Manufacturing processes

Experiment # 4
Experiment Title:
To reduce the thickness of workpiece using shaper machine.

Objectives:
 To develop an understanding of shaper machines
 To learn functions of its various parts
 To observe basic operations performed on it
Apparatus:
 Shaper machine
 Workpiece (aluminum)
Cutting tool (high speed steel)
Shaper Machine:

Theory:
What is a Shaping Machine?
A type of machine tool that follows a linear toolpath with linear relative motion between the
workpiece and a single-point cutting tool is a shaping machine or shaper. The cut produced by
the machine is similar to that produced by a lathe machine. [1]

Figure 1: Shaping Process [1]

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The image shows that the surface of a work part is removed by a tool have a linear motion on a
stationary workpiece. The purpose of a shaper machine is to create vertical and horizontal flat
surfaces or inclined surfaces.
Between 1791 and 1793, Samuel Bentham made a tool called a shaper. From the middle of the
19th century to the 20th century, shapers were used a lot in factories. Most machine tools like
grinding, milling, and broaching machines have replaced shapers in the industrial world. [1]

Components of shaper machine:

We came across various terms related to a shaping machine while studying the working
principle. Let us study all the parts that are common in all types of shapers below. [1]

Figure 2: Shaping Machine Line Diagram [1]

Base:
The base of the shaper holds all of the weight of the machine tool, and it is bolted to the shop
floor. It is generally made of cast iron. It absorbs vibrations and other forces imparted during
shaping operation. [1]

Column:
The column is also made of cast iron in a box shape. It is set on the base of the shaper. It has
precisely machined guideways on top that allow the ram to move back and forth. For the cross

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rail to move, there are guideways on the front vertical face. The ram-driving mechanism is inside
the column. The base holds the column in place. [1]

Table:
The table is one of the crucial components of the device which is mounted on the saddle. The
elevating screw and cross feed rod can be turned to move the table both horizontally and
vertically. It is a casting that resembles a box with precisely machined top and side surfaces. The
table has T-Slots to clamp the work and is secured with support to increase rigidity. [1]

Vice:
Clamp or vice is mounted on the table to hold the workpiece firmly while the shaping process is
in progress. [1]

Cross rail:
This part is fixed to the vertical guideways of the column. By turning an elevating screw, which
enables the cross rail to glide on the vertical face of the column, the table can be elevated or
lowered to meet the varying sizes of the task. [1]

Saddle:
It is fixed to the Cross rail securely on the top of the table. The rotation of the cross-feed screw
causes the crosswise movement of the saddle which moves the table in the same direction. [1]

Ram:
It is a component in the shaping machine that reciprocates using a quick return motion
mechanism on the guideways at the top of the column while holding the tool in place. It contains
a screwed shaft to adjust the working position. [1]

Tool Head:
With the down-feed screw handle, the tool head secures the cutting tool and allows for both
vertical and rotational movement. A tool head of shaping machine assembly has a vertical slide
is made up of a swivel base with graduated degrees. [1]

Clapper Box:
The clapper box is a hinged mechanism within the tool head that allows for quick tool changes
and adjustments. It secures the tool post, which in turn holds the cutting tool itself. [1]

Feed Mechanism:
The feed mechanism provides precise movement of the table relative to the ram. This allows for
controlled removal of material during each cutting stroke. The feed can be automatic or manual
depending on the specific shaper model. [1]

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Ram Speed Control Lever:

This lever adjusts the speed of the reciprocating ram that carries the cutting tool. A higher speed
allows for faster material removal but might require a more robust cutting tool and could affect
surface finish. A slower speed provides more control and is suitable for delicate cuts or harder
materials. [1]

Table Feed Control Lever:

This lever controls the movement of the table in small increments after each cutting stroke. By
precisely feeding the table closer to the ram, you can gradually remove material and achieve the
desired final dimensions. The feed rate needs to be balanced with the ram speed and tool
selection for optimal chip formation and surface finish. [1]

Stroke Length Set:

This adjustment determines the horizontal travel distance of the ram during its cutting stroke. A
longer stroke allows for shaping larger areas in fewer passes but might require a more powerful
machine for heavier cuts. A shorter stroke is suitable for smaller features or intricate details. [1]

Electric Panel:
The electric panel houses various buttons and switches for overall machine operation. It typically
includes: main power switch, emergency stop button, forward/reverse switch and overload
protection. [1]

Types of Shaping Machines:

Horizontal Type Shaping Machine?
The ram is moving in a reciprocating motion in these types of shaper machines. When the ram
reciprocates, it keeps the tool on a horizontal axis. The horizontal shapers are used for the shaping
of external grooves, keyways, and other similar features. [1]

