1.

Discuss the following:

a. Shaper - A shaper is a type of machine tool that uses linear relative motion
between the workpiece and a single-point cutting tool to machine a linear
toolpath. Its cut is analogous to that of a lathe, except that it is (archetypally)
linear instead of helical.
A metalworking shaper is somewhat analogous to a metalworking planer,
with the cutter riding a ram that moves relative to a stationary workpiece,
rather than the workpiece moving beneath the cutter. The ram is typically
actuated by a mechanical crank inside the column, though hydraulically
actuated shapers are increasingly used. Adding axes of motion to a shaper
can yield helical toolpaths, as also done in helical planning.

b. Value of the shaper - Shaping machines are machine tools which by way of
chip removal give workpieces the desired shape, dimension and surface
finish. They produce mainly flat surfaces, shoulders, grooves and similar
shapes.

2. What are the safety measures in operating shaper?

PERSONAL PROTECTIVE EQUIPMENT

Safety glasses must be Long and loose hair Hearing protection

worn at all times in work must be contained. must be worn.
areas.

Sturdy footwear must be Close fitting/protective Rings and jewellery

worn at all times in work clothing must be worn. must not be worn.
areas.

PRE-OPERATIONAL SAFETY CHECKS

 Locate and ensure you are familiar with all machine operations and controls.
 Ensure all guards are fitted, secure and functional. Do not operate if guards are missing or faulty.
 Check workspaces and walkways to ensure no slip/trip hazards are present.
 Ensure cutter is in good condition and securely mounted.
OPERATIONAL SAFETY CHECKS
 Keep clear of moving machine parts.
 Follow correct clamping procedures. Keep overhangs as small as possible and check work piece is secure.
 Ensure you have selected correct speed and rate.
 Ensure you have set the correct depth of cut.
ENDING OPERATIONS AND CLEANING UP
 Switch off the machine when work completed.
 Before making adjustments and measurements or before cleaning swarf accumulations, switch off and bring
the machine to a complete standstill.
 Leave the machine and work area in a safe, clean and tidy state.
POTENTIAL HAZARDS AND INJURIES
 Sharp cutters.
 Skin irritation.
 Moving machine parts.
 Eye injuries.
 Metal splinters and burrs.
 Hair/clothing getting caught in moving machine parts.

3. Give the parts of the shaper and discuss their functions

a. Base - It is the main body of the machine. It consists all element of machine. It works as pillar for other
parts. Base is made by cast iron which can take all compressive loads.

b. 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. It is attached by the rocker arm
which provide it motion in crank driven machine and if the machine is hydraulic driven it is attached
by hydraulic housing.

c. 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.

d. 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.

e. Clapper box - It carries the tool holder. The main function of clapper box is to provide clearance for tool
in return stock. It prevents the cutting edge dragging the work piece while return stock and prevent tool
wear.

f. 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.
g. Cross ways - It consist vertical and horizontal table sideways which allow the motion of table. It is
attached with some cross movement mechanism.

h. Stroke adjuster - It is attached below the table. It is used to control the stroke length which further
controls the ram movement.

i. Table supports - These are attached front side of the table and used to support the weight of table
during working.

4. Discuss how shaper tool operates

Shaper machine works on the quick return mechanism. It is used to shape the metal or make flat
surfaces, making grooves and slots. It cuts the metal in one stroke in back motion or in froth motion
and the remaining one is useless. The working of shaper machine can be described as follow.

- First the job is fixed to the machine table.

- The single point cutting tool is mounted on the tool post situated on the ram.
- Now the motor start by manually which create reciprocating motion of ram by quick return
mechanism.
- When the ram is in reciprocating motion, the tool rubs the work piece, which removes
unwanted material from it. It cuts the metal in forward stroke.
- While return strokes the clapper provide the clearance between tool and work piece, which
make sure no cutting in return stroke. If the tool cuts material in both in forward and return
stroke it give poor surface finish and also cause for tool wear.

