By Rohith R 6th Sem Mechanical Engg

1. 6TH SEM- Mechanical ENGINEERING
Subject PROJECT WORK
BATCH-3
1

2. MOHAMMED USMAN.A PAVAN KUMAR.S
ROHITH.R SHAHID ZAMAN.A.P
VIJAY.P VISHWANATH.H.R
IRSHAD AHMED KUSHAL KUMAR.K
ROHITH GOWDA.K.L SANDESH.N.R
SHESHADRI.M.R SUNIL KUMAR.V
VRUSHANKA.M
Guided by :
Presented by :
Mr. M.N. RAVI
Mr. JAGADEESHA 2

3. “Topic 
Service And
Overhauling Of
Shaper Machine”
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4. SHAPER MACHINE
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5. INTRODUCTION
 The shaping machine is used to machine flat metal
surfaces especially where a large amount of metal
has to be removed. Other machines such as milling
machines are much more expensive and are more
suited to removing smaller amounts of metal, very
accurately.
 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.
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6. WORKING PRINCIPLE:
The job is rigidly fixed on the machine table. The
single point cutting tool held properly in the tool
post is mounted on a reciprocating ram. The
reciprocating motion of the ram is obtained by a
quick return motion mechanism. As the ram
reciprocates, the tool cuts the material during its
forward stroke. During return, there is no cutting
action and this stroke is called the idle stroke. The
forward and return strokes constitute one operating
cycle of the shaper.
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7. CLASSIFICATION
There are mainly two types of shapers:-
 Horizontal Shapers.
I) Plain Shapers II) Universal Shapers.
 Vertical Shapers.
 Crank Shapers.
 Gear shapers.
 Hydraulic Shapers.
Both shapers depending upon whether the ram and the cutting
tool reciprocates in the horizontal plane or in the vertical plane.7

8. Crank shapers are most commonly used. A
rocker arm, operated by a crank pin from the main driving
gear, gives the ram of the crank shaper a back-and-forth
(reciprocating) motion.
Gear shapers are driven by a gear and rack
assembly. Gear shapers have a reversible electric motor
or mechanical mechanism which quickly returns the ram,
in readiness for another cut.
Hydraulic shapers are driven by movement of
a piston in an oil-filled cylinder. Mechanical features on
these shapers are the same as those on crank shapers.
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9. PRINCIPAL PARTS OF SHAPER
Base
Column
Table
Cross Rail
Ram
Tool Head
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10.  Base- The base is the necessary bed or support
required for all machines tools. All other parts are
mounted on and above the base. The bed takes up the
total dead weight of the machine as well as the dynamic
load during machining operations.
 Cross rail-The cross rail is mounted on the front of the
body frame and can be moved up and down. The vertical
movement of the cross rail permits jobs of different
heights to be accommodated below the tool. Sliding
along the cross rail is a saddle which carries the work
table.
 Column-The column of the shaper is a hollow casting and is
mounted on the base. It houses the drive mechanism for the ram and
the table.
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11.  Table- The worktable of a shaper is fastened to the front of the
column. The table moves across the column on crossrails to give the
feed motion to the job.
 Ram- The ram carries the tool head at its front end and travels in
“guideways” to give straight line reciprocating motion to the tool. The
ram is either mechanically driven or hydraulically operated. A single
point tool is fastened in the tool post. 11

12. Tool Head- It
holds the cutting tool
and is fastened to the
front of the ram. The
tool is held in a tool
holder/tool post
similar to the lathe
tool post. The tool
post and the tool
block fit snugly in the
clapper box and is
hinged at the upper
edge.
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13. MECHANISM OF SHAPING MACHINE
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14. QUICK RETURN MECHANISMS
These types of machine tool are of rectilinear cutting
motion therefore, the rotary motion of the drive is converted
into reciprocating motion.
The metal is removed in the forward cutting stroke, while
the return stroke goes idle and no metal is removed during
this period.
The cutting mechanism is so designed that it moves at a
comparatively slower speed during forward cutting stroke,
whereas during the return stroke it allow the ram to move at a
faster speed to reduce the idle return time.
This mechanism is known as quick return mechanism.
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15. The reciprocating movement of the ram and the
quick return mechanism of the machine are
generally obtained by anyone of the following
methods:
1.Lever rocker arm mechanism (shaper).
2.Slider crank mechanism (slotter).
3.With worth quick return mechanism (shaper
and slotter).
4.Hydraulic system ( all the 3 types).
5.Variable speed reversible motor (slotter and
planer).
6.Rack and pinion mechanism (planer).
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16. DIFFERENT TYPES OF CUTTING
TOOLS USED IN SHAPER
16

