Shaper Machine
Introduction:
A Shaping Machine is a reciprocating type of machine tool used for producing flat Surfaces in horizontal,
vertical or angular planes on the small to a medium-sized workpiece.
It is also used for machining convex and concave surfaces, for key-way cutting, slotting, grooving, etc
In a shaper, the work is held on the machine table and the ram carrying the tool
moves forward & backward over it during the cutting action in reciprocating
motion Refer Fig.
As each chip is cut-off, ram and tool return to the end of the stroke and the work
is positioned for another cut.
This involves moving the table horizontally by an amount equal to one chip
thickness so that the work is ready for the next cutting stroke.
The machining is performed during the forward stroke only and the return stroke
is idle.
Principle Parts of Shaper Machine:
1. Base
The base is a heavy cast iron body that acts as a support for all the fixed and operating parts of the machine
which are mounted on it.
2. Column
The column is a hollow structure consisting of two walls and cast from cast iron.
It is a rigid structure and gives support to the ram on its top way and is supported by the base.
There is a cross-rail carrying the table and the drives, to move the table up and down or crosswise.
On the left-hand side of the column, a lid is provided for inspection and oiling of the internal mechanisms.
For operating the machine, levers and handles are provided on the other side of the column.
3. Cross Rail
Cross rail is a box-like structure over which the saddle slides horizontally.
It is mounted on the front vertical guide-ways of the column.
The table cross feed screw and the cross rail vertical feed screw are housed inside it.
4. Saddle
The saddle is mounted on the cross oil.
By rotating the crossfeed screw by hand or by power, the saddle moves in a cross-wise direction.
5. Table
The table is made of cast iron and it is also a box-type structure,
It holds and supports the workpiece during the operation and slides along the cross rail to provide feed to
the workpiece.
6. Ram
Ram is a reciprocating member and carries the shaper head in its front on which the cutting tool is mounted.
It is semi-cylindrical in form and slides on the accurately machined guideways provide on the top of the
column.
7. Shaper head (Tool head)
Tool head is clamped firmly to the front of the ram and
consists of a tool slide, tool post, and clapper box.
The tool head can be swiveled to any angle to enable
the tool to take angular cuts. Ref Fig.
Vertical feed to the tool is given by the vertical tool
feed screw and the slide movement can be measured
by using a micrometer dial near to the handle.
The apron is clamped to the vertical slide by clamping
screw.
Apron consists of a clapper box, clapper block, and a
tool post.
The clapper block is connected to the clapper box by
using a hinge pin.
During the forward cutting stroke of the ram, the
clapper block is rigidly supported in the clapper box and
on the return stroke, the block hinges outwards
swinging on the hinge pin.
Classification of Shaper
Shapers are classified in a number of ways as follows:
1. According to the type of mechanism used for giving reciprocating motion to the ram
a. Crank type b. Geared type c. Hydraulic type
2. According to the position and travel of the ram
a. Horizontal type b. Vertical type c. Traveling head type
3. According to the type of design of the table
a. Standard shaper b. Universal shaper
4. According to the type of cutting stroke
a. Push type b. Draw type
Shaper Mechanism
In shaper, the rotary movement of the driving motor is converted into the reciprocating movement of the ram
by the mechanism provided in the column of the machine.
In shaper, the only forward stroke of the ram is a working stroke, when the metal is removed and there turn
stroke goes idle and no metal is removed during this period.
Due to this mechanism, the ram holding the tool is allowed to move at a comparatively slower speed during
the forward cutting stroke, whereas during the return stroke, the ram moves at a faster rate to reduce the
idle return time.
There are three methods of obtaining a quick return mechanism.
o Crank and slotted link mechanism
o Hydraulic mechanism
o Whitworth quick return mechanism
Figure shows the Principle of a Quick Return Mechanism
When the link is in position CD1 the ram will be at the extreme
backward position of its stroke, and whenitisat CD2, the ram will
reach the extreme-forward position.CD1 and CD2 are shown
tangent to the crank pin circle.
Therefore, forward cutting stroke takes Place when the crank
rotates through the angle B1k B2 and the return stroke takes
Place when the cant rotates through the angle B2 LB1.
It is clear from the Fig.6.4 that the angle made by forwarding
stroke i.e.B1 K B 2is greater than the angle made by return stroke
i.e. B2 L B1.
The angular velocity of the crankpin is constant during the return
stroke and hence it is completed within a shorter time for which it
is called a Quick Return Mechanism.