5. Discuss the following:

• Shapers cutting tools

- Shapers are mainly classified as standard, draw-cut, horizontal, universal, vertical,
geared, crank, hydraulic, contour and traveling head, with a horizontal arrangement
most common. Vertical shapers are generally fitted with a rotary table to enable curved
surfaces to be machined (same idea as in helical planning). The vertical shaper is
essentially the same thing as a slotter (slotting machine), although technically a
distinction can be made if one defines a true vertical shaper as a machine whose slide
can be moved from the vertical. A slotter is fixed in the vertical plane

• The types of cutting tools for cutting mild steel

- Carbon tool steel, High speed steel tool (HSS), Cemented carbide, Ceramics tool,
Cubic boron nitride Tool (CBN), Diamond tool.

• The shaper cutting tool specification

- 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.
6. Discuss the following

• Shaper tool holders

- The tool holder and high-speed-steel bit have largely superseded the forged tool
for shaper work. The tool bit may be ground to the shape required to accomplish
the desired result for practically any operation. shows a patented tool holder
(Armstrong) which, in the smaller size, is used for shaper work and, in the larger
size, is very efficient for use in the planer. The construction of this tool holder
permits the tool bit to be securely and rigidly held in any one of the five positions
shown in b, so that horizontal, vertical, or angular cuts, either right-hand or left-
hand, may be made. Another advantage of this tool holder lies in the fact that for
heavy cuts the tool holder may be reversed in the tool post (and, of course, the
tool bit is also reversed, Since the cutting edge is then back of the shank of the
tool, the tendency of the tool to chatter or to " dig in any case the tool bit should
not be allowed to project too far as these will result in unnecessary spring . Other
types of tool holders are used in

• Speed and Feeds

- The cutting speed of a shaper is the speed at which the metal is removed by the
cutting tool in one minute. In other words, only the forward cutting stroke is
considered. The speed is expressed in metre per minute.
Feed is the relative movement of the work or tool in a direction perpendicular to
the axis of reciprocation of the ram per double stroke. It is expressed in mm per
stroke.

• Cutting speed calculations

7. Discuss the following:

• How to hold the work

- Any device that is used to a secure a workpiece against the forces of machining.
The most basic work holding device is a simple clamp, but work holding can also
involve complex fixtures that are custom-built for particular parts. Other common
work holding devices include vises and chucks, as well as indexers or rotary tables
that are able to change the part’s position while it is held, so the machine can
reach various features. In most machining applications, work holding also locates
the part.

• The devices for holding a work

- Vise (locking plier) is the most common and simple work holding device used in a
shaper. Different types of vises are used in a shaping machine according to the
need and they are Plain vise, Swivel vise and Universal vise.
- Clamps and Stop Pins. T – bolts are fitted into the T – slots of the table. The work
is placed on the table the work is supported by a rectangular strip at one end and
by a stop pin at the other side. The screw is tightened to secure the work properly
on the machine table.
- T-bolts, Clamp and Step Blocks. The step blocks are used in combination with T-
bolts and clamps to hold the work directly on the machine table. T-bolts are fitted
in the T-slots of the machine table. One side of the clamp holds the work and the
other side rests on a step of the step block. The different steps of the block are
useful in levelling the clamp when holding works of different heights. A nut on the
top of the clamp holds the work rigidly.
- Angle plate resembles the English alphabet ‘L’. It is accurately machined to have
two sides at right angles. Slots are provided on both the sides. One of the sides is
bolted to the machine table and the workpieces are held on the other side.
- V – block is a metal block having a ‘V’ shaped groove on it. It is used for holding
cylindrical workpieces. Operations like keyway cutting, slot cutting and machining
flat surfaces can be performed on the cylindrical workpieces held on a ‘V’ block.
- Special Fixtures. When internal keyways are to be machined on the holes, the
work is held with a special fixture. The fixture has a V-block attached to it and the
cylindrical work is mounted on it.

