both
directions.
The reciprocating motion of the table provides the cutting action.
Planers can handle much larger parts than shapers due to their construction and
motion capabilities.
Feature Planning (Planer) Shaping (Shaper)
Primary Cutting Provided by the workpiece
Provided by the tool (ram/tool moves)
Motion (table moves)
Feed Motion Provided by the tool Provided by the workpiece/table
Can handle large/heavy
Workpiece Size Suitable for smaller workpieces
workpieces
Machine Ram/tool moves, table is stationary or cross-
Table moves, tool is stationary
Component Moving fed
Large flat surfaces, grooves, Small flat surfaces, keyways, slots,
Application
slots on heavy workpieces angular/concave/convex surfaces
Heavy rigid bed to support
Construction Lighter machine, smaller bed and column
workpiece
Key Point:
Planning = work moves, tool stationary
Shaping = tool moves, work stationary
JOYJIT GHOSH
ME 23
2302109