7

SHAPER

1 INTRODUCTION

intended primarily to
of machine tool
reciprocating type vertical, or
Theshaper is a be horizontal,
surfaces. These surfâces may surface composedof
produce flat can produce any
the shaper surface.
[Link] general, Modern shapers c a n generate contoured
straught line elements. was developed
in the year 1814 by James
The metal working shaper
Fox
1.2 TYPES OF SHAPERS the general
are classified in a number
of ways depending upon are
apers intended. Shapers
for which they are
or the purpose
Tes of design
casified under the following heading.
mechanism
giving
giving
usedJor Geared
According to the type of
reciprocating motion to the ram: (a) Crank type (b)
Lype (c) Hydraulic type. and travel ofram: (a) Horizontal type
ccording to the position
6) Vertical type (c) Traveling head type.
table: (a)
Standard shaper
to the type of design of the
ording
0) Universal shaper type (b)
Draw
to the type of cutting stroke : (a) Push
OPding
type.
Crank shaper: This is the most common type of shaper in which a single
point the length of the
strokeCutting
o tool is givenn a reciprocating
Tec a motion equal to table.
redwhil
adjustable
an
n while the work is in position on
construct clampe mechanism to change
Creular n , the crank
crank dper
shaper employs a crank ated in the
motio
Non ofof a
a l
wwachine to reciprocating1 motion
large gear of the ram.
called Thegear
"bull incorporated
ower
bull gear receives power

ntAtp./[Link] shap columns/shaper_column.

