1.3.1 Shaper

MODULE 1.
RECIPROCATING
MACHINES
26 December 2022 MET 307 MTM GEC TSR 2022 1
MODULE 1.3
• SHAPING MACHINES
• Types – Size – Principal parts – Mechanism –
Work holding devices.
• Operations performed – Tools – Cutting speed,
feed and depth of cut – Machining time-
Surface roughness obtainable.

SHAPING MACHINES (SHAPER)


• Shaper is Machine tool which produces flat
surfaces in horizontal, vertical or inclined planes
depending upon the orientation of the cutting
tool.

Single point cutting tool is used for machining.
Tool is clamped in the tool post, mounted on the
ram of the machine tool.
The ram reciprocates to and fro.
Tool cuts the material in the forward stroke.
No cutting during return stroke.
Job is held rigidly in a vice.

Stroke starts slightly before the work piece (a) and

ends after the work piece (b)
Total stroke length = l+a+b

SHAPING MACHINES - SIZE
The size of a shaper can be specified by
the maximum length of stroke or cut it
can make.
Usually the size of shaper ranges from
175 to 900 mm.

SHAPING MACHINE- MAIN PARTS
• 1. BASE 5. CROSS RAIL
• 2. COLUMN 6. SADDLE
• 3. RAM 7. TOOL HEAD
• 4. TABLE 8. CLAPPER BOX

• 1. BASE:
• It is the main body of the machine tool
• It consist all elements of the machine tool
• It works as pillar for other parts.
• Base is made by cast iron which can take all
compressive loads.

• 2. Column:
• Column is attached to the base. It provides the
housing for the crank slider mechanism.
• The slide ways are attached upper section of
column which provide path for ram motion.

• 3. Ram:
• It is the main part of the shaper machine.
• It holds the tool and provides the reciprocating
motion to it.
• It is made by cast iron and move over ways on
column.

• 4. Table: (Work Table)
• It is the metal body attached over the frame.
• Its main function is to hold the work piece and
vice over it.
• It has T slots which used to clamp vice and
work piece over it.

• 7. Cross Rail:
• It consist vertical and horizontal table
sideways which allow the motion of table.
• It is attach with some cross movement
mechanism.

• 8. Saddle
• Saddle is fixed to the cross rail and supports
the table.
• If the table is removed, the work can be bolted
or clamped to the T slots in front of the saddle.
• Crosswise movement of the saddle causes the
work table to move sideways.

• 9. Tool head:
• It is situated at the front of the ram.
• Its main function is to hold the cutting tool.
• The tool can be adjusted on it by some of
clamps.

• 10. Clapper box:
• It carries the tool holder.
• The main function of clapper box is to provide
clearance for tool in return stock.
• It prevents the cutting edge dragging the work
piece while return stock and prevent tool wear.

SHAPING MACHINE- MECHANISM
• In shaper, rotary movement of the drive is
converted into reciprocating movement by
the mechanism contained within the column
of the machine.

• The reciprocating movement of the ram and the

quick return mechanism of the machine are
usually obtained by any one of the following
methods
• 1. Crank and slotted link mechanism
• 2. Whitworth quick return mechanism
• 3. Hydraulic shaper mechanism

1. CRANK AND SLOTTED LINK
MECHANISM
The slotted link mechanism is used for

converting the linear motion of a slider into
rotational motion or vice-versa.

MECHANISM
The slotted link rocks from side to side, driven

by the sliding block on the bull wheel.
MECHANISM
An electric motor drives a pinion gear, which
further dives the bull gear (wheel).
A radial slide is provided on the bull wheel.
A sliding block is assembled in this slide.
The bull wheel has a crank pin which is
connected to the sliding block.
A rocker arm s freely fitted to this crank pin.
The sliding block slides in the slot provided in
the rocker arm called slotted link.

MECHANISM
The bottom end of the rocker arm is pivoted
and its upper end is connected to the ram by
a pin.
When the pinion gear rotates along the bull
wheel, the crank will also rotate.
Due to this the rocker arm sliding block also
rotates in the same circle.
The sliding block slides up and down in the
slot.
This movement transmitted to the ram which
reciprocates.
WHITWORTH QUICK RETURN
MECHANISM

MECHANISM
In this mechanism consider a fixed link DC.
The crank CA revolves about the fixed
centre C.
A slider attached to the crank pin at A slides
along the slotted lever AP.
This makes the slotted lever oscillate about
the pivoted point C.
A short link PR transmits the motion from AP
to the arm which reciprocates with the tool
along the line of stroke.