Crank and Slotted Link Mechanism
The crank and slotted link mechanism is shown in Fig
The crank AB rotates about the fixed center A, the end B having the form of a sliding block that fits the slot in
the link CD.
As B rotates about A, it slides up and down in link
CD and causes this to oscillate about the center c
(pivot point of the slotted link) so that as CD
oscillates, the ram is operated backward and
forwards.
The quick return feature is derived from the
configuration of the mechanism.
When the link in the position CD1 tangential to
the pitch circle of B, the ram will be at the
extreme backward position of is stroke and when
it is at D2, the extreme forward position of the
stroke will have been reached.
The time is taken by cutting and idle stroke of the ram is proportional to the angles B 2 KB1 and B2 LB1
respectively.
The ratio between cutting time and idle time may be determined from the formula
𝑪𝒖𝒕𝒕𝒊𝒏𝒈 𝒕𝒊𝒎𝒆 𝑨𝒏𝒈𝒍𝒆 𝑩𝟐 𝑲𝑩𝟐
=
𝑪𝒖𝒕𝒕𝒊𝒏𝒈 𝒕𝒊𝒎𝒆 𝑨𝒏𝒈𝒍𝒆 𝑩𝟐 𝑳𝑩𝟐
Cutting time to return time ratio usually varies between 2:1 and the practical limit is 3:2.
The cutting speed and return speed is not constant throughout the stroke. It is minimum when rocker arm is
at the two extremities and speed is maximum when the rocker arm is vertical
Whitworth Quick Return Mechanism
The Whitworth quick return mechanism is used in a shaper machine which is shown in Fig.
In this mechanism driving crank 3 rotates in the clockwise direction with the uniform angular speed.
The slider C which is attached at the end of the driving link also reciprocates in slotted link 1 and causes to
oscillate the slotted link 1 about pivot point B.
The link 5 is attached at the end of slotted link 1 which carries the ram and tool.
When the driving crank moves from position ac" to ac' through an angle Q in a clockwise direction then the
tool moves back from f ' to f ".
Thus the angle turned by driving crank i.e. 𝜽 will be for cutting stroke and return stroke will be for angle or
(𝟑𝟔𝟎° − 𝜽)
Since driving link 3 rotates at uniform angular speed, the ratio of cutting stroke to return stroke time will be
given by,
𝑻𝒊𝒎𝒆 𝒐𝒇 𝒄𝒖𝒕𝒕𝒊𝒏𝒈 𝒔𝒕𝒓𝒐𝒌𝒆 𝑨𝒏𝒈𝒍𝒆 𝑨𝒏𝒈𝒍𝒆 𝜽 𝜽
= =
𝑻𝒊𝒎𝒆 𝒐𝒇 𝒓𝒆𝒕𝒖𝒓𝒏 𝒔𝒕𝒓𝒐𝒌𝒆 𝑨𝒏𝒈𝒍𝒆 𝑨𝒏𝒈𝒍𝒆 𝟑𝟔𝟎 𝟑𝟔𝟎° − 𝜽
As is always greater than, therefore the ratio is always greater than 1. Hence time required for cutting stroke
is greater than return stroke.
Thus for return stroke, no cutting operation is done in a shaper machine. So it is quicker than cutting stroke.
Hence this mechanism is called a quick return mechanism.
Hydraulic Mechanism
The hydraulic mechanism is used as a Quick Return Mechanism.
The shaper ram in the position as shown moves from left to
[Link] oil from the reservoir is drawn through the filter by a
gear pump which is driven by an electric motor.
The pump delivers a constant quantity of oil to the control
valve and from the control valve the oil can be delivered to
either side of the piston in the cylinder situated under the
ram.
To which side of the piston the oil will be delivered is
determined by the position of the control lever of the control
valve.
Figure shows a Constant Volume Hydraulic Mechanism
The same volume of oil is delivered on both sides of the
piston, but the intensity of pressure is different due to the
difference in the effective area of the piston.
Due to the difference in pressure, the ram travels at a faster rate in the return stroke than in the forward
stroke.
The stroke length of the ram is adjusted by adjusting the distance between the two stops. The cutting speed is
controlled by using the throttle valve during the cutting stroke.
Feed Mechanism
In shaper, both down feed and crossfeed movements may be obtained. These feed movements are provided
intermittently and during the end of return stroke only.
Vertical or bevel surfaces are produced by rotating the down feed screw of the tool head by hand.
Crossfeed movement is given by rotating the crossfeed screw either by hand or power.
Rotation of crossfeed screw causes the table to move sideways through a pre-determined amount at the end
of each return stroke.
