INTRODUCTION

1
 CHAPTER 1
INTRODUCTION
A Shaper is a type of machine tool that uses linear relative motion between the
work piece and a single-point cutting tool to machine a linear tool path. Its cut is
analogous to that of a lathe, except that it is linear instead of helical. The work piece
mounts on a rigid, box-shaped table in front of the machine. The height of the table
can be adjusted to suit the work piece, and the table can traverse sideways underneath
the reciprocating tool, which is mounted on the ram. Table motion may be controlled
manually, but is usually advanced by automatic feed mechanism acting on the feed
screw. The ram slides back and forth above the work. At the front end of the ram is a
vertical tool slide that may be adjusted to either side of the vertical plane along the
stroke axis. This tool-slide holds the clapper box and tool post, from which the tool
can be positioned to cut a straight, flat surface on the top of the work piece. The tool-
slide permits feeding the tool downwards to deepen a cut. The tool-slide permits
feeding the tool downwards to deepen a cut. When a load is placed on the input rod of
the scotch yoke by an actuator, sideward thrust causes the input rod and yoke arm to
bow and twist. This increases the friction on the sliding nut. At the extreme positions
of travel of the sliding nut, the bowing and twisting become severe and the yoke arm
tends to bind. Diagrammatic representation of tool feed direction is shown below,

1.1; Horizontal surface

2
 1.2; Vertical surface

1.3; Inclined surface

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,
1. Crank type
2. Geared type
3. 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.

3
 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 swivelled 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.
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 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.
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. This invention relates to improvements in machines for
building pneumatic tires
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

4
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. Tire shaping machine
invention relates to improvements in machines for building pneumatic tires. 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 neighbourhood 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. 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. 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

5
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.

6
SCOTCH YOKE MECHANISM

7
 CHAPTER 2
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.
2.1 INTERNAL COMBUSTION ENGINE USES
Under ideal engineering conditions, force is applied directly in the line of travel
of the assembly. The sinusoidal motion, co-sinusoidal velocity, and sinusoidal
acceleration (assuming constant angular velocity) result in smoother operation. The
higher percentage of time spent at top dead centre (dwell) improves theoretical engine
efficiency of constant volume combustion cycles. It allows the elimination of joints
typically served by a wrist pin, and near elimination of piston skirts and cylinder
scuffing, as side loading of piston due to sine of connecting rod angle is mitigated.
The longer the distance between the piston and the yoke, the less wear that occurs, but
greater the inertia, making such increases in the piston rod length realistically only
suitable for lower RPM (but higher torque) applications.
The Scotch yoke is not used in most internal combustion engines because of
the rapid wear of the slot in the yoke caused by sliding friction and high contact
pressures. This is mitigated by a sliding block between the crank and the slot in the
piston rod. Also, increased heat loss during combustion due to extended dwell at top
dead centre offsets any constant volume combustion improvements in real
engines.[5] In an engine application, less precent of the time is spent at bottom dead
centre when compared to a conventional piston and crankshaft mechanism, which

8
reduces blow down time for two-stroke engines. Experiments have shown that
extended dwell time does not work well with constant volume combustion Otto cycle
engines. Gains might be more apparent in Otto cycle engines using a stratified direct
injection (diesel or similar) cycle to reduce heat losses.
2.2 APPLICATIONS
This setup is most commonly used in control valve actuators in high-
pressure oil and gas pipelines.
1. Although not a common metalworking machine nowadays, crude shapers can
use Scotch yokes. Almost all those use a Whitworth linkage, which gives a
slow speed forward cutting stroke and a faster return.
2. It has been used in various internal combustion engines, such as the Bourke
engine, SyTech engine and many hot air engines and steam engines.
3. The term scotch yoke continues to be used when the slot in the yoke is shorter
than the diameter of the circle made by the crank pin. For example, the side
rods of a locomotive may have scotch yokes to permit vertical motion of
intermediate driving axles.
4. What is essentially a Scotch yoke, is used in the Tide-Predicting Machine No.
2 to generate a sinusoidal motion

9
COMPONENTS

10
 CHAPTER 3
COMPONENTS
The components used in the dual side shaper machine are
1. Frame
2. Pulley
3. Single Phase Induction Motor
4. V-Belt
5. Shaft
6. Roller Bearing
7. Shaping Tool
3.1 FRAME
A frame is often a structural system that supports other components of a
physical construction and/or steel frame that limits the construction's extent
3.2 PULLEY
A pulley is a wheel on an axle or shaft that is designed to support movement
and change of direction of a taut cable or belt, or transfer of power between the shaft
and cable or belt. In the case of a pulley supported by a frame or shell that does not
transfer power to a shaft, but is used to guide the cable or exert a force, the supporting
shell is called a block, and the pulley may be called a sheave.
A pulley may have a groove or grooves between flanges around
its circumference to locate the cable or belt. The drive element of a pulley system can
be a rope, cable, belt, or chain. The pulley as one of six simple machines used to lift
weights.[1] Pulleys are assembled to form a block and tackle in order to
provide mechanical advantage to apply large forces. Pulleys are also assembled as part
of belt and chain drives in order to transmit power from one rotating shaft to another
3.3 SINGLE PHASE INDUCTION MOTOR
An induction motor or asynchronous motor is an AC electric motor in which
the electric current in the rotor needed to produce torque is obtained
by electromagnetic induction from the magnetic field of the stator winding. An

