International Journal of Modern Studies in Mechanical Engineering (IJMSME)

Volume 3, Issue 3, 2017, PP 40-48

ISSN 2454-9711 (Online)
DOI: http://dx.doi.org/10.20431/2454-9711.0303005
www.arcjournals.org

A Dual Side Shaping Machine for Industrial Applications

Dr. M. K. Marichelvam1, Mr. K.Kandakodeeswaran2
1,2
Department of Mechanical Engineering, Mepco Schlenk Engineering College,
Sivakasi, Tamilnadu, India

*Corresponding Author: Dr. M. K. Marichelvam, Department of Mechanical Engineering, Mepco

Schlenk Engineering College, Sivakasi, Tamilnadu, India

Sivakasi,
Abstract: Most of the industries are having a Tamilnadu, India
various types of reciprocating machines for performing
machine operation on small size of work. Usually shaper, broaching machine and planner are used for
machining a small area of work with less quantity. These machines are used for machining very small area of
plain surface, vertical surface, angular surface, grooving etc. It removes the materials from job only at
forward stroke. So it takes more machining time to complete the product. In order to overcome this problem,
a small dual shaper machine is developed for machining two work pieces at a same time. In this machine, it
has both the direction of ram movement and it removes a material from two work pieces simultaneously. So,
the machining time will be reduced and the production rate will be increased.
Keywords: shaper, dual side shaper, machining Centre

1. INTRODUCTION
In general, the shaper can produce any surface composed of straight line elements. Modern shapers
can generate contoured surface. The main purpose of shaping machine is to machine plain horizontal
surface. It is possible to from vertical and angular surfaces also. With proper tools and accessories
even irregular surfaces can be formed. As per the of motion of the shaper they are
 Crank type
 Geared type
 Hydraulic type
By moving the work piece across the path of the reciprocating tool a flat surfaces is generated
regardless of the shape of the tool. With the special tools, attachments and devices for holding the
work, a shaper can also be used to cut external and internal keyways, gears, racks, dovetails, T-slots
and other miscellaneous shapes. Shaping is essentially an inefficient method of metal removal but the
simplicity of the process coupled with short set up time and cheap tooling makes it extremely useful
for the single job.
The most common type of horizontal shapers is the production push cut shaper. This type of shaper
consists of a frame or column supported on a base, a reciprocating ram and work table. The frame
houses the drive mechanism of the shaper. The tool slide swivel base is held on the circular seat on
the ram and is graduated to indicate the angle of swivel. The apron consisting of the clapper box the
clapper block and the tool post is clamped on the vertical slide by a screw. It can be swiveled about
the apron swivel in by releasing the clamping screw. The clapper blocks which carries the tool post is
connected to the clapper box means of a hinged pin. The researchers suggested that a shaping machine
for dividing a deformable mass, such as a meat product, into separately shaped portions comprises a
stock container, at least two piston-cylinder units for alternately feeding in the mass from the stock
container to a shaping plate provided with shaped recesses, and also means for removing the shaped
portions from the shaping plate [1].
Some authors suggested that twin mounted double sided reciprocating shaping mechanism is provided
which is formed in the shape of an acute isosceles triangle whereby the bottom is opened to the
ground and each cutting mechanism is bent or deformed along the longitudinal axis to form to a

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A Dual Side Shaping Machine for Industrial Applications

conical shape when rotated about the center axis of the isosceles triangle. The twin mounted double
sided reciprocating shaping mechanism is adapted to be used for cutting and shaping and forming
trees, bushes and the like in the contour of a cone [2].
The invention relates to a machine for cutting down and shaping trees, designed to cut down, strip and
truncate trees, consisting of a support and cutting down-stripping-truncating equipment likely to be
adapted to a self-propelling device, said equipment carrying a movable framework on which the
cutting-truncating and stripping elements are positioned, a machine wherein the components there of
are substantially secured along a one and same axis, the stripping element carrying at least two blades
is explained in [3].This invention relates to improvements in machines for building pneumatic tires
[4]. It includes features which are beneficial in the building of almost any standard type of pneumatic
tire, although it is most particularly suited to the fabrication of radial ply tires. In the manufacture of
radial ply tires, comprised of single or multiple plies composed of wire and/or textile, it is
conventional practice to wind the rubberized ply or plies on a revolving cylindrical tire building drum
with the wires or cords forming high angles.
Some authors suggested that multi-touch capacitive touch sensor panel can be created using a
substrate with column and row traces formed on either side of the substrate. To shield the column
(sense) traces from the effects of capacitive coupling from a modulated Vcom layer in an adjacent
liquid crystal display (LCD) or any source of capacitive coupling, the row traces can be widened to
shield the column traces, and the row traces can be placed closer to the LCD [5].Tire shaping machine
invention relates to improvements in machines for building pneumatic tires [6]. It includes features
which are beneficial in the building of almost any standard type of pneumatic tire, although it is most
particularly suited to the fabrication of radial ply tires.
In the manufacture of radial ply tires, comprised of single or multiple plies composed of wire and/or
textile, it is conventional practice to wind the rubberized ply or plies on a revolving cylindrical tire
building drum with the wires or cords forming high angles (in the neighborhood of 90) to a plane that
is perpendicular to the finished tire axis. The opposite ends of the ply or plies are each then folded
around a rubberized bead wire, and sidewall and under breaker stock are added. The semi-completed
carcass is then removed from the tire building drum and placed on a shaping machine (or,
alternatively, the carcass may have originally been built on a shaping machine drum), wherein a low
angle wire breaker strip (or circumferential restraining ply) and a tread slab are added thereto, and the
tire is brought to its ultimate shape is explained in [7].The application of the breaker strip or strips to
the semi-completed tire carcass is a critical step in the fabrication of a tire. It requires that the
circumference of the tire carcass be extended to the precise diameter at which this component is to be
added is explained in [8]. Normally in the manufacturing industry the shaping machine is used to
manufacture a component, the time consumption is more, if single tool is used to manufacture the
component. In order to reduce the time taken to produce a component, a new type of shaper machine
was developed. In this new type of machine two shaping tools are used. Therefore two work pieces
can be machined at the same time. In dual side shaper machine the machining time will be less when
to normal shaper. The power consumption is same in both the shaper machine, and the speed of the
ram will be controlled.
2. DESIGN CALCULATIONS OF THE COMPONENTS
The components used in the dual side shaper machine are
 Frame
 Pulley
 Single Phase Induction Motor
 V-Belt
 Shaft
 Roller Bearing
 Shaping Tool
2.1. V -Belt Design Calculation
Large pulley diameter = 30cm = 300mm