QUICK RETURN CRANK MECHANISM

MECHANISM
• The ram moves at a comparatively slower speed
during the forward cutting stroke.
• During the return stroke, the mechanism is so
designed to make the tool move at a faster rate
to reduce the idle return time.
• This mechanism is known as quick return
mechanism.
• As the ram moves at a faster rate during return
stroke, the time taken becomes less.
• The total machining time decreases and the rate
of production
26 December 2022 increases.
MET 307 MTM GEC TSR 2022 27
MECHANISM
• The driving gear which contains the sliding
block rotates at a constant speed.
• The sliding block causes the slotted link to
rotate but because it has a different centre of
rotation, its speed is not constant.
• The angle through which the driving gear and
slotted link rotate on the forward stroke is
greater than the angle through which they
rotate on the return stroke.
• This imparts the slow forward and quick return
motion to the slider.
MECHANISM
• We see that the angle made by the forward or
cutting stroke is greater than the angle α
described by the return stroke.
• Hence the name QUICK RETURN
MECHANISM

QUICK ETURN MECHANISM
• In Quick Return Mechanism, the ram is
driven by a slotted link which pivots at its lower
end and is attached to the ram by a loose
connecting link at its upper end.
• The slotted link engages with the crank pin
mounted on the driving wheel which rotates at
constant speed and causes the link to oscillate
and the ram to reciprocate.
• A gearbox controls the speed of the driving
pinion, thus providing a range of speeds for
the ram.

3.Hydraulic shaper mechanism

• In a hydraulic shaper, reciprocating movement
of the ram is obtained by hydraulic power.
• Oil under high pressure is pumped into the
operating cylinder fitted with a piston.
• The end of the piston rod is connected to the
ram.


• The high pressure oil first acts on one side of the

piston and then on the other causing the piston
to reciprocate and the motion is transmitted to
the ram.
• The speed of the ram is changed by varying the
amount of liquid delivered to the piston by the
pump.

SHAPING MACHINES TYPES
Shapers are classified according to various
aspects;
According to position and movement of ram the
shapers are classified in to three types
a. Horizontal type
b. Vertical type
c. Travelling head type

a. HORIZONTAL TYPE SHAPER
As the name indicates these shapers have the
motion of ram along the horizontal axis.
This type of shapers is generally used for

generation of fine and flat surfaces.

B. VERTICAL TYPE SHAPER
In these shapers the tool containing ram has its
motion in vertical direction.
In vertical shaper the ram may be driven by

various types like crank driven, screw driven,
gear driven, or by hydraulic power.

b. VERTICAL TYPE SHAPER
Vertical shaping machines finds many applications
in deep hole boring, machining internal surfaces,
keyways, grooves etc. vertical shaper has a very
robust table which can have cross, longitudinal,
and rotational movement.
In some of the vertical machines, provision is made
to allow adjustment of the ram to an angle of
about 100 from the vertical position.

b. VERTICAL TYPE SHAPER

c. TRAVELLING HEAD TYPE SHAPER
This type of shaper is generally employed for
machining very large objects that cannot be
mounted on the table of the machine and cannot
be moved.
In this machine the ram having reciprocating
movement also provides crosswise movement
simultaneously such that the tool can cut the
required shape on the work piece.

c. TRAVELLING HEAD TYPE SHAPER

aspects;
3) Shapers are classified in to two types based on
design of the work table
a. Standard shaper
b. Universal shaper

a. STANDARD SHAPER
In these shaper the table has only two movements
i.e. vertical and horizontal.
The table may or may not be supported on the
other end.

b. UNIVERSAL SHAPER
In these shapers in addition to the above
mentioned two movements of the standard
shaper it provides two more directions.
1) By swivelling the table about a axis ram ways.
2) The table can be tilted about an axis
perpendicular to the 1 st one.
So due to these two features any operation at
any angle can be performed very easily.
So it is termed as a universal shaper.

b. UNIVERSAL SHAPER

aspects;
4) Based on type of cutting stroke employed these
are classified in to
a. Push type
b. Draw type

a. PUSH TYPE SHAPER
It is one of the most commonly used shaper.
In this the metal is removed when the ram is
moving away from the column.
This type of shaper pushes the work piece while
removing the work piece away from it so this
shaper is called as push type shaper.

b. DRAW TYPE SHAPER
It is just a reverse of the push type shaper.
In these machines the metal is removed from the
work piece when the ram is moving towards the
column.
The tool is required to be mounted in opposite
direction to the normal conditions.
The vibrations on machine components are also
damped to some extent.