11
induction motor can therefore be made without electrical connections to the rotor. An
induction motor's rotor can be either wound type or squirrel-cage type.
Three-phase squirrel-cage induction motors are widely used as industrial drives
because they are rugged, reliable and economical. Single-phase induction motors are
used extensively for smaller loads, such as household appliances like fans. Although
traditionally used in fixed-speed service, induction motors are increasingly being used
with variable-frequency drives (VFDs) in variable-speed service. VFDs offer
especially important energy savings opportunities for existing and prospective
induction motors in variable-torque centrifugal fan, pump and compressor load
applications. Squirrel cage induction motors are very widely used in both fixed-speed
and variable-frequency drive (VFD) applications.
3.4 V-BELT
V belts (also style V-belts, vee belts, or, less commonly, wedge rope) solved
the slippage and alignment problem. It is now the basic belt for power transmission.
They provide the best combination of traction, speed of movement, load of the
bearings, and long service life. They are generally endless, and their general cross-
section shape is roughly trapezoidal (hence the name "V"). The "V" shape of the belt
tracks in a mating groove in the pulley (or sheave), with the result that the belt cannot
slip off. The belt also tends to wedge into the groove as the load increases-the greater
the load, the greater the wedging action-improving torque transmission and making
the V-belt an effective solution, needing less width and tension than flat belts. V-belts
trump flat belts with their small center distances and high reduction ratios. The
preferred center distance is larger than the largest pulley diameter, but less than three
times the sum of both pulleys. Optimal speed range is 1,000–7,000 ft/min (300–
2,130 m/min). V-belts need larger pulleys for their thicker cross-section than flat belts.
3.5 SHAFT
A shaft is a rotating machine element, usually circular in cross section, which is
used to transmit power from one part to another, or from a machine which produces
power to a machine which absorbs power. The various members such
as pulleys and gears are mounted on it.

12
3.6 ROLLER BEARING
A rolling-element bearing, also known as a rolling bearing, is a bearing which
carries a load by placing rolling elements (such as balls or rollers) between two
bearing rings called races. The relative motion of the races causes the rolling elements
to roll with very little rolling resistance and with little sliding.
One of the earliest and best-known rolling-element bearings are sets of logs
laid on the ground with a large stone block on top. As the stone is pulled, the logs roll
along the ground with little sliding friction. As each log comes out the back, it is
moved to the front where the block then rolls on to it. It is possible to imitate such a
bearing by placing several pens or pencils on a table and placing an item on top of
them. See "bearings" for more on the historical development of bearings.
A rolling element rotary bearing uses a shaft in a much larger hole, and
cylinders called "rollers" tightly fill the space between the shaft and hole. As the shaft
turns, each roller acts as the logs in the above example. However, since the bearing is
round, the rollers never fall out from under the load.
Rolling-element bearings have the advantage of a good trade-off between cost,
size, weight, carrying capacity, durability, accuracy, friction, and so on. Other bearing
designs are often better on one specific attribute, but worse in most other attributes,
although fluid bearings can sometimes simultaneously outperform on carrying
capacity, durability, accuracy, friction, rotation rate and sometimes cost. Only plain
bearings are used as widely as rolling-element bearings.
3.7 SHAPING TOOL
A file is a tool used to remove fine amounts of material from a work piece. It is
common in woodworking, metalworking, and other similar trade and hobby tasks.
Most are hand tools, made of a case hardened steel bar of rectangular, square,
triangular, or round cross-section, with one or more surfaces cut with sharp, generally
parallel teeth. A narrow, pointed tang is common at one end, to which a handle may
be fitted.
A rasp is a form of file with distinct, individually cut teeth used for coarsely
removing large amounts of material.

13
Files have also been developed with abrasive surfaces, such as natural or
synthetic diamond grains or silicon carbide, allowing removal of material that would
dull or resist metal, such as ceramic

14
CHAPTER 4

15
 CHAPTER 4
CONSTRUCTION
Table 1; Construction details

SL. NO. PART DESCRIPTION MATERIAL DIMENSIONS

Mild steel tubes-

Frame is a rigid body that Base 450mm x
1 rectangular Cross
supports the entire mechanism. 300mm
section
Crank is a rotating part, Which
2 is either a hand driven or motor Mild steel Ø210mm
driven.
Slotted bar has a slot in which
3 the crank pin engages or slides Mild steel 185x 65x25mm
over it.
Crank pin is welded on a crank
Ø25 mm and 70mm
4 at a pitch circle diameter Mild steel
length
(PCD)of 130 mm.
Shaft is a rotating machine
element, which is Cutting tool is
a tool that is used to remove
material from the work piece by
Ø30 mm and 200
5 means of used to transmit the Steel
mm length
torque. One end of the shaft is
connected to the handle slot and
other end of the shaft is welded
to the centre of the
Connecting rod is used to
connect the slotted bar to the Ø15 mm and length
6 Mild steel
cutting tool on either sides of the 450mm
bar.

