Shaper

What is Shaper?
The shaper is a machine tool used for:
​ Producing flat or plane surfaces which may be in a horizontal, a vertical or an angular
plane.
​ Making slots, grooves and keyways.
​ Producing contour of concave/convex or a combination of these.

Construction and Parts of Shaper

1. Clapper Box

●​ Function: The clapper box holds the cutting tool and allows it to lift slightly during the
return stroke of the ram. This prevents the cutting tool from dragging on the workpiece,
which would cause unnecessary wear and friction.​

●​ Analogy: Imagine a sliding door that lifts a little as it moves, ensuring it doesn’t scrape
the surface as it goes back.​

2. Tool

●​ Function: The tool is the cutting element that removes material from the workpiece. It is
held in the tool slide and can be adjusted to various angles depending on the operation.​

●​ Analogy: Think of this as the saw blade in a hand saw, which does the actual cutting.​

3. Tool Post

●​ Function: The tool post holds the cutting tool in place securely during the operation. It
is mounted on the ram and can be adjusted to set the position of the tool.​

●​ Analogy: Like the clamp that holds a tool or piece of material steady on a workbench.​
4. Ram Adjustment Nut

●​ Function: The ram adjustment nut is used to adjust the ram's position or its
movement during the shaping process. This allows for fine control of the cutting tool's
motion.​

●​ Analogy: It's similar to adjusting the tension or alignment on a machine, like tightening
or loosening a screw.​

5. Ram

●​ Function: The ram is the main moving part of the shaper. It holds the cutting tool and
moves it in a back-and-forth (reciprocating) motion to cut the workpiece. The ram is
powered by the drive mechanism and is responsible for advancing and retracting the
tool.​

●​ Analogy: The saw blade that moves back and forth, doing the cutting.​

6. Ram Locking Handle

●​ Function: The ram locking handle is used to lock the ram in place or to control its
movement. It ensures the ram does not move unintentionally during setup.​

●​ Analogy: Like the lock on a door that holds it in place until you’re ready to open it.​

7. Column

●​ Function: The column provides vertical support to the entire machine. It holds the ram,
tool slide, and other components steady.​

●​ Analogy: Think of this as the frame or structure of a house, which supports the rest of
the building.​
8. Cross Feed

●​ Function: The cross feed mechanism moves the table horizontally, allowing the
workpiece to be fed into the cutting tool after each stroke.​

●​ Analogy: Like the sliding surface of a table that lets it move forward during a cutting
operation.​

9. Cross Rail

●​ Function: The cross rail holds the table and cross feed mechanism and allows them
to be adjusted in height, providing flexibility for different workpiece sizes.​

●​ Analogy: Similar to a movable shelf on a bookshelf that adjusts its height for different
items.​

10. Vertical Feed

●​ Function: The vertical feed mechanism moves the table vertically, allowing for deeper
cuts in the workpiece or fine-tuning the position of the workpiece relative to the tool.​

●​ Analogy: Think of this as adjusting the height of a workbench to make the material
reach the proper level for cutting.​

11. Driving Pulley

●​ Function: The driving pulley transmits power from the motor to the drive mechanism,
which moves the ram back and forth, thus powering the shaper’s cutting motion.​

●​ Analogy: Like the pulley system that moves a conveyor belt or any mechanical system
that transfers power.​
12. Base

●​ Function: The base is the foundation of the shaper, providing support and stability for
the entire machine. It helps to absorb vibrations during cutting.​

●​ Analogy: The foundation of a building or structure, ensuring everything else is

supported and level.​

13. Table

●​ Function: The table is where the workpiece is placed. It is mounted on the cross feed
mechanism and moves in the horizontal (side to side) and vertical directions,
depending on the type of work being done. The workpiece is clamped to the table for
stability during the shaping process.​

●​ Analogy: The workbench where the material is held while you cut or shape it.