Work holding devices in Shaper
• Work pieces can be held and supported on the
shaper table directly or by having some special
devices. Depending on the size and shape of
the work, it may be supported on the table by
any one of the following methods.
• Shaper vice
• Clamps and stop pins
• T-bolts and step blocks
• Angle plate
• V – Block
• Special fixture
• 1. Shaper Vice
• Vice is the most common and simple work
holding device used in a shaper.
• Different types of vices are used in a shaping
machine according to the need and they are
Plain vice, Swivel vice and Universal vice.

• 2. Clamps and Stop Pins:
• T – bolts are fitted into the T – slots of the table.
The work is placed on the table .
• The work is supported by a rectangular strip at
one end and by a stop pin at the other side.
• The screw is tightened to secure the work
properly on the machine table.

• 3. T-bolts, Clamp and Step Blocks:
• The step blocks are used in combination with T-
bolts and clamps to hold the work directly on the
machine table.
• T-bolts are fitted in the T-slots of the machine
table. One side of the clamp holds the work and
the other side rests on a step of the step block.
• The different steps of the block are useful in
levelling the clamp when holding works of
different heights.

• 3. T-bolts, Clamp and Step Blocks:

• 4. Angle Plate:
• Angle plate resembles the English alphabet ‘L’.
• It is accurately machined to have two sides at
right angles.
• Slots are provided on both the sides.
• One of the sides is bolted to the machine table
and the work pieces are held on the other side.

• 5. V – block
• V – block is a metal block having a ‘V’ shaped
groove on it.
• It is used for holding cylindrical work pieces.
Operations like keyway cutting, slot cutting and
machining flat surfaces can be performed on the
cylindrical work pieces held on a ‘V’ block.

• 6. Special Fixtures
• When internal keyways are to be machined on
the holes, the work is held with a special fixture.
The fixture has a V-block attached to it and the
cylindrical work is mounted on it.

.
Operations performed in Shaper
MET 307 MTM GEC TSR 2022 58

26 December 2022
Operations performed in Shaper
• Different types of operations are performed in a
shaping machine.
• They are broadly classified as:
• Regular operations
• Special operations

Regular Operations in Shaper
• Machining Horizontal Surfaces:
• A shaper is mostly used to machine a flat, true
surface on a work piece.
• Horizontal surfaces are machined by moving the
work mounted on the machine table at a cross
direction with respect to the ram movement.
• The clapper box can be set vertical or slightly
inclined towards the uncut surface.
• This arrangement enables the tool to lift
automatically during the return stroke.
• The tool will not drag on the machined surface.
• Machining Horizontal Surfaces:

• Machining Vertical Surfaces:
• A vertical cut is made while machining the end of
a work piece.
• The feed is given to the tool by rotating the down
feed screw of the vertical slide.
• The table is not moved vertically for this purpose.
The apron is swivelled away from the vertical
surface being machined as shown in the diagram.

• Machining Vertical Surfaces:

• Machining Angular Surfaces:
• If the surface to be machined is neither horizontal
nor perpendicular, the surface is called inclined
surface.
• Machining ‘V’ grooves and dovetail grooves are
some examples for angular machining.

• Machining Angular Surfaces:

Special Operations in Shaper
• Special Operations:
• Apart from machining horizontal, vertical and
vertical flat surfaces, the shaping machine can do
some special machining operations.
• Dove tail groove

• V block
• Tongue and groove joint

• Machining dove tail groove
• Dove tail joint is machined on two separate
pieces of work as male and female elements.
• The required shape is marked on the face of the
work and the unwanted metal is first removed by
the round nose tool.
• A special form tool is used to finish the
machining.

• Machining a ‘V’ block
• The required shape of a ‘V’ block is marked on
the face of the work and machining is done by
any suitable method of angular machining.

• Machining a tongue and groove joint:
• The male and female elements of the tongue and
groove joint having vertical surfaces is machined
after the exact shape is marked on the face of the
work.


• Machining External Keyways
• Machining external keyways refers to the cutting
of long slots along the length of cylindrical rods.
• Initially a round nose tool is used and then a
square nose tool is used to finish the operation.
• A hole of depth equal to the depth of the keyway
is made at the blind end to leave a clearance to
the tool at the end of the stroke.

• Machining External Keyways

• Machining Internal Keyways
• Internal keyways are cut inside the holes of gears
and pulleys.
• It is done by holding the tool on a special tool
holder called ‘snout bar’.
• The snout bar is directly fitted on the clapper
block.

• Machining Internal Keyways

• T-slot Machining
• The shape of the T-slot is marked on the face of
the work.
• A parting off tool is fitted on the tool post and a
rectangular slot is machined at the middle for the
required depth.
• The broad base of the ‘T’ slot is machined by a T-
slot cutting tool.