imn_19.html
 288 ELEMENTS OF WORKSHOP TECHNOLOGY
either fronm an individual motor or from an overhead line shaft if it is a belt
driven shaper.
Geared type: The reciprocating motion of the ram in some type of shaper
is effected by means of a rack and pinion. The rack teeth which are cut
directly below the ram mesh with a spur gear. The pinion meshing with the
rack is driven by a gear train. The speed and the direction in which the
machine will traverse depend on the number of gears in the gear train. This
type widely used
of shaper is not very
movement of the
Hydraulic shaper: In a hydraulic shaper, reciprocating
ram is obtained by hydraulic power. Oil under high pressure is pumped
rod is
the piston
into the operating cylinder fitted with a piston. The end of
connected to the ram. The high pressure oil first acts on one
side of the
and the
piston and then on the other causing the piston to reciprocate
motion is transmitted to the ram. The piston speed is changed by varying
the amount of liquid delivered by the pump. One of the most important
and force of the
advantages of this type of shaper is that the cutting speed
ram drive are constant from the very beginning
to the end of the cut. It also
eliminates shock and
offers great flexibility of speed and feed control,
the cutting tool is overloaded,
permits slip or slowing up of motion when
Another advantage is that
protecting the parts or the tools from breakage.
the machine does not make any noise and operates very quietly.
Horizontal shaper: In a horizontal shaper, the ram holding the tool
are mainly used to
reciprocates in a horizontal axis. Horizontal shapers
produce flat surfaces.
Vertical shaper: Ina vertical shaper, the ram holding the tool reciprocates
in a vertical axis. In some of the vertical machines provision is made to
allow adjustment of the ram to an angle of about 10 degrees from the
vertical position. Vertical shapers may be crank driven, rack driven, screw
driven or hydraulic power driven. The work table of a vertical shaper can
be given cross, longitudinal, and rotary movement. The tool used on a
vertical shaper is entirely different from that used on a horizontal shaper.
Vertical shapers are very con venient for machining internal surtaces,
keyways, slots or grooves. Large internal and external gears may also be
machined by indexing arrangement of the rotary table. There are vertical
shapers which are specially designed for machining internal keyways.
They are then called keys eaters.
Travelling head shaper: In a traveling head shaper, the ram carrying the
tool while it reciprocates moves crosswise to give the required feed.
Heavy and unwieldy jobs which are very di ticult to hold on the table of a
 SHAPER 289
ifit is a belt
standard shaper and fed past the tool are held static on the basement of the
machine while the ram reciprocates and supplies the feeding movements.
Standard or plain shaper: A shaper is termed as standard or plain when
the table has only two movements, vertical and horizontal, to give the feed.
The table may or may not be supported at the outer end.
Universal shaper: In a universal shaper, in addition to the two
movements provided on the table of a standard shaper, the table can be
swiveled about an axis parallel to the ram ways, and the upper portion of
second horizontal axis perpendicular to the
the table can be tilted about a
Ssure is pumpeu first axis. As the work mounted on the table can be adjusted in different
e end of the piston rod is planes, the machine is most suitable for different types of work and is
first acts on one side of the A universal shaper is mostly used in tool
piston to reciprocate and the given the name "Universal".
room work.
speed is changed by varying
of shaper in
. One of the most important Push type shaper: This is the most general type
common practice. The metal is removed when the ram moves away from
used
cutting speed and force of the
g to the end of the cut. It also the column, i.e. pushes the work.
ontrol, eliminates shock and Draw type shaper: In a draw shaper, the metal is removed when the ram
he cutting tool is overloaded, moves towards the column of the machine, i.e. draws the work towards the
ge. Another advantage is that machine. The tool is set in a reversed direction to that of a standard shaper.
rates very quietly. The ram is generally supported by an overhead arm which ensures rigidity
and eliminates deflection of the tool. In this shaper the cutting pressure acts
er, the ram holding the tool towards the column which relieves the crossrail and other bearings from
I shapers are mainly used to excessive loading and allows to take deep cuts. Vibration in these
machines is practically eliminated.
nholding the tool reciprocates
to
7.3 PRINCIPAL PARTS
aachines provision is madethe
Fig.7.1 illustrates different parts of a standard shaper.
f about 10 degrees fromscrew Base: The base is the necessary bed or support required for all machine
ank driven, rack driven, can tools. The base may be rigidly bolted to the floor of the shop or on the
table of a vertical shaper bench according to the size of the machine. It is so designed that it can take
on a
vement. The tool used up the entire load of the machine and the forces set up by the cutting tool
used on a horizontal shaper. over the work. It is made of cast iron
machining internal surfaces, to resist vibration and take up high
also be compressive load.
gears may
d external are
vertical Column: The column is a box like casting mounted upon the base. It
otary table. There
machining internal keyways. encloses the ram driving mechanism. Two accurately machined
guideways
are
ront
provided
vertical
on the top of the column on which the ram reciprocates. The
face of the column which serves as the guideways for the
shaper, the ram carrying the CrOSsrail is also accurately machined. The lid on the left side of the column
J required feeu. ay be opened for inspection and oiling of the internal mechanism with
to give the the table of a
icult to hold on
 290 ELEMENTS OF wORKSHOP TECHNOLOGY
for
the coumn. The other side of the column contains levers, handles,
etc.
operating the machine.
5
30 nmimmn
4 13 10
11
1
15- 12
Figure 7.1 Parts of a standard shaper
4. Apron clamping bolts, 5. Downfeed
1. Table support, 2. Table, 3. Clapper box,
7. Position of stroke adjustment
hand wheel, 6. Swivel base degree graduations,
9. Ram, 10. Column, 11. Driving pulley,
handwheel, 8. Ram block locking handle,
15. Elevating screw.
12. Base, 13. Feed disc, 14. Pawl mechanism,
the front vertical guideways of the
Crossrail: The crossrail is mounted on
