SHAPER

1. Shaping machine:

Fig1. Cutting action of shaping machine.

Shaper is a reciprocating type of machine tool in which ram moves the cutting
tool in backward and forward in a straight line.

2. Operations done using shaper:

Various operations which can be performed on a shaper are:
a. Horizontal shaping
b. Vertical shaping
c. Shaping of grooves slots steps and keyways
d. Angular shaping
e. Cutting of splines and gear teeth
f. Irregular cutting

a) Horizontal shaping:

fig 2. Horizontal shaping.

 • Horizontal cutting is most commonly carried out on a shaper to
obtain flat surfaces.
• The job is held in the vice and an appropriate tool is held in the
tool head of the shaper.
• The length and position of the stroke are adjusted to machine the
whole length of the job.
• Cutting speed and feed are then adjusted depending on if it is
roughing or finishing cut. Proper inclination of the tool and depth
of cut are also set.
• Cross feed of the table is given initially by hand till the cut starts
and then the power feed is employed.
• After the tool has cut full width of the job, shaper is stopped and
the job is inspected.

b) Vertical shaping

Fig3. Vertical shaping

• The clapper box is swiveled away from the face of the work to be
cut.
• The tool is fed downwards by rotating the down feed screw by
hand at the end of return stroke.
• On the end of return stroke the tool swings away from the work
and gives clearance, which prevents the work from being scored.
• Vertical cutting is carried out in order to make grooves, keyways,
parting off and squaring up the ends and shoulders.

c) Shaping of grooves slots steps and keyways:

 Fig4. Shaping grooves
• For shaping grooves, slots and keyways , a square nose tool similar
to lathe parting tool is used.
• Keyways, slots and recesses may be shorter than the full length of
the job. In such cases a hole is drilled at the closed end. This is
necessary to prevent chips piling up and possibly breaking the tool.
• A flat nosed tool is employed for cutting keyways.

d) Angular shaping:

Fig5. Shaping angular faces

• For shaping angular faces the swivel head is set to the required angle.
• In the fig, the clapper box is swung away from the face to be
machined. Tool feed is applied by slide hand wheel.
• Angular facing is carried out in order to machine inclined surfaces,
beveled surfaces, dovetails etc.

e) Cutting of splines and gear teeth:

 Fig6. Cutting of splines and gear teeth

• For cutting the first spline or gear tooth, the workpiece is held
between the centers axactly in the way keyway is cut.
• After this the workpiece is rotated by the required amount using the
index plate.
• The index pin is then locked by engaging the index pin with the
corresponding hole in the circumference of the index plate.
• Now the second spline is cut.
• This procedure is repeated until the spline or gear tooth is cut on the
whole circumference of the workpiece.

f) Irregular cutting:

Fig7. Irregular cutting

• Before cutting an irregular shape the, the same is scribed on the
surface of the workpiece.
 • After the workpiece is secured in position on the shaper, the operator,
by skilful manipulation of the horizontal and vertical feeds, guides the
cutting tool so that it will follow the layout lines.

3. Classification of shaper:

Shapers may be classified on the basis of :

a) Design of work table as:
i) Standard shaper: in this type of shaper work table has only vertical and
horizontal movements. The work table may not have the vertical
support at its front.
ii) Universal shaper: has a work table which may be swiveled around two
horizontal axes and also adjusted horizontally and vertically. As
compared to standard shaper, the universal shaper can be used to
machine a wide variety of jobs.
b) Driving mechanism as:
i) Crank shaper: this is the most common type of shaper. Such shapers
have a crank and slotted link mechanism to constitute the quick return
motion in driving mechanism. The crank changes the circular motion
of the power source to the reciprocating motion of the ram.
ii) Hydraulic shaper: the drive in hydraulic shaper is neither a crank nor
gear rather it is a hydraulic circuit. In this the reciprocating motion of
the ram is obtained by the application of oil pressure on the piston in
the cylinder. End of the piston rod is connected to the ram of the
shaper.
iii) Geared shaper: this is not commonly used. A geared shaper has got a
rack under its arm. The rack is driven by spur gear.
c) Direction of travel of ram as:
i) Horizontal shaper: this has a ram which reciprocates in horizontal axes
only. horizontal shapers are very commonly used to produce flat
surfaces.
ii) Vertical shaper: this has a ram which reciprocates in vertical plane. It
possesses a rotary work table. It is used to generate internal surfaces,
keyways, holes etc.
iii) Traveling head shaper: this has a reciprocating arm mounted on a
saddle which travels sideways along the bed. The ram carries the tool
slide. Heavy duty jobs are kept stationary on the base of the traveling
head shaper and machined as ram reciprocates.

