SHAPER

SHAPER
Objectives: To produce a square pin head from a round head using a shaper machine,
ensuring precise dimensions and a smooth surface finish.
Introduction:
A shaper is a machine tool that uses linear motion between a single-point cutting tool and the
workpiece to machine flat surfaces, grooves, angles, and other shapes. Commonly used in
tool rooms or for prototype work, it requires simple tooling and minimal operator attention
during cutting. The primary function of a shaper is to create flat surfaces through the linear
movement of the tool and the workpiece. Horizontal shapers are the most common type,
featuring key components for efficient operation.
Horizontal Shaper Machine

Parts of Shaper:
Base: A robust cast iron structure that supports the column and all working parts like the ram,
work-table, and drive mechanism.
Column: A ribbed, cellular casting containing the crank and slotted link mechanism, driving
motor, speed gearbox, and controls. Provides slideways for the ram and table.
Ram: Slides back and forth on the column's top to power the cutter. Its stroke length and
position are adjustable.
Tool Head: Holds and positions the cutting tool for angular and vertical cuts with adjustable
swivel and hand feed mechanisms.
Clapper Box: Prevents the cutting tool from digging into the work during the return stroke
via a hinged design.
Cross Rail: A heavy casting on the column's front that holds horizontal slideways for the
table and adjusts for workpiece thickness.
Table: Cast iron with T-slots to secure workpieces, offering adjustable movement for feeding
work under the cutter.
Saddle: Manually adjusts the depth of cut along the Y-axis, with fine adjustment via the tool
head's hand crank.
Tool Holders: Larger than lathe holders, designed for flat surfaces with smaller rake and
clearance angles.
Work Holding: Workpieces are secured using a specialized shaper vice or directly clamped
onto the table.
Quick Return Mechanism
This is the most common type of shaper in which a single point cutting tool is given a
reciprocating equal to the length of the stroke desired while the work is clamped in position
on an adjustable table. In construction, the crank shaper employs a crank mechanism to
change circular motion of a large gear called “bull gear” incorporated in the machine to
reciprocating motion of the ram. The bull gear receives power either from an individual
motor or from an overhead line shaft if it is a belt driven shaper. The shaping machine is used
to machine flat metal surfaces. The reciprocating motion of the mechanism inside the shaping
machine can be seen in the diagram. As the disc rotates the top of the machine moves
forwards and backwards, pushing a cutting tool. The cutting tool removes the metal from
work which is carefully bolted down.
Quick return mechanism for shaper

Shaper Specifications:
• Length of Stroke
• Maximum Horizontal Travel of Table
• Maximum Vertical Travel of Table
• Maximum distance from Table to Ram
• Maximum Vertical Travel of Tool Slide
• Length &Width of Table Top
• Length &Depth of Table Side
• Power of Motor
Operations on Shaper
Machining Vertical Surface:

The tool is fed downward in vertical cutting so swivel the clapper box from the face of the
work to be cut. The tool is fed downwards by rotating the down feed screw by hand at the end
of return stroke. On the return stroke the tool swings away from the work and gives
clearance, which prevents the work from being scratched. Start cutting from highest
point towards the bottom.
Machining Horizontal Surface:

Set the vice jaws length perpendicular to the ram movement. Hold the job length- wise
parallel to the tool stroke so that maximum stroke of the tool may be utilized. Hold the
appropriate tool in tool head. Set the proper inclination of the tool and depth of cut. Give
cross feed to the tool initially by hand till the cut start and then employ power feed.
Machining Angular Surfaces:

Set the swivel head to the required angel for shaping angular faces. The clapper box is to be
swung away from the face to be machined. The tool is to be fed by the slide hand wheel. The
apron top is also swivelled in the direction away from the surface to be machined. Feed the
tool during return stroke. Repeat the procedure to finish the work.
Some unusual work such as slotting operation, pocketing, T-Slot Cutting, Vee - Block
Cutting, Grooving, Spur Gear cutting using straight tooth, etc, can also be done, if needed, by
developing and using special attachments.
Slotting operation Pocketing operation T-Slot cutting
Vee-block Cutting Groove Cutting Spur Gear
Procedure:
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Precautions:
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Conclusions:

SHAPER

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SHAPER

Horizontal Shaper Machine

Quick return mechanism for shaper

Machining Vertical Surface:

Machining Horizontal Surface:

Machining Angular Surfaces:

Slotting operation Pocketing operation T-Slot cutting

Vee-block Cutting Groove Cutting Spur Gear

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