Design and Fabrication of Dual Side Shaper Machine Project

Abstract
Most of the industries are having various types of reciprocating machines for
performing machine operation on small size of work. A shaping machine is mainly
used for shaping the tools, which may be horizontal, vertical or inclined. In a dual
shaper machine, materials are shaped from both sides, which makes it more
advantageous than usual shaper. Dual Shaper machine helps industries to achieve
high production rate at a minimal amount of time and cost. Dual Shaper machine
reduces the production cost as well as the time. In this project, a dual side shaper
machine is designed with the help of quick return mechanism, the rotary motion
of the motor is converted into linear motion of the tool which shapes the material
mounted on the vice from both the side. The quick return mechanism converts
rotary motion into reciprocating motion, but unlike the crank and slider, the
forward reciprocating motion is at slower rate than the return stroke. DC motor is
connected with the mechanism with the help of chain and sprocket. Whole
mechanism is built on rugged metal frame.

Components
 
  AC Motor
Bearing and Bearing Cap
Belt Drive
Metal Frame

AC MOTOR
AC induction motors are the most common motors used in industrial motion
control systems, as well as in main powered home appliances. Simple and rugged
design, low-cost, low maintenance and direct connection to an AC power source
are the main advantages of AC induction motors. Various types of AC induction
motors are available in the market. Different motors are suitable for different
applications. Although AC induction motors are easier to design than DC motors,
the speed and the torque control in various types of AC induction motors require
a greater understanding of the design and the characteristics of these motors.This
application note discusses the basics of an AC induction motor; the different
types, their characteristics, the selection criteria for different applications and
basic control techniques.

• A.C MOTOR DATETAILS:

Bearing
Outer Diameter of Bearing (D) = 37 mm
Thickness of Bearing (B) = 12 mm
Inner Diameter of the Bearing (d) = 12 mm
Ball and roller bearings are used widely in instruments and machines in order to
minimize friction and power loss. While the concept of the ball bearing dates back
at least to Leonardo da Vinci, their design and manufacture has become
remarkably sophisticated. This technology was brought to its p resent state of
perfection only after a long period of research and development. The benefits of
such specialized research can be obtained when it is possible to use a
standardized bearing of the proper size and type. However, such bearings cannot
be used indiscriminately without a careful study of the loads and operating
conditions. In addition, the bearing must be provided with adequate mounting,
lubrication and sealing. Design engineers have usually two possible sources for
obtaining information which they can use to select a bearing for their particular
application:

Belt
A belt is a loop of flexible material used to link two or more rotating shafts
mechanically, most often parallel. Belts may be used as a source of motion, to
transmit power efficiently, or to track relative movement. Belts are looped over
pulleys and may have a twist between the pulleys, and the shafts need not be
parallel. In a two pulley system, the belt can either drive the pulleys normally in
one direction (the same if on parallel shafts), or the belt may be crossed, so that
the direction of the driven shaft is reversed (the opposite direction to the driver if
on parallel shafts). As a source of motion, a conveyor belt is one application
where the belt is adapted to carry a load continuously between two points

Metal Frame: The metal frame is generally made of mild steel bars for machining,
suitable for lightly stressed components including studs, bolts, gears and shafts. It
can be case-hardened to improve wear resistance. They are available in bright
rounds, squares and flats, and hot rolled rounds
Suitable machining allowances should therefore be added when ordering. It does
not contain any additions for enhancing mechanical or machining properties.
Bright drawn mild steel is an improved quality material, free of scale, and has
been cold worked (drawn or rolled) to size. It is produced to close dimensional
tolerances. Straightness and flatness are better than black steel. It is more
suitable for repetition precision machining. Bright drawn steel has more
consistent hardness, and increased tensile strength. Bright steel can also be
obtained in precision turned or ground form if desired.

WORKING PRINCIPLE

Shaper is the metal cutting machine tool designed for cutting flat work piece by a
tool. Shaping is used to machine thin and soft plates. The operation of machine is
simplified to few simple operations involving a motor and tool head arrangement.
When the crank is driven by a motor or by handle, the crank rotates about the
axis, so the crankpin slides inside the slot of the slotted plate. As the crank
rotates, the slotted bar reciprocates due to the sliding of crank pin. The
connecting rod attached with the slotted plate on both sides, reciprocates as the
crank rotates. The cutting tool is attached at the both sides of connecting rod, to
carry out the cutting operation. Since the cutting tool is placed on both sides,
operation can be done at both the sides of the machine
EXPERIMENTAL MODEL

Construction TheFrame is a rigid body that supports the entire mechanism. Mild
steel tubes- rectangular Cross section Crank is a rotating part, Which is either a
hand driven or motor driven. Slotted bar has a slot in which the crank pin engages
or slides over it. Crank pin is welded on a crank at a pitch circle diameter (PCD)of
130 mm. Mild steel Ø25 mm and 70mm length Shaft is a rotating machine
element, which is used to transmit the torque. One end of the shaft is connected
to the handle slot and other end of the shaft is welded to the centre of the crank
disc.Steel Connecting rod is used to connect the slotted bar to the cutting tool on
either sides of the bar. The connecting rod is supported at the frame. Mild steel
Plummer block is used for holding rotating shafts with help of bearing and other
parts. Brass Ø30 mm the fabricated system has the ability of quick lifting and
portability. It is easier to use and maintained cost is less.Cutting tool is a tool that
is used to remove material from the work piece by means of shear deformation.
Cutting tool must be stronger than work piece. In shaper machine the cutting tool
moves in a direction normal to the work piece. Ex: High speed steel, carbon steel,
carbides, etc. The cutting tool material must have the properties such ashigh
hardness and strength at high temperature, good toughness and high tool life.
High Speed Steel(HSS) Nut is a hollow material where bolts are inserted. Mild
steel Ø6 mm Bolt is moved inside nut. It has head, shank, thread portion. Mild
steel Ø10 mm

CONCLUSION
this project is made with pre planning, that it provides flexibility in operation. This
innovation has made the more Desirable and Economical. This project is designed
with the hope that it is very much economical and it also helped us to know the
periodic steps in completing a project work. Thus we have completed the project
successfully.