Shaper

Introduction
 The shaping machine (Known as Shaper) is a Machine tool which
produces flat surfaces in horizontal, vertical or inclined planes depending
upon the orientation of the cutting tool especially where a large amount
of metal has to be removed.

 Also used to make slots, grooves and keyways and producing contour of
concave/convex or a combination of these.
Introduction
 The components of the shaper include a ram (that hold shaper tool), which
moves relative to a column to provide the cutting motion, and a worktable that
holds the workpart and accomplishes the feed motion.
 The tool does useful work i.e., cutting only in the one stroke (generally during
forward stroke) of the ram.
 During the cutting stroke the work part is fixed on the worktable while tool
reciprocate to remove the material from the surface.

Note* The reciprocating motion of the ram is obtained by a quick return motion mechanism.
 Working Steps
 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.
 As the ram reciprocates, the tool cuts the
material during its cutting stroke
(generally in forward stroke ).
 During 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.

Note* The reciprocating motion of the ram is obtained by a quick return motion
mechanism.
Working Principle
 Since useful work is done only during the cutting stroke of ram, the
mechanism driving the ram is so designed that the return stroke is
completed in much less time than the Cutting stroke.
 This can be achieved using Quick Return Mechanism
 A quick return mechanism is used where there is a need to convert rotary
motion into reciprocating motion. As depicted in the figure, the disc rotates
the black slide moves forwards and backwards.
Working Principle

 The crank AB rotates with a uniform angular speed.

 The crank pin B is in the shape of a die block which is free to slide inside the
slot in the slotted lever OBC .
 This slotted lever is pivoted at O and the other end C is connected to the ram
by a short link arm.
Working Principle

 When the crank AB rotates clockwise from position AB1 to AB2 , the ram
moves forward from left to right and when it rotates from position AB2 to
AB1 the ram returns back to its original position.
 Clearly the time taken to complete forward stroke is proportional to angle
(α) and the return stroke is completed in less time which is proportional to
angle (β).
 Since returns stroke take less time and hence named quick return motion
mechanism.
Principle Parts of a Shaper

 The main parts of the Shaper machine is Base, Body (Pillar, Frame, Column),
Cross rail, Ram, Tool head (Tool Post, Tool Slide, Clamper Box Block) and
worktable.
Principle Parts of a Shaper

 Base: The base is a heavy cast iron casting which is fixed to the shop floor. It
supports the body frame and the entire load of the machine. Also it absorbs
and withstands vibrations and other forces which are likely to be induced during
the shaping operations.

 Body (Pillar, Frame, Column): It is mounted on the base and houses the drive
mechanism comprising the main drives, the gear box and the quick return
mechanism for the ram movement. The top of the body provides guide ways for
the ram and its front provides the guide ways for the cross rail.

 Cross rail: The cross rail is mounted on the front of the body frame and can be
moved up and down. The vertical movement of the cross rail permits jobs of
different heights to be accommodated below the tool. Sliding along the cross
rail is a saddle which carries the work table.

 Ram and tool head: The ram is driven back and forth in its slides by the slotted
link mechanism (i.e. quick return motion mechanism). The back and forth
movement of ram is called stroke and it can be adjusted according to the length
of the work-piece to be-machined.
Specifications

 Length of the Stroke

 Maximum Vertical and Horizontal travel of the worktable
 Maximum height available in between Table and Ram
 Size of the worktable
 Maximum vertical travel of the tool slide
 Power of the motor
 Ram cycles per minute or Strokes per minute
 Floor Space required
Classification

Shapers are classified according to various aspects.

1) Based on type of mechanism employed for the movement of the

cutting tool i.e. tool carrying ram, the shapers are classified in to three
types
a. Crank type
b. Gear type
c. Hydraulic type

2) 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
Classification

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

4) Based on type of cutting stroke employed

a. Push type (cutting stroke is in forward stroke)
b. Draw type (cutting stroke is in return stroke)

5) Based on method of transmitting power employed

a. Geared driven Shaper
b. Cone Pulley Belt driven Shaper

6) Based on the length of Stroke

a. 30 cm shaper
b. 45 cm shaper
c. 60 cm shaper
Types
Standard Shaper :
It is most commonly used shaper. It consist of plain table that may or may not have
vertical supports at its front. Provision for table to swivel may or may not be present.
The material is peel it off in forward direction.

Draw Cut shaper:

Similar to standard shaper in construction but is comparatively heavier. Its main
difference from standard shaper is that it peels off metal chips during backward stroke.

Horizontal 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.

Vertical Shaper:
these shapers have the motion of ram along the vertical axis.

Crank Shaper:
Shapers whose ram reciprocates with the help of crank mechanism
Types
Geared Shaper:
Shapers whose ram reciprocates with the help of gear mechanism ( A rack under the
ram is used for to and fro motion).

Hydraulic Shaper:
The movement of ram is provided by hydraulic pressure in this type of shaper.

Contour Shaper :
Contours shapers are standard shapers fitted with an additional tracer mechanism. In
this sharper template and follower are used to reproduce a contour similar to the
shape of template.
 It is suitable for producing shapes that cannot produced by other shaper.

Universal Shaper:
It is called universal shaper since the job can be tilted about in any direction through
the required angle with the help of swivel vice.

 In this shaper a special type of table present that can swung about a horizontal
axis (parallel to the ram). The top of the table can also tilt.
Operations

1) Horizontal Cutting
2) Cutting vertical and angular surfaces
3) Irregular cutting
4) Machining a thin job on a shaper
5) Keyway cutting