mohammad ali jinnah university, islamabad. shaper machine · pdf filemohammad ali jinnah...

Mohammad Ali Jinnah University, Islamabad.

Shaper Machine Project Report

Author: Zaheer ul hauqe

Shaper Machine | Zaheer ul hauqe

Page 1 of 16 Mohammad Ali Jinnah University, Islamabad.

Abstract

This is a student term project report regarding Shaper Machine and encloses the said machines’ theory,

analysis via various software, tables containing simulation results and graphical solution. The findings

and results of the machine along with the design are also discussed under separate headings.



A thesis submitted in partial fulfilment of the requirements for the degree of Bachelor of Science in Mechanical

Engineering at the Mohammad Ali Jinnah University, Islamabad to Mr. Saeed regarding the term project named

Shaper Machine. Names and Registration no’s of our group are:

Zaheer ul Haque Me113008

Talal Ahmad Me113118

Dilber Khan Me113

Zohaib Ahmad Me113022



TABLE OF CONTENTS Introduction .......................................................................................................................................................... 4

Theory ................................................................................................................................................................... 4

Crank-Slider Mechanism ................................................................................................................................... 4

Quick Return Mechanism ................................................................................................................................. 6

Methodology ........................................................................................................................................................ 7

Analysis ................................................................................................................................................................. 9

Conclusion ........................................................................................................................................................... 15

Bibliography ........................................................................................................................................................ 16



SHAPER MACHINE

INTRODUCTION Shaper Machine is one of the simplest and important machines of the industry. It is a type of machine tool

that uses linear relative motion between the workpiece and a single-point cutting tool to machine a linear

tool path. A shaper is analogous to a planer, but smaller, and with the cutter riding a ram that moves

above a stationary workpiece, rather than the entire work piece moving beneath the cutter. The ram is

moved back and forth typically by a crank (Flywheel) and this mechanism works on the basic principle of

quick return.

Roe (1916) credits James Nasmyth with the invention of the shaper in 1836. Shapers were very common

in industrial production from the mid-19th century through the mid-20th.1

We selected this machine as our term project because of its simplicity and ease of fabrication. Every

theory that this machine involves was the basics we studied in our text book2, so along the partial

fulfillment of the course, it was also intended to strengthen the concepts and get a hands-on experience

on the practical part of Mechanical engineering.

THEORY The shaper machine involves two theoretical concepts of Machine designing i.e. crank-slider mechanism and

quick return.

Crank-Slider Mechanism

Crank-Slider mechanism is an arrangement of mechanical parts designed to convert straight-line motion

to rotary motion, as in a reciprocating piston engine, or to convert rotary motion to straight-line motion,

as in a reciprocating piston pump.

1 http://en.wikipedia.org/wiki/Shaper 2 Design Of Machinery by Robert L. Norton, 3rd Edition.

http://en.wikipedia.org/wiki/Planer_(metalworking)

http://en.wikipedia.org/wiki/Crank_(mechanism)

http://en.wikipedia.org/wiki/Shaper



3

The basic nature of the mechanism and the relative motion of the parts can best be described with the

aid of the accompanying Figure 1, in which the moving parts are lightly shaded. The darkly shaded part 1,

the fixed frame contains a cylinder, depicted in cross section by its walls DE and FG, in which the piston,

part 4, slides back and forth. The small circle at A represents the main crankshaft bearing (Ground), which

is also in part 1. The crankshaft, part 2, is shown as a straight member extending from the main bearing

at A to the crankpin bearing at B, which connects it to the connecting rod, part 3. The connecting rod is

shown as a straight member extending from the crankpin bearing at B to the wristpin bearing at C, which

connects it to the piston, part 4, which is shown as a rectangle. The three bearings shown as circles

at A, B, and C permit the connected members to rotate freely with respect to one another. The path of B is

a circle of radius AB; when B is at point h the piston will be in position H, and when B is at point j the

piston will be in position J.

For example, say on a gasoline engine, the head end of the cylinder (where the explosion of the gasoline-

air mixture takes place) is at EG; the pressure produced by the explosion will push the piston from position

H to position J; return motion from J to H will require the rotational energy of a flywheel attached to the

crankshaft and rotating about a bearing collinear with bearing A. On a reciprocating piston pump the

crankshaft would be driven by a motor.

3 slider-crank mechanism. [Art]. Encyclopædia Britannica Online. Retrieved 01 January, 2014, from http://www.britannica.com/EBchecked/media/7447/Slider-crank-mechanism

Figure 1

http://www.britannica.com/EBchecked/topic/371928/mechanism

http://www.britannica.com/EBchecked/topic/211745/flywheel



Quick Return Mechanism

It is a reciprocating motion, in which the return is made more rapidly than the cutting stroke, so as to

reduce the idling time. The name does not actually mean the ‘return’ being faster. Provided the crank

movement is reversed4, it can also become ‘Quick Forward mechanism’.

