Pneumatic shaper machine project

1. i
INTERNAL COMBUSTION ENGINE
ABDI SAMAD MOHAMED AWAYS ID: 31
ABDULLAHI OMAR MOHAMOOD ID: 41
LIIBAAN HUSEIN JIMALE ID: 59
An assignment submitted in full filamentof the
Requirements for the machine tool course
Faculty of Engineering
Department of electromechanical
Somali national university
December 2019

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Abstract
The pneumatic Shaper machine is a reciprocating type of machine tool
basically used to produce Horizontal, Vertical or Inclined flat surfaces by means of
straight-line reciprocating single-point cutting tools similar to those which is used in
lathe operation, The flat surface produced may be horizontal, vertical or inclined at an
angle. pneumatic shaper machine is efficient machine which works by pneumatic
power, inserted of crank & shaping link mechanism here pneumatic power is
employed with quick return mechanism this system consists of ram, pneumatic
cylinder, time circuit when air from compressor is send to double acting cylinder via
solenoid valve, this valve will make the cylinder to move too & for as per the single
from the timer. Time will be programmed with delay.

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Table of contents
Contents…………………………………………………………………………...pages
Abstract...................................................................................................................... i
Table of contents...................................................................................................... iii
List of figures........................................................................................................... vi
1 Introduction........................................................................................................ 1
1.1 Brief History of shaper machine .................................................................. 2
1.2 Pneumatic systems ...................................................................................... 2
1.3 Main Pneumatic System Components.......................................................... 2
1.3.1 Pneumatic Cylinder.............................................................................. 2
1.3.2 Solenoid Valve..................................................................................... 3
1.3.3 Flow Control Valve.............................................................................. 4
1.3.4 Air Compressor.................................................................................... 4
1.3.5 Pressure regulating component............................................................. 5
1.4 Working Principle of Pneumatic System ..................................................... 5
1.5 The advantages of pneumatic systems ......................................................... 6
1.5.1 High effectiveness................................................................................ 6
1.5.2 High durability and reliability............................................................... 6
1.5.3 Simple design....................................................................................... 7
1.5.4 High adaptability to harsh environment ................................................ 7
1.5.5 Safety................................................................................................... 7
1.5.6 Easy selection of speed and pressure .................................................... 7
1.5.7 Environmental friendly......................................................................... 7
1.5.8 Economical .......................................................................................... 7
1.6 Limitations of pneumatic systems................................................................ 8
1.6.1 Relatively low accuracy ....................................................................... 8
1.6.2 Low loading......................................................................................... 8

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1.6.3 Processing required before use ............................................................. 8
1.6.4 Uneven moving speed .......................................................................... 8
1.6.5 Noise.................................................................................................... 8
1.7 Application of pneumatics........................................................................... 9
1.8 Characteristics of pneumatics ...................................................................... 9
1.9 Disadvantages for Pneumatics ..................................................................... 9
2 Literature Review............................................................................................. 10
3 Types of shaper machine .................................................................................. 11
3.1 According to the type of mechanism used for giving reciprocating motion to the
ram: ..................................................................................................................... 11
3.1.1 Crank type shaper............................................................................... 11
3.1.2 Geared type shaper............................................................................. 12
3.1.3 Hydraulic type shaper......................................................................... 12
3.2 According to the position and travel of ram: .............................................. 13
3.2.1 Horizontal type shaper........................................................................ 13
3.2.2 Vertical type shaper............................................................................ 14
3.2.3 Travelling head type shaper................................................................ 14
3.3 According to the type of design of the table:.............................................. 15
3.3.1 Standard shaper.................................................................................. 15
3.3.2 Universal shaper................................................................................. 15
3.4 According to the type of cutting stroke:..................................................... 15
3.4.1 Push type shaper ................................................................................ 15
3.4.2 Draw type shaper ............................................................................... 15
4 Construction and Working Principle of Shaper Machine................................... 16
4.1 Principle of operation of shaper machine................................................... 16
4.2 Shaper mechanism .................................................................................... 16
4.2.1 Whitworth Quick Return Mechanism ................................................. 17