column. It has two parallel guideways on
its top in the vertical plane that
are perpendicular to the ram
axis. The table may be raised or lowered to
screw which
accommodate different sizes of jobs by rotating an elevating
causes the crossrail to slide up and
down on the vertical face of the
the crossrail
column. A horizontal cross feed screw which is fitted within
and parallel to the top guideways of the crossrail actuates the
table to move
in a crosswise direction.
Saddle: The saddle is mounted on the crossrail which holds the table
on its top. Crosswise movement of the saddle by rotating
the cross
firmly
feed screw by hand or power causes the table to move sideways.
Table: The table which is bolted to the saddle receives crosswise and
vertical movements from the saddle and crossrail. It is a box like casting
 SHAPER 291
having T-slots both on the top and sides for clamping the work. In a
universal shaper the table may be swivelled on a horizontal axis and the
upper part of the table may be tilted up or down. In a heavier type shaper,
the front face of the table is clamped with a table support to make it more
rigid.
Ram: The ram is the
reciprocating member of
the shaper. This is semi-
cylindrical in form and
heavily ribbed inside to
make it more rigid.t
slides on the accurately
machined dovetail
guideways on the top of
the column and is
connected to the
reciprocating mechanism
contained within the INVRG|
column. It houses a 10
screwed shat for altering
the position of the ram
7.2 Toolhead of a shaper
with respect to the work
Figure
1. Downfeed screw micrometer dial, 2.
and holds the tool head at Downfeed screw, 3. Vertical slide, 4. Apron, 5.
the extreme forward end. Apron clamping bolt, 6. Clapper block, 7.
Toolpost, 8. Washer, 9. Apron swivel pin, 10.
Toolhead: The toolhead Swivel base
of a shaper holds the tool
igidly, provides vertical
and angular feed movement of the tool and allows
the tool to have an
The vertical slide of the toolhead
automatic relief during its retum stroke. the ram. The swivel
has a swivel base which is held on a circular seat on
slide may be set
base is graduated in degrees, so that the vertical
the
or at any desired angle. By rotating
perpendicular to the work surface the tool executes down
downfeed screw handle, the vertical slide carrying
while machining vertical or angular
Teed or angular feed movement of cut may be adjusted by
a
Surlace. The amount of feed or depth downfeed screw. Apron consisting
ot
on the top of the
micrometer dial vertical slide
the
is clamped upon
cpper box, clapper block and tool postserew, the apron may be swiveled
Dy a serew. By releasing the clamping
the pron swivel pin either towards left
or towardsright with respect
upon to provide reliet to
the
vertical slide. This arrangement is necessary
The The two vertical walls on
the
Owhile making vertical or angular cuts. block which is connected
to it
apron called clapper hox houses the clapper
292 ELEMENTs OF WORKSHOP TECHNOLOGY
mounted upon clapper
the block.
by means of a hinge pin. The tool post is
fits securely to the clapper
On the forward cutting stroke the clapper block
frictional
box to make a rigid tool support. On the return stroke a slight
drag of the tool on the work litts the
block out of the clapper boxanda
from dragging
sufficient amount preventing the tool cutting edge
from any damage due
consequent The work surface is also prevented
wear.
illustrates the tool head of a shaper.
to dragging. Fig.7.2
7.4 SHAPER SIZE
maximum length of stroke or cut
The size of a shaper is determined by the of
from 175 to 900 mm. The length
it can make. The usual size ranges
size of the machine, the size of a
stroke indicates, in addition to the general
Thus in a 250 mm shaper
cube that can be held and planed in the shaper. feed
from 0 to 250 mm, the cross
the length of stroke may be adjusted
mm and the extreme
bottom position of
adjustment of the table will be 250 accommodate a work piece 250 mm
the crossrail will permit the table to
high. indicates the overall size of
The length of stroke of a shaper merely
as the type of drive:
belt drive or
the shaper. Other particulars, such of the
individual motor drive, power input, floor space required, weight
amount of feed, etc. are
return stroke ratio, number and
machine, cutting to
also sometimes necessary.
7.5 SHAPER MECHANISM
the drive is converted into reciprocating
In a shaper, rotary movement of
column of the
movement by the mechanism contained within the
the reciprocating movement. n
machine. The ram holding the tool gets
while
a standard shaper metal
is removed in the forward cutting stroke,
the return stroke goes idle and no metal
is removed during this period.
to reduce the time
To reduce the total machining time it is necessary
mechanism should be so
taken by the return stroke. Thus the shaper
the tool to move at a
designed that it can allow the ram holding
forward cutting stroke, the
comparatively slower speed during the
material and machining
cutting speed depending upon the type of
allow the ram to
condition, whereas during the return stroke it can
move at a faster rate to reduce the idle return time.
This mechanism is
movement of the
known as quick return mechanism. The reciprocating
ram and the quick return mechanism of the machine are usually
obtained by any one of the following methods:
I. Crank and slotted link mechanism
2. Whitworth quick return mechanism
3. Hydraulic shaper mechanism
 SHAPER 293
3 7
8
10
17 18
2
13
L14
16
C-15
Figure 7.3 Crank and slotted link mechanism
5. Handwheel for
1. Driving pinion, 2. Ram, 3. Screwed shaft, 4. Clamping lever,9. Slotted link or
position of stroke adjustment 6.7. Bevel gears, 8. Ram block,
rocker am, 10. Bull gear sliding block, 11. Crank pin, 12. Rocker arm sliding
arm pivot, 16. Bull gear slide,
block, 13. Lead screw. 14. Bull gear, 15. Rocker
17,18. Bevel gears.
Crank and slotted link mechanism: The crank and slotted link
to the
mechanism is shown in Fig.7.3. The motion or power is transmitted
from an
bull gear 14 through a pinion I which receives its motion
control mechanism.
individual motor or overhead line shaft through speed
of
Speed of the bull gear may be changed by ditferent combination gearing
Bull gear 14 Is a
or by simply shifting the belt on the step cone pulley.
to the centre of the bull gear
large gear mounted within the column. Bolted
is a radial slide 16 which carries a sliding block 10 into which the crank
will cause the crank pin 1l to
pin 7 is fitted. Rotation of the bull gear the
revolve at a uniform speed. Sliding block 12 which is mounted upon
 294 ELEMENTS OF wORKSHOP TECHNOLOOY

