BITS EDU. CAMPUS

By:1. Priyal Panchal 1400501190572. Kedar Parekh 1400501190583. Harshal Parikh 1400501190594. Anant Parmar 1400501190605. Ankur Parmar 140050119061

SHAPER MACHINEAbout Shaper Machine and it’s operations:

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Shaper • A shaper is a machine tool that uses reciprocating straight line

motion of the tool and a perpendicular feed of the job or the tool.

• By moving work piece across the path of the reciprocating tool a flat surface is generated regardless of the shape of the tool.

• Shaping is essentially an inefficient method of metal removal but the simplicity of the process coupled with short set up tooling makes it extremely useful for one-off type of jobs.

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Standard shaper

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Classification

• 1. Horizontal push cut shapers• 2. Universal tool room shapers• 3. Horizontal draw cut shapers• 4. Travelling head shapers• 5. Special purpose shapers like gear shapers

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1. Horizontal push cut shaper• The most common type of

horizontal shaper is the production push cut shaper.• This type shaper consist of

frame supported on a base , a reciprocating ram and a work table.• The total construction is

shown in figure.6

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2. Universal shaper

• A universal shaper is similar to plain production shaper except that it has a table which can be tilted to various angles.• The table can be swiveled around tow horizontal

axes parallel and perpendicular.• As compared to a standard shaper the universal

shaper can be used to machine a wide.

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3. Draw cut shaper

• The basic difference between push cut and draw cut shaper is that in the latter type, during cutting stroke the tool is pulled across the work by the ram instead of being pushed

• There is little tendency for vibration as tensile stress is exerted on the ram during the cut

• This permits the use of large form tools without resulting in tool chatter on the work

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4. Travelling head shaper

• A travelling head shaper has a reciprocating ram mounted on a saddle which travels sideways along head.

• Heavy and unwisely jobs which can not be mounted on the table of a standard shaper and fed past the tool are held stationary on the base of this shaper and machined by the reciprocating ram which is provided with the feed motion.

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5. Gear shaper

• A gear shaper is a machine tool for cutting the teeth of internal or external gears. The name shaper relates to the fact that the cutter engages the part on the forward stroke and pulls away from the part on the return stroke, just like the clapper box on a planer shaper.• The cutting tool is also gear shaped having the same pitch as the

gear to be cut. However number of cutting teeth must be less than that of the gear to be cut for internal gears. For external gears the number of teeth on the cutter is limited only by the size of the shaping machine. For larger gears the blank is sometimes gashed to the rough shape to make shaping easier.

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Hydraulic Shaper Machine

Crank and Slotted Link Mechanism

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Quick Return Mechanism

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Shaper Machine

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Feed Mechanism• The feed for shapers is usually obtained by means of a pawl & ratchet mechanism.•

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Actual Feed Mechanism

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Feed Mechanism• Pawl and ratchet mechanism is used when the shaper table is to be moved through a

small axial distance.

• As shown, the pawl is used to move the table back & forth with the help of an eccentric pushes the ratchet through one or more teeth in each forward stroke while it just slides over the ratchet in the backward stroke

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Feed Mechanism• This mechanism is used when the angular movement of the ratchet screw is

converted into linear movement of the sliding member by screw principle.• The feed rate per stroke can be changed by adjusting the eccentricity of the crank pin

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Shaper size• The size of shaper designates its longest nominal cutting stroke.• Thus a 600mm shaper has a ram travel to drive a tool across a 600mm long surface.• A 600mm shaper is able to machine a plane surface of (600x600)mm.• The feasible size of overhanging ram limits the largest size of shaper.

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Specifications• Numerous other details are required to specify a shaper.

• Given below are complete specifications of a 450 mm :-

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Specifications• Length of stroke• Maximum vertical &

horizontal travel of table• Maximum distance from table

to ram• Power of motor• Approx. wt• Floor space required• Strokes per minute

• 450mm• 515mm &

500mm(respectively)

• 15mm• 2.25kW / 3 HP• 1000kg• (1800x1200)mm• 15-90 27

Shaper tools:-

• Shaper tools are single point tools similar to lathe tools and are frequently held in same way. The few differences between shaper and lathe tools are given below...

• The lathe tool is subjected to a uniform, practically constant cutting pressure, shaper tool has to withstand repeated shocks caused by cutting strokes...

• The shaper tools generally have larger nose compared to lathe tools to withstand the shock loading. In many cases the back rake angle is also made negative...

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Shaper tools:-

• A shaper tool is more rigid and heavier than a lathe tool...• A lathe tool has sufficient side clearance angles as it is to be

continuously fed sideways. In a shaper feed is given only at the end of stroke hence a smaller clearance angle of the 2-3 degree in enough. Front clearance 4degree for cast iron and steel. Smaller clearance angles give strength to the tool...• In a lathe the effective rake and clearance angles can be varied by raising

or lowering the tip of the tool relative to work piece centre. In a sharper this is not possible because sharper tools are always clamped perpendicular to the work piece surface... 29

The available sharper tools can be classified into the following varieties:

• Roughing and finishing tools.• Straight and cranked neck tools.• Left hand and right hand tools.• Round nose, straight nose and flat nose tools.• Slot cutting, parting off and side-recessing tools.

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Setting the Shaper for the Shaping operation

In the setting of a shaper m/c, setting of length of stroke, position of stroke, number of ram cycles, feed rate and position of tool head & clapper box is involved.

Usually the length of the stroke is adjusted more than the length of the work piece in case of removing of material from the whole length of work piece, as the shaper may achieve a good velocity through out the piece. But with a view to have the job done in less strokes and less time, the length of stroke is taken as low as possible. 34

Setting the Shaper for the Shaping operation

In addition to stroke length, the position of stroke is also important to achieve precise shape.

After completing every stroke, the position and length of stroke is changed, if needed.

Also the angle of stroke or the shaper tool is important. It is controlled by the angle of clapper box and its movement. The angle is set accordingly to the shape to be made on the work piece.

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Setting the Shaper for the Shaping operation

The tool head is set to cut the required surface of the work piece. The work pieces are usually held on a table or fitted in a vise, over the saddle.

• The forces exerted on the work piece during an operation, are directed against the fixed jaw of vise for rigidity. Here, the false jaws of copper, lead or brass are held tightly between the jaws of vise and the work piece to prevent the wear and tear due to the forces to the jaws.

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Cutting Time For Shaper 

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Cutting Time For Shaper

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THANK YOU

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