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4.2.2 Automatic feed mechanism ................................................................ 18
4.3 Construction:............................................................................................. 20
4.3.1 Base ................................................................................................... 21
4.3.2 Body (Pillar, Frame, and Column):..................................................... 21
4.3.3 Cross rail:........................................................................................... 21
4.3.4 Ram ................................................................................................... 21
4.3.5 Table.................................................................................................. 22
4.3.6 Saddle ................................................................................................ 22
4.3.7 Column .............................................................................................. 22
4.3.8 Tool head ........................................................................................... 22
4.4 Operations performed on shaper machine .................................................. 24
4.4.1 Horizontal cutting: ............................................................................. 24
4.4.2 Vertical cutting: ................................................................................. 25
4.4.3 Inclined cutting: ................................................................................. 25
4.4.4 Irregular cutting: ................................................................................ 25
4.5 Specification of shaper machine: ............................................................... 25
4.6 Application of Shaper Machine ................................................................. 26
4.7 Advantages of shaper machine: ................................................................. 26
4.8 Disadvantages of shaper machine: ............................................................. 27
5 Conclusion....................................................................................................... 28
Reference ................................................................................................................ 29

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List of figures………………………………………………….............................pages
Figure 1.1 Pneumatic shaper machine........................................................................ 1
Figure 1.2 pneumatic cylinder .................................................................................. 2
Figure 1.3 solenoid valve........................................................................................... 3
Figure 1.4 Flow control valve.................................................................................... 4
Figure 1.5 Air compressor ......................................................................................... 5
Figure 1.6 pneumatic shaper components .................................................................. 6
Figure 3.1 crank type shaper machine...................................................................... 11
Figure 3.2 Geared type shaper ................................................................................. 12
Figure 3.3 Hydraulic type shaper............................................................................. 13
Figure 3. 4 Horizontal type shaper........................................................................... 13
Figure 3.5 Vertical type shaper................................................................................ 14
Figure 4.1 Whitworth quick return…………………………………………………..17
Figure 4.2 Components of Automatic feed mechanism……………………………..19
Figure 4.3 Main parts of shaper machine…………………………………………….20
Figure 4.4 Components of tool head………………………………………………...23
Figure 4.5 The four operations performed on shaper………………………………..24

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1 Introduction
In past years, Conventional mechanical shaper machine is used in industries.
In this shaper machine gear arrangement is used to give liner motion to the machine
tool towards to the workpiece. The workpiece mounts on a rigid, box shaped table in
front of the machine. The height of table can be adjusted suitable to the workpiece.
In all shaper machine cutting stroke is controlled and return stroke is fast, this
can be done by a mechanism which is named as ‘whit worth quick return mechanism’.
In conventional shaper machine stroke length can be adjusted by shaper dogs.
In modern era, whole mechanical shaper machine is replaced by pneumatic shaper
machine due its ease operation and reliability.
Pneumatic system is that i uses compressed air to transmit & control energy
and are widely used in robotics and automation applications due to their multiple
advantages, e.g. low cost, high power-weight ratio, cleanness, etc. However, the
compressibility of the working fluid and the highly nonlinear nature of the pneumatic
systems pose great difficulty in their control.
In this modern shaper machine whole construction is same, but method of
actuation is changed. The gear arrangement is totally replaced by a double acting
hydraulic cylinder. Hydraulic cylinders are the device which uses hydraulic energy to
achieve mechanical movement i.e. linear. A machine tool is used as per application
for example producing v slots v shape tool is used. In this hydraulic shaper machine
quick return is achieved by placing flow control valve and check valve in return line.
Figure 1.1 Pneumatic shaper machine

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1.1 Brief History of shaper machine
Roecredits James Naismith with the invention of the shaper in 1836. Shapers
were very common in industrial production from the mid-19th century through the
mid-20th. In current industrial practice, shapers have been largely superseded by other
machine tools (especially of the CNC type), including milling machines, grinding
machines, and broaching machines. But the basic function of a shaper is still sound;
tooling for them is minimal and very cheap to reproduce; and they are simple and
robust in construction, making their repair and upkeep easily achievable [1].
Thus they are still popular in many machine shops, from jobbing shops or
repair shops to tool and die shops, where only one or a few pieces are required to be
produced and the alternative methods are cost- or tooling-intensive. They also have
considerable retro appeal to many hobbyist machinists, who are happy to obtain a
used shaper or, in some cases, even to build a new one from scratch.
1.2 Pneumatic systems
A pneumatic system is a system that uses compressed air to transmit and
control energy. Pneumatic systems are used in controlling train doors, automatic
production lines, and mechanical clamps.
1.3 Main Pneumatic System Components
1.3.1 Pneumatic Cylinder
A pneumatic cylinder is an operative device in which the state input energy of
compressed air i.e. pneumatic power is converted in to mechanical output power.
Mechanization is defined as the replacement of manual effort by mechanical power.
Figure 1.2pneumatic cylinder