crank pin l is fitted within the slotted link 9. The slotted link 9 which is
also known as the rocker arm is pivoted at 15 at its bottom end attached to
the frame of the column. The upper end of the rocker arm is forked and
connected to the ram block 8 by a pin. As the bull gear rotates causing the
crank pin to rotate, the sliding block 12 fastened to the crank pin /l will
rotate on the crank pin circle, and at the same time will move up and down
the slot in the slotted link 9 giving it a rocking movement which is
communicated to the ram. Thus the
rotary motion of the bull gear is Vekocity Cut
converted to reciprocating
movement of the ram.
principle of quick return Retum
motion
The
is illustrated in Fig.7.4.
N

When the link is in the position PM,

the ram will be at the extreme
backward position of its stroke, and
when it is at PN, the extreme
c,
forward position of the ram will
have been reached. PM and PN are
shown tangent to the crank pin
Figure 7.4 Principle of quick
circle. The forward cutting stroke, return
therefore, takes place when the
crank rotates through the angle C, KC2 and the return stroke takes place
when the crank rotates through the angle C2LC1. It is evident that the angle
stroke is greater than the angle
CKC2 made by the forward or cutting
C2LC, described the retum stroke. The angular velocity of the crank pin
by
completed within a shorter
being constant the return stroke is, therefore,
motion.
time for which it is known as quick return
returm time may be
The ratio between the cutting time and
determined from the formula:

Cutting time
7.1
Return time
2:1 and the
Cutting time to return time ratio usually varies between
this mechanism
practical limit is 3:2. The only disadvantage lies with the
that the cutting speed and retum speed is not constant throughout
and the
stroke. It is minimum when the rocker arm is at the two extremities
speed is maximum when the rocker arm is vertical. of
Adjusting the length of stroke: Fig.7.3 illustrates how the length
to the
stroke in a crank shaper can be adjusted. The erank pin // is fastened
travel may be
sliding block 10 which can be adjusted and the radius of its
 296 ELEMENTS OF WORKSHOP TECHNOLOGY
The clamping lever 4 must be
adjusted with respect to the work piece.
made.
tightened after the adjustment has been
Whitworth quick return mechanism:
The Whitworth return
quick
of the
mechanism is shown in Fig.7.7
and a simple line diagram
mechanism is shown in
Fig.7.8. The bull gear is
mounted on a large fixed
pin A upon which it is free
plate 4
to rotate. The crank
is pivoted eccentrically
at 5.
upon the fixed pin
Fitted on the face of the bull
2 on
pin
gear is the crank -
the top of which is mounted
the sliding block 3. Sliding
block 3 fits into the slot Figure 7.66 Stroke length adjustment
B.
Short stroke
A. length,
provided on the crank plate
of crankpin,
1. Position
Long stroke length.
4. At the other end of the 9 and
connects the crank plate by a pin
crank plate 4, a connecting rod 6
will rotate at a constant speed the
the ram 8 by a pin 7. When bull gear
crank pin 2 with the sliding block 3
will rotate on a crank circle of radius
the crank plate to rotate about the
A2 and the sliding block 3 will cause
D 6 8
B
T7777
777777777
A
3
E
2
Figure 7.7 Whitworth quick return mechanism
1. Driving pinion, 2. Crank pin, 3. Sliding block, 4. Crank plate,
5. Pivot for crank plate, 6. Connecting rod, 7. Connecting pin for ram,
8. Ram, 9. Pin, A. Fixed pin.
the
point 5 with a variable angular velocity. Pin 9 fitted on the other end of
crank plate 4 will rotate in a circle and the rotary motion of the pin 9 will
be converted into reciprocating movement of the ram similar to the crank
and connecting rod mechanism. The axis of reciprocating of the ram passes
through the pin 5 and is normal to the line A5
 SHAPER 297
When the pin 2 is at the position C the ram will be
at the extreme
backward position but when the pin is at the position B, the extreme
forward position of the ram will have been reached. When the
pin 2 travels
from C to B the crank pin 9 passes through the backward
position to the
forward position in the cutting stroke, and the return stroke is completed
when the pin 2 travels from B to C or the pin 9 passes from the forward
position to the backward position. As the angular velocity of the crank pin
is uniform, the time taken by the crank pin 2 to travel through an arc
covering CEB is greater than the time taken to move through an are
covering BDC. Thus a quick return motion is obtained by the mechanism.
The length of stroke of the ram may be changed by shifting the
position of pin 9 closer or away from the pivot 5. The position of stroke
may be altered by shifting the position of pin 7 on the ram.
Hydraulic shaper mechanism: In a hydraulic shaper the ram is moved
forward and backward by a piston moving in a cylinder placed under the
ram. The machine mainly consists of a constant discharge oil pump 2, a
valve chamber, a cylinder, and a piston 7. The piston rod 6 is bolted to the
4
-D- 5
6
-7
3 -A
2 E
return mechanism
Figure 7.8 Line diagram of quick
block, 4. Crank pin forFixed
.Driving pinion, 2. Crank plate, Sliding
3.
7. Bull gear, A.
for crank plate, 6. Ram,
connecting rod, 5. Pivot
pin.
under high pressure is pumped from
ram body. As shown in Fig. 7.9 the oil to the right
through the valve chamber
CServoir 7 and is
made to pass
on the piston 7. This c a u s e s the
SIde of the oil cylinder 5 exerting pressure stroke, and any
oil
C o n n e c t e d to the piston 7 to
perform forward reservoir
to the
is discharged
the left side of the cylinder extreme forward
stroke, the
Cn 0n end of
nrough the throttle valve 3. At the the valves 12 to alter
lever 9 causing
snaper dog 8 hits against the reversing
 SHAPER 299

he excess oil flows out through the relief valve 11 to the reservoir
maintaining uniform pressure during cutting stroke. A hydraulic shaper is
now widely used for having many advantages. Some of them are listed
below.

1. The cutting and return speeds are practically constant

throughout the stroke. This permits the cutting tool to work
uniformly during cutting stroke.
2. The reversal of the ram is obtained quickly without any shock as
the oil on the other end of the cylinder provides cushioning
effect.
3. Infinite number of cutting speeds may be obtained from zero to
the maximum value and the control is easier.
4. speed, greater number of cutting
With a
high rate
of return a
strokes may be available within the range of cutting speed.
5. The relief valve ensures safety to the tool and the machine when
the machine is overloaded.