• Machining a Rack Gear
• Rack gear cutting is a process of cutting teeth
elements at linear pitch on a flat piece of work.
Firstly, the groove is machined with a square
nose parting tool. Then, the groove is further
machined with a form tool conforming the shape
of the teeth.

• Machining Irregular Surfaces
• A shaper can also produce a contoured surface
using a round nose tool.
• To produce a small contoured surface a forming
tool is used.
• If the curve is sufficiently large, powered cross
feed along with manual down feed is so adjusted
that the tool will trace the required contour.

Tool materials in Shaper
• The material of the cutting tool used in a shaping
machine should have more hardness and temper
when compared to the material of the work piece.
So, the shaper tools are made of the following
materials
• High Carbon Steel
• High Speed Steel
• Carbide tipped tool
• Stellite tool
• (Stellite is a cobalt-chromium alloy designed for wear resistance)

Types of Shaper Tools
• According to the type of work and the type of
operation, various tools are used in a shaper.
• According to the direction of cutting:
• Right hand ( R. H ) tool :
• This is a tool used for machining by moving the
job from right to the left.
• Left hand ( L. H ) tool :
• This is a tool used for machining by moving the
job from left to right.

• Roughing tool :
• When it is required to remove a good amount of
material from the work piece, roughing tools are
used.
• The cutting edge will be very thick, sharp and
strong to withstand the cutting pressure and to
dissipate the heat generated at the cutting point.
The surface obtained will be very rough.

Finishing tool :
After the rough machining is performed, the
finishing tool is used to obtain a very high
quality of surface finish.
The cutting edge will be either flat or
slightly convex.

Goose neck tool :
It is a special type of tool used for finish
machining.
Very good surface finish will be obtained.
The cutting edge of goose neck tool has a
springy action.

According to the shape of the cutting edge

Round nose tool.
Square nose tool.

• Round nose tool:
• This is used for roughing operations.
• The tool has no top rake.
• It has side rake angle, in between 10 to 20°.
Round tool is of two types, plain and bent
types.
• The plain straight type is used for rough
machining of horizontal surface.

• Square nose tool:
• This tool is used for finishing operations.
• The cutting edge may have different widths.
• It is also used to machine the bottom surfaces
of key ways and grooves.

Slot cutting tool
Wide rectangular or square grooves are
known as slots.
Rough machining of the slot is carried out
using round nose tool.
After that, a slot cutting tool is used for finish
machining work.

T-slot cutting tool
The central rectangular (or square) slot is first
machined using rough machining tool and
then by using parting tool (or slot cutting tool).
After that, a T-slot cutting tool is used to
machine underneath the rectangular groove.

Form tool :
Form tools are made to suit some specific
requirements for machining V shaped grooves
or similar special shaped grooves in concave
or convex form.


Cutting speed, feed and depth of cut
in Shaper
• Cutting Speed
• The cutting speed of a shaper is the rate at which
the metal is removed by the cutting tool in one
minute.
• In other words, only the forward cutting stroke is
considered.
• The speed is expressed in metre per minute.

in Shaper
• Cutting Speed = (length of cutting stroke / time
required by the cutting stroke)
In practice, it is difficult to measure exactly the time

taken during the forward cutting stroke.

in Shaper
• Let L= length of cutting stroke,
m = ratio between return time and cutting time,
n = number of double strokes per min.
v = cutting speed expressed in m/min.
From the above equation,
Time taken by cutting stroke/min =
(length of cutting stroke/ cutting sped in m/min)
= L/(1000 x v)

in Shaper
m = (return stroke time/ cutting stroke time),
So, return stroke time = (m x cutting stroke time)
= (m x L) / (1000 v)
And cutting stroke time = (return stroke time/ m),
= (m x L) / (1000 v) m
= L / (1000 v)
Time to complete 1 double stroke
= [L / (1000 v)] + [(m x L) / (1000 v) m]
= [L / (1000 v)] (1+m)
= [L (1+m)/ 1000v]

in Shaper
No. of Double stroke / min
n = 1/ [L (1+m)/ 1000v]
= 1000v / [L (1+m)]
So
Cutting Speed v = n [L (1+m)]/ 1000

in Shaper
• Feed
• Feed is the relative movement of the work or tool
in a direction perpendicular to the axis of
reciprocation of the ram per double stroke.
• It is expressed in mm per stroke.

in Shaper
• Depth of Cut
• Depth of cut is the thickness of metal that is
removed during machining.
• The perpendicular distance measured between
the machined surface and the uncut surface of
the work piece is taken.
• It is expressed in mm.