Figure 3: Horizontal Shaping Machine [1]

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Vertical Type Shaping Machine:

The reciprocating motion of the ram in these sorts of shaper machines occurs in a vertical plane
where the table supports the object. Vertical shapers may be manually operated, rack-driven, screw-
driven, or powered by hydraulics. [1]

Figure 4: Vertical Shaping Machine [1]

The workpiece can travel in any direction, including transverse, longitudinal, and rotating. This
type of shaper can machine internal surfaces, slots, and keyways. [1]

Working Principle of Shaping Machine:

The working principle of a shaping machine is based on a quick return mechanism like
Whitworth.

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Figure 5: Quick Return Mechanism of Shaping Machine [1]

A rigid table on the machine supports the workpiece. Over the workpiece, the ram moves back
and forth as shown in the animation above. A vertical tool slide is adjusted to either side of the
vertical plane along the stroke axis, which is located at the front of the ram.
The geometry of the linkage causes the ram to travel more quickly on the return stroke than the
forward stroke (cutting stroke). As the shaper works on the quick return mechanism, the sliding
action of the slider is aided by the rotating link.
One of the four mechanisms i.e. crank and slotted, whit worth quick return, hydraulic, and
automatic table feed mechanism, is responsible for the quick return mechanism and reciprocating
movement of the ram. The automatic table feed is commonly used today which employs a pawl
and ratchet mechanism in a shaping machine. [1]

Advantages of shaper machine:

 Single-point cutting tools are affordable.
 These machines have holding mechanisms for any workpiece.
 It can make sharp or smooth edges.
 The machine has a simple setup process and quick tool changes.
 In many cases, the machine user interface is easily understood.
 There is a negligible delay between the parts. [2]

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Disadvantages of shaper machine:

 The cutting speed is slow and action happens only in the forward stroke.
 There is only one cutting tool and no other tools are utilized in this machine.
 Machines with more than one cutting tool, only one can be serviced.
 There is a restriction of using one shaping tool at a time. [2]

Applications:
1. Internal splines are made with a shaper machine.
2. It makes straight and flat planes in horizontal, vertical, or angle.
3. It can also make teeth for gears.
4. Pulleys or gears can be made with keyways in these machines.
5. It also makes shapes that are convex, concave or a mix of the two. [2]

Working Parameters:
 Tool slider least count: 0.05mm
 Stroke length least count: 10mm
 Stroke length maximum: 500mm
 Stoke length set lever: 10mm-500mm
 Cutting tool: High speed steel (single point cutting tool)
 Carbide tip for harder material
 HSS for soft material
 Ram speed control lever:
a. For A: speed is 34.5m/min
b. For B: speed is 138m/min
 Power + ideal stroke= 01
 Depth of cut: 0.5mm
 Stroke Length: 140mm
 Cutting Speed: 25m/min

Procedure:
 Mount the workpiece securely on the shaper's table.
 Set the appropriate cutting speed based on the material of the workpiece and the type of
cut you are making.
 Adjust the cutting depth to the desired level.
 Make sure the cutting tool is lubricated to reduce friction and heat during the cutting
process.
 Turn on the shaper and allow it to reach its full operating speed.
 Start the cut by bringing the cutting tool into contact with the workpiece. Move the tool
in a smooth, controlled motion.
 Observe the cut and make any necessary adjustments to the speed, depth, or tool position.
 After completing the cut, the required shape is obtained.

Comments:
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 Follow correct clamping procedures. Make sure that the workpiece is properly fit.
 Do not leave a shaper running unattended.
 Do not leave any equipment on top the machine.
 Ensure that you have selected correct speed, depth and rate.
 Before adjusting and measurements or before cleaning swarf accumulations, switch off
and bring the machine to a complete standstill.

Conclusion:
In conclusion, the shaper is a useful tool for creating precise, repetitive cuts in metal and wood. It
offers a high level of accuracy and versatility. A shaper machine can turn an uneven workpiece
into square/rectangle flat surface by reducing its thickness but requires a certain level of skill and
experience to operate safely and effectively. However, there are some limitations to the shaper.
It is a relatively slow machine, and may not be suitable for high-volume production operations.
Additionally, the shaper requires a high level of skill and experience to operate, and the cutting
process can be hazardous if proper safety procedures are not followed.

References

[1] 29 04 2024. [Online]. Available: https://testbook.com/mechanical-engineering/shaping-machine-

diagram-and-process.

[2] 29 04 2024. [Online]. Available: https://themechanicalengineering.com/shaper-machine/.

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