Hydraulic Shaper

A constant speed motor runs a pump which

delivers oil at constant pressure in the line
Through flow control valve to 4 way regulating
valve. It admits oil under pressure to each end
on the piston alternately and allowing oil from
opposite end to return to reservoir. The flow
of oil in each end is accomplished with the
help of trip dogs and pilot valve. As ram
completes it stroke, trip dog will trip the pilot
valve which operate 4 way regulating valve to
alter the direction flow of oil.
a. Stroke length is adjusted by using trip dogs at desired
location
b. The speed of ram is proportional to oil pressure and area
of piston.
Advantage: a) cutting speed remains constant
during cutting and return speed remains constant
during return stroke.
b) Ram reverses quickly without experiencing any
shock as inertia of the working parts is
comparatively small.
c) Range and number of cutting speed are large.
d) More stroke/min is possible
e) Ability to change length and position of stroke.
Disadvantage: initial cost and maintenance cost too
high.
 Numerical problems
1. Calculate the rpm of the bull gear of a mechanical shaper if cutting speed is 35m/min. with adjusted stroke
length 250mm. Assume ratio of cutting stroke to idle stroke as 1.5.
Solution: let rpm of bull gear be N. So, for 1 rev. time needed is 1/N min. Out of this 1/N min, cutting time is
(15/25)x(1/N) min.
Dist. Travelled=(35m/min)x(15/25)x(1/N)min=250/1000 N=(35X15X1000)/(250X25)=84 RPM.

2. A part measuring 300mmx100mmx40mm is to be machined using hydraulic shaper along its wide face.
calculate the machining time taking approach and overtravel as 25mm each. take cutting speed as 15m/min
and machining allowance on either side of plate width is 5mm and feed is 0.4mm/stroke.
Solution: Leff  L  Lo  La =300+25+25=350mm
No. of stroke required= (100+5+5)/0.4 =275
Being hydraulic shaper, cutting speed i.e assumed uniform speed in a stroke =15000mm/min.
Time required for machining= ((350x2)/15000)x275=12.83 min.

3. A shaper is operated at 2 cutting stroke per second and is used to machine a work-piece of 150mm length at
a cutting speed of 0.5m/s using a feed of 0.4 mm/stroke and a depth of cut of 6mm. (a) calculate the total
machining time to produce 800 components each 100 mm width. (b) if forward stroke is over 230degree,
calculate % of time when tool is not contacting work.
Solution: No. of stroke required= (100+5+5)/0.4=275
Machining time/piece needed=(275/2) s
Total machining time = ((275/2)x800)/3600 hr=30hrs.
cutting time for a stroke= α/(α+β)N=230/(360X120)=.0053min
Idle time for a stroke =β/(α+β)N=130 /(360x120)=.003 min
% of time tool not contacting work= (.003/.0083)x100= 37.5%
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