Shaper: Al Qadissiya University College of Engineering Mechanical Department
Shaper: Al Qadissiya University College of Engineering Mechanical Department
Shaper: Al Qadissiya University College of Engineering Mechanical Department
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. 23.1. 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. The principal of shaping operation is shown in Fig. 23.2 (a, b).
Modern shapers can also generate contoured surface as shown in Fig. 23.3. A shaper is
used to generate flat (plane) surfaces by means of a single point cutting tool similar to a
lathe tool.
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AL QADISSIYA UNIVERSITY COLLEGE OF ENGINEERING MECHANICAL DEPARTMENT
Lecturer : Amar AL-Baaji Manufacturing processes II Lecture no.:
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 cutting action and functioning of clapper box is shown in Fig.23.4
during forward and return stroke.
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AL QADISSIYA UNIVERSITY COLLEGE OF ENGINEERING MECHANICAL DEPARTMENT
Lecturer : Amar AL-Baaji Manufacturing processes II Lecture no.:
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cutting speed and force of the ram drive are constant from the very beginning to the end
of the cut.
4- 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.
PRINCIPAL PARTS OF SHAPER
Some of important parts are discussed as under.
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.
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 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. A horizontal
cross feed screw is fitted within the cross rail and parallel to the top guide ways of the
cross rail. This screw actuates the table to move in a crosswise direction.
Saddle :The saddle is located on the cross rail and holds the table on its top. Crosswise
movement of the saddle by rotation the cross feed screw by hand or power causes the
table to move sideways.
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.
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AL QADISSIYA UNIVERSITY COLLEGE OF ENGINEERING MECHANICAL DEPARTMENT
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Ram :It is the reciprocating part of the shaper, which reciprocates on the guide ways
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.
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. In a standard shaper metal is
removed in the forward cutting stroke, while the return stroke goes idle and no metal is
removed during this period as shown in Fig. 23.4. 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
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Lecturer : Amar AL-Baaji Manufacturing processes II Lecture no.:
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Fig. 23.7 Machining horizontal Fig. 23.8 Machining vertical Fig. 23.9 Machining angular
vertical surface on shaper surface on shaper surface on shaper
Fig. 23.10 Slot cutting Fig. 23.11 Keyway cutting Fig. 23.12 Machining irregular on
shaper on shaper surface on shaper
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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. In addition to
machining large work, the planer is frequently used to machine multiple small parts held
in line on the platen. 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. Tool heads are mounted on a horizontal cross rail that can be moved up and
down. Cutting is achieved by applying the linear primary motion to the workpiece
(motion X) and feeding the tool at right angles to this motion (motion Y and Z). The
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AL QADISSIYA UNIVERSITY COLLEGE OF ENGINEERING MECHANICAL DEPARTMENT
Lecturer : Amar AL-Baaji Manufacturing processes II Lecture no.:
primary motion of the worktable is normally accomplished by a rack and pinion drive
using a variable speed motor.
As with the shaper, the tool posts are mounted on clapper boxes to prevent interference
between the tools and work-piece on the return stroke and the feed motion is intermittent.
The size of a standard planer is specified by the size of the largest solid that can
reciprocate under the tool. In addition to this, some other parameters such as table size
(length and width), type of drive, number of speeds and feeds available, power input,
weight of the machine, floor space required etc. may be required to specify a planer
completely.
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
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Shaper Planer
1-The work is held stationary and the 1-In a planer, the tool is stationary and the
cutting tool on the ram is moved back and
workpiece travels back and forth under the
forth across the work.
tool.
2- It is used for shaping much smaller jobs.
2- A planer is meant for much larger jobs
than can be undertaken on a shaper. Jobs
as large as 6 metre wide and twice as
long can be machined on a planer.
3- A shaper is a light machine.
3- It is a heavy duty machine.
4- Shaper can employ light cuts and finer 4- Planer can employ heavier cuts and
feed coarse feed,
5- A shaper uses one cutting tool at a time 5- Several tools can cut simultaneously on
6- The shaper is driven using quick- return a planer
link mechanism . 6- The drive on the planer table is either by
7- It is less rigid and less robust. gears or by hydraulic means.
.
7- Because of better rigidity of planer, as
compared to that of a shaper, planer can
give more accuracy on machined surfaces
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3. Pit planer
4. Edge or plate type planer
5. Divided table planer
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