SHAPING OPERATIONS

Shaper – primarily intended to produce flat surfaces (horizontal, vertical and inclined) using a single
point cutting tool mounted on a reciprocating arm. Main significance is ease of WP holding, quick
adjustment and relatively simple design.

Working Principle of a shaper: WP is rigidly held in a suitable WP holding device (vice or clamped
directly on the table). The single point tool is held on a tool post mounted on the ram of the machine. The
ram reciprocates to and fro such that the tool cuts in the forward stroke. No cutting takes place in the
return stroke (idle stroke). However, in draw cut shaper, cutting takes place in the return stroke while the
forward stroke remains idle. The WP is given an indexed feed (equal feed each time after every cut) in the
direction normal to the cutting action of the tool.

Quick return mechanism: Except the draw cut shaper, in all other shaper, the forward stroke is the
cutting stroke and the return stroke is idle stroke. Hence, it is strived that the return stroke is as fast as
possible so as not to waste anytime. This mechanism of quickly pulling the tool back in the return stroke is
called quick return mechanism. In practice, it is achieved by (1) crank and slotted link mechanism (like in
rail wheels); and (2) hydraulic mechanism.

Crank and slotted link mechanism: a slotted link called rocker arm is attached to the ram on one end and
pivoted at the other end (forming a fulcrum). The slotted part of the rocker arm contains a slide block
which can slide up and down the slot. The slide block is connected to an adjusting screw via a crank pin
and the other end of the adjusting screw is connected to the centre of a bull gear (via bevel gears). The
bull gear is rotated by a bull gear pinion directly driven by the power shaft. Now as the bull gear rotates,
the slotted disc rotates – in the forward stroke the slotted disc rotates the adjusting screw by a cutting
angle α (the rocker arm and to be more specific the slide block moves from the position B1 to B2. This
makes the ram move from the extreme rear position to extreme forward position. On the return stroke, the
slotted arm moves from B2 to B1 (disc moves a return angle β). The cutting angle is more than the return
angle implying forward (cutting) stroke consumes more time than the return (idle) stroke; ratio is
approximately 3:2 (cutting angle approx 220° and return angle approx 140°).
Hydraulic mechanism: During the forward stroke, the control valve lever is at the right position (R2) and
the oil from the reservoir goes to the right hand side of the cylinder (or piston) via A. This creates extra
pressure on the piston and it moved from right to left (forward stroke of the ram). During this cycle, the oil
from the right hand side of the cylinder moves out of the cylinder to the reservoir via B. A stop is attached
to the ram body which throws the control valve lever to R1 position at the end of the forward stroke. At
this point, oil now flows into the LHS of the cylinder and oil flows out of the cylinder on the RHS to the
reservoir. This constitutes the return stroke. At the end of the return stroke, another stop actuates the
control valve lever to go from R1 to R2. The length of the stroke is determined by maintaining the
distance between the two stops of the ram.

Principal parts of a shaper:

Base: it is heavy robust CI body which acts as the support for all the other parts of the machine mounted
over it.
Column: It is box type CI body mounted on the base and acts as housing for all the operating mechanism
and electrical controls. It also acts as a support for other parts of the m/c such as ram, cross-rail etc. on its
top it carries guideways on which the ram reciprocates. In the front, it carries vertical guideways for the
cross rail.
Cross rail: is attached to the column at its front on the vertical guideways. The cross carries horizontal
guideways at its front. An apron to which is bolted the machine table slides along these horizontal
guideways to provide cross feed to the table.
Table: It is of CI heavy construction. It holds and supports the WP during operation. It slides along the
cross rail to provide cross feed (horizontal) to the WP. Automatic feed to the table is given by means of an
eccentric driven ratchet and pawl mechanism. Up and down vertical motion to the table is provided by
means of a vertical leadscrew (operated by the table traverse screw). The table carries T slots on its top
and side faces for clamping and holding the WP.
Ram: It carries the toolhead and moves along the dovetail guideways to provide a straight line motion to
the tool. It carries the mechanism for adjustment of ram position inside it.
Tool head: it is a device in which the tool is held. It can slide up and down in the guideways provided at
the ram. It can also be swung at a desired angle (up to 60º) to set the tool at the desired position.
Vice: It is the WP holding device mounted on the table. The WP may be directly clamped to the table as
well.
Drive: An electric motor fitted to the back of the machine is used from which the drive is transferred to
the gear box through V belts. Usually a two speed induction motor and a three speed gear box is provided
which gives 6 different speeds to the ram. Gears are changed with a lever present at the back of the m/c.
 For adjusting the feed, remove the nut and move the eccentric and again tighten the nut. To
increase the rate of feed, the eccentric should be moved away from the centre and vice versa.
Tool slide: Height of the tool can be adjusted by moving the tool head by means of a tool slide handwheel.
For swivelling the toolhead, unscrew the nuts provided at the back of the tool head, swivel it up to the
desired angle and tighten the nuts. Maximum inclination is up to 60º on either side of vertical.
For setting the length of the stroke desired, bring the ram to the extreme rear position and then
adjust the same by Ram adjustment nut and lock it by turning the Ram locking handle.
Clapper box: the shaping machine usually cuts on the forward stroke and does not on the backward
stroke. So it is not required for the tool to be in contact with the work piece when it is on the backward
stroke. This is ensured by the Clapper box, a device which is hinged to the ram. The lifting of the cutting
tool by the clapper box ensures longer tool life and also accidental scratches or other machining defects on
the work piece/final product.
Classification of Shapers:
Classified based the length of the stroke, type of driving mechanism, direction of travel of the ram, design
of table etc.
Standard Shaper: common shaper consisting of a plain table. In some versions, the table can swivel
about a horizontal axis parallel to the ram (for machining inclined flat surfaces). Material is cut in forward
stroke and return stroke is idle.
Draw-cut Shaper: similar to standard shaper except (1) it is of heavy construction (for heavy WP) and (2)
material is cut on the return stroke and the forward stroke is idle.
Horizontal Shaper: The ram and the tool reciprocate in a horizontal plane. Popular design.
Universal Shaper: It is similar to the horizontal shaper except for two additional movements for the table
(or WP) – (1) table can be swung about a horizontal axis parallel to the ram ways, (2) the table can be
tilted about another horizontal axis which is normal to the ram ways and the above table axis.
Vertical Shaper: The ram reciprocates in the vertical direction and the table is circular rotary type. It
looks like a vertical slotting machine. But the difference in them is that, in the vertical shaper, vertical
movement may be adjusted 10 on either side of the vertical for inclined shaping operation. The vertical
slotting m/c has its ram movement in the vertical direction only.
Geared Shaper: it is classified based on driving mechanism. This type of shaper carries a rack under its
ram which is driven by spur gears. It has become obsolete nowadays.
Crank Shaper: they carry a crank and slotted link mechanism for their ram movement. It has become
popular these days.
Hydraulic Shaper: in these shapers, hydraulic pressure is used for driving the ram. It is popular and better
because it enables constant speed and force from start to end of the cut.
Contour Shaper: it is a standard shaper fitted with an additional tracer mechanism. In this a template and a
follower are used to replicate the contours of a template (not possible in other shapers).
Travelling head Shaper: It is specifically designed for machining large and heavy WP which cannot be
held on the table. Hence, the WPs are loaded on the floor or the base of the shaper and then machined.
Herein, the ram, in addition to reciprocating also gets a cross feed movement. (WP does not move, but the
ram moves horizontally over the WP surface).

Types of Shaper tools:

1. According to the shape – straight, cranked, goose neck etc.
2. According to the direction of cutting – left hand and right
3. According to the operations – down cutting or surfacing, side recessing, parting off, squaring etc.
4. According to the degree of finish – roughing and finishing
5. According to the shape of cutting edge – round nose and square nose.