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The main advantages of an pneumatic system are usually economy and
simplicity, the latter reducing maintenance to a low level. It also has outstanding
advantages in terms of safety.
Pneumatic systems operate on supply of compressed air, which must be made
available, in sufficient pressure to suit the capacity of the system. The main part of
any facility for supply of compressed air is by means using reciprocating compressor.
A compressor is a machine that takes in air at a certain pressure and delivered the air
at a high pressure.
The cylinder is a double acting cylinder one, which means that the air
pressure operates alternatively. The air from the compressor is passed through the
regulator which controls the air pressure to required amount by adjusting its knob.
1.3.2 Solenoid Valve
The solenoid valve is one of the important parts of a pneumatic system. This
valve is used to control the direction of air flow in the pneumatic system. The
directional valve does this by changing the position of its internal movable parts. This
valve was selected for speedy operation and also for the modification of the machine
into automatic machine by means of using a solenoid valve. A solenoid is an electrical
device that converts electrical energy into force and straight line motion.
Figure 1.3solenoid valve

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1.3.3 Flow Control Valve
A flow control valve regulates the flow or pressure of a fluid. Control valves
normally respond to signals generated by independent devices such as flow meters or
temperature gauges. Control valves are fitted with actuators and petitioners.
Pneumatically-actuated Diaphragm Valves are widely used for control purposes in
many industries, although quarter-turn types such as ball, gate and butterfly valves are
also used.
Figure 1.4Flow control valve
1.3.4 Air Compressor
An air compressor is a device that converts power into potential energy stored
in pressurized air (i.e., compressed air). By one of several methods, an air compressor
forces more air into a storage tank, increasing the pressure. When the tank pressure
reaches its upper limit the air compressor will shuts off. The compressed air will held
in the tank until called into use. The energy contained in the compressed air can be
used for a variety of applications. When tank pressure reaches its lower limit, the air
compressor turns on and repressurizes the tank.

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The main function of the air compressor is to compress the air up to the
required air pressure.
Figure 1.5Air compressor
1.3.5 Pressure regulating component
Pressure regulating components are formed by various components, each of
which has its own pneumatic symbol:
i. Filter – can remove impurities from compressed air before it is fed to the
pneumatic components.
ii. Pressure regulator – to stabilise the pressure and regulate the operation of
pneumatic components
iii. Lubricator – To provide lubrication for pneumatic components.
1.4 Working Principle of Pneumatic System
Starting with air compresses, its function is to compress air from a low
pressure (usually atmospheric) to a higher pressure level. The compressed air goes to
solenoid valve through flow control valve. The flow control valve is used to control
the air flow to the cylinder. This flow is adjusted manually by the nap is fixed above
the flow control valve, then this air goes to the 5/2 solenoid valve. The 5/2 solenoid
valve having one input port, two output port and two exhaust port. The workpiece
mounts on a rigid box-shaped table in front of the machine. Table motion can be
controlled manually. The ram slides forward and return on the work.

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The pneumatic source of power with control accessories is used to drive the
ram to obtain the forward and return strokes.
Figure 1.6pneumatic shaper components
1.5 The advantages of pneumatic systems
Pneumatic control systems are widely used in our society, especially in the
industrial sectors for the driving of automatic machines. Pneumatic systems have a lot
of advantages.
1.5.1 High effectiveness
Many factories have equipped their production lines with compressed air
supplies and movable compressors. There is an unlimited supply of air in our
atmosphere to produce compressed air. Moreover, the use of compressed air is not
restricted by distance, as it can easily be transported through pipes.
1.5.2 High durability and reliability
Pneumatic components are extremely durable and can not be damaged easily.
Compared to electromotive components, pneumatic components are more durable and
reliable.