Feed mechanism: In a shaper both downfeed and crossfeed movements

may be obtained. Unlike a lathe, these feed movements are provided
intermittently and during the end of return stroke only. Vertical or
bevel surfaces are produced by rotating the downfeed screw of the
toolhead by hand. Crossfeed movement is used to machine a flat
horizontal surface. This is done by rotating the crossfeed screw either
by hand or power. Rotation of the crossfeed screw causes the table
mounted upon the saddle to move sideways through a predetermined
amount at the end of each return stroke so as to bring the uncut surface
of the work in the direct path of the reciprocating tool.
Fig.7.10 illustrates the automatic cros feed mechanism of a
shaper. The rotation of the bull gear causes the driving disc 8 to rotate
In a particular direction. The driving disc 8 is T-slotted and position of
the crank pin 9 attached to the connecting rod may be altered to give
aiierent throw of eccentricity. The other end of the connecting rod is
aitached to the rocking arm by a pin 7. The rocking arm is fulcrumed at
0, the centre of the ratchet wheel 5. The ratchet wheel 5 is keyed to the
Crossfeed screw. The rocking arm houses a spring loaded pawl 4 which
IS straight on one side and bevel on the other side. As the driving disc
rolates, the connecting rod starts reciprocating and the rocking arm
rocks on the fulcrum 6. When the driving disc rotates through half of
ne revolution in the clockwise direction, top part of the rocking arm
moves in the clockwise direction and the pawl 4 being slant on one side
slips over the teeth of the ratchet wheel 5 imparting it no movement. As
he driving disc rotates through the other half, the top of the rocking
 300 ELEMENTS OF WORKSHOP TECHNOLOGY
arm now moves in the
anticlockwise direction
and the straight side of
the pawl engages with 3
the teeth of the ratchet
wheel causing the wheel
to move in
anticlockwise direction
only. As the driving disc
is connected to the bull
9
gear the table feed
movement is effected
when the bull gear or the
driving disc rotates
through half of the
revolution, i.e., during
stroke Figure 7.10 Automatic feed mechanism of
return only.
Rotation through other a shaper
half imparts no feed 1. Knob, 2. Pin, 3. Helicalspring, 4. Pawl, 5. Ratchet
movement. To reverse wheel, 6. Rocker arm fulcrum, 7. Rocker arm
connecting pin, 8. Driving disc, 9. Crank pin.
the direction of rotation
of ratchet wheel and
consequently the feed, a knob I on the top of the pawl 4 after removing the
pin 2 is rotated through 180 degrees.
The amount of feed may be altered by shifting the position of crank
pin 9 with respect to the centre. Greater the throw of eccentricity, more will
be the rocking movement of the arm and the pawl will pass through three
or four teeth on the ratchet wheel at a time imparting greater feed
movement.
7.6 WORK HOLDING DEVICES
The top and sides of the table of a shaper have T-slots for clamping
work. The work may be supported on the table by the following methods
the
depending on the nature of the work piece.
. Clamped in a vise
2. Clamped on the table
3. Clamped to the angle plate
4. Clamped on a V-block
5. Held between shaper index centre
 SHAPER 301
Shaper vises: Fig.7.11 illustrates a typical shaper vise. A vise is a quick
of holding and locating relatively small and regular shaped work
pieces. It consists of a
base. table, screw, fixed 3 4
and movable jaws. The
base has a projection or
E 0
tongue which fits into the
slot of the machine table.
For properly securing it to
the table lugs are provided 6
for clamping the vise by
9
T-bolts. The work is
clamped between fixed
and movable jaws by
rotating the Screw.
Wherever possible the vise
is so placed on the table
that the tool while cutting
exerts direct pressure upon UU-10
the jaws. A machine vise Figure 7.11 Shaper vise
may be classified under 1. Screw, 2. Movable jaw, 3. Hold down, 4. Work,
following headings. 5.
Parallels, 6. Handle, 7. Base, 8. Clamping bolt,
9. Swivelling base, 10. Lug.
1. Plain vise
(a) Single screw
(b) Double screw
2. Swivel vise
3. Universal vise
A plain vise is the most simple of all the types. The vise may have a
Single screw or double screws for actuating the movable jaw. The double
Screws add gripping strength while taking deeper cuts or handling heavier
Jobs.
In a swivel vise the base is
VIse
graduated in degrees, and the body of the
may be swivelled at any desired angle on a horizontal plane. The
Swiveling arrangement is useful in bevelling the end of work piece.
A universal vise
may be swivelled like a swivel vise. In addition to
that, thebody may be tilted in a vertical plane up to 90 degrees from the
horizontal. An inclined surface may be machined by a universal vise.
Parallels: Fig.7.11 illustrates the use of parallels. When the height of the
Job 1s less than the height of the
jaws of the vise, parallels are used to raise
and seat the work piece above the vise jaws and parallel with the vise
bottom. Parallels are
square or rectangular bars of steel or cast iron,
 ELEMENTS OF wORKSHOP TECHNOLOGY
302
are available in
hardened and ground with opposite sides parallel. They
various sizes for seating work pieces of different heights and are always
used in pairs.
downs. Hold downs
Fig.7.11 illustrates the use of hold
or
Hold downs:
used for holding thin pieces of work in a shaper vise. Hold
grippers are
jaws
than the vise
of smaller height
downs are also used for holding work
The hold down is a hardened
where suitable parallels are not available.
tapered at an angle of 5°.
wedge shaped piece with its two working edges
of the vise and the work piece.
Hold downs are placed between two jaws
of the hold down exerts
When the screwtightened the typical shape
is
or on the
downward pressure the work to hold it tight on the parallels
on
vise table.
When the work piece is too large to be held
Clamping work on the table: on the shaper table. In holding work
in a vise it must be fastened directly
on the table, clamping bolts
should not be unduly tightened to produce
to clamp different
distortion of the work. The different methods employed
table are:
types of work on a shaper
1. T-bolts and clamps.
2. Stop pins.
3. Stop pins and toe dogs.
4. Strip and stop pins.
T-bolts and clamps:
A7
Fig.7.12 illustrates the use
of T-bolts and clamps for
holding the work. T-bolts
having T-heads are fitted in
the T-slots of the table. The
length o the threaded
portion is sufficiently long
in order to accommodate
Figure 7.12 Use of T-bolt and clamnp
different heights of work.
1. Step block, 2. T-bolt, 3. Clamp, 4. Work
The T-bolts are illustrated
in Fig.5.6. The clamps are
made of steel having slots at the centre for fitting the bolt. One end of the
[Link] the other end rests fulcrum,
clamp rests on the side of the on a
block. The fulcrum block should be of the same height as the part being
clamped. The bolt is placed as near to the work as possible and the nut is
then tightened. To hold a large work on the table a series of clamps and T
bolts are used all round the work.
Stop pins: Fig.7.13 illustrates stop pins. A stop pin is a one-leg
screw clamp. As the tool moves forward to perform cutting stroke the work
 SHAPER 303

out of
tends to be pushed
under the
its position
of the cutting
pressure
used to
tool. Stop pins
E
are

the work from

prévent
out of position.
corhing
The body of the stop pin
is fitted in the hole or slot
on the table and the screw

is tightened till it forces

against the work.
Stop pins and toe
dogs: Fig.7.14 illustrates
of stop pins and Figure 7.13 Stop pins
the use
1. Body, 2. Screw.
toe dogs. While holding
2.
thin work on the table
stop pins in conjunction
with toe dogs are used. A
toe dog is similar in shape
to that of a centre punch
or a cold chisel. The head
Figure 7.14 Use of stop pin
and toe dog
end of a toe dog is drilled
1. Toe dog, 2. Work, 3. Stop pin.
slightly so that the end of
the stop pin screw may fit
A large number of stop pins
into it. Fig.7.15 shows two types oftoe dogs. is
work. When screw of the stop pin
and toe dogs are placed all round the
on the table.
tightened, the work is gripped down
2 3

o Figure 7.15 Toe dogs 7.16 Use of strip and stop pins
1. Strip, 2. Work, 3. Stop pin.
strip of and
illustrates the working
Strip and stop pins: Fig.7.16 sufficient thickness is held on

