Working Principle of Shaper

SHAPER
Shaper is a reciprocating type of machine tool in which the ram moves the cutting tool backwards and
forwards in a straight line. The basic components of shaper are shown in Fig. 1. It is intended primarily to
produce flat surfaces. These surfaces may be horizontal, vertical, or inclined. In general, the shaper can
produce any surface composed of straight-line elements.
WORKING PRINCIPLE OF SHAPER:

A single point cutting tool is held in the tool holder, which is mounted on the ram. The workpiece is rigidly
held in a vice or clamped directly on the table. The table may be supported at the outer end. The ram
reciprocates and thus cutting tool held in tool holder moves forward and backward over the workpiece. In a
standard shaper, cutting of material takes place during the forward stroke of the ram. The backward stroke
remains idle and no cutting takes place during this stroke. The feed is given to the workpiece and depth of cut
is adjusted by moving the tool downward towards the workpiece. The time taken during the idle stroke is less
as compared to forward cutting stroke and this is obtained by quick return mechanism. The principal of
shaping operation is shown in Fig. 2 (a, b). Modern shapers can also generate contoured surface as shown in
Fig.3. A shaper is used to generate flat (plane) surfaces by means of a single point cutting tool similar to a
lathe tool. The cutting action and functioning of clapper box is shown in Fig.23.4 during forward and return
stroke.
TYPES OF SHAPERS:
Shapers are classified under the following headings:
(1) According to the type of mechanism used for giving reciprocating motion to the ram
(a) Crank type
(b) Geared type
(c) Hydraulic type
(2) According to the type of design of the table:
(a) Standard shaper
(b) Universal shaper
(3) According to the position and travel of ram:
(a) Horizontal type
(b) Vertical type
(c) Traveling head type
(4) According to the type of cutting stroke:
(a) Push type
(b) Draw type.
1. CRANK SHAPER:
This is the most common type of shaper. It employs a crank mechanism to change circular motion of a large
gear called “bull gear” incorporated in the machine to reciprocating motion of the ram. The bull gear receives
power either from an individual motor or from an overhead line shaft if it is a belt-driven shaper.
2. GEARED SHAPER:
Geared shaper uses rack and pinion arrangement to obtain reciprocating motion of the ram. Presently this
type of shaper is not very widely used.
3. HYDRAULIC SHAPER:
In hydraulic shaper, reciprocating motion of the ram is obtained by hydraulic power. For generation of
hydraulic power, oil under high pressure is pumped into the operating cylinder fitted with piston. The piston
end is connected to the ram through piston rod. The high pressure oil causes the piston to reciprocate and
this reciprocating motion is transferred to the ram of shaper. The important advantage of this type of shaper
is that the cutting speed and force of the ram drive are constant from the very beginning to the end of the
cut.
4. STANDARD SHAPER:
In standard shaper, the table has only two movements, horizontal and vertical, to give the feed.
5. UNIVERSAL SHAPER:
A universal shaper is mostly used in tool room work. In this type of shaper, in addition to the horizontal and
vertical movements, the table can be swiveled about an axis parallel to the ram ways, and the upper portion
of the table can be tilted about a second horizontal axis
perpendicular to the first axis.
6. HORIZONTAL SHAPER:
In this type of shaper, the ram holding the tool reciprocates in a horizontal axis.
7. VERTICAL SHAPER:
In vertical shaper, the ram reciprocates in a vertical axis. These shapers are mainly used for machining
keyways, slots or grooves, and internal surfaces.
8. TRAVELLING HEAD SHAPER:

In this type of shaper, the ram while it reciprocates, also moves crosswise to give the required feed.
9. PUSH TYPE SHAPER:

This is the most general type of shaper used in common practice, in which the metal is removed when the
ram moves away from the column, i.e. pushes the work.
10. DRAW TYPE SHAPER:
In this type of shaper, the cutting of metal takes place when the ram moves towards the column of the
machine, i.e. draws the work towards the machine. The tool is set in a reversed direction to that of a standard
shaper.
PRINCIPAL PARTS OF SHAPER