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1.5.3 Simple design
The designs of pneumatic components are relatively simple. They are thus
more suitable for use in simple automatic control systems.
1.5.4 High adaptability to harsh environment
Compared to the elements of other systems, compressed air is less affected by
high temperature, dust, corrosion, etc.
1.5.5 Safety
Pneumatic systems are safer than electromotive systems because they can
work in Inflammable environment without causing fire or explosion. Apart from that,
overloading in pneumatic system will only lead to sliding or cessation of operation.
Unlike electromotive components, pneumatic components do not burn or get
Overheated when overloaded.
1.5.6 Easy selection of speed and pressure
The speeds of rectilinear and oscillating movement of pneumatic systems are
easy to adjust and subject to few limitations. The pressure and the volume of air can
easily be adjusted by a pressure regulator.
1.5.7 Environmental friendly
The operation of pneumatic systems does not produce pollutants. The air
released is also processed in special ways. Therefore, pneumatic systems can work in
environments that demand high level of cleanliness. One example is the production
lines of integrated circuits.
1.5.8 Economical
As pneumatic components are not expensive, the costs of pneumatic systems
are quite low. Moreover, as pneumatic systems are very durable, the cost of repair is
significantly lower than that of other systems.

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1.6 Limitations of pneumatic systems
Although pneumatic systems possess a lot of advantages, they are also subject
tomany limitations.
1.6.1 Relatively low accuracy
As pneumatic systems are powered by the force provided by compressed air,
their operation is subject to the volume of the compressed air. As the volume of air
may change when compressed or heated, the supply of air to the system may not be
accurate, causing a decrease in the overall accuracy of the system. Technological
Studies Pneumatic Systems.
1.6.2 Low loading
As the cylinders of pneumatic components are not very large, a pneumatic
system cannot drive loads that are too heavy.
1.6.3 Processing required before use
Compressed air must be processed before use to ensure the absence of water
vapour or dust. Otherwise, the moving parts of the pneumatic components may wear
out quickly due to friction.
1.6.4 Uneven moving speed
As air can easily be compressed, the moving speeds of the pistons are
relatively uneven.
1.6.5 Noise
Noise will be produced when compressed air is released from the pneumatic
components.

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1.7 Application of pneumatics
i. Internal flat surfaces.
ii. Enlargement and finishing non-circular bounded by a number of flat surfaces .
iii. Internal grooves and slots of rectangular and curved section.
iv. Internal key way and spines of rectangular ,straight tooth of internal spur
gear’s internal curved surface of circular section ,internal oil grooves
etc………
v. Pneumatics is good for straight movements, but, with the right linkage can be
used for rotation or other movements.
1.8 Characteristics of pneumatics
i. Vertical tool reciprocating with down stroke acting.
ii. Longer stroke length.
iii. Lees strong and rigid.
iv. An additional rotary feed motion of the work table.
v. Used mostly for machining internal surfaces.
1.9 Disadvantages for Pneumatics
i. Initial weight cost is high ~15lbs
ii. Requires fine tuning for optimum use limited uses with larger actuators

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2 Literature Review
M. Anil et al. studied advanced shaper machine. In advanced shaping machine
the vertical slots are provide on one side of the shaping machine. The slots can be
used to move vertically (either upwards or downwards) the bull gear position. It
makes us easy to change the bull gear position; it means centre of the bull gear
position can be moved away or towards the pivot pin. When the bull gear is move
downwards or towards the pivot pin stroke length can be increased or vice versa. In
advanced shaping machine the stroke length can be varied in two types, one is to
change the distance between centre of the bull gear and crank pin and another is to
change the vertical distance between centre of the bull gear and pivot pin. So in an
advanced shaping machine, without changing the diameter of the bull gear and height
of shaping machine, we can increase the stroke length greatly [2].
Bharat et al made the efforts to develop an electro pneumatic circuit for
shaping operations using a shaper machine. This makes the operations semi-automatic
producing shaping operations by a single point cutting tool. The three movements of
the shaper are reciprocating movement of the ram, crosswise movement of the tool
lead across the cross rail and vertical up and down movement of the table. The above
movements are being automated using electro-pneumatic components such as
pneumatic cylinders, direction control valves, flow control valves and other electrical
and electronics devices. For automation of the shaper, an electro-pneumatic circuit is
developed with the help of sensors, solenoids, electrical and electronic devices. The
electro pneumatic circuit developed is simulated, executed and will be interfaced with
PLCs, L10/L20 manufactured by BOSCH –REXROTH Germany. A prototype of the
set-up is also planned for better understanding and demonstration purpose [3].