Fig. shows the Automatic Crossfeed Mechanism of a Shaper.
In shaper, an automatic cross feed of the table is obtained by
a Ratchet and pawl mechanism.
It consists of a slotted disc that carries a T-slot which is
rotated by a bull gear of the shaper.
In this T-slot an, adjustable pin is fitted and to this connecting
rod is attached.
The other end of the connecting rod is attached to the lower
end of the rocker arm of the Pawl mechanism.
The rocker arm swings about the fulcrum and at its upper
end carries a spring-loaded pawl.
The adjustable pin is set eccentric with the slotted disc
center.
The slotted disc at its back carries a spur gear which is driven by a bull gear.
As the disc rotates, the adjustable pin being eccentric with the disc center causes the connecting rod to
reciprocate.
This, in turn, makes the rocker arm to swing about the fulcrum, to move the pawl over one or more teeth and
thus transmit an intermittent motion to the crossfeed screw which moves the table.
As the lower end of the pawl is beveled on one side, it facilities the power feed tope rate in either direction.
To reverse the direction of rotation of ratchet wheel and consequently the feed, a knob on the top of the
pawl after removing the pin is rotated through 180 .̊
The amount of feed may be altered by shifting the position of crankpin with respect to the center of the
driving disc. Greater the throw of eccentricity more will be the rocking movement of the rocker arm.
Advantages and Disadvantages of Shaping Machine
Advantages:
Shaping machine requires less time for process setup.
Shaping process has a higher production rate.
Shaping machine employes a quick return mechanism to minimize idle time.
It uses relatively inexpensive tools.
It is suitable for light-duty operations.
Disadvantages:
The cost of machining is higher than milling or broaching.
Due to the higher cost, it confines to the small quantity production.
It is not suitable for the machining of large parts.
It can not be used for heavy-duty operations.
It can not be employed with heavy cuts and coarse feed.
It has less accuracy and rigidity than a planer.
Shaper Operations
The different operations which can be performed on shaping machine are listed below:
1. Machining Horizontal Surface 2. Machining Vertical Surface 3. Machining Angular Surface
4. acMhining a V or Keyway Curved Surface 5. Cutting Splines or Gears.
1. Machining Horizontal Surface:
Set the vice jaws length perpendicular to the ram movement.
Hold the job length-vise parallel to the tool stroke so that the maximum
stroke of the tool may be utilized. (Refer Fig.)
Adjust the cutting speed and feed depending upon the surface finish required
i.e. rough or finish.
Hold the appropriate tool in the tool head. Set the proper inclination of the
tool and depth of cut.
Give cross feed to the tool initially by hand
till the cut start and then employ Power feed.
After the tool has cut the full width of the
job, stop the shaper, inspect the job and set another depth of cut
Repeat the above-said procedure.
2. Machining Vertical Surfaces
The tool is fed Repeat the downwards in vertical cutting as swivel the apron
from the face of the work to be cut as shown in Figure.
The tool is fed downwards by rotating the down feed screw by hand at the end of the return stroke, Give the
feed about 0.25 mm.
On the return stroke, the tool wings away from the work and gives clearance which prevents the work from
being scored.
Start cutting from the highest point towards the bottom.
Repeat the procedure for another cut.
3. Machining Angular Surfaces
Set the swiveling hand to the required angle for shaping angular faces as shown
in Fig.
The apron is to be swung away from the face to be machined.
The tool is to be fed by the slide handwheel.
The tool head is also swiveled in the direction away from the surface to be
machined.
Feed the tool during the return stroke.
Repeat the procedure to finish the work.
4. Machining Keyways and Grooves
For shaping grooves, slots and keyways, a square nose tool similar to the lathe
paring tool are to be used.
Fix the tool in the tool head rigidly.
Avoid excessively overhung and ensure that the tool clearances are not so
great as to weaken the tool.
Start the machine and give feed during the return stroke
Repeat the cut till the end of the operation Ref figure.
5. Gutting Splines or Gears
Hold the workpiece between the centers.
Use index head for cutting equally spaced splines and gear teeth.
Cut the first spline or gear tooth on the workpiece exactly in the way, a keyway
is cut.
Rotate the workpiece by the required amount using the index plate.
Lock the index plate by engaging the index pin with the corresponding hole in the circumference of the
index plate.
Cut the second spline.
Repeat the procedure, till the splines or gear teeth have been cut on the whole circumference of the
workpiece.
Use separate tools for cutting splines and gear teeth.