Shaper Machine

 1.1 Introduction:

A shaper is a standard machine tool that can machining smooth, flat, or partially rounded surfaces. A shaper tool cuts the material in a back-and-forth motion, the tool cuts in its forward direction while the work piece is in the tank of the work table. The work table is fixed at the top. The work table slides vertically after each stroke of the tool. It can shape work pieces up to 600 mm in length. This is not a production machine for repair work or small machines. Slides can be cut.

1.2 Types of shapers:

 There are two types of sapper machines

i.                    Horizontal shaper

ii.                  Vertical shaper

              i. Horizontal Shaper:

The tool of this shaper cuts in the horizontal plane in its forward stroke.

a. Mechanical shaper:

                Its complete working system consists of mechanical parts, gears and levers. Especially the stroke is produced by the ram stroke, the details of which will be read later.

b. Hydraulic Shaper:

                    A modern type of shaper. In which the reciprocating movement of the ram is done by a hydraulic piston and cylinder. A valve controls the flow of oil in and out of the hydraulic cylinder. The valve opening and closing system is connected to the stroke return. The line diagram of this shaper is given below.

                           

ii. Vertical Shaper:

A vertical shaper tool moves up and down and cuts in a downward stroke.

Note. The size of a shaper is taken from the length of its stroke, while the longer the stroke of a shaper, the more cubic pieces of size the shaper can machining.

1.3 Construction of Shaper:

It is not too difficult for an operator to understand the shaper system as he understands the working principles of the machines

1.4 Parts of Shaper:

Rem:

The top part of the shaper that moves the tool back and forth in its dual slides

Start and Stop button:

As you know it is used to run and stop the machine black button is to run and red button is to stop the machine

Oil Pressure Gauge:

A gauge is used to check the pressure of the lubricating oil

Gear Shifting Lever:

There are two levers to change the shaper to eight different speeds, which are connected to the gearbox. The gears in the box run in the presence of oil to minimize wear and tear.

Back Gear Lever:

It is also connected to the gearbox and is used to change gears

 

Power Cross Feed Selector:

A cross feed selector lever is used to select the desired feed from the available feeds.This system is connected to a cam and this cam determines the amount of feed.

Stroke Indicator Dial:

It shows the stroke of the ram in inches or millimeters

Stroke Adjusting Shaft:

It adjusts the stroke length by inserting an L-shaped handle and turning it to increase or decrease the stroke length. Bull Gear has two gears in the center of the shaft in front of the shaft. Fit which makes the radius of the crank pin more or less. To understand this system, with the help of the instructor, see the bull gear system by opening the shaper so that you can get to the bottom of the system.

Power Rapid Traverse Lever:

The work table is usually lowered by hand by turning the handle up or down in one direction. With this power lever, we can quickly slide the table to save time.

Cross Feed Engagement Lever:

This selects right-left or parallel feed

Cross Feed Manual Control:

Cross feed can be given with the help of handle.

Rail Elevating Manual Control:

The cross rail can be moved up and down by rotating this lever by hand

Cross rail:

It acts as a pendent for the work table.

Apron:

It carries the table attached to the rail and slides right or left over the rail.

Rail Clamp Control:

With its help, the rail can be fixed at the required position during operation.

Table Support:

It provides support to the work table so that the table does not fall down during the working stroke.

Work table:

It acts as a base under the bank to which the work is fastened with the help of various work holding means

Vise:

Place the work piece on the work table and fix it in the correct position

Ram Adjusting Shaft:

Used to adjust the stroke condition of the ram

Tool Post:

A variety of shaping tools can be attached to it

Tool Lifter:

When the shaper is on the voice stroke, it lifts the tool up slightly so that the tool does not break

Swivel Head:

This is a clipper box blade that can be adjusted to cut salami at any angle.

Feed Screw Crank:

The tool post is used to give vertical feed or diagonal feed and with its collar we can control the depth of cut.

Electric Clutch and Brake Control:

The electric clutch works to start or stop the machine.

1.5: Lubricating the shaper:

For better working of a machine it is necessary that its oiling is done properly. Lubricating machines is a matter of skill and knowledge. Shaper oiling is not a difficult task for a student who knows the lubrication of lathe machine, however, the necessary information related to it is included here.

Before starting Shaper:

 (1) Boxes which are filled with oil so that the oiling of the running system inside them is                 continuous to fill the oil level in the gearbox or transmission box.