4) Shaper size and specifications

The size of the shaper is classified according to the maximum length of the stroke.
Specifications:
Maximum ram stroke 700mm
Maximum tool overhang 840mm
Distance between table surface and ram Maximum 400mm
 Minimum 80mm
Dimensions of table working surface 700mm* 450mm
Maximum travel of table Horizontal 700mm
Vertical 320mm
Principle movement motor power 2785*1750*1780 mm

5) Shaper cutting tools:

Fig8. Shaping tool geometry

• Shaper cutting tools are single point tools similar to lathe tools and are frequently
held in the same type of holders.
• The little difference that a shaper tool has from lathe tool is that the lathe tool has
a constant, fairly uniform cutting pressure exerted on it whereas shaper tool is
subjected to a series of sudden shocks caused by its repeated hammering into the
workpiece. To withstand these shocks it is necessary that shaping tool should
have a larger nose radius compared to lathe tool.
• Shaper tool is more rigid and heavier than the lathe tool.
• Lathe tool has sufficient side clearance angle as it has to be fed sideways, whereas
in shaper tool, since feed is given at the end of the cutting stroke a small clearance
angle is necessary.
• Shaper tools are of two basic kinds: forged and tool bits. Tool bits are more
widely used because of their economy, cutting life and ease with which they are
sharpened.
•

6. Parts of a shaper.
 Fig9. Parts of a shaping machine

1. Base: the base of the shaper supports the column or pillar which supports all the
working parts such as ram, worktable etc.
2. Column or pillar or body: the shaper has a column which is a ribbed casting of cellular
construction. The top of the column carries the ram sideways. The crank and slotted link
mechanism that drives the ram is contained within the column. The driving motor,
variable speed gear box, levers, handles and other controls of shaper are also contained in
the column.
3. Cross rail: the cross rail carries the horizontal table slideways and mounted on the
vertical slideways of the column. The cross rail can be raised or lowered by means of an
elevating screw in order to compensate for different thickness of the workpiece.
4. Saddle: saddle is gibbed to the cross rail and supports the table. Crosswise movement
of the workpiece causes the saddle to move sideways.
5. Table: the table is a box shaped casting with T-slots in its upper surface and down one
side. The work table is bolted to the saddle and can be moved vertically and crosswise
with the help of saddle and cross rail.
6. Ram: ram is rigidly based casting and is located on top of the column. The ram is
moved back and forth in its slide by the slotted link mechanism.
7. Tool head: the tool head slides in a dovetail at the front of the ram by means of T-bolts.
It can swivel 0 º to 90º in a vertical plane. Tool head can be raised or lowered by hand
feed for vertical cuts on workpiece. The tool head holds the tool. The tool head imparts
the tool, the necessary vertical and angular feed movements.

7. Shaper drive mechanisms:

Some of the shaper drive mechanisms are:
 1) Slotted link quick return mechanism:

Fig 10. Slotted link mechanism.

Slotted link quick return mechanism has been shown in the figure.
It is very common in mechanical shapers.
The bull wheel has a slot and crank pin A is secured in this slot. At the same time it can
slide in the slotted crank B.
When the bull wheel rotates, crank pin A also rotates and side by side slides through the
slot in slotted crank B.
This makes the slotted crank to oscillate about its one end C.
This oscillating motion of the slotted crank (through the link D) makes the ram to
reciprocate.

2) The whitworth quick return mechanism:

 Fig11. Whitworth quick return mechanism
Crank BC rotates at a uniform speed.
During the cutting stroke the point C travels from Y to X through Z.
The ram is returned at high speed as crank rotates from X to Y through T.
Then: time for cutting stroke/ time for return stroke = 360 – θ/θ
Since θ is smaller than 360- θ, the time for cutting is more than idle stroke time. And thus
the name quick return motion.

3) Automatic feed mechanism:

Fig 12. Automatic feed mechanism

Automatic feed mechanism consists of a pawl and ratchet mechanism with driving disc
connected to it. The pawl is spring loaded so as to move the teeth on the ratchet only in
one direction. The change of pawl direction changes the direction of cross feed
movement. The ratchet wheel is connected directly to the table feed screw, and hence the
rotation of the pawl gives the cross feed movement of the table. The driving disc
connected to the bull gear, gives an oscillating motion to the pawl housing, with the help
of the connecting rod.
In operation as the driving disc rotates continuously, the rotation is converted into
oscillatory motion of the pawl through the connecting rod. With the pawl engaged in
retched teeth as shown in the figure, it gives an anticlockwise movement to the wheel
which in turn rotates the table screw and hence the table moves by an equivalent
transverse distance, thereby giving cross feed to the table. Since the driving disc is
connected to the bull gear the table feed is affected only when the bull gear, hence the
driving disc rotates through one half of the revolution, and during the return stroke only.
During the other half rotation, the pawl moves back in clockwise direction and it slips
over the ratchet teeth because of its shape.