14. Vice

●​ Function: The vice is a clamping tool used to securely hold the workpiece in place on
the shaper's table during the cutting process.​

●​ Location: It is mounted on the table of the shaper, typically positioned near the work
area.
Working Principle of a Mechanical Shaper
The working principle of a mechanical shaper is based on the reciprocating motion of the
cutting tool. The tool moves back and forth across the workpiece, with the cutting action
occurring during the forward stroke. The return stroke of the tool doesn’t perform cutting but is
used to reposition the tool for the next stroke. Let’s break down the process step by step:

Step 1: Power Source

●​ The shaper is powered by an electric motor, which drives a crank mechanism.​

●​ This motor converts electrical energy into mechanical energy, which powers the
machine to move the ram (the part that holds the cutting tool).​

Step 2: Ram and Cutting Tool Movement

 ●​ The main component of the shaper is the ram, which holds the cutting tool. The ram
moves in a reciprocating motion (back-and-forth motion) across the workpiece.​

●​ The cutting tool is mounted on the ram and it removes material from the workpiece
during the forward stroke (cutting stroke).​

Analogy: Think of it as using a saw. The forward motion of the saw is used to cut the material,
while the backward motion of the saw doesn’t cut, it just prepares the tool for the next stroke.

Step 3: Cutting Stroke (Forward Stroke)

●​ During the cutting stroke (the forward stroke), the cutting tool is engaged with the
workpiece. The tool is pressed against the material and removes a small amount of
material with each stroke.​

●​ The depth of cut and the feed rate are controlled by the mechanical feed mechanism
(which moves the workpiece slowly into the tool).​

Analogy: It’s like cutting a piece of wood with a hand saw. Each time you push the saw
forward, you remove a little bit of wood.

Step 4: Return Stroke (Non-Cutting Stroke)

●​ After the cutting stroke, the ram moves in the opposite direction (return stroke) and
pulls the tool back to its original position.​

●​ During the return stroke, the tool is not cutting the workpiece. It is lifted slightly using
the clapper box to avoid dragging across the surface.​

Analogy: This is like the pulling motion of the saw when you pull it back, but it’s not cutting
anything during this motion.

Step 5: Feeding the Workpiece

●​ After each cutting stroke, the workpiece is fed into the tool by a mechanical feed
mechanism. This means the workpiece is moved slightly forward after each stroke to
 ensure that the tool keeps cutting the next section of the material.​

●​ The amount the workpiece moves forward after each stroke is called the feed. The feed
rate is controlled by the feed gearbox.​

Analogy: Imagine you are cutting a long piece of wood. After each cut, you push the wood a
little further towards the saw to ensure continuous cutting.

Step 6: Repeating the Process

●​ The process repeats: the tool moves forward to cut, moves back to the starting point,
and the workpiece is fed forward slightly after each stroke.​

●​ This process continues until the desired shape or surface is obtained.​

Step 7: Final Adjustment

●​ Final adjustments can be made using the tool post (which holds the cutting tool) or the
feed mechanism to ensure that the tool cuts at the correct depth and the workpiece is
fed at the right rate.

Working of the Mechanical Shaper (Overview):

1.​ The motor drives the system.​

2.​ The crank mechanism converts rotational motion into reciprocating motion.​

3.​ The ram moves the cutting tool in a back-and-forth motion (reciprocating motion).​

4.​ During the cutting stroke, the tool removes material from the workpiece.​

5.​ The return stroke occurs without cutting, allowing the tool to move back to its starting
point.​

6.​ The workpiece is fed forward after each cutting stroke to ensure continuous cutting.​
 7.​ The process repeats until the required shape is achieved.​
​

Crank And Slotted Link Mechanism

●​ Ram (2): Holds the cutting tool and moves it back and forth (reciprocating motion) across
the workpiece.​

●​ Clamping Lever (4): Secures the ram in place or adjusts its position during the operation.​

●​ Screwed Shaft (3): Used to fine-tune the position of the ram through the clamping lever.​

●​ Handwheel for Position of Stroke Adjustment (5): Allows manual adjustment of the stroke
length of the ram.​

●​ Bevel Gear (6, 7): Transmits rotary motion from the driving system to the crank and
slotted link mechanism.​

●​ Driving Pinion (P): Transfers power from the motor to the bevel gears to drive the
system.​

●​ Ram Block (8): Houses and supports the cutting tool during the reciprocating motion.​