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A Dual Side Shaping Machine for Industrial Applications

Small pulley diameter =4cm =40mm

Belt width = 38.5cm =385mm
Power =100W
Speed of motor =1300 rpm
Rated power =150T
2.1.1. Selection of the V Belt
From PSG data book for 100W, A section belt is chosen.
2.1.2. Selection of Pulley Diameter
I=D/d=N/n
7.5=N/n n=1300/7.5=173.33
Recommended minimum diameter d=75 mm
I=300/40 = 7.5mm
Recommended C/D ratio =0.85
2.1.3. Calculation Pitch Length
From PSG data book page no 7.61

L= 2c+ /2(D+d)+
C=385mm
=0.85
C=0.85*300=255 mm
C=255mm

L= 2*385+ /2(300+40)+
L=1347.96mm
Standard length L= 2703 mm
2.1.4. Calculation of Maximum Power Capacity
A KW= ( -0.765* )s*125

=2.72m/s

A KW= ( -0.765* )2.72*125

A KW=0.49KW
2.1.5. Calculation of Arc of Contact
α

α
=139.48 degree
Correction factor Fd =0.89
Normal torque at 16hrs
Fa=1.3
Fc= 0.94
2.1.6. Calculation of Number of Belt
Number of belt =

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A Dual Side Shaping Machine for Industrial Applications

=
= 0.3 1
Number of belt = 1belt
2.1.7. Calculation of Actual Length
Standard Length (L) = 2703mm
A )
)
A =542.25mm
B= =
=8450mm
C = A+
=542.25+
C=1076.90mm
3. MODELING OF MACHINE AND MACHINE COMPONENTS
The 3-D modeling of machine and the components is carried out in Solid Works software. The
modeling application also provides “features based” solid bodies by directing editing capabilities,
which allow changing and updating solid bodies by directing editing the dimensions of a solid feature
or by other geometric construction techniques.
3.1. Parts to be Designed
The various parts to be designed in solid works software are
 Shaft
 Pulley
 Work table
 Angle
 Ram
 Work piece
3.2. Isometric View of Dual Shaper
The isometric view of dual shaper machine is illustrated in Figure 1

Figure1. Isometric View of Dual Shaper

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A Dual Side Shaping Machine for Industrial Applications

3.3. Pulley
The modelling of pulley is depicted in Figure 2. The pulley material used here is cast iron.

Figure2. Isometric View of Pulley

3.4. Table
The isometric view of table is depicted in Figure 3.

Figure3. Isometric View of Table

3.5. Shaft
The isometric view of shaft is shown in Figure 4.

Figure4. Isometric View of Shaft

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A Dual Side Shaping Machine for Industrial Applications

3.6. Wheel
The isometric view of wheel is shown in Figure 5.

Figure5. Isometric View of Wheel

3.7. Ram
The isometric view of ram is depicted in Figure 6.

Figure6. Isometric View of Ram

4. LAYOUT OF THE MACHINE AND MECHANISMS USED
The components (or) parts are assembled and the machining process is carried out. The fabrication of
dual side shaper machine is clearly shown in figure 7.

