Shop Exercise 5

Mapa University
Muralla St. Intramuros, Manila

Department of Mechanical and Manufacturing Engineering
SHOP PRACTICE NO.5

Cross Peen Hammer
ANGELES, Marison C.
ME-2
ME137L/ A3
GRADE
2015100221
Group 04
Engr. Jose V. Hernandez

Instructor
OBJECTIVES:
1. To familiarize the students with the different parts and uses of a shaper and its uses.
2. To be able to operate a vertical type of shaper.
3. To be able to make a cross peen hammer.
METHODS AND ANALYSIS:

Shaper is used in cutting flat surfaces in horizontal and angular cutting. There are many
kinds of work that a shaper can do depending on the selection of tools and its setting.
MATERIALS:
1 piece round metal 4 1/2 inches x 1 inch diameter.
TOOLS AND EQUIPMENT TO BE USED:

Ball Hammer
Bench Metal Vise
Center Punch
Chalk
Countersink Drill Bit
Cutting Oil
Drill Bit
Drill Chuck
Drill Chuck Key
Electric Drill Press
Face shield (2 pieces)
File
Gloves
Level Gauge
Paint Brush
Push-Pull meter
Tool Post Wrench
T-Wrench
Vernier Caliper
Vertical Shaper and its Accessories
Vice Grip
Work Bench
SAFETY RULES and PRECAUTION in using a SHAPER MACHINE:
1. Use proper attire.
2. Use an eye protection.
3. Remove the metal chips using a brush, not by hands.
4. Fasten the workpiece, tool, and tool holder before starting the machine.
5. Do not take any measurement while the machine is in motion.
6. Be sure to know how to stop the machine.
7. Do not place anything on the moving parts of the shaper.
8. Be sure that you know what are doing.
9. Do not make any horseplay while operating the machine.
10. Always practice proper housekeeping habit.
PROCEDURE:
1. Check the machine vise installed in the shaper. Use level gauge to make sure that it is in
level.
2. Secure the workpiece by clamping it on the machine vise. Again, level the workpiece with
level gauge.
3. Tighten the vise so the work will not move. Start calibrating the shaper.
4. Loosen the longitudinal screw and adjust the stroke to zero or minimum.
5. Loosen the stroke indicator; adjust the ram so that the tool bit is in the center of the
workpiece. Fasten the stroke indicator.
6. Adjust the stroke according to the length of the workpiece. Fasten the longitudinal screw
and check the stroke manually by rotating the flywheel.
7. Adjust the clutch according to the speed, the longer the stroke, the faster the speed.
8. Start the machine.
9. Cut first the center of the workpiece by moving the cross feed. The cross feed screw can
be used manually or automatically.
10. Adjust the feed screw handle for every complete longitudinal face cut by turning the 30
clockwise of the spindle feed screw.
11. The complete cutting for the top and bottom is 18.00mm. After completing the cut, stop
the machine.
12. Mark the position of the workpiece before removing it from the vise for the next cutting.
13. Move the machine table by the cross feed screw so you can easily set-up the workpiece.
The next face should be the adjacent side of the finished face of the workpiece.
14. The final cutting of the second face will coincide with the first face in order to obtain the
same dimensions. Repeat for all sides.
15. Remove the workpiece and mark the measurement with the inclination on one end of the
workpiece according to the drawing.
16. Adjust the strike for a short one and reduce the cutting speed.
17. Remove the workpiece from the vise.
18. Mark the hammer head with the center punch. Bore a hole through the hammer head.
19. Replace the drill bit and then create a countersink on both sides of the hammer head.
20. File the workpiece for smoother edges.
QUESTIONS:
1. What is the advantage of a vertical shaper?

- It offers versatility and economy in place of the higher metal removal rates of
traditional horizontal milling machines. Vertical milling machines are less complex
than horizontal machines because the one-piece tool head eliminates the need for
complicated gearing inside the vertical column.
2. What are the principal parts of a shaper?

- The principal parts of a shaper are Base, Column, Table, Cross Rail, Ram, and Tool
Head.
3. How can you set the length stroke of the shaper?

