CHAPTER-4 SHAPER

Shaper:-
The shaper is a reciprocating type of machine tool intended to produce
flat surfaces. The surface nay be horizontal, vertical or inclined

Working principle:-
The job is fixed rigidly in a suitable vice or directly clamped on the
machine table. The tool is held in the tool post mounted on the ram of the
machine. This ram reciprocates to and fro , and in doing so , makes the tool
to cut the material in the forward stroke. No cutting takes place during the
return stroke of the ram. It is called idle stroke. The job is given an intended
feed, in a direction normal to the line of action of the cutting tool.

Types of shapers:-
1. According to the type of mechanism used for giving reciprocating
motion to the ram.
a. Crank type
b. Geared type
c. Hydraulic type
2. According to the position and travel of ram .
a. Horizontal type
b. Vertical type
c. Travelling head type
3. According to the type of design of the table
a. Standard shaper
b. Universal shaper
4. According to the type of cutting stroke
a. Push type
b. Draw type
Specification of shaper:-
1. Maximum length of stroke(175-900mm)
2. Maximum horizontal travel of table
3. Maximum vertical travel of table
4. Maximum distance from table to ram
5. Tool box, vertical adjustment
6. Length and width of the table
7. Numbers and range speeds available
8. Numbers and range feeds available
9. Horse power and speed of driving motor
10. Weight of the machine and floor space required

Crank shaper:-

This a most common type of shaper. It uses a crank mechanism to

change circular motion of a large bull gear into reciprocating motion of the
ram

Geared type:-

The reciprocating motion is effected by means of rack and pinion

Hydraulic shaper:-

The reciprocating motion is obtained by hydraulic power.

Horizontal shaper:-
The ram reciprocates in a horizontal axis
Vertical axis:-
The ram reciprocates in a vertical axis
Travelling head shaper:-
The ram reciprocates and moves crosswise to give required feed
Standard or plain shaper:-
The table has two movements, vertical and horizontal to give the
feed
Universal shaper:-
In addition of the two movements, the table can be swivelled about
on axis parallel to the ram ways.
Push type:-
The most general type of shaper used in common practice . the metal
is removed when the ram moves away from the column
Draw type shaper :-

The metal is removed when the ram moves towards the column of
the machine, draws the work towards the machine. The tool set is reversed
direction to that of a standard shaper.

DIFFERENT PARTS OF A SHAPER:-

BASE:-

The base provides stability for the shaper as it supports all other
equipments present as well as absorb the forces coming due to the cutting .
it is made of cast iron and have a necessary arrangements of bolts so that it
can be bolted to the factory floor.

Column(housing):-

The column of the shaper is a hollow casting and is mounted on the

base. It houses the ram driving mechanism. For the ram and table, on the
top of the column, necessary guide ways are provided for the linear
movement of the ram and the front vertical face is for cross rail.
Cross rail:-

The cross rail is mounted on the front vertical guideways of the

column. It has two parallel guide ways on its top vertical plane that are
perpendicular to the ram axis. The table may be raised or lowered to
accommodate different sizes of job by rotating elevating screw.

Saddle:-

The saddle is mounted on the cross rail which holds the table . on its
top crosswise movement of the table is powered by rotating cross feed
screw.

Table:-

The work table of a shaper is fastened to the front of the column. The
table is provided T-slots for mounting the work pieces. The table can be
moved up and down and crosswise by cross rail and saddle. Jobs can be
held by vice.

Ram:-

The ram is a reciprocating member of the shaper. It is

semicylindrical in form and heavily ribbed inside to make more rigid. It
slides on the guideways of the column. A single point cutting tool is
fastened in the tool post.

Tool head:-

The single point cutting tool is held in the tool post. The tool head
holds the tool provides vertical and angular feed movement and allows the
tool to have an automatic relief during return stroke. The vertical side of the
tool head has a swivel base which is held on a circular seat on the room.