16
 Plummer block is used for
7 holding rotating shafts with help Brass Ø30 mm
of bearing and other parts.
Means of shear deformation.
Cutting tool must be stronger
than work piece. In shaper
machine the cutting tool moves
in a direction normal to the work
piece. Ex: High speed steel, High Speed
8 -
carbon steel, carbides, etc. The Steel(HSS)
cutting tool material must have
the properties such as high
hardness and strength at high
temperature, good toughness
and high tool life.

Nut is a hollow material where

9 Mild steel Ø6 mm
bolts are inserted.

Bolt is moved inside nut. It has

10 Mild steel Ø10 mm
head, shank, thread portion.

17
MACHINING TIME CALCULATION

18
 CHAPTER 5
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

19
WORKING PRINCIPLE

20
 CHAPTER 6
WORKING PRINCIPLE

6.1; Dual side shaper machine

A shaper is used to machine a single job by using a single point cutting tool and
hence it cannot be used for high production rate. This project intends to use shaper for
high production as well. A small Scotch yoke mechanisms has been thus devised to
demonstrate the dual side machining time reduction in shaping machines. This
shaping machine has an idle stroke during its return motion. This project is uses the
idle stroke as cutting stroke and hence increase the production rate. This can be
achieved by an addition of clapper box with a tool such that the arrangement on tool
such that the arrangement on tool holder has one tool clamed on the clapper box
individually. This stroke would be a rough cutting for the job compared to the forward
stroke. The motor source of power with switch accessories is used to drive the ram on
the guide plate to obtain the forward and return strokes. By this arrangement the
machining time of a work piece is reduced by the half the time when compared with
the conventional machines.
The shaping is the metal cutting machine tool designed to cut flat work piece
by a motor. Shaping is used to machining thin and soft plates. The operation of the
unit is simplified to a few simple operations involving a motor and tool head
arrangement. As shown in the figure a motor is arranged to actuate the scotch yoke
mechanisms. The tool head and the motor are arranged in the same frame. The tool
head is connected with the guide plate which leads to the cam. A guide way is

21
provided to guide the rod which is coupled with the cam. This cam is coupled with the
motor arrangement. When the motor starts to rotate the centre bolt connected with the
motor starts to move front and back. Here the rotary motion is converted into
reciprocating motion. This motion conversion leads to the operation of shaping
cutting. The work piece is held in a vice in both side of the tool to carry out the cutting
operation. The after operation done by the work blank the motor switch off releases
the clamping and shaping head to its original position.

22
ADVANTAGES

23
 CHAPTER 7
ADVANTAGES
1. Easy construction and operation.
2. Process can be operated.
3. Direct conversion of rotary motion into reciprocating motion.

24
DISADVANTAGES

25
 CHAPTER 8
DISADVANTAGES
1. Less application in real life.
2. High wearing rate due to mechanical contact.
3. Guide ways are necessary for proper reciprocating motion of arms.

26
BILL OF MATERIALS

27
 CHAPTER 9
BILL OF MATERIALS
Table 2; Bill of materials
SL.
COMPONENTS QUANTITY
NO.
1 Scotch yoke mechanism 1
2 AC motor 1
3 Cam plate 1
4 Pulley 2
5 Vice 2
6 Stand 1
7 V-belt 1

28
COST OF PROJECT

29
 CHAPTER 10
COST OF PROJECT
Table 3; Cost of project
SL.
COMPONENTS COST
NO.
1 Scotch yoke mechanism 2000
2 AC motor 1250
3 Cam plate 600
4 Pulley 350
5 Vice 950
6 Stand 875
7 V-belt 250
8 Other expenses 750
Total 7025

30
CONCLUSION

31
 CHAPTER 11
CONCLUSION
We have designed a dual side shaper with appropriate dimensions and analysed
various properties for a cutting tool (Shaper tool) using scotch yoke mechanism. We
have applied various rapid wear of the slot in the yoke caused by sliding friction and
high contact pressures. This wear can be reduced or controlled by maintaining
lubricant near yoke. Scotch yoke mechanism plays an important role in shaping,
planning, and slotting machine. This Mechanism is also used in scotch yoke engines.
This can also be used in valve actuators in high-pressure oil and gas pipelines. It has
been used in various internal combustion engines, such as the Bourke engine, SyTech
engine, and many hot air engines and steam engines. It is best suitable for machining
brittle materials like iron, copper, zinc etc.
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.

32
REFERENCES

33
 CHAPTER 12
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.

34
PHOTOGRAPHY

35
 CHAPTER 13
PHOTOGRAPHY

13.1; Photography

36