8. Discuss the following:

• How to test the work seat

- The work may be held in a vise without additional tools when it is large enough so
that the stock to be removed is above the vise jaws. Thin stock may be raised to a
convenient height in the vise by placing a pair of parallels under the work. A round
bar of soft metal (for a steel wedge) is found to be helpful in preventing wide
pieces of material from being forced out of the vise. Use of a cylinder of soft metal
to provide line contact on the edge of work. This prevents the movable jaw from
providing a lifting movement to the work as the screw is tightened. As the work is
 tightened, it is tapped onto the parallels with a Babbitt hammer and the free jaw
of vise takes some play. After tightening, the parallels are checked so see that
they are firmly in contact with the bottom of the workpiece.

• How to shape rectangular work or similar piece square and parallel

- Checking Jaw of Vise being Square with the Stroke of the Ram: For this purpose,
first fasten the vise securely to the table with the solid jaw towards the ram. Place
an indicator in the tool holder so that the point of the indicator touches the
finished surface. Note the movement of the indicator as the vise is moved
perpendicular to direction of stroke with the aid of the cross-feed.
- Checking Jaw of Vise for being Parallel with the Stroke of the Ram: For checking
that the solid jaw of the vise is parallel with the stroke of the ram, fasten the vise
securely to the table with the edge of the solid jaw parallel to the ram. Place an
indicator in the tool holder with the point of the indicator touching the finished
surface of the jaw

• How to shape slots, keyways, etc.

- To cut a key way in a bore the following “stuff” is required.

- 1 well lubed shaper with a long enough stroke to cut the key way + ¾”, and a way
of stopping the clapper from clapping. (If you read one of my replies to the “Alba
1A post”, the “allen head cap screw”, or set screws).
- 1 shaper vise or large angle plate to hold the work
- 1 key seat bar that will fit in the bore with the finishing cutter installed
- 1 of each, ¼”wide roughing cutter and finishing key way cutter of the required key
size
- 1 machinist square at least a 12” blade, 18” to 24” preferred
- 1 small machinist square 4”
- 1 flash light (torch) as the Brit’s say
- 1 can of cutting lubricant and a
- 1” brush (we used an old soup can) 1 only 6” scale
- 1 can of layout blueing
- 1 scriber 1 only 6” half round smooth file 1 piece of key stock of the required size
1 HSS tool bit ½ of the width of the key to be cut
- 1 lead or brass hammer (dead blow)
- 1 set of matched parallels
- 1 work bench to put all this stuff on, shapers, are for cutting metal, not storing
tooling
- The key seat bars are shop made to suit the shaper being used. They are made up
as follows: The bar is just like a normal boring bar from a lathe, with a ½”square
hole through the end at 90°, but modified to attach to the tool post hole in the
clapper. Bars are made of 1045 or 4140 steel, on one end a square hole is cut into
the bar to hold the key way cutter bit. In this end of the bar, two set screws hold
the bit in place one small set screw on the side to push the bit to the side of the
square hole, and a larger set screw in the end of the bar to securely hold the bit in
place. On the smaller bars you may only have room for the one large set screw on
the end . The square hole for the cutter must be straight (up and down) through
the bar, and the square hole is set square on the bar, what is meant here is, when
the cutter is placed in the bar, it is not cocked to the axis of the bar, the cutter's
corner cutting edges must enter the bore at the same time, if only one cutting
edge contacts the work the bar will be pushed to one side of the bore, you will
have cut a tipped key way (angled from the bore). This square slot can be done
various ways, first, in the shaper using a vise with a V block, in a lathe using a
simple milling attachment, in a miller using a staggered tooth saw, you cut a
double depth slot then place a piece of square carbon in the slot , then a piece of
key stock “V’d for welding or brazing to the end of the bar, or the “easiest
method”, in a drill press, Drill and ream a hole then use a store bought “square
hole tool bit sleeve” pressed in, then checked for square, adjusted by inserting a
piece of key stock held in a vise, until square hole is aligned as above then drill and
tap for set screws.( Dam, another secret exposed) see pic below. Oh yes these
sleeves allow you to build custom boring bars for your lathe as well as portable
boring bars for field machining.