The swivel base is graduated in degrees so that the vertical slide may
be set perpendicular to the work surface at any desired angle. By rotating
the down feed screw handle, the vertical slide carrying the tool executes
down feed or angular feed movement while machining vertical or angular
surface.

The amount of feed or depth of cut may be adjusted by a micrometer

dial on the top of the down feed screw. Apron consisting of clapper box,
 clapper block and tool post is clamped upon the vertical slide by a screw.
By releasing the clamping screw , the apron may be swivelled upon the
apron swivel pin either towards left or towards right w.r.t the vertical slide.
This arrangements is necessary to provide relief to the tool while making
vertical or angular cuts.

The two vertical walls on the apron called clapper box houses the
clapper block which is connected to it by means of a hinge pin. The tool
post is mounted upon the clapper block.

On the forward cutting stroke the clapper block fits securely to the
clapper box to make a rigid tool support on the return stroke a slight
frictional drag of the tool on the work lifts the block out of the clapper box
a sufficient amount preventing the tool cutting edge from dragging and
consequent wear. The work surface is also prevented from any damage due
to dragging.

Shaper mechanism:-
The metal is removed in the forward cutting stroke, while the return
stroke no matal is removed during this period.

To reduce the total machining time it is necessary to reduce time taken

by the return stroke. The shaper mechanism should be so designed that it
can allow the ram holding the tool to move at comparatively slower speed
during the forward cutting stroke and during the return stroke the ram move
faster rate to reduce the idle return time. The mechanism is called quick
return mechanism.

1. Crank and slotted mechanism

2. Whitworth quick return mechanism
3. Hydraulic shaper mechanism
Crank and slotted link mechanism:-
The motion or power is transmitted to the bull gear through a pinion
which receives is motion from an individual motor or overhead line shaft
through speed control mechanism. Speed can be changed by shifting gears.

A radial slide is bolted to the centre of the bull gear , carries a sliding
block into which the crank pin is fitted . rotation of the bull gear causes the
crank pin to rotate at a uniform speed. Sliding block which is invented on
the crank pin is fitted within the slotted link. The slotted link is pivoted at
its bottom end attached to the frame of the column. The upper end is forked
and connected to the ram block by a pin.

As bull gear rotates causes the crank pin to rotate, the sliding block
fastened to the crank pin will rotate on the crank pin circle, and at same
time will move up and down in the slot giving a rocking movement which
is communicated to the ram. The rotary motion of the bull gear converted to
reciprocating movement of the ram.

When the link is in the position PM.ram will be at the extreme

backward of its stroke.

When at PN – extreme forward position PM

&PN are tangent to the crank pin circle.

C1C2⇨ forward cutting strokeC2

C1 ⇨return stroke
 It is clear that the angle made by the forward stroke> return stroke.
The angular velocity is constant and rotated by speed metre and the crank
rotates at uniform speed.
Generally varies 2:1 and practical 3:1

Whitworth quick return mechanism:-

A bull gear is mounted on a large fixed pin a upon which i is free to
rotate. The crank plate is pivoted eccentrically upon the fixed pin at 5.fitted
on the face of the bull gear is the crank pin 2 on top of which sli ing block
is mounted. Sliding block fits into the slot provided on the crank plate. ,a
connecting rod connects the crank plate by a pin and the ram by a pin.
 When the bull gear will rotate at constant speed the crank pin with
the sliding block will rotate on a crank pin with the sliding block will rotate
on a crank circle of radius A2 and the sliding block will cause the crank
plate to rotate about the point 5 with a variable angular velocity.

Pin fitted on the other end of the crank plate will rotate in a circle
and the rotary motion of the pin will be converted into reciprocating
movement in the ram. Similar to crank and connecting rod mechanism. The
axis of reciprocating of the ram passes through the pin and normal to the
line A3.