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3 Types of shaper machine
Shapers are classified in number of ways depending upon the general features
of design or the purpose for which they are intended, Shapers are classified under the
following headings [4].
3.1 According to the type of mechanism used for giving reciprocating motion to
the ram:
3.1.1 Crank type shaper
This is the most common type of shaper in which a single point cutting tool is
given a reciprocating equal to the length of the stroke desired while the work is
clamped in position on an adjustable table. In construction, the crank shaper employs
a crank mechanism to change circular motion of a large gear called “bull gear”
incorporated in the machine to reciprocating motion of the ram. The bull gear receives
power either from an individual motor or from an overhead line shaft if it is a belt
driven shaper.
Figure 3.1crank type shaper machine

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3.1.2 Geared type shaper
The reciprocating motion of the ram in some type of shaper is affected by
means of arrack and pinion. The rack teeth which are cut directly below the ram mesh
with a spur gear. The pinion meshing with the rack is driven by a gear train. The
speed and the direction in which the machine will traverse depend on the number of
gears in the gear train. This type of shaper in not very widely used
Figure 3.2Geared type shaper
3.1.3 Hydraulic type shaper
In a hydraulic shaper, reciprocating movement of the ram is obtained by
hydraulic power. Oil under high pressure is pumped into the operating cylinder fitted
with a piston. The end of the piston red is connected to the ram. The high pressure oil
first acts on one side of the piston and then on the other causing the piston to
reciprocate and the motion ist5ransmitted to the ram. The piston speed is changed by
varying the amount of liquid delivered by the pump.

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One of the most important advantages of this type of shaper is that the cutting
speed and force of the ram drive are constant from the very beginning to the end of
the cut. It also offers great flexibility of speed and feed control., eliminates shock and
permits slip or slowing up of motion when the cutting tool is overloaded, protecting
the parts or the tools from breakage. Another advantage that the machine does not
make any noise and operates very quietly.
Figure 3.3 Hydraulic type shaper
3.2 According to the position and travel of ram:
3.2.1 Horizontal type shaper
In a horizontal shaper, the ram holding the tool reciprocates in a horizontal
axis. Horizontal shapers are mainly used to produce flat surfaces.
Figure 3.4Horizontal type shaper

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3.2.2 Vertical type shaper
In a vertical shaper, the ram holding the tool reciprocates in a vertical axis. In
some of the vertical machines provision is made to allow adjustment of the ram to an
angle of about10 degrees from the vertical position. Vertical shapers may be crank
driven, rack driven, screw driven or hydraulic power driven.
The work table of a vertical shaper can be given cross, longitudinal, and
rotary movement. The tool used on a vertical shaper is entirely different from that
used on a horizontal shaper. Vertical shapers are very convenient for machining
internal surface, keyways, slots or groves. Large internal and external gears may also
be machined by indexing arrangement of the rotary table.
Figure 3.5Vertical type shaper
3.2.3 Travelling head type shaper
In a travelling head shaper, the ram carrying the tool while it reciprocates
moves crosswise to give the required feed. Heavy and unwieldy jobs which are very
difficult to hold on the table of a standard fed past the tool are held static on the
basement of the machine while reciprocates and supplies the feeding movements.

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3.3 According to the type of design of the table:
3.3.1 Standard shaper
A shaper is termed as standard or plain when the table has only two
movements, vertical and horizontal, to give the feed. The table may or may not be
supported at the outer end.
3.3.2 Universal shaper
In a universal shaper, in addition to the two movements provided on the table
of a standard shaper, the table can be swivelled about an axis parallel to the ram ways,
and upper portion of the table can be tilted about a second horizontal axis
perpendicular to the first axis. As the work mounted on the table can be adjusted in
different planes, the machine is most suitable for different types of work and is given
name "Universal". A universal is mostly used in tool room work.
3.4 According to the type of cutting stroke:
3.4.1 Push type shaper
This is the most general type of shaper used in common practice. The metal is
removed when the ram moves away from the column, i.e. pushes the work.
3.4.2 Draw type shaper
In a draw shaper, the metal is removed when the ram moves towards the
column of the machine, i.e., draws the work towards the machine. The tool is set in a
reversed direction to that of a standard shaper. The ram is generally supported by an
overhead arm which ensures rigidity and eliminates deflection of the tool.