Stop pins for holding the work. Work having with

tongue
is a long bar having
a

e lable by strip and stop pins. A strip with bolts is titted in

the T-slot of the
for the T-bolts. The strip
noles fitting within the slot. The
nuts are then
able, the tongue of the strip fitting
rest on one side
of the work. The stop
g e n e d so that the strip plate may
304 ELEMENTs OF WORKSHOP TECHNOLOGY
the other end of the work so that the
pin screws are then tightened from
work may be clamped between stop pins strip and plate.
Angle plate: Fig.5.15 illustrates
the use angle plate. For holding "L"
of an
used. Angle plates are made of cast
shaped work piece, angle plates are of exactly 90°. One of the sides
iron and is planed on two sides to an angle work by
while the other side holds the
is clamped to the table by T-bolts
clamps.
V-block. For holding round rods
V- block: Fig.7.17 illustrates the use of a its two
on two V-blocks at
V-blocks used. Work may be supported
are
ends and is to the
clamped
table by T-bolts and clamps.
The tool may be made to
3
reciprocate between the two
clamps for cutting grooves
or key ways.
V-blocks are
made of cast iron or stecel
and are accurately
machined.
Figure 7.17 Use of V-block
5. Clamp
Shaper centers: Fig.7.18 1.T-bolt, 2. V-block, 3. Work, 4. Nut,
illustrates a shaper center. or
used for cutting equally spaced grooves
This is a special attachment it may be used
of a round work. In special cases,
splines on the periphery headstock and a tailstock,
centre consists of a
for cutting gears. A shaper the
between two centres. Mounted upon
and the work is mounted The
4 which meshes with the worm.
headstock spindle is the worm gear
worm shaft. Rotation
of the handle 2 causes
handle 2 is connected with the work through
the worm gear 4 to rotate and
the motion is transmitted to the
on the top of the
carrier. After cutting a slot or groove
a catch plate and 3 and
amount by an index plate
work, it may be turned to a predetermined index
the worm gear shaft. The
index pin I. The index plate is mounted on
locked in any
around its circumference and is
plate has a series of holes Index
desired position by engaging the index pin
in the corresponding hole.
numbers of holes.
plates are provided with various
7.7 SHARPER OPERATIONS
to generate a tlat
A shaper is a versatile machine tool primarily designed
Surface by a single point cutting tool. But it may also be used to perform
which a sharper can
many other operations. The different operations
perform are as follows:
I. Machining horizontal surface
2. Machining vertical surface
 SHAPER 305
[Link] angular surface
grooves, and
keyways.
4. Cutting slots,
surface.
5. Machining irregular
or cutting gears.
6. Machining splines
horizontal
illustrates machining
horizontal surface: Fig.7.19
Machining
Use of sharper centre
Figure 7.18 5. Work.
Index plate, 4. Worm gear,
1. Index pin, 2. Worm handle, 3.
used to machine a flat, true
surface on a work piece. A shaper is mostly
surface on a work piece held in a vise or
other holding devices. After the
work is properly held on the table, a
planing tool is set in the tool post with
minimum overhang. The table is
raised till there is a clearance of 25 to
30 mm between the tool and the work
0 piece. The length and position of
stroke are then adjusted. The length of
stroke should be nearly 20 mm longer
than the work and the position of
stroke is so adjusted that the tool
begins to move from a distance of 12
to 15 mm before the beginning of the
cut and continues to move 5 to 8 mm
after the end of the cut. Proper cutting
speed and feed is then adjusted. Short
strokes should be given with high
Figure 7.19 Machining speed while long strokes with slow
speed. Both roughing and finishing
horizontal surface cuts are performed to complete the
For
Job. roughing cut speed is decreased but feed and depth of cut is
reased. Depth of cut is adjusted by rotating the down feed screw of the
ncad. The amount of depth of cut is adjusted by a micrometer dial. The
306 ELEMENTS OF WORKSHOP TECHNOLOGY
depth of cut for roughing work usually ranges from 1.5 to 3 mm, while for
finishing work, it ranges from 0.075 to 0.200 mm. Feed is adjusted about
one half the width of the cutting
edge of the tool so that each cut
will overlap the last cut giving a
smooth surface finish.
Machining vertical surface:
Fig7.20 illustrates machining
vertical surface on work piece.
A vertical cut is made while
machining the end of a work
piece, squaring up a block
or
cutting shoulder. The work is
mounted in the vise or directly on
the table and the surface to be
machined is carefully aligned
with the axis of the ram. A side
cutting tool is set on the tool post Figure 7.20 Machining vertical
surface
and the position and length of
1. Apron, 2. Work.
stroke is adjusted. The vertical
slide is set exactly at zero position
and the apron is swiveled in a
direction away from the surface
being cut. This is necessary to
enable the tool to move upwards
and away from the work during Jut
return stroke. This prevents the
side of the tool from dragging on
the planed vertical surface during
return stroke. The downfeed is
given by rotating the down feed
sCrew by hand. The feed is about
0.25 mm given at the end of each
2
return stroke. Both roughing and
finishing cuts are performed to AA
complete the job.
Machining angular surface:
Fig.7.21 llustrates machining of Figure
7.21 Machining angular
an
angular surface on a work 1. Work, 2. surface
piece. An Apron, A, Swivelling angle
angular cut is made at
of the vertical slide.
any angle other than a
to the horizontal or to
right angle
the vertical
 SHAPER 307
toolhead is
vertical slide of the
table and the from the
o n the towards right
is set on left or
The work either towards so
from the work
plane. required angle urther swiveled away
tothe is then downfeed is
stroke. The
Swiveled
The apron
position.
work during return can also
be
vertical
will clear the surface
Angular
at the tool the
downfeed
screw.
a
universal vise without
ven by rotating shaper or by using
universal
achined in a
mao
swiveling t h e t o o l h e a d .
can very
tools a shaper
suitable
With external keyways
keyways:
Cutting
slots and on a
work or cut slots or
machine slots
or grooves For cutting
conveniently pulleys or gears. selected. Fig.7.22
keyways on tool is
and internal similar to a parting of
on shafts shows cutting
n o s e tool
and Fig.7.23
keyways a square keyways a shaft by
first
of external a r e cut on
illustrates cutting External keyways of the holes
internal keyways
in a shaper. The diameter
end of the keyway. and the
at the blind width of the keyway
drilling a hole oversize than
the
keyway. This
is
should be 0.5 to 0.8 than the depth of the
mm
stroke.. The
1.5 m m larger end of the
depth should be aboutclearance on the tool at the stroke will
leave a' that the
necessary to carefully adjusted so cuttingg
of stroke is is reduced
while
length and position hole. The speed
the clearance the tool on a
special tool
terminate exactly at
cut by holding the end of the
a keyway. Internal
keyways a r e the work at
tool post will
not hit against
box to prevent
the tool
holder so that the in the clapper the work to
block is locked on
stroke. The clapper return stroke.
Lubrication is
necessary
Tom lifting during tool from w e a r
due to dragging
of the
preveht the cutting edge A
Figure 7.23 Cutting8
gure 7.22 Cutting external keyway external keyway
Vise
1. Vise, 2. Tool, 3. Work. 2. Work., 3.
1. Tool bit,
contoured
a
also produce
Machining irregular surface: A shaper
surface
can
or a
combination of
tool
any or
the
ahou . a convex or concave surface a forming 1S
aces. To produce a small contoured with
used
used. If in conjunction
ower-crossfeed
the urve is sufficiently large, trace the required
that the tool will
need is so adjusted and downs
both the feeds
are
ne contour has too many ups
 TECHNOLOGY
WORKSHOP
ELEMENTS OF
308
tool is selected for machining
irregular
A round nose
operated by hand. cut the apron may
be set vertical but if the curve
is
surfaces. For a shallow or left away from the
swiveled towards right
the apron is
quite sharp, shows machining of
a c o n c a v e surface using a
surface to be cut. Fig.7.24
round nose tool.
illustrated
Machining splines or cutting gears: By using an index centre,
in Fig.7. 18, a gear or equally
spaced
spline may be cut. between
The work is mounted
two centres and a spline
is cut similar
to the cuttingof a keyway. After the
first is cut, the work is rotated
spline
through a predetermined amount by
using the index plate and index pin.
The periphery of a gear blank is
divided, and equally spaced grooves Figure 7.24 Machining
are cut by using an index plate having irregular surface
proper hole circles. While cutting gear
a formed tool is used.
7.8 SHAPER TOOLSS
The cutting tool used in a shaper is a single point cutting tool having rake,
clearance and other tool angles similar to a lathe tool. It differs from a lathe
tool in tool angles. Shaper tools are much more rigid and heavier to
withstand shock experienced by the cutting tool at the commencement of
each cutting stroke. In a lathe tool the effective angle of rake and clearance
may be varied by raising or lowering the point of the tool in relation to the
centre of the work, but in a shaper the tool angles cannot be changed as the
tool is always clamped perpendicular to the surface of the work. When it
becomes necessary to change the tool angles it can only be done by
grinding. In a lathe tool sufficient amount of side clearance angle must be
provided as the tool is continually fed sideways tracing a helical path, but
in a shaper tool as the feed is given at the end of cutting stroke, a very
small clearance angle is necessary to give relief to the side cutting edge. In
a shaper tool the amount of side clearance angle is only 2 to 3° and the
front clearance angle is 4° for cast iron and steel. Small clearance angle
adds strength to the cutting edge. As the tool removes metal mostly from
its side cutting edge, side rake of 10° is usually provided with little or no
front rake. The side rake angle to be provided is dependent upon the kind
of metal being cut, the hardness of the tool
material, type of cut: roughing
or
finishing, and other factors which intluence the rake angle. A shaper
 9HAPER 309

left hand Figure 7.26 A left hand

Figure 7.25 A
roughing tool for planing finishing tool for planning

F
Figure 7.28 A left hand
Figure 7.27 A left hand
side finishing tool
side roughing tool

can also use a right hand or left hand tool. The left hand tool is more
the cut better than the right
Common because it permits the operator to see material for a shaper tool
hand [Link] speed steel is the most common
ur Shock resistant cemented carbide tipped tool is also used where harder
 310
ELEMENTS OF 311
WORKSHOP TECHNOLOY SHAPER