- To set the length stroke of the shaper start it by measuring the workpiece then add
25mm or 1 inch.
4. What is the right position of the tool post to the tool holder?
- The right position of the tool post to the tool holder is that it must be perpendicular to
each other.
5. How can you check if the workpiece is parallel with the table vise?
- Using the level gauge is a simple way of checking if the workpiece is parallel to the
table vise.
6. Where do you start cutting the round bar to for a square finish?
- Start from the center going to the left and right in cutting the round bar. Do in all sides
and it will turn to a square bar.
7. What are the criteria to be followed in setting the cutting speed of the shaper?
- In setting up a mechanically operated shaper, the length of cut (in inches) is known,
and the cutting speed (in feet per minute) is selected according to the kind of metal
being cut. It is then necessary to compute the strokes per minute since that is how the
shaper speed is controlled.
8. What causes the chattering noise in the shaper?

- The shaper has chatter caused by alternate compression; release waves between the tool
and the work making ripples and chatter. This is machine rigidity and speeds and feeds
stuff.
9. Can you cut a thin workpiece in a shaper? How?

- Yes you can. Just put a bed to the work piece to adjust its height and start cutting the
work piece.
10. Finishing cutting requires what kind of speed? Why?

- Finishing cutting requires fast speed for finer cuts. Also, the feed is not that deep.
MECHANICAL DRAWINGS:
TOP VIEW (SCALE 1mm : 1mm)
FRONT VIEW (SCALE 1mm : 2mm)
12.00
15.00
RIGHT SIDE VIEW (SCALE 1mm :2mm)
12.00
15.00
ISOMETRIC VIEW (SCALE 1:2)

DISCUSSION:
In current industrial practice, shapers have been largely superseded by other machine tools
(especially of the CNC type), including milling machines, grinding machines, and broaching
machines. But the basic function of a shaper is still sound; tooling for them is minimal and very
cheap to reproduce; and they are simple and robust in construction, making their repair and upkeep
easily achievable. Thus they are still popular in many machine shops, from jobbing shops or repair
shops to tool and die shops, where only one or a few pieces are required to be produced and the
alternative methods are cost- or tooling-intensive. They also have considerable retro appeal to
many hobbyist machinists, who are happy to obtain a used shaper or, in some cases, even to build
a new one from scratch.
A shaper is a type of machine tool that uses linear relative motion between the workpiece
and a single-point cutting tool to machine a linear toolpath. Its cut is analogous to that of a lathe,
except that it is (archetypally) linear instead of helical. A shaping machine is used to machine
surfaces. It can cut curves, angles and many other shapes. It is a popular machine in a workshop
because its movement is very simple although it can produce a variety of work.
CONCLUSION:
In this activity, students were able to familiarize with the different parts and uses
of a shaper. Also, students learned what, why and how it is used. The shaper is used
primarily for producing a flat or plane surface which may be in a horizontal, a vertical or
an angular plane. It is also for making slots, grooves and keyways. And it is also used as
producing contour of concave/convex or a combination of these. Also, students were able
to operate a vertical type of shaper with the help of the lab assistant. Finally, students were
able to make a cross peen hammer.
RECOMMENDATION:
Listening and understanding the things that the lab assistant are saying would be highly
recommended, since it will be the source of your knowledge for your project or workpiece. Also,
brush the metal excess occasionally. These metal excess may stick to your shoes, so if theres
metal excesses on the floor, use the broom and the dustpan of the laboratory. Finally, be careful
on using the machine, and do not rush things because it may cause accidents or inaccurate
measurements.
REFERENCES:
- http://www.metalartspress.com/howtos/advantages-vertical-milling-machine
- http://engineering.myindialist.com/2009/principle-and-working-of-shaper-
machine/#.WZ1knj7yvX4
- https://en.wikipedia.org/wiki/Shaper#History
- http://www.technologystudent.com/equip1/shape1.htm

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Mapa University

Muralla St. Intramuros, Manila

SHOP PRACTICE NO.5

Engr. Jose V. Hernandez

METHODS AND ANALYSIS:

TOOLS AND EQUIPMENT TO BE USED:

1. What is the advantage of a vertical shaper?

2. What are the principal parts of a shaper?

3. How can you set the length stroke of the shaper?

8. What causes the chattering noise in the shaper?

9. Can you cut a thin workpiece in a shaper? How?

10. Finishing cutting requires what kind of speed? Why?

TOP VIEW (SCALE 1mm : 1mm)

FRONT VIEW (SCALE 1mm : 2mm)

ISOMETRIC VIEW (SCALE 1:2)

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