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4 Construction and Working Principle of Shaper Machine
4.1 Principle of operation of shaper machine
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.
A single point cutting tool is rigidly held in the tool holder, which is mounted
on the ram. The work piece is rigidly held in a vice or clamped directly on the table.
The table may be supported at the outer end. The ram reciprocates and thus cutting
tool held in tool holder moves forwards and backwards over the work piece. In a
standard shaper, cutting of material takes place during the forward stroke of the ram
the backward stroke remains idle. This is obtained by "Quick Return Mechanism".
The depth of the cut is adjusted by moving the tool downwards towards the
workpiece. The feed motion is given to the workpiece and follows the "Pawl and
Ratchet mechanism".
4.2 Shaper mechanism
In a shaper, rotary movement of the drive is converted into reciprocating
movement byte mechanism contained within the column of the machine. The ram
holding the tool gets the reciprocating movement. In a standard shaper metal is
removed in the forward cutting stroke, while the return stroke goes idle and no metal
is removed during this period. To deduce the total machining time it is necessary to
reduce the time taken by the stroke.
Thus the shaper mechanism should be so designed that it can allow the ram
holding the tool to move at a comparatively slower speed during the forward cutting
stroke, the cutting speed depending upon the type of material and machining

23. 17
condition., whereas during the return stroke it can allow the ram to move at a faster
rate to reduce the idle return time. This mechanism is known as quick return
mechanism.
The reciprocating movement of the remand the quick return mechanism of the
machine are usually obtained by: Whitworth quick return mechanism and automatic
feed mechanism.
4.2.1 Whitworth Quick Return Mechanism
The Whitworth quick return mechanism is shown in Figure and a simple line
diagram of the mechanism is shown in Fig. 4.2.1 The bull gear is mounted on a large
fixed pin A upon which it is free to rotate. The crank plate 4 is pivoted eccentrically
upon the fixed pin at 5. Fitted on the face of the bull gear is the crank pin 2 on the top
of which is mounted the sliding block 3. Sliding block 3 fits into the slot provided on
the crank plate4. At the other end of the crank plate 4, a connecting rod 6 connects the
crank plate by a pin 9 and the ram 8 by a pin 7.
Figure 4.1Whitworth quick return
1. Driving pinion, 2. Crank pin, 3. Sliding block, 4. Crank plate, 5. Pivot for crank
plate, 6. Connecting rod, 7. Connecting pin for ram, 8. Ram, 9. Pin, A. Fixed pin.
When bull gear will rotate at a constant speed the crank pin 2 with the sliding
block 3will rotate on a crank circle of radius A2 and the sliding block 3 will cause the

24. 18
crank plate rotate about the point 5 with a variable angular velocity. Pin 9 fitted on the
other end of the crank plate 4 will rotate in a circle and the rotary motion of the pin 9
will be converted into reciprocating movement of the ram similar to the crank and
connecting rod mechanism.
The axis of reciprocating of the ram passes through the pin 5 and is normal to
the line A5.When the pin 2 is at the position C the ram will be at the extreme
backward position but when the pin is at the position B, the extreme forward position
of the ram will have been reached.
When the pin 2 travels from C to B the crank pi 9 passes through the backward
position to the forward position in the cutting stroke, and the return stroke is
completed when the pin 2 travels from B to C or the pin 9 passes from the forward
position to the backward position. As the angular velocity of the crank pin is uniform,
the time taken by the crank pin2 to travel through and are covering CEB is greater
than the time taken to move through and are covering BDC.
Thus a quick return motion is obtained by the mechanism. The length of stroke
of the ram may be changed by shifting the position of pin 9 closer or away from the
pivot 5. The position of stroke may be altered by shifting the position of pin 7 on the
ram.
4.2.2 Automatic feed mechanism
In a shaper both down feed and cross feed movements may be obtained.
Unlike a lathe, these feed movements are provided intermittently and during the end
of return stroke only. Vertical or bevel surfaces are produced by rotating the down
feed screw of the tool head by hand. Cross feed movement is used to machine a flat
horizontal surface. This is done by rotating the cross feed screw either by hand or
power. Rotation of the cross feed screw causes the table mounted upon the saddle to
move stroke so as bring the uncut surface of the work in the direct path of the
reciprocating tool.