●​ Slotted Link (9): Converts the rotary motion of the crank into the reciprocating motion of
the ram.​

●​ Crank Pin (11): Connects the crank to the slotted link, enabling the transfer of rotary
motion to linear motion.​

●​ Sliding Block (12): Provides stability to the crank and slotted link for smooth movement.​

●​ Lead Screw (13): Moves the workpiece into the tool after each stroke.​

●​ Rocker and Pivot (15): Allows adjustment of the cutting tool’s angle or position for
different cutting operations.​

●​ Crank (16): Converts rotary motion from the motor into reciprocating motion for the ram.
1.​ Motor Rotation (Input Power):​

○​ The mechanism is powered by an electric motor, which provides rotary motion.​

○​ The motor’s power is transferred through a drive mechanism (such as gears or

pulleys) to the crank.​

2.​ Crank Rotation:​

○​ The crank rotates around a fixed axis, continuously powered by the motor.

3.​ Slotted Link Movement:​

 ○​ The crank is connected to a slotted link. The slotted link has a slot through
which a pin moves.​

○​ As the crank rotates, it moves the slotted link in a controlled manner.

4.​ Transfer of Motion to the Ram:​

○​ The other end of the slotted link is connected to the ram (the part that holds the
cutting tool).​

○​ As the slotted link moves, it causes the ram to move in a reciprocating motion
(back-and-forth), which is necessary for cutting the workpiece.

5.​ Forward Stroke (Cutting Stroke):​

○​ During the forward stroke, the cutting tool (held by the ram) engages the
workpiece, and material is removed.​

○​ The cutting stroke is where the tool performs the actual cutting operation.

6.​ Return Stroke (Non-Cutting Stroke):​

○​ After the forward stroke, the ram moves in the opposite direction (the return
stroke). The cutting tool is slightly lifted using a clapper box to avoid dragging
across the workpiece during this stroke.​

○​ The return stroke doesn’t cut, but it sets the tool up for the next cutting stroke.

7.​ Feeding the Workpiece:​

○​ After each cutting stroke, the workpiece is fed into the tool by a feed
mechanism. This ensures that the cutting tool keeps cutting the material at the
proper position.​

○​ The feed is controlled by a gearbox or mechanical feed system that determines

how far the workpiece moves after each stroke.
Automatic Feed Mechanism
https://www.youtube.com/watch?v=RSBwIuAIEoM

Parts of the Pawl and Ratchet Mechanism:

1.​ Pawl:

Function: The pawl is a spring-loaded lever that engages with the teeth of the ratchet
wheel. It ensures that the ratchet wheel rotates in only one direction (during the feed
stroke) and prevents it from moving backward.​

2.​ Ratchet Wheel:​

​
The ratchet wheel has teeth around its circumference, which the pawl engages with.
The wheel rotates incrementally by one step after each engagement by the pawl, moving
the workpiece forward.​

3.​ Spring:​
​
The spring keeps the pawl in contact with the teeth of the ratchet wheel. It ensures the
pawl engages properly and maintains the mechanism's function.​
​
 4.​ Cross Feed Screw:​
​
The cross feed screw helps move the workpiece into position after each cutting
stroke. It works in conjunction with the ratchet wheel to ensure that the workpiece
advances correctly.​
​

5.​ Ratchet Arm:​

The ratchet arm supports the ratchet wheel and holds it in place. It helps in rotating the
wheel incrementally after each feed stroke.​

6.​ Slotted Disc:​

​
The slotted disc guides the motion of the pawl and ensures it engages with the ratchet
wheel at the correct position.​

7.​ T-Slot:​
​
The T-slot holds the pawl in position and allows it to move in a controlled manner as it
engages with the ratchet wheel.​

8.​ Crank Pin:​

​
The crank pin is part of the mechanism that drives the whole system. It is connected to
the crank, which rotates to provide the motion needed for the entire mechanism.​

9.​ Connecting Rod:​

○​ Function: The connecting rod transmits the rotary motion from the crank pin to
the ratchet wheel. It connects the rotating crank to the rest of the feed
mechanism.​

○​ Analogy: Similar to how a linkage in a car engine connects various moving

parts together.