17. OPERATIONS PERFORMED ON SHAPER
 Operations involved in shaping a rectangular job on
shaper.
 Machining a thin job on shaper.
 Cutting an angle on a large job.
 Cutting a dovetail bearing on a shaper.
 Shaping a V or keyway in a block.
 Shaping regularly angled component.
 Shaping an irregularly curved surface.
 Cutting a keyway on a shaper when the keyway does
not extend the entire length of the shaft.
 Machining angular surfaces on shapers.
 Sequence of machining sides of a rectangular piece
square and parallel. 17

18. ADVANTAGES OF SHAPERS
 The single point cutting tools used in shapers are
inexpensive, these tools can be easily grounded to
any desirable shape.
 The simplicity and ease of holding work, its easy
adjustment, and the simple tool give the shaper its
great flexibility.
 Shaper set up is very quick and easy and can be
readily changed from one job to another.
 Thin or fragile jobs can be conviniently machined
on shapers because of lower cutting forces.
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19. LIMITATIONS
 Shape only one piece of stock at a time.
 Shape stock only if longer than 25 cm (10 in).
 Support long pieces of wood with extension tables
or roller supports.
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20. SERVICE & OVERHAULING OF
SHAPER MACHINE
THE FOLLOWING PARTS ARE DISMANTLED TO SERVICE
AND SOME OF THEM WERE REPLACED.
 TOOL POST
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This tool post as been dismantled each and every
part for diesel waste and some parts. We have
made the reading visible and also painted the tool
post. The alignment is corrected

