Shaper Machines

A shaper machine is a machine used primarily for producing flat surfaces that may be in
horizontal, vertical, and even angular planes.

The shaper is a machine tool used primarily for:

(1). Producing a flat or plane surface which may be in a horizontal, a vertical or an
angular plane.
(2). Making slots, grooves and keyways.
(3). Producing contour of concave/convex or a combination of these.

Types of shapers

1. Crank shaper – also known as column shaper. The vertical column of this
machine supports the ram, worktable and drilling mechanism.
2. Hydraulic shaper – almost similar to a crank shaper. The two only differs in the
fundamentals of moving the ram. In the hydraulic shaper, the ram is moved by
a flow of oil from a high pressure pump which acts against the piston.
3. Vertical shaper – also known as slotter shaper. It is composed of a vertical ram
that moves up and down and can be adjust up to 5o in shaping angles. The
tool head located in the ram can be set at 180o in a horizontal plane.

FIGURE 1 – CRANK SHAPER

1
FIGURE 2 – HYDRAULIC SHAPER

FIGURE 3 – VERTICAL SHAPER

2
 FIGURE 4 – CONVENTIONAL SHAPER MACHINE

Main Parts of a Shaper

1. Base – serves as the foundation of the machine; is made of casting materials.
2. Column – also known as frame; a hallow rectangular casting where the driving
mechanism for the ram is attached.
3. Cross bail – a casting located across the front of the column that permits the
table to move vertically and horizontally. This part is controlled by the elevating
screw.
4. Saddle – also known as an apron; a flat casting located between the table and
the dress rail.
5. Table and table support – a casting of rectangular shape with an opening at
the front and bottom. The table support extends either from under the work
table to the base or from the front of the work table on the base.
6. Ram – supports the cutting tool and guides it over the workpiece during the
cutting process.
7. Tool head – it holds the tool and adjust it to the desired position for cutting.
The ball crank in the head is used for manual feed for the tool up and down.
8. Driving mechanism – changes circular motion to reciprocating motion and this
is done with an eccentric, ca and crank pin.

3
 FIGURE 5 – MAIN PARTS OF A SHAPER

FIGURE 6 – PRINCIPAL PARTS OF A SHAPER

4
 Forward and return strokes are transmitted to the ram by the circular motion of
the crank often called a “bull wheel acting through the crankpin and rocker arm.”
Whether the bull wheel revolves fast or slowly is determined by the speed for which the
machine has been set.
The bull wheel shaper revolves; the crankpin describes a circular path and
moves the rocker arm. The rocker arm pivots at its lower end and on a hinge pin, and
the upper end is connected to the shaper ram by a link attached to the clamp block. The
slot in the rocker arm prevents the crank pin from clocking the bull wheel and rocker
arm together so that neither could move. The link which is connected to the clamp
blocks makes possible for the ram to travel back and forth horizontally.
1
In the return stroke, the ram travels faster. It is almost 1 2 times the cutting stroke.
The rotating of the crank pin reverses the direction of the rocker arm causing the ram to
begin its return stroke.

Toolholders and Cutting Tools for the Shaper

Types of Toolholder

1. Lathe toolholder
2. Swivel head
3. Extension

The shaper toolholder varies in sizes depending on the size of the tool and the
workpiece. The tool cannot be adjusted for clearance of 2o to 3o because there is no
rocker in the tool post. The shaper tool is usually given about 10o rake angle depending
upon the hardness of the material. The lathe toolholder and tool bit performed
satisfactorily if not given too much clearance. The swivel toolholder permits the tool to
be held securely in any one of the available five positions. Cutting tools must be
properly grounded and must have proper clearance in both of its sides and ends to
ensure longer life. A right-hand tool has its cutting point at the right, while a left-hand
tool has it to the left.

5
 FIGURE 7 – SHAPER TOOL HEAD

FIGURE 8 – NOMENCLATURE OF SINGLE POINT CUTTING TOOL

6
Shaper working devices

1. Shaper vise – the most common work holding device with the base graduated
in degrees that makes it possible to swivel at any angle. Vise is equipped with
a fixed and a movable jaws.
2. Parallel bars and hold down bars – used to ensure flatness and commonly
held in the vise while the hold down grips the workpiece.

Mounting a workpiece on the shaper table

In mounting a workpiece on a shape, it is natural to know the shape of the object

to prepare the necessary devices for setup. However, when the workpieces are around,
a V-block is commonly used. And for other shapes of workpieces, a clamp with a
standard block is used. To check the correctness of the position, solid square, surface
gauge, or dial indicator is used. A toe dogs with the help of shims is also advisable.
Sometimes even a planed jack is used for easy setups.

Shaper speeds and feeds

The factors affecting the cutting speed of the shaper are:

1. The nature of material to be cut
2. Amount of feed per stoke
3. Efficiency of cutting tool
4. The condition of the machine
The cutting speed of the shaper is the rate of speed of the tool travel per stroke
of a given length per unit of time usually in minutes. In most shapers, the cutting stroke
3
takes 5th of the cycle time and the formula for shaper cutting speed (CS).
CS = 0.14 x N x L

Where: CS = cutting speed in ft/min

N = strokes/min
L = length of stroke

Example problems

1. What is the cutting speed of a medium carbon steel which cutting stroke per
minute is 80 and which length is 10”?

Solution:
CS = 0.14 x N x L
= 0.14 x 80 x 10
= 112 fpm

2. What is the stroke per minute of a mild steel which cutting speed is 200 fpm
having a total length of 16”?

7
 Solution:
CS = 0.14 x N x L
CS
=N
0.14 ×L
Therefore,
200 ft/min
N = 0.14 ×6
≈ 89.2 strokes/min

Feed

The feed for the shaper can be operated by hand or by power. The amount of
feed is based on the following:
1. Depth of cut
2. Condition of the machine
3. Cutting speed
4. Finishing desired

How to adjust the necessary length of strokes in a ram

1. For a mechanically driven shaper, first loosen the knob that locks the stroke
setting shaft. A modern shaper maintains the length of strokes automatically.
2. Turn the stroke setting shaft in the desired direction until the ram pointer
registers the correct length plus the required amount for the overlap on each
end of the workpiece. Turning the shaft in one direction lengthens the strokes
and turning in the opposite direction shortens it. The adjustment length of
stroke is always made before adjusting for position over the workpiece. Always
1 1
allow about 4 " beyond the workpiece on the forward stroke and about 2 " in the
return stroke behind the workpiece. Then tighten the ram clamp.