Machining time in Shaper
• Machining time:
• It is the time required for machining the work
surface to the required dimensions.

• Machining time:
• Let
• L = the length of the stroke in mm
• B = breadth of work in mm
• S = feed in mm/ double stroke
• M = ratio return to cutting time
• V = cutting speed in m/min

• Machining time:
• We know,
Time to complete 1 double stroke
= [L (1+m)/ 1000v]
Total no. of double strokes required
to complete the job = B/s
So, Time taken to complete the cut

= [L B(1+m)/ 1000vs]


1.3.1 Shaper

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

1.3.1 Shaper

Uploaded by

Copyright:

Available Formats

MODULE 1.

26 December 2022 MET 307 MTM GEC TSR 2022 2

26 December 2022 MET 307 MTM GEC TSR 2022 3

26 December 2022 MET 307 MTM GEC TSR 2022 4

26 December 2022 MET 307 MTM GEC TSR 2022 5

26 December 2022 MET 307 MTM GEC TSR 2022 6

Stroke starts slightly before the work piece (a) and

Total stroke length = l+a+b

26 December 2022 MET 307 MTM GEC TSR 2022 8

26 December 2022 MET 307 MTM GEC TSR 2022 9

26 December 2022 MET 307 MTM GEC TSR 2022 10

26 December 2022 MET 307 MTM GEC TSR 2022 11

26 December 2022 MET 307 MTM GEC TSR 2022 12

26 December 2022 MET 307 MTM GEC TSR 2022 13

26 December 2022 MET 307 MTM GEC TSR 2022 14

26 December 2022 MET 307 MTM GEC TSR 2022 15

26 December 2022 MET 307 MTM GEC TSR 2022 16

26 December 2022 MET 307 MTM GEC TSR 2022 17

26 December 2022 MET 307 MTM GEC TSR 2022 18

• The reciprocating movement of the ram and the

26 December 2022 MET 307 MTM GEC TSR 2022 19

The slotted link mechanism is used for

26 December 2022 MET 307 MTM GEC TSR 2022 20

The slotted link rocks from side to side, driven

26 December 2022 MET 307 MTM GEC TSR 2022 22

26 December 2022 MET 307 MTM GEC TSR 2022 24

26 December 2022 MET 307 MTM GEC TSR 2022 25

26 December 2022 MET 307 MTM GEC TSR 2022 26

26 December 2022 MET 307 MTM GEC TSR 2022 29

26 December 2022 MET 307 MTM GEC TSR 2022 31

26 December 2022 MET 307 MTM GEC TSR 2022 32

26 December 2022 MET 307 MTM GEC TSR 2022 33

26 December 2022 MET 307 MTM GEC TSR 2022 34

• The high pressure oil first acts on one side of the

26 December 2022 MET 307 MTM GEC TSR 2022 35

26 December 2022 MET 307 MTM GEC TSR 2022 36

This type of shapers is generally used for

26 December 2022 MET 307 MTM GEC TSR 2022 37

In vertical shaper the ram may be driven by

26 December 2022 MET 307 MTM GEC TSR 2022 38

26 December 2022 MET 307 MTM GEC TSR 2022 39

26 December 2022 MET 307 MTM GEC TSR 2022 40

26 December 2022 MET 307 MTM GEC TSR 2022 41

26 December 2022 MET 307 MTM GEC TSR 2022 42

26 December 2022 MET 307 MTM GEC TSR 2022 43

26 December 2022 MET 307 MTM GEC TSR 2022 44

26 December 2022 MET 307 MTM GEC TSR 2022 45

26 December 2022 MET 307 MTM GEC TSR 2022 46

26 December 2022 MET 307 MTM GEC TSR 2022 47

26 December 2022 MET 307 MTM GEC TSR 2022 48

26 December 2022 MET 307 MTM GEC TSR 2022 49

26 December 2022 MET 307 MTM GEC TSR 2022 51

26 December 2022 MET 307 MTM GEC TSR 2022 52

26 December 2022 MET 307 MTM GEC TSR 2022 53

26 December 2022 MET 307 MTM GEC TSR 2022 54

26 December 2022 MET 307 MTM GEC TSR 2022 55

26 December 2022 MET 307 MTM GEC TSR 2022 56

26 December 2022 MET 307 MTM GEC TSR 2022 57

MET 307 MTM GEC TSR 2022 58

26 December 2022 MET 307 MTM GEC TSR 2022 59

26 December 2022 MET 307 MTM GEC TSR 2022 61

26 December 2022 MET 307 MTM GEC TSR 2022 62