In non-quick return mechanisms, the crank angle is in-line with the reciprocating motion of the rocker

thus giving equal division of crank’s circular movement for the return and forward movements of the

slider. In contrast, the quick return mechanisms have the crank angle placed at some angle to the rocker,

so now the crank angles are not equal for the strokes of rocker. The 360 degrees of crank are now divided

into α and β for the return and forward rocking motion of slider respectively. These parameters along with

their difference δ form usual 180 degrees are given by:

𝑇𝑅 =𝛼

𝛽

As

𝛼 + 𝛽 = 360

Thus

𝛿 = |180 − 𝛼| = |180 − 𝛽|

5

4 In case of our term project, reversing the polarity of the motor voltage. 5 Design of Machinery by Robert L. Norton, 2nd Edition.

Figure 2



METHODOLOGY The shaper machine term project was chosen on the basis of its simplicity. The group indulged in various

discussions and meetings with the course instructor. After declining 2 other designs the final design (Figure 3,

page 5) was selected and we sat upon calculating every minor detail. Drawings were made and simulations

were run on several software such as MATLAB, FOURBAR SLIDER, Working Model and Microsoft Excel.

We chose wood as our primary work material as it is easier to work on and is easier on the pocket. We did

not spend time on choosing the particular type as it wasn’t necessary on a project of such small scale. For the

driving motor we decided to get it from a worn out microwave oven as it would have low RPM yet sufficient

torque.

After the drawing board session and upon finalizing we contacted local carpenters and sat up a meeting. We

chose the professionals as we would couldn’t have made it with the finishing and in less time as the

carpenter could have.

The biggest problem that we faced was making the craftsman understand what we really wanted him to

make as he couldn’t speak in technical terms and we couldn’t in layman’s language. After a tiring session of

talks and teaching him the drawings, he finally understood.

We had to change several parameters in his workshop as designing something in a room is very different

form making it in a workshop. The availability of machines and proper tools plus the assumptions that we

made in the designing process were causing problems in the real world. This exercise also made us realize the

practical implementation is different from designing and one should keep the technical aspects of the

workshop facility, such as tools available there, in mind for the smooth flow of the process.

The design parameters of the project in final form are:



6

Figure 3

6 Drawn By the Author via AutoCAD 2013 (Mechanical suite).



ANALYSIS We simulated the machine on several software and their findings are given below.

7 Figure 4

8Figure 5

7 Working Model Simulation Snapshot. 8 Four Bar Slider Simulation Snapshot.

Figure 4

Figure 5



We used Microsoft Excel 2013 to get analytical solutions. The following table represents position, velocity,

and acceleration analysis. Here Crank Angle represents the position of crank for every degree with respect

to X-axis of global coordinate system placed at its center, and the data is in degrees. θ3 is the angle of

coupler link with respect to x-axis of local coordinate system placed at coupler-slider pin joint and this

data is also in degrees. d is the position of slider from global coordinate system and is in centimeters. ω3

is the velocity of coupler with respect to global coordinate system and is in Radians per Seconds. d' is the

slider’s velocity with respect to global coordinate system and is in centimeter per second. α3 is coupler’s

acceleration in Radians per Second square and is also with respect to global coordinate system. d'' is

slider’s acceleration with respect to global coordinate system and is in Radians per Second square.

Crank Angle (Deg) θ3 (Deg) d (cm) ω3 (Rad/sec) d' (cm/sec) α3 (Rad/ Sec^2) d'' (cm/sec^2)