Fig. 5 shows the parts of a standard shaper. The main parts are given as under.
1. Base
2. Column
3. Cross-rail
4. Saddle
5. Table
6. Ram
7. Tool head
8. Clapper box
9. Apron clamping bolt
10. Down feed hand wheel
11. Swivel base degree graduations
12. Position of stroke adjustment hand wheel
13. Ram block locking handle
14. Driving pulley
15. Feed disc
16. Pawl mechanism
17. Elevating screw
BASE:
It is rigid and heavy cast iron body to resist vibration and takes up high compressive load. It supports all other
parts of the machine, which are mounted over it. The base may be rigidly bolted to the floor of the shop or on
the bench according to the size of the machine.
COLUMN:
The column is a box shaped casting mounted upon the base. It houses the ram-driving mechanism. Two
accurately machined guide ways are provided on the top of the column on which the ram reciprocates.
CROSS RAIL:
Cross rail of shaper has two parallel guide ways on its top in the vertical plane that is perpendicular to the rai1
axis. It is mounted on the front vertical guide ways of the column. It consists mechanism for raising and
lowering the table to accommodate different sizes of jobs by rotating an elevating screw which causes the
cross rail to slide up and down on the vertical face of the column.
SADDLE:
The saddle is located on the cross rail and holds the table on its top.
TABLE:
The table is a box like casting having T -slots both on the top and sides for clamping the work. It is bolted to
the saddle and receives crosswise and vertical movements from the saddle and cross rail.
RAM:
It is the reciprocating part of the shaper, which reciprocates on the guideways provided above the column.
Ram is connected to the reciprocating mechanism contained within the column.
TOOL HEAD:
The tool head of a shaper performs the following functions-
(1) It holds the tool rigidly,
(2) It provides vertical and angular feed movement of the tool, and
(3) It allows the tool to have an automatic relief during its return stroke. The various parts of tool head of
shaper are apron clamping bolt, clapper box, tool post, down feed, screw micrometer dial, down feed screw,
vertical slide, apron washer, apron swivel pin, and swivel base.
SPECIFICATION OF A SHAPER:
The size of a shaper is specified by the maximum length of stroke or cut it can make. Usually the size of
shaper ranges from 175 to 900 mm. Besides the length of stroke, other particulars, such as the type of drive
(belt drive or individual motor drive),
floor space required,
weight of the machine,
cutting to return stroke ratio,
number and amount of feed,
power input etc. are also sometimes required for complete specification of a shaper.
SHAPER MECHANISM:
In a shaper, rotary motion of the drive is converted into reciprocating motion of the ram by the mechanism
housed within the column or the machine. The shaper mechanism is so designed that it moves the ram
holding the tool at a comparatively slower speed during forward cutting stroke, whereas during the return
stroke it allow the ram to move at a faster speed to reduce the idle return time. This mechanism is known as
quick return mechanism. The reciprocating movement of the ram and the quick return mechanism of the
machine are generally obtained by anyone of the following methods:
(1) Crank and slotted link mechanism
(2) Whitworth quick return mechanism, and
(3) Hydraulic shaper mechanism
CRANK AND SLOTTED LINK MECHANISM:

In crank and slotted link mechanism (Fig. 6), the pinion receives its motion from an individual motor or
overhead line shaft and transmits the motion or power to the bull gear. Bull gear is a large gear mounted
within the column. Speed of the bull gear may be changed by different combination of gearing or by simply
shifting the belt on the step cone pulley. A radial slide is bolted to the centre of the bull gear. This radial slide
carries a sliding block into which the crank pin is fitted. Rotation of the bull gear will cause the bush pin to
revolve at a uniform speed. Sliding block, which is mounted upon the crank pin is fitted within the slotted link.
This slotted link is also known as the rocker arm. It is pivoted at its bottom end attached to the frame of the
column. The upper end of the rocker arm is forked and connected to the ram block by a pin. With the
rotation of bull gear, crank pin will rotate on the crank
pin circle, and simultaneously move up and down the slot in the slotted link giving it a rocking movement,
which is communicated to the ram. Thus the rotary motion of the bull gear is converted to reciprocating
motion of the ram.
SURFACES PRODUCED ON SHAPER:
1. Horizontal plain surface
2. Vertical plain surface
3. Inclined surface
4. Grooved surface
5. Slotted surface
6. Stepped surface
SHAPER OPERATIONS:
A shaper is a machine tool primarily designed to generate a flat surface by a single point cutting tool. Besides
this, it may also be used to perform many other operations. The different operations, which a shaper can
perform, are as follows:
1. Machining horizontal surface (Fig.7)
2. Machining vertical surface (Fig. 8)
3. Machining angular surface (Fig. 9)
4. Slot cutting (Fig. 10)
5. Key ways cutting (Fig. 11)
6. Machining irregular surface (Fig. 12)
PLANER
Like a shaper, planer is used primarily to produce horizontal, vertical or inclined flat surfaces by a single point
cutting tool. But it is used for machining large and heavy workpieces that cannot be accommodated on the
table of a shaper. Planer is mainly of two kinds namely open housing planer and double housing planer. The
principle parts of the open housing planer are shown in Fig 23.14(a). The principle parts of the double
housing planer are shown in Fig 23.14(b). The bigger job is fixed with help of the grooves on the base of the
planer and is accurately guided as it travels back and forth. Cutting tools are held in tool heads of double
housing planer and the work piece is clamped onto the worktable as shown in Fig. 23.14(b). The worktable
rides on the gin tool heads that can travel from side to side i.e., in a direction at right angle to the direction of
motion of the worktable. The primary motion of the worktable is normally accomplished by a rack and pinion
drive using a variable speed motor.
WORKING PRINCIPAL OF PLANER:

Fig. 23.15 depicts the working principle of a planer. In a planer, the work which is supported on the table
reciprocates past the stationary cutting tool and the feed is imparted by the lateral movement of the tool.
The tool is clamped in the tool holder and work on the table. Like shaper, the planner is equipped with
clapper box to raise the tool in idle stroke. The different mechanisms used to give reciprocating motion to the
table are following-
1. Reversible motor drive
2. Open and cross belt drive
3. Hydraulic drive
TYPES OF PLANERS:
Planers may be classified in a number of ways, but according to general construction,
these are the following types:
1. Double housing planer
2. Open side planer
3. Pit planer
4. Edge or plate type planer
5. Divided table planer
DIFFERENCE BETWEEN SHAPER AND PLANER:

Working Principle of Shaper

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SHAPER

WORKING PRINCIPLE OF SHAPER:

8. TRAVELLING HEAD SHAPER:

9. PUSH TYPE SHAPER:

PRINCIPAL PARTS OF SHAPER

CRANK AND SLOTTED LINK MECHANISM:

WORKING PRINCIPAL OF PLANER:

DIFFERENCE BETWEEN SHAPER AND PLANER:

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