25. 19
Figure 4.2Components of Automatic feed mechanism
1. Knob, 2. Pin, 3. Helical spring, 4. Pawl, 5. Ratchet wheel, 6. Rocker Arm Fulcrum.
7. Rocker arm connecting pin, 8. Driving disc. 9. Crank Pin.
Figure illustrates the automatic cross feed mechanism of a shaper. The rotation
of the bull gear causes the driving disc 8 to rotate in a particular direction. The driving
disc 8 its- slotted and position of the crank pin 9 attached to the connecting rod may
be altered to give different throw of eccentricity. The other end of the connecting rod
is attached t the rocking arm by a pin 7. The rocking arm is fulcrum at 6, the centre of
the ratchet wheel 5.The ratchet wheel 5 is keyed to the cross feed screw.
The rocking arm houses a spring loaded pawl 4 which is straight on one side
and bevel on the other rotates, the connecting rod starts reciprocating and the rocking
arm rock son the fulcrum 6. When the driving disc rotates through half of the
revolution in the clock wise direction, top part of the rocking are moved in the
clockwise direction and the pawl 4 being slant on side slips over the tee5th of the
ratchet wheel 5 imparting it no movement. As the driving disc rotates through the
other half, the top of the rocking arm now moves in the anticlockwise direction and
the straight side of the pawl engages with the teeth of the ratchet wheel causing the
wheel to move in anticlockwise direction only. As the driving disc is connected to the
bull gear the table feed movement is effected when the bull gear or the diving disc
rotates through half of the revolution, i.e., during return stroke only. Rotation through
other half imparts no feed movement.

26. 20
To reverse the direction of rotation of ratchet wheel and consequently the feed,
a knob on the top of the pawl 4 after removing the pin 2 is rotated through 180
degrees.
The amount of feed may be altered by shifting the position of crank pin 9 with
respect to the centre. Greater the throw of eccentricity, more will be the rocking
movement of the arm and the pawl will pass through three or four teeth on the wheel
at a time imparting greater feed movement.
4.3 Construction:
The main parts of the Shaper machine is Base, Body (Pillar, Frame, Column),
Cross rail, Ram, Table, Saddle, Column and tool head (Tool Post, Tool Slide,
Clamper Box Block).
Figure 4.3 Main parts of shaper machine

27. 21
4.3.1 Base
The base is the necessary bed or support required for all machine tools. The
base may be rigidly bolted to the floor of the shop or on the bench according to the
size of the machine. It is so designed that it can take up the entire load of the machine
and the forces setup by the cutting tool over the work. It is made of cast iron to resist
vibration and take up high compressive lad.
4.3.2 Body (Pillar, Frame, and Column):
It is mounted on the base and houses the drive mechanism compressing the
main drives, the gear box and the quick return mechanism for the ram movement.
The top of the body provides guide ways for the ram and its front provides the guide
ways for the cross rail.
4.3.3 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.
4.3.4 Ram
The ram is the reciprocating member of the shaper. This is semi- cylindrical in
form and heavily ribbed inside to make it more rigid. It slides on the accurately
machined dovetail guide ways on the top of the column and is connected to the
reciprocating mechanism contained within the column. It houses a screwed shaft for
altering the position of the ram with respect to the work and hoods the tools head at
the extreme forward end.

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4.3.5 Table
The table which is bolted to the saddle receives crosswise and vertical
movements from the saddle and cross rail. It is a box like casting having T – slots
both on the top and sides for clamping the work. In a universal shaper the may be
swivelled on a horizontal axis and the upper part of the table may be tilted up or
down. In heavier type shaper, the front face of the table is clamped with a table
support to make it more rigid
4.3.6 Saddle
The saddle is mounted on the cross rail which holds the table firmly on its top.
Crosswise movement of the saddle by rotating the cross feed screw by hand or power
causes the table to move sideways.
4.3.7 Column
The column is a box like casting mounted upon the base. It encloses the ram
driving mechanism. Two accurately machined guide ways are provided on the top of
the column on which the ram reciprocates. The front vertical face of the column
which serves as the guide ways for the cross rail is also accurately machined. The lid
on the left