5 200.883751 13.420669 -0.818920 5.062129 0.480925 -72.031500

10 199.592633 13.424298 -0.802861 3.056722 0.674119 -72.207795

15 198.331290 13.381250 -0.781534 1.057868 0.860171 -71.565669

20 197.107945 13.292203 -0.755139 -0.912269 1.038862 -70.147856

25 195.930497 13.158253 -0.723885 -2.832841 1.209887 -68.006145

30 194.806507 12.980892 -0.687991 -4.684551 1.372833 -65.200425

35 193.743176 12.761984 -0.647688 -6.449867 1.527176 -61.797672

40 192.747326 12.503742 -0.603224 -8.113205 1.672278 -57.870850

45 191.825369 12.208690 -0.554865 -9.661076 1.807396 -53.497685

50 190.983276 11.879636 -0.502901 -11.082200 1.931704 -48.759303

55 190.226540 11.519635 -0.447644 -12.367580 2.044315 -43.738733

60 189.560135 11.131951 -0.389431 -13.510537 2.144315 -38.519294

65 188.988480 10.720019 -0.328625 -14.506686 2.230798 -33.182891

70 188.515394 10.287408 -0.265615 -15.353882 2.302908 -27.808299

75 188.144064 9.837782 -0.200810 -16.052102 2.359875 -22.469466

80 187.877004 9.374864 -0.134640 -16.603293 2.401057 -17.233940

85 187.716035 8.902395 -0.067551 -17.011173 2.425968 -12.161477

90 187.662256 8.424106 0.000000 -17.281000 2.434305 -7.302916

95 187.716035 7.943682 0.067551 -17.419308 2.425968 -2.699358

100 187.877004 7.464734 0.134640 -17.433633 2.401057 1.618287

105 188.144064 6.990773 0.200810 -17.332227 2.359875 5.629391

110 188.515394 6.525186 0.265615 -17.123774 2.302908 9.323339

115 188.988480 6.071218 0.328625 -16.817123 2.230798 12.698934

120 189.560135 5.631951 0.389431 -16.421033 2.144315 15.763531

125 190.226540 5.210294 0.447644 -15.943953 2.044315 18.531964



130 190.983276 4.808972 0.502901 -15.393828 1.931704 21.025351

135 191.825369 4.430515 0.554865 -14.777949 1.807396 23.269821

140 192.747326 4.077253 0.603224 -14.102820 1.672278 25.295262

145 193.743176 3.751312 0.647688 -13.374082 1.527176 27.134101

150 194.806507 3.454612 0.687991 -12.596449 1.372833 28.820185

155 195.930497 3.188868 0.723885 -11.773691 1.209887 30.387748

160 197.107945 2.955585 0.755139 -10.908631 1.038862 31.870483

165 198.331290 2.756066 0.781534 -10.003172 0.860171 33.300695

170 199.592633 2.591412 0.802861 -9.058351 0.674119 34.708497

175 200.883751 2.462527 0.818920 -8.074406 0.480925 36.121024

180 202.196101 2.370119 0.829515 -7.050874 0.280751 37.561596

185 203.520835 2.314707 0.834452 -5.986706 0.073743 39.048801

190 204.848800 2.296626 0.833546 -4.880416 -0.139920 40.595432

195 206.170553 2.316032 0.826614 -3.730258 -0.359958 42.207250

200 207.476367 2.372901 0.813486 -2.534437 -0.585914 43.881545

205 208.756254 2.467038 0.794006 -1.291373 -0.817064 45.605522

210 210.000000 2.598076 0.768044 0.000000 -1.052323 47.354556

215 211.197210 2.765474 0.735507 1.339880 -1.290147 49.090457

220 212.337377 2.968517 0.696351 2.727196 -1.528433 50.759943

225 213.409977 3.206305 0.650600 4.159175 -1.764447 52.293628

230 214.404589 3.477748 0.598362 5.630892 -1.994784 53.605893

235 215.311045 3.781552 0.539851 7.134828 -2.215377 54.596088

240 216.119611 4.116199 0.475400 8.660493 -2.421579 55.151467

245 216.821189 4.479933 0.405479 10.194150 -2.608332 55.152146

250 217.407543 4.870734 0.330700 11.718715 -2.770417 54.478154

255 217.871526 5.286304 0.251821 13.213868 -2.902794 53.018232

260 218.207303 5.724049 0.169729 14.656435 -3.000974 50.679671

265 218.410547 6.181066 0.085428 16.021038 -3.061408 47.398032

270 218.478595 6.654146 0.000000 17.281000 -3.081815 43.145408

275 218.410547 7.139779 -0.085428 18.409443 -3.061408 37.935912

280 218.207303 7.634178 -0.169729 19.380490 -3.000974 31.827444

285 217.871526 8.133313 -0.251821 20.170460 -2.902794 24.919375

290 217.407543 8.632955 -0.330700 20.758942 -2.770417 17.346515

295 216.821189 9.128734 -0.405479 21.129660 -2.608332 9.270321

300 216.119611 9.616199 -0.475400 21.271077 -2.421579 0.868642



305 215.311045 10.090893 -0.539851 21.176705 -2.215377 -7.674609

310 214.404589 10.548412 -0.598362 20.845136 -1.994784 -16.178761

315 213.409977 10.984479 -0.650600 20.279849 -1.764447 -24.473878

320 212.337377 11.395006 -0.696351 19.488830 -1.528433 -32.406168

325 211.197210 11.776147 -0.735507 18.484069 -1.290147 -39.841316

330 210.000000 12.124356 -0.768044 17.281000 -1.052323 -46.666054

335 208.756254 12.436424 -0.794006 15.897906 -0.817064 -52.788371

340 207.476367 12.709520 -0.813486 14.355338 -0.585914 -58.136794

345 206.170553 12.941216 -0.826614 12.675562 -0.359958 -62.659114

350 204.848800 13.129512 -0.833546 10.882045 -0.139920 -66.320860

355 203.520835 13.272848 -0.834452 8.998983 0.073743 -69.103723

360 202.196101 13.370119 -0.829515 7.050874 0.280751 -71.004053

The Following Graphs are based upon the above data:

The above Graph is of Coupler Angle (Theta 3) vs Crank Angle (Theta 2) and shows the different angles of

coupler link w.r.t local co-ordinate axis placed at slider- pin.

185

190

195

200

205

210

215

220

225

0 50 100 150 200 250 300 350 400

θ3 (Deg)

Figure 6



This one is a simple representation of Slider Position at various crank angles. It’s a simple fall with the

maximum distance being covered at 180 degrees and then it rises back to its position in the same fashion

because of the constant velocity of the motor.

ω3 is the coupler links velocity and has its rise and fall in a similar fashion as that of crank’s angle.

0

2

4

6

8

10

12

14

16

0 50 100 150 200 250 300 350 400

d (cm)

-1.00

-0.80

-0.60

-0.40

-0.20

0.00

0.20

0.40

0.60

0.80

1.00

0 50 100 150 200 250 300 350 400

ω3 (Rad/sec)

Figure 7

Figure 8



The above Graph is of Slider Velocity for every Crank Angle. As visible the line goes to –15 cm/sec and

then in the other cycle reaches up to 22 cm/sec representing Quick return mechanism.

In comparison with the figure 8 acceleration of coupler link is positive and thus its velocity increasing. At

180 degrees acceleration is almost zero and velocity at the peak value where it stays constant for an

instant and then decelerates to initial value.

-20

-15

-10

-5

0

5

10

15

20

25

0 50 100 150 200 250 300 350 400

d' (cm/sec)

-4

-3

-2

-1

0

1

2

3

0 50 100 150 200 250 300 350 400

α3 (Rad/ Sec^2)

Figure 9

Figure 10



This Graph is of Slider Acceleration for various crank angles. Initially there is negative acceleration but is

increasing as the rocker is returning but the forward stroke gives the hike that can be seen here.

CONCLUSION The shaper is an amazing yet simple machine. Combining two textbook concepts has created a very

simple easy to use machine which use cannot be denied and is important for the smooth flow of the

industry.

This project has given us the practical experience of engineering and has taught us valuable lessons.

Theory and practical implementation are two very different things yet they cannot be separated and

none can survive without the other.

During this project we faced many setbacks but as determination is a vital quality to sustain success, we

managed and completed the task within the given time. Although a lot can be improved and a lot can be

thought over. From my point of view it still lacks precision and finishing which would greatly reduce the

friction and in turn increase the torque output. The increase in RPM would also elevate the efficiency

level and a flywheel can make the process smoother.

Yet it was a great success for me and my group, we really worked hard and put our hearts into it. I think

we have achieved more than we imagined and that gives me satisfaction and the hope to strive harder,

the next time.

-80

-60

-40

-20

0

20

40

60

80

0 50 100 150 200 250 300 350 400

d'' (cm/sec^2)

Figure 11



BIBLIOGRAPHY


www.technologystudent.com/equip1/shape1.html

http://www.merriam-webster.com/dictionary/quick%20return

http://www.wisc-online.com/ViewObject.aspx?ID=ENG20704

http://www.robives.com/mechanisms/quickreturn#.Usk5lfQW1eU

http://www.robives.com/mechanisms/crankslider

http://www.softintegration.com/chhtml/toolkit/mechanism/crankslider/

http://ditogear.com/tag/crankslider/

Design of Machinery by Robert L. Norton, 2nd Edition.

Design Of Machinery by Robert L. Norton, 3rd Edition.

slider-crank mechanism. [Art]. Encyclopædia Britannica Online. Retrieved 01 January, 2014, from

http://www.britannica.com/EBchecked/media/7447/Slider-crank-mechanism


http://www.merriam-webster.com/dictionary/quick%20return

http://www.wisc-online.com/ViewObject.aspx?ID=ENG20704

http://www.robives.com/mechanisms/quickreturn#.Usk5lfQW1eU

http://www.robives.com/mechanisms/crankslider

http://www.softintegration.com/chhtml/toolkit/mechanism/crankslider/

http://ditogear.com/tag/crankslider/

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