How to set the cutting tool for cutting

1. The tool must be set slightly inclined against the workpiece.

2. Set the clapper box so that its top slants slightly away from the cutting edge of
the tool. This permits the tool to swing away from the workpiece on the
backstroke of the ram, thus, protecting the cutting edge from unnecessary
wear.

Shaper operation

1. Roughing – shaping the given stock and having the excess material remain
with a tolerable allowance for finishing.
2. Finishing – shaping the given material into the required dimension given in the
plan by using a finishing cutting tool.
3. Angular cutting – may be accomplished in one of these three ways:
a. By setting the workpiece at an angle

8
 b. By setting the cutting edge of the tool at an angle corresponding to the
angle to be produced on the workpiece
c. By swiveling the tool head to guide the tool in the required angle for cutting.
4. Keyway or slot cutting – cutting a groove to serve as locking place for the shaft
and gear as in keyway. Slotting is the process of making grooves as in
shafting where a key place to lock on the pulley or gear to be placed.
5. Contouring – cutting irregular surfaces.
6. Internal cutting – done for jobs such as cutting internal keyways, internal
slotting, and machine internal surface.

Advantages of Shaper Machines:

1. The single point cutting tools used in shapers are inexpensive, these tools can be
easily grounded to any desirable shape.
2. The simplicity and ease of holding work, its easy adjustment, and the simple tool
give the shaper its great flexibility.
3. Shaper set up is very quick and easy and can be readily changed from one job to
another.
4. Thin or fragile jobs can be conveniently machined on shapers because of lower
cutting forces.

Planer Machine

It is a large machine intended for producing flat surfaces on a piece of work. It

differs from a shaper machine in that work in the planer machine is held on the table,
which is the one making the stroke, while the cutter is placed steadily in the tool head.
In the shaper machine, the work is held stationary on the table where it is connected.
Large works which are awkward to machine in a shaper are done in a planer.

Principal parts of a planer

1. Bed – is cat and looks like a box; acts as the foundation.

2. Table – is cast and rectangular in shape; commonly mounted on top of the
bed, the table is to hold the work.
3. Housing – is cast, usually large, primarily placed vertically which straddles the
table and bed. Its the main mechanism for operating the tool heads.
4. Cross rail – placed in the vertical ways of the housing and mounted in a
horizontal position. It can be moved up and down by means of screw.
5. Saddle – fitted on the cross tail. At its front saddle is fitted on the tool head
together with a vertical screw for the feed to move the tool head vertically. The
left and right tool heads have their own saddle and can be moved
independently.
6. Toolhead – where the tool post is attached. This is connected to the saddle
and hinged to the head to raise the cutting tool and make it ride on top of the

9
 work. For this reason, the cutting edge of the tool is protected from damage,
permitting the automatic traverse feed to operate without interruption. Two
head tools are commonly found: one in the vertical position on the cross rail
and another on the horizontal position on the housing.

How to determine the size of the planner?

The size of the planer can be determined by knowing the biggest work that can
be set on the table and under the housing.

Two methods that drive the planer.

1. Mechanically driven planer – the machine table is driven by gears and a rack
gear attached under the side of the table.
2. Hydraulic driven planer – is moved by a non-reversing motor that drives the
pump at a constant speed.

Types of planer

1. Double housing planer – where the table is moved between the two housing
which support the cross rail and tool head.
2. Open side planer – can machine work wider than the table.

Mounting a work on a planer

There are many ways of mounting a workpiece. A vise is usually placed on the
table and is used to hold small pieces of work. Big pieces of work are commonly
clamped directly to the table. To check the squareness and level of the setting, a planer
jack, vertical jack, or bracing jack is used. A planer gauge is used to ensure that the
cutting tool is with a required distance from the table or to check the surface finish of the
work.

Speed and feed of the planer

The planer can cut at only one speed. Like the shaper machine, the return stroke
is faster than the cutting stroke.

10
Check Your Knowledge

1. Differentiate a shaper machine from a planer machine.

2. How can we determine the size of the shaper?
3. How can we determine the HP required for a shaper machine?
4. When do we need to use a shaper machine?
5. Is it advisable to use a shaper machine to make a dovetail? If yes, explain your
answer.
6. What is a ram?
7. Differentiate a mechanical shaper from a hydraulic shaper.
8. Name three types of shaper machine.
9. Explain the driving mechanism of a shaper machine.
10. What are the different types of toolholder used in a shaper machine?
11. Differentiate a cutting stroke from a return stroke.
12. Name the different work holding devices for a shaper machine.
13. Briefly explain how to adjust the cutting stroke in a shaper machine.
14. How can we check the accuracy of a setting of a workpiece in a shaper?
15. When do we need to use a vertical shaper?
16. What us slotting?
17. What is contour shaping?
18. What are the uses of parallel bars?
19. Explain how to shape a contour.
20. What are the uses of V-block and step block?

11