This document summarizes an internship project on a shaper machine and shaping process. The project aims to apply learning from a manufacturing processes course to daily operations at a factory. Key topics covered include an introduction to shaper machines and the shaping process, the principle of how a shaper machine works, its main parts like the base, column, and ram, and advantages like quick setup times while limitations include slower cutting speeds. An example job cutting a keyway slot on a gear is provided.

1. Internship Project
Shaper Machine & Shaping Process
B.Tech Mechanical Engineering – 3rdSemester

2. Scope of Project :-
In this project we have tried to relate our learning from 3rd
semester of B.Tech Mechanical Engineering with daily working
process inside the factory.
In Manufacturing Processes we have learned and studied
about Shaper machine and Shaping process. As we have
Shaper machine inside factory premises which is being used
on daily bases for various jobs for which we have taken
“Shaper Machine and Shaping Process” as a project.

3. Content:-
• Introduction to Shaper Machine & Shaping Process
• Principle of Shaper Machine
• Quick Return Mechanism
• Block Diagram of Shaper Machine
• Parts of Shaper Machine
• Advantages & Disadvantage of Shaper Machine
• In-House :- JOB/Experiment

4. Introduction to Shaper Machine & Shaping Process :-
• It is reciprocating type of machine tool used for producing flat surfaces.
• Surfaces may be horizontal, vertical or inclined.
• Modern shapers can produce contoured surfaces.
• It uses reciprocating straight line motion of the tool and a perpendicular feed of the job or the tool.
• By moving the work piece across the path of the reciprocating tool, a flat surface is generated regardless of
the shape of the tool.
Shaper Machine :-
Shaping Process :-
Shaping (sometimes called slotting) is a machining process whereby a work piece is held on the machine table,
which is then advanced into the path of a reciprocating ram, upon which is mounted a single-point cutting
tool.

5. Principle of Shaper Machine :-
On a shaper, job is fixed on the work table (i.e. job remains stationary) and the tool cuts while reciprocating
over the job. The tool is mounted on a reciprocating ram and the table which supports the job is fed normal
to the tool motion at each stroke of the ram.
The tool cuts in the forward stroke generally, only in case of a draw-cut shaper the tool cuts in backward
stroke of the ram.

6. Quick Return Mechanism :-
• 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.
• 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.

7. Block Diagram of Shaper Machine :-
Block Diagram

8. Parts of Shaper Machine :-
1. Base :-
• It is made of cast iron to resist vibration and takes up high compressive load.
• It is so designed that it can take up the entire load of the machine and the
forces set up by the cutting tool over the work.
2. Column :-
• It is a box like casting mounted upon the base.
• It encloses ram driving mechanism.
• It is provided with guideways on its top to enable the ram to slide on it.
3. Ram :-
• It is a reciprocating member which reciprocates on the guideways provided above the column.
• It carries a tool-slide on its head and a mechanism for adjusting the stroke length.

9. Parts of Shaper Machine :-
4. Cross-rail :
• It is mounted on the front vertical guideways of the column.
• It has two parallel guideways on its top in the vertical plane that are perpendicular to the ram axis. The table
may be raised or lowered to accommodate different size of jobs by rotating an elevating screw which causes
the cross-rail to slide up and down on the vertical face of the column.
5. Table :
• It is made of cast iron and is rectangular in shape.
• It has T-slots on its top surface.
• The table can be moved upward, downward or sideward with the help of elevating
• screws and other feed handle

10. Advantages :-
1. The set up of shaper is very quick and easy and can be readily changed from one job to another.
2. The work can be held easily.
3. The single point tools used are in inexpensive ; these tools can be easily grounded to any desired shape.
4. Lower first cost.
5. The cutting stroke has a definite stopping point.
Limitations :
1. A shaper, by nature, is a slow machine, because of its straight line, forward and return (idle) stroke. The
single point tool requires several strokes to complete a work.
2. The cutting speeds are not usually very high since difficulties are encountered in designing machine tools
with high speeds of reciprocating motion due to high inertia forces developed in the motion of the units and
components of the machine.
Advantages & Disadvantage of Shaper Machine :-

11. Job/Experiment
Job type :- Key Way Slot Cutting
Location :- Apollo tyres In-house
Gear without Keyway
BEFORE AFTER
Gear with Keyway
Keyway Cutting
WORK IN PROCESS

12. Thank you