WORKSHOP EXERCISE 6

Student’s Name: Matric No.: PN/ME/22/__

Level/Class: 100 Practical Exercise 6 Date: 15 – 08 – 2023
Title: Skills Acquisition in Shaping Operations
AIMS: To acquaint the students with the knowledge of operating the horizontal shaper to produce
simple machine components and spare parts.
OBJECTIVES: The objective of the practical exercise is for the students to be able to
use the knowledge acquired to perform a variety of shaping operations in the shaper such as:
i. Generating Plain surfaces of different orientations
ii. Slotting and grooving, etc.
iii. Cutting external and internal key-ways in a shaft and pulley or gear
Background Theory: Working Principle: The job is rigidly fixed on the machine table. The single-
point cutting tool/ held properly in the tool post is mounted on a reciprocating ram. The reciprocating
motion of the ram is obtained by a quick return motion mechanism. As the ram reciprocates, the tool
cuts the material during its forward stroke. During the return, there is no cutting action and this stroke
is called the idle stroke. The forward and return strokes constitute one operating cycle of the shaper.
Machine/Tools/Material: Shaping Machine, spanners, Steel rule, dot punch, Ball peen hammer,
surface gauge, scriber, vernier calliper, height gauge, V-block, surface plate, and H.S.S. shaping tool,
Ø32 X 35 mild steel bar.
DIAGRAM: Shaping Apparatus

Main Parts of Shaping Machine

Holding a Rectangular Workpiece in the Machine Vice

 Types of Shaing Operations in Shaping Machines

A Given Workpiece of ∅32 X 35 M. S. Bar To be Shaped To Square Bar

Shaping Operation Sequence:
i. Hold the workpiece securely directly on the machine table or in the machine vice.
ii. Fix the cutting tool in the shaper tool head with a minimum overhang as shown in the figure.
iii. Raise the machine table close to the cutting tool.
iv. Adjust the length and position of the stroke. Note: The stroke length is about 20mm longer
than the work and the stroke is adjusted such that the tool starts about 10-15 mm before the
workpiece and continues about 10 mm after the end of the cut.
v. Mount the workpiece on the machine table and set the surface to be machined parallel to the
axis of the stroke.
vi. Fit a side cutting tool in the shaper tool head as shown in the figure.
vii. Adjust the length of the stroke as described in the section above.
viii. Give the cutting speed by rotating the down feed screw by hand (0.25 -0.50 mm)

Procedure:
i. The two ends of the workpiece are first smoothened by filing and applying chalk on its surface.
ii. Place the workpiece on the V-block and mark the centre on the end face using a surface gauge,
scriber, and Vernier height gauge.
iii. Mark the square on the end face according to the required dimensions.
iv. By using a dot punch made permanent indentation marks on the workpiece.
v. The tool is fixed to the tool post such that the tool movement should be exactly perpendicular
to the table.
vi. The workpiece is then set in the vice such that the tool is just above the workpiece.
vii. Adjust the length of the stroke.
viii. Make sure that the line of action of the stroke should be parallel to the surface of the
workpiece.
ix. Give depth of cut by moving the tool and feed is given to the workpiece during the return
stroke of the ram.
x. Continue the process, until the required dimensions are to be obtained.
xi. Repeat the process for all four sides.
xii. Finally make a key way on one side according to the given dimensions.

Result/Conclusion: _______________________________________________________________
________________________________________________________________________________

Study Guide Questions

1. State at least five (5) important precautions as regards the safety of the operator.
2. Make neat sketches of the Shaping Swivel Tool-head
Closing: 1. Remove the workpiece, and clean and tidy up the machine.
2. Return all the tools used to the store.
3. Submit your workpiece to the Workshop Officer-In-Charge
 WORKSHOP EXERCISE 6
Student’s Name: Matric No.: N/ME/22/__
Level/Class: 100 Practical Exercise 6 Date: 16 – 08 – 2023
Title: Skills Acquisition in Shaping Operations
AIMS: To acquaint the students with the knowledge of operating the horizontal shaper to produce
simple machine components and spare parts.
OBJECTIVES: The objective of the practical exercise is for the students to be able to
use the knowledge acquired to perform a variety of shaping operations in the shaper such as:
iv. Generating Plain surfaces of different orientations
v. Slotting and grooving, etc.
vi. Cutting external and internal key-ways in a shaft and pulley or gear
Background Theory: Working Principle: The job is rigidly fixed on the machine table. The single-
point cutting tool/ held properly in the tool post is mounted on a reciprocating ram. The reciprocating
motion of the ram is obtained by a quick return motion mechanism. As the ram reciprocates, the tool
cuts the material during its forward stroke. During the return, there is no cutting action and this stroke
is called the idle stroke. The forward and return strokes constitute one operating cycle of the shaper.
Machine/Tools/Material: Shaping Machine, spanners, Steel rule, dot punch, Ball peen hammer,
surface gauge, scriber, vernier calliper, height gauge, V-block, surface plate, and H.S.S. shaping tool,
Ø32 X 35 mild steel bar.
DIAGRAM: Shaping Apparatus

Main Parts of Shaping Machine

Holding a Rectangular Workpiece in the Machine Vice

 Types of Shaing Operations in Shaping Machines

A Given Workpiece of ∅32 X 35 M. S. Bar To be Shaped To Square Bar

 Shaping Operation Sequence:
ix. Hold the workpiece securely directly on the machine table or in the machine vice.
x. Fix the cutting tool in the shaper tool head with a minimum overhang as shown in the figure.
xi. Raise the machine table close to the cutting tool.
xii. Adjust the length and position of the stroke. Note: The stroke length is about 20mm longer
than the work and the stroke is adjusted such that the tool starts about 10-15 mm before the
workpiece and continues about 10 mm after the end of the cut.
xiii. Mount the workpiece on the machine table and set the surface to be machined parallel to the
axis of the stroke.
xiv. Fit a side cutting tool in the shaper tool head as shown in the figure.
xv. Adjust the length of the stroke as described in the section above.
xvi. Give the cutting speed by rotating the down feed screw by hand (0.25 -0.50 mm)

Procedure:
xiii. The two ends of the workpiece are first smoothened by filing and applying chalk on its surface.
xiv. Place the workpiece on the V-block and mark the centre on the end face using a surface gauge,
scriber, and Vernier height gauge.
xv. Mark the square on the end face according to the required dimensions.
xvi. By using a dot punch made permanent indentation marks on the workpiece.
xvii. The tool is fixed to the tool post such that the tool movement should be exactly perpendicular
to the table.
xviii. The workpiece is then set in the vice such that the tool is just above the workpiece.
xix. Adjust the length of the stroke.
xx. Make sure that the line of action of the stroke should be parallel to the surface of the
workpiece.
xxi. Give depth of cut by moving the tool and feed is given to the workpiece during the return
stroke of the ram.
xxii. Continue the process, until the required dimensions are to be obtained.
xxiii. Repeat the process for all four sides.
xxiv. Finally make a key way on one side according to the given dimensions.

Result/Conclusion: _______________________________________________________________
________________________________________________________________________________

Study Guide Questions

3. State at least five (5) important precautions as regards the safety of the operator.
4. Make neat sketches of the Shaping Swivel Tool-head
Closing: 1. Remove the workpiece, and clean and tidy up the machine.
2. Return all the tools used to the store.
3. Submit your workpiece to the Workshop Officer-In-Charge
 m

Swivel Tool Head

https://www.theengineerspost.com/shaper-machine-operations/#google_vignette

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