Figure7. Layout of the dual side shaper machine

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A Dual Side Shaping Machine for Industrial Applications

4.1. Mechanisms Used in Dual Shaper

The mechanism used in the dual shaper is explained below.
4.1.1. Scotch Yoke Mechanism
The Scotch yoke (also known as slotted link mechanism) is a reciprocating motion mechanism,
converting the linear motion of a slider into rotational motion or vice versa. The piston or other
reciprocating part is directly coupled to a sliding yoke with a slot that engages a pin on the rotating
part. The location of the piston versus time is a sine wave of constant amplitude, and constant
frequency given a constant rotational speed. This mechanism is generally found on shaping machines
where single point cutting tool is mounted on the front of the slider or ram, in a hinged tool post. The
tool cuts on the slow forward stroke and lifts over the work piece on the quick return stroke. The
slotted link rocks from side to side, driven by the sliding block on the bull wheel. The various views
of the proposed dual shaper machine is shown in below figures 8-10.

Figure8. Front View of Dual Shaper

Figure9. Top View of Dual Shaper

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A Dual Side Shaping Machine for Industrial Applications

Figure10. Side View of Dual Shaper

4.2. Machining Time Calculation
Length of the cutting stroke = 50 mm
Time required by cutting stroke = 2 sec
Cutting speed = 25mm/sec
Plate size = 20*20*20
Total length of stroke = 20+20
= 40mm
Cutting time for single work piece = 40/25
=1.6sec
This dual shaper return time = 1.6/2
= 0.8sec
Total time = 2.4sec
Total number of stroke necessary to complete the cut = 40/2
= 20 mm
Total time required to complete the cut = 2.4*20/60
= 0.8min

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A Dual Side Shaping Machine for Industrial Applications

5. CONCLUSIONS AND FUTURE RESEARCH

In this paper, a dual side shaper is designed and fabricated. This dual side shaper machine is used to
manufacture components similar to a standard shaper machine. However, the machining time required
for this dual shaper is less as compared to the normal shaper. Hence, the production rate is increased
in the dual side shaper machine when compared to the normal shaper. The designed dual shaper has
been used for only trial production. In the future it would be used for commercial production in
industries.
REFERENCES
[1] Hnatovsky, C., Shvedov, V. G., Shostka, N., Rode, A. V., & Krolikowski, W. (2012). Polarization-
dependent ablation of silicon using tightly focused femtosecond laser vortex pulses. Optics Letters, 37(2),
226-228.
[2] D.M. Karnakis, J. Fieret, P.T. Rumsby, M.C. Gower, shaping using reshaped pulsed Gaussian laser beams,
in: Proceedings of SPIE, vol. 4443, 2001.
[3] "Cigar bunch shaper mechanism." U.S. Patent 2,102,298, issued December 14, 1937.
[4] Safdar, S., Li, L., Sheikh, M. A., & Liu, Z. (2007). Finite element simulation of laser tube bending: Effect
of scanning schemes on bending angle, distortions and stress distribution. Optics & Laser Technology,
39(6), 1101-1110.
[5] SP Hotelling, BR Land (2011) ‘DUAL SHAPER’- US patent7,920,129.
[6] KR Lessard, JM McElrathJr (1983) ‘DOUBLE SIDE RECIPROCATING SHAPER’-US Patent 4,383,401.
[7] T.V. Sundararajamoorthy and N. Shanmugam (1982) ‘MACHINE DESIGN’, Anuratha Publications,
Chennai, India.
[8] Khurmi,R.S and Gupta, J.K.(1997) ‘A TEXTBOOK OF MACHINE DESIGN’, S. Chand Publications,
New Delhi, India.
AUTHORS’ BIOGRAPHY
M. K. Marichelvam, received his B.E. degree in Mechanical Engineering from
Madurai Kamaraj University, Madurai, India, in 2000. He has obtained a Masters
in Engineering in Industrial Engineering from Madurai Kamaraj University,
Madurai, India, in 2002. He has obtained Ph.D. in Mechanical Engineering from
Anna University, Chennai, India in 2015. He is currently working as Assistant
Professor (Sr. Grade) in Mechanical Engineering Department, Mepco Schlenk
Engineering College, Sivakasi, India. His active areas of interests are
Manufacturing Scheduling, Multi-objective optimization, Industrial and Production
Management and optimization techniques. He has published many research papers in the Journals of
International repute. He has presented papers at several international conferences.
K. Kandakodeeswaran, received his B.E. degree in Mechanical Engineering
from Anna University, Chennai, India, in 2012. He obtained Master degree in
Computer Integrated Manufacturing from Anna University, Chennai, India, in
2014. He is currently working as an Assistant Professor in Mechanical
Engineering Department, Mepco Schlenk Engineering College, Sivakasi, India.
His areas of interests are Design and Manufacturing. He has published a research
papers in the Journals of International repute. He has presented papers at some
national conferences.

Citation: Dr. M. K. Marichelvam & Mr. K. Kandakodeeswaran (2017). A Dual Side Shaping Machine for
Industrial Applications, International Journal of Modern Studies in Mechanical Engineering (IJMSME),
3(3), pp.40-48, DOI: http://dx.doi.org/10.20431/2454-9711.0303005.
Copyright: © 2017 Dr. M. K. Marichelvam & Mr. K. Kandakodeeswaran This is an open-access article
distributed under the terms of the Creative Commons Attribution License, which permits unrestricted use,
distribution, and reproduction in any medium, provided the original author and source are credited

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