Presentation by ANAS AHMAD ME1 B1 batch 1214340024 Submited to TOPIC SHAPER MACHINE Submited to PRO. DEEPAK SHARMA IMSEC mechanical department

overview In this presentation we are going to discuss the one important mechanical machines , i.e. , shaper machine

SHAPER Shaper is Machine tool which produces flat surfaces in horizontal, vertical or inclined planes depending upon the orientation of the cutting tool. Features: Single point cutting tool is used for machining. Tool is clamped in the tool post mounted on the ram of the machine. The ram reciprocates to and fro, tool cuts the material in the forward stroke, No cutting during return stroke. Job is held rigidly in a vice

PRINCIPLE HORIZONTAL SHAPER – PARTS AND SKETCH SHAPER MECHANISMS OPERTIONS DONE ON SHAPER CLASSIFICATION OF SHAPER SPECIFICATIONS OF SHAPER MACHINING TIME CALCULATIONS

HORIZONTAL SHAPER

VERTICAL SHAPER

HYDRAULIC SHAPER

MAIN PARTS OF CRANK SHAPER

PRINCIPAL PARTS OF SHAPER Base Column Table Cross Rail Ram Tool Head

Forward stroke is the cutting stroke Forward stroke is the cutting stroke. Return stroke the tool does not cut, Double stroke= cutting stroke + return stroke Stroke starts slightly before the work piece (a) and ends after the work piece (b) Total stroke length = l+a+b

Operations done using a shaper Machining Horizontal Surfaces • Machining Vertical Surfaces • Machining Angular Surfaces • Cutting Slots, Grooves & Key ways • Machining irregular surfaces • Machining Splines / Cutting Gears

Main parts of a shaping machine 1. BASE 5. CROSS RAIL 2. COLUMN 6. SADDLE 3. RAM 7. TOOL HEAD 4. TABLE 8. CLAPPER BOX

PARTS OF SHAPER BASE made of cast iron. Provides support for other parts of machine. COLUMN- box type casting mounted vertically on top of base. It has 2 guide ways. One vertical guideway in the front over which a cross slide moves up and down. 2nd horizontal guide ways on top over which ram reciprocate. The reciprocating mechanism is housed inside the column

PARTS OF SHAPER CROSS RAIL IT IS MOUNTED ON THE F RONT VERTICAL GUIDE WAYS. THE TABLE CAN BE LOWERED OR RAISED BY ADJUSTING THE CROSS RAIL TABLE- mounted on a saddle which is located above the cross rail. Top and and sides are accurately machined and have T slots. RAM- supports tool head on its front. It reciprocates on accurately machined guideways on top of column

Contind…. TOOL HEAD fitted on the face of ram. Holds the tool rigidly. Provide vertical and angular feeds for the tool Tool head can be positioned at any angle

Classification of shapers 1 Position of ram travel • Horizontal Shaper- Ram holding the cutting tool moves In horizontal plane • Vertical Shaper-The cutting tool moves in vertical plane • Traveling head Shaper-Cutting tool reciprocates & moves cross wise simultaneously

3 Acc. to Driving Mechanism: a) Crank type - Driving mechanism is by crank & gear b) Geared type - Driven by Rack & Pinion mechanism c) Hydraulic Shaper - Driven by oil pressure developed by a pump, which is run by an electric motor

Acc. to the Table Design : a) Standard shaper- Work Table can be moved 1.Vertically & 2. Horizontally b) Universal Shaper- Table can be moved 1. Horizontally 2. Vertically 3. Swivelled & 4. Tilted This is mostly used in Tool Rooms

Acc. to Cutting Stroke action a) Push Type Shaper- Standard Shaper. • Metal is removed when the ram moves away from column • Most common type used in practice • Unless otherwise specified, the term shaper refers to Push type Shaper b) Draw Type Shaper • Metal is removed when the tool is drawn towards the column • Allows heavier cuts to be made • Less vibration during cutting

Specifications of Shaping Machine • Max.length of Stroke of Ram • Type of Drive • Power input • Floor Space required • Weight of the Machine • Cutting to Return Stroke ratio • Feed

Machining of horizontal surface The work surface is held securely on the table and tool is fixed in the tool head with minimum overhang, as shown in figure. The table with fixed work piece is raised close to the tool; the length and position of the stroke are adjusted. The stroke length is about 20mm longer than the work and stroke is adjusted such that the tool starts about 10-15 mm before work piece and continues about 10 mm after the end of cut.

Contind.. Work piece is mounted on the table and the surface to be machined is set parallel to stroke axis. A side cutting tool is fitted in the tool head as shown in figure. The length of stroke is adjusted as described in section 5.1. The cutting feed is given by rotating the down feed screw by hand (0.25 -0.50 mm

mechanism

Advantages It provide economical and simple tooling. A shaper is easy to set up and can be used on any flat or angular surface

Disadvantages Due to simple point tooling shaper is not suited for production work The amount of metal removed with one tool is insignificant as compared to other machining methods

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