Working Principle of the Pawl and Ratchet Mechanism:

The Pawl and Ratchet mechanism works by allowing step-by-step forward motion of the
workpiece. Here’s how it works:

1.​ Crank Motion:​

 ○​ The motor powers the crank. As the crank rotates, the crank pin rotates,
transmitting the motion to the connecting rod.​

2.​ Ratchet Wheel Rotation:​

○​ The connecting rod drives the ratchet wheel. As the crank pin moves, it turns
the ratchet wheel a small increment (one tooth at a time).​

○​ The pawl is spring-loaded and engages with the teeth of the ratchet wheel,
allowing it to rotate in only one direction (forward).​

3.​ Feed Motion:​

○​ As the ratchet wheel turns, it advances the workpiece by a small, controlled

amount.​

○​ After each cut is made by the tool, the workpiece is moved forward into position
for the next cut, ensuring precise and consistent feed.​

4.​ Non-Return Action:​

○​ The pawl prevents the ratchet wheel from turning backward, so the workpiece
only moves forward and not backward.​

5.​ Repeat Process:​

○​ The entire mechanism works cyclically, with the ratchet wheel advancing
incrementally after each stroke, until the cutting process is complete.

Types of Shaping Operations:

1.​ Flat Surface Shaping​

○​ Function: Used to create flat surfaces on the workpiece.​

○​ Process: The cutting tool is moved in a straight line, removing material from the
workpiece to form a flat surface.​

○​ Use: It is the most common type of shaping operation, used to smooth and finish
surfaces for various types of machines or components.​

○​ Example: Creating a flat face on a metal block.

2.​ Groove Shaping (Grooving or Slotting)​

○​ Function: Used to cut grooves or slots into a workpiece.​

○​ Process: A narrow cutting tool moves in and out of the material, making a groove
of the desired width.​

○​ Use: This is typically used to create keyways, slots for bolts, or other narrow
indentations in a workpiece.​

3.​ Contour Shaping (Curved Surface Cutting)​

○​ Function: This operation is used to produce curved profiles or complex shapes on

a workpiece.​

○​ Process: The cutting tool moves along a curved path to shape the material into a
specific profile.​

○​ Use: It is used to make non-linear shapes like radius cuts, fillets, or complex
patterns.​

○​ Example: Creating curved surfaces on components such as gears or cam

profiles.

4.​ Edge Shaping (Edge Cutting)​

○​ Function: This operation is used to cut edges or profiles of the workpiece.​

○​ Process: The tool cuts along the edge of the workpiece, often for finishing
operations or creating precise features like chamfers or bevels.​

○​ Use: Often used to create angled edges, chamfered edges, or radius edges on
machine parts.​

○​ Example: Creating a beveled edge on a metal plate or finishing the edge of a

gear.
 5.​ Stroke Length Adjustment​

○​ Function: The stroke length refers to how far the tool moves during each pass. It
determines the depth of cut and the feed rate.​

○​ Process: The length of the stroke is adjusted based on the material being shaped
and the type of operation.​

○​ Use: Shorter strokes are typically used for finer finishes or precise cuts, while
longer strokes are used for heavier cuts.​

○​ Example: Adjusting the stroke to remove a deeper cut during a flat surface
shaping operation.

1. Cutting Speed (v_c):

The cutting speed is the speed at which the cutting tool moves through the material during the
forward stroke.

2. Feed Rate (f):

The feed rate is the distance the workpiece moves into the cutting tool for each stroke.​

3. Machining Time (T):

The total time required to complete the cutting operation is given by:
4. Material Removal Rate (MRR):

The volume of material removed per unit of time is:

5. Cutting Force (F):

The force required to remove the material during cutting is given by:

●​ A = Cross-sectional area of the cut (mm²)​

The area of the cut AAA is given by:

6. Power Consumption (P):

The power required for the cutting operation is:

7. Power Limitations and Cutting Force (for Optimizing Depth of Cut):

To ensure the machine’s power is not exceeded, the maximum allowable cutting force can be
derived from the machine’s power.