When the pin cutting stroke is at position C ⇨ extreme backward position

When the pin cutting stroke is at position B ⇨ forward position

CB = cutting stroke (backward to forward)

BC = return stroke(forward to backward)

As angular velocity of the crank pin is uniform for the time taken i.e,
Hydraulic shaper mechanism:-
In a hydraulic shaper the ram is moved forward and backward by a
piston moving in a cylinder placed under the ram.

The machine consists of a constant discharge oil pump, a value

chamber, a cylinder and a piston. The piston rod is bolted to the ram body.
The oil under a high pressure is pumped from the reservoir and is made to
pass through the valve chamber to the right side of the oil cylinder exerting
pressure on the piston. This causes the ram connected to the piston to
perform forward stroke ward by a piston moving in a cylinder placed under
the ram.
 The machine consists of a constant discharge oil pump, a value
chamber , a cylinder and a piston. The piston rod is bolted to the ram body.
The oil under a high pressure is pumped from the reservoir and is made to
pass through the valve chamber to the right side of the oil cylinder exerting
pressure on the piston.

This causes the ram connected to the piston to perform forward

stroke, and any oil present on the left side of cylinder is discharged to the
reservoir through the throttle valve. At the extreme of forward stroke, the
shaper dog hits against the reversing lever causing the valves to alter their
positions within the valve chamber oil under high pressure is now opened to
the left side of the piston causing the ram to perform return stroke.

Oil present on the right side of the piston is now discharged to the
reservoir. At the end of the return stroke another shaper dog hits against the
reversing lever altering the direction of stroke of the piston and thus the
cycle is repeated.
 The quick return motion is effected due to the difference in stroke
volume of the cylinder at both ends, the left hand being smaller due to the
presence of piston rod. As the pump is a constant discharge one, within a
fixed period, the same amount of oil will be pumped into right or left hand
side of the cylinder.

This will mean that the some amount of oil will be packed within a
smaller stroke volume causing the oil pressure to rise automatically and
increasing the speed during the return stroke.

Automatic cross feed mechanism:-

In a shaper both down feed and cross feed can be obtained. Vertical
or bevel surfaces are produced by rotating the down feed screw of the tool
head by hand. Cross feed movement is used to machine a flat horizontal
surface. This is done by rotating the cross feed screw by hand or power.
 Rotation of the cross feed screw causes the table to move sideways at
the end of each return stroke to bring the uncut surface of the work. This is
done by automatic cross feed mechanism of shaper.

The rotation of the bull gear causes the driving disc to rotate in a
particular direction. The driving disc is T- slotted and position of the crank
attached to the connecting rod may be altered to give different throw of
eccentricity. The other end of the connecting rod is attached to the rocking
arm by a pin. The rocking arm is fulcrum at the centre of the ratchet wheel.
The ratchet wheel is keyed to the cross feed screw. The rocking arm houses a
spring loaded pawl which is straight on one side and bevel on the other side..

As the driving disc rotates, the connecting rod starts reciprocating and
the rocking arm rocks on the fulcrum. When the driving disc rotates through
half of the revolution in the clockwise direction, top part of the rocking arm
moves in clockwise direction and the pawl being slant on one side slips over
the teeth of the ratchet wheel imparting it no movement.

As the driving disc rotates through the other half, the top of the
rocking arm now moves in the anticlockwise direction and the straight side
of the pawl engages with the teeth of the ratchet wheel causing the wheel to
move in anticlockwise direction only. As the driving disc is connected to the
bull gear the table feed movement is effected when the bull gear or driving
disc rotates through half of the revolution i.e, during return stroke only.

Rotation through other half imparts no feed movements. To reverse

the direction of rotation of ratchet wheel and feed, a knob on the top of the
pawl after removing the pin is rotated through 180°.

The movement of feed may be altered by shifting the position of crank

pin w.r.t the centre. Greater the through the eccentricity more will be the
rocking movements of the arm and the pawl will pass through three or four
teeth on the ratchet wheel at a time imparting greater feed movement.