21. •VICE
The vice as dismantled, washed with
diesel and painted
TABLE
The table as dismantled from
vertical column. For worn out surfaces
we have applied metal paste putty and
from sand paper with water we have
scribed to smooth surface finishing.
And alignment corrected
And finally we have painted for
aesthetic appearance.
The slider as fitted below the table
slide has machined for perfect fit.
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22. •RAM
The ram as been removed from head of the column .For worn out
surfaces we have applied metal paste putty and from sand paper with water
we have scribed to smooth surface finishing.
And finally we have painted for aesthetic appearance
GEAR BOX
The gear box has been dismantled each parts for service. The
frame has been re-machined; Brazing has been done due to
worn out. For worn out surfaces we have applied metal paste
putty and from sand paper with water we have scribed to smooth
surface finishing. The gears are washed with diesel. The outer
parts are finally we have painted for aesthetic appearance
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23. •PAWL MECHANISM
We have dismantled every parts of the pawl mechanism, we have
purchase a new spring with is fitted in the handle. The pin has been
welded and brought in shape so that it as to engage with gear teeth to
push the gear automatically moving table left to right vice versa while
machining. The cotter pin was producing more sound will moving so we
have replaced by nail by grinding to required shape
•BULL GEAR MECHANISUM The bull gear parts are dismantled
to service each and every part. We
have applied grease to gears and
also painted to protect from
corrosion. The sliding block and
slider are also washed with diesel.
The surrounding of this mechanism
is painted with red.
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24. •MOTOR
The motor as be
serviced and finally we
have painted for aesthetic
appearance.
•BELT DRIVE ( V-BELT)
This belt is used to
drive the ram. this
are replace by new
one due to old was
cut off and worn out
the belt sizes are
B47 and C59
•BEARING (THRUST BEARING)
This are used to enable
rotational or linear
movement, while
reducing friction and
handling stress. We have
replaced due to worn out
old one. Set of 2 are
purchased
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25. •SCREW ROD AND NUT
The screw rod is re-machined
to a required dimension and
accurately. The nut is newly
manufactured because old one
was damaged
•CHROMING
The handles, measuring disc, down
feed handle etc and many others were
chromed for aesthetic outlook
appearance.
•OTHER PARTS
The many other
parts like jibs, sliding plats,
bevel gears, collars, blocks,
nuts, bolts, washers, rods etc.,
and this part are washed by
diesel and oiled to protect from
corrosion.
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26. ELEVATING SCREW
This screw is used to support
and move the table up and down this part
is wash by diesel and finally applied
grease to free movement.
•SUPPORTING JACK TYPE The frame support type was
replaced by jack type. In which base of
the jack was welded by a 10mm flat and
drilled either two sides with respect to the
bed holes. Then at the top of the jack the
L-section flat is welded, So that the angle
plate slides over that.
We need to rotate the jack to required
height while doing operation. The reason
of making jack type because previously
we need to loosen the nut and bolt then
bring it too required position and to adjust
it, it was so complicated, then we
analysed and build this type we become
more easy compare to frame
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27. •FEED INDICATOR(additional)Shaper tool feed indicating arrangement is made
by us is as shown in figure. It is a direct measuring
arrangement. the purpose of this arrangement is to know the
down feed of tool in to the work piece this arrangement
mainly consists of 50*200mm 2 m.s flat,1/2’’ 2 bush nuts,
dia15*400mmm.s rod, scriber(point indicator),150mm scale,
dia25*60mm m.s rod, 60*80mm s.s flat.
It involves following operations. first we welded 2 m.s flat like
‘t’joint then make two 12mm drilling holes, on the upper flat
then we clamped to the shaper table using bolt and nuts, then
we make the dia20*50mm drilling hole inside the
dia25*60mm round rod it is welded on the m.s flat vertically
which holds the dia15*400mm rod, then we takes 2 bush nuts
and we make 6.5mm drilling hole in both the nuts and we
done taping operation using 8mm tap wrenches to insert the
screws ,then one bush nut is welded to the second m.s flat it
helps to lock the dia15*400mm m.s rod to the required height
,then we weld the scriber with the another bush nut it insert to
the rod it is free to move throughout the rod it helps to adjust
scriber to the required height , then we take the s.s flat and
make 3 drilling holes of dia9mm to clamp it to the tool post
using nuts and bolts ,then we fixed the 150mm scale using
gum, then we place a work piece in the vice when tool
touches the work piece we adjust the scriber to zero by
moving the bush nut up and down ,then as well as we feed
give to tool scriber moves on the scale thus indicates the mm
of feed of the tool in to the work piece. 27

28. OVERALL PAINT
Overall paint to get aesthetic appearance. 28

29. SL NO PARTICULARS AMOUNT
1. Gear box re-machining 4500/-
2. Chroming 1500/-
3. Cross slide-screw rod & nut(change) 3000/-
4.. Table supporting stand(Jack type)(Additional) 2500/-
5. Two set of thrust bearing 500/-
6. Slider machining 350/-
7. V- belts 600/-
8. Bolts, Nuts & other materials 4050/-
9. Painting ( over coating paint)
1. NC patti, tinner
2. Emeracy paper
3. Paint as per choice
4. Diesel & Grease
5. wastes
4250/-
10. Feed indicator (Additional) 500/-
Total 21750/-
ESTIMATION & COSTING
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30. ESTIMATION COST GRAPH
4500
1500
3000
2500
500350
600
4050
4250
500
Amount
Gear box re-
machining
Chorming
Screw rod & Nut
Table stand
Bearing
Slider Machining
V- Belt 30

31. EXPERIMENT GALLERY
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32. CONCLUSION
PROJECT REPORT
This is my privilege to express my sincerest regards to my report co-coordinator,
Mr. M.N.RAVI and Mr. JAGADEESHA , for there valuable inputs, guidance and
constructive criticism throughout the duration of my project work.
I deeply express my sincere thanks to HOD Mr. M.N. RAVI for encouraging and
allowing me to present the report of project.
I sincerely thank to our team members who are totally involved in project work for
the final output and supported throughout the duration of project and their
dedication.
Thank you.
REFERENCE
Referenced:
Source: INTERNET Wikipedia
Guidance by: Foreman: Mr. Jagadeesha
Mechanic: Mr. Bhaskar
(Meletha Enterprises)
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