Performance on Shaper Machine

4.1  Introduction

A shaping machine (usually called shaper) is mainly used for producing flat surfaces, which may be horizontal, vertical or inclined. Sometimes irregular or curved surfaces are also produced by shapers. In shaping, a tool is given a reciprocation motion with the help of mechanism provided on the machine that changes circular motion in to the reciprocating motion. The shaping machine is indispensable in tool rooms due to its great flexibility, easy of work holding, quick adjustment and used of tools of relatively simple shape and size. It is also very useful in die making shops, maintenance shops and production shops.

4.2  Working principle

In a shaping machine the job is held in a suitable device (generally vice) clamped rigidly on the machine table. The cutting tool is held in the tool post mounted on the ram of the shaper.
The arm reciprocates to-and-fro, and in doing so cuts the material held in the vice during the cutting stroke. Generally, the cutting action takes place in the forward stroke, which is also known as the cutting stroke. No cutting of material takes place during the return stroke of the ram which is termed as the idle stroke. The job is given an index feed with the help of a cross-rail mechanism fitted inside
the table.

4.3  Classification of shapers

Shapers are classified in the following ways:

• According to the length of stroke
  • 30 cm shaper
  • 40 cm shaper
  • 60 cm shaper
• According to the cutting action
  • Push type shaper
  • Draw cut type shaper
• According to the movement of the ram
  • Horizontal shaper
  • Vertical shaper or slotter
• According to the drive
  • Mechanical shapers
  • Crank-driven shapers and Geared shaper
  • Hydraulic shapers
• According to the method of transmitting power
  • All geared shaper
  • Cone pulley belt-driven shaper
• According to the movement of the table
  • Simple shaper
  • Universal shaper

4.4  Principal parts of a shaper

Various important parts of a shaper machine is listed below as illustrated in figure 5.1.

• Base : It is the main body of the machine. It consist all element of machine. It works as pillar for other parts. Base is made by cast iron which can take all compressive loads
• Column : Column is attached to the base. It provides the housing for the crank slider mechanism. The slide ways are attached upper section of column which provide path for ram motion.
• Cross-rail : It consist vertical and horizontal table sideways which allow the motion of table. It is attach with some cross movement mechanism.
• Table : It is the metal body attached over the frame. Its main function is to hold the work piece and vice over it. It has two T slots which used to clamp vice and work piece over it.
• Ram : It is the main part of the shaper machine. It holds the tool and provides the reciprocating motion to it. It is made by cast iron and move over ways on column.
• Tool head : It is situated at the front of the ram. Its main function is to hold the cutting tool. The tool can be adjusted on it by some of clamps.

Fig. 4.1 Principal Parts of a Shaper

4.4  Operations performed on a shaper

• Horizontal cutting
• Cutting vertical and angular surfaces
• Irregular cutting
• Machining a thin job on a shaper
• Keyway cutting

Fig. 4.2 Shaper machine

4.5  Shaper size and specification

The shaper machine is specified by the below factors:

1. Maximum distance from table to ram
2. Size of side table top
3. Size of side table
4. Power of motor
5. Maximum vertical travel of tool slide.
6. Ram cycles per minute or strokes per minute
7. Approximate net weight
8. Floor space required

Table 4.1 – Specifications for Anoop brand (Rajkot, India) shaping machine (Model – ASM – 18”)

Shaper Machine Job

Fig. 4.3  job on shaper machine (Drawing)

ACTUAL JOB PHOTOGRAPHS