 (2) Oil the motor so that there is no difficulty while running.

  (3) Fill the oiling return basins.

Usual Daily oiling:

 Perform daily oiling of the following total parts and locations.

1. All slides.

2. Clean the work table and bench.

3. Clean and oil the ram rail and slide.

4. Oiling the feed screw and its bearings.

5. Oil the clipper box pin.

Weekly oiling:

There are specific places where Oil Weekly is written. Oil on the first day of every week of Monday. Or on the next day of a weekly holiday.

1. Fill the rim oil holes and oil the rim adjusting system.

2. Oil the speed change levers.

3. Oiling the crank clutch.

Monthly Oil Checking;

Check the oil tanks on the first Saturday of every month and top up the oil level.

1.6 Shaper's Stroke System:

Given below is the line diagram of the stroke system. In which the Bull Gear (B) is rotated by a small gear P. There is a screw as the radius of the Bull Gear. When this screw is rotated, the radius of the crank pin is approximately R. To rotate this screw, the stroke adjusting shaft is rotated with the help of a handle. There are two gears in front of this shaft in the center of the bull gear. moves along which rotates the radial screw of the crank. The sliding block decreases the cranking radius R. From this system, the stroke length is adjusted according to the work piece being small or large.

 

The working length of the stroke is required at the place. For example, at the end of the work table or at the beginning. This is called position of stroke. There is a system inside the ram to fix the position of the stroke. Loosen the stroke adjusting lever on top of the ram. By turning the stroke adjusting screw, when the tool cuts to the required position, the upper lever is tightened, which corrects the stroke position.

The crank pin radius of the gear can be reduced. And the location of the working stroke can also be determined. Considering the figure below, it can be seen that the bull gear rotates in the clockwise direction by rotating the crank pin from P1 to P2 to form the forward stroke. And the return stroke from P2 to P1 is the cutting stroke. The speed of the forward stroke is slow and the return stroke turns quickly. While the bill wheel rotates at the same speed. It takes more time for the crank pin to rotate more angles from p1 to p2. And less time is required for the less angle rotation from p2 to p1. These two strokes have a specific relationship between them, on the basis of which the cutting speed of the shaper is determined.

1.7 Shaper Tools:

A trained person who is skilled in turning tool grinding of lathe machine.

 He finds no difficulty in making or grinding shaper tool. The job of lathe

 machine is round while the job of shaper is stationary but cutting in both

 places. The principal is the same. Here we are giving the shapes and

 descriptions of various shaper tools.

1. Ruffing Tool:

Rough tool is used for plane shaping as per figure. It is a left hand tool. 

Conversely right hand tool can also be ground.

2. Finishing Tool:

Finishing tools are ground as per figure, this is a left hand tool, you can

 also make a right hand tool.

3. Parting or slotting tool:

The tools prepared according to the various shapes are used for cutting,

 cutting, and parting. The thickness of the tool is ground according to the 

width of the groove. And a relief angle of one degree is given from both 

sides. So that the tool does not slip and Don't chatter.

4. Do-Tail Tools:

According to figure a do-tail roughing tool and figure b do-tail finishing

 tool are shown so that other hand tools can also be ground against them.

5. Key way tool:

The tool shown in the figure is used to cut a keyway in a pulley or wheel

 hub. The tool is held in a workbench and moves back and forth in its hole 

to cut a way similar to a parting tool.

1.8 Cutting Speed ​​and Feed of Shaper:

The cutting speed of a shaper depends on its working stroke per minute. The

 distance traveled per stroke is found in millimeters and multiplied by the

 stroke per minute. The time is determined. The determined distance is

 divided by this fraction of a minute and divided by 1000, then its speed is

 known.

Tool distance in cutting /min = N*L

Job length in mm = L

Cutting Stroke/min = N

        Cutting speed in meter's /min = N*L / 1000 .......(1)

  In normal shapers, the ratio between cutting stroke and return stroke time

 is 2:3. The cutting stroke time is longer, while the return stroke returns

 very quickly. The relative sum of time is 5. So the time of cutting stroke

 will be 3/5 Now divide equation (1) by 3/5.

Cutting Speed ​​= N*L /1000 / 3/5

or C.S N*L /1000 *3/5 = N*L / 600 meter/min

or Nos. of cutting strokes per min = c.s x 600 / L

L = Length of job to be cut in m.m