measure
dificult to
it is
c a l culate
ula
the cutting speed,
to
practice,
In taken
time
the
forward
etactly
the
350 u r t n g

cuting
stroke.
The
return
ratio

time
the
the
350
Aerween
and
40 w
cutting
time

double
strokes

Number
of of
or r.p.m.
minute
per should be
wheel
the bull speed
The cutting
known.
obtained
from the
may be
aquation (7.2).
Figure 7.29 A left hand dovetail
cutting tool for roughing Figure 7.30 A left hand
han dovetail Let, L= the -2°
cutting tool for finishing stroke in
A parting or slotting tool
material is to be length ofcutting Figure 7.31
machined. As in a lathe, tool holders are also used to hold mm
the tool bits. Some of the most m the
common cutting tools are: between return
time to cutting
time.
the ram per
minute
ratio double strokes of
the number of
1. A left hand roughing tool for planing of the bull wheel
(Fig.7.25) or r.p.m.
2. A left hand finishing tool for planing (Fig.7.26) in m/min.
the cutting speed expressed
3. A left hand side facing tool for vertical shaping and for shaping
From the equation No. (7.2), stroke in mm
sharp coner (roughing) (Fig.7.27) length of cutting
4. A left hand side facing tool (finishing) (Fig.7.28) min
Time taken by the cutting stroke, cutting speed in
m/min
5. A left hand dovetail cutting tool (roughing) (Fig.7.29)
6. A left hand dovetail cutting tool (finishing) (Fig.7.30) retum stroke time
L
7. A parting or slotting tool. (Fig.7.31.) and, cutting stroke time
1,000x v
7.9 CUTTING SPEED, FEED AND DEPTH OF CUT the metal
rate at which
the
the cutting speed is mx.L
Cutting speed: In shaper, minute. In a
a
in metre per
the cutting tool. This is expressed
expressed by of retum stroke time =
m x
cutting stroke timne 1,000x v
is removed by continuous the cutting
speed is
action is cutting action 1s
the cutting the L mxL
work. But in a shaper
lathe as the
of the only during Time taken to complete one double stroke i

the peripheral speed is considered 1,000x v 1,000x v

the cutting speed
intermittent. In a shaper
in a shaper is L -(1+ m) 7.3
The cutting speed
forward cutting stroke.
calculations:
1,000xv
Cuting speed
Number of double strokes per minute
expressed by theformula:
cuttingstroke or
.p.m. of the bull wheel
length ofthe
Cutting speed =
time required
by the
cutting
stroke
L+m)
1000x v
 ELEMENTS OF
WORKSHOP
=
1000x v TECHNOLOGY SHAPER 313
been The cutting
L(1+ m) and,
assumed speed so
nL(1+m) Total number
of double strokes required
in that the calculated is
reality, in a crank cutting stroke the 1,000
1.4 to complete the job
uniform. driven is average
completed at acutting speed as it
shaper cutting Lx BCl+m)
the
The factors speed and uniform speed. has Total time
taken to complete
the cut
1,000x v xs
discussed in [Link] govern the speed is But,
return
2.17. amount of not
Example 7.1 cutting speed are same as the time required for taking
a complete cut on a plate 600 x
strokes per Ina shaper work, the vample 7.2: Find is 9 m/min. The return time to cutting time ratio is 1:4
oMmm,if the cutting speed
cutting [Link] is 30 and the ratio length of stroke is 200
of return time pd the feed
is 3 mm. The
clearance at each end is 75
mm.
not ordinarily
mm, length of more than 900 mm is
to
cutting timenumber of
is 2:3. double In a shaper a
stroke
is placed on the table to take a
cut of 600 mm plus
Find the uailable so the work
the clearances.
Cutting speed= nL(l+m) 30x 200 1+
600+75 +75 =
750 mmn.
1,000 Total length ofstroke
=
1,000 750 x 60
Cutting time
F
sec.
30x 200x5 1,000x 9
10 m/min.
Feed: Feed (s) is the 1,000x 3 Return stroke time
relative movement of the Cutting stroke timne
perpendicular
is
to the axis of tool
reciprocation of the ram
or work in a direction
expressed in mm. The feed is per double
always given at the end of
stroke and .
Return time= 5x
when the tool is not return stroke
cutting
the metal. The selection of feed is
dependent 25
upon the kind of metal, type
of job, etc.
Total time for one complete double stroke = 5+=sec.
Total number of double strokes necessary to complete the cut
Depth of cut: Depth of cut (1) is the thickness of metal that is removed in
one cut. It is the
perpendicular distance measured between machined 900
surface and non-machined surface of the work piece. 300
3
7.10 MACHINING TIME 25x 300
Total time required to complete the cut =F 31.25 min.
If the length of cutting stroke, breadth of the job, feed and cutting speed are 4x 60
known, the time required complete the job may be calculated as
to
TABLE 7.1 AVERAGE VALUE OF CUTTING SPEED AND FEED
Let,
L = the length of the stroke in mm
Material
B =
the breadth of the work in mmn. High carbon steel High speed steeltool Cemented carbide
S t h e feed expressed in mm/double stroke.
time. m/min mm
the ratioreturn time to cutting
mn m/min mm m/min
m=
in m/min. Cast iron
the cutting speed Mild steel 1.5 18 2 30 0.125-0.5
12 1.25 1.5 45 0.125-0.5
24
Brass 30 0.25-0.35s
Then from equation (7.3), 48 1.25 60
one double stroke
L(1+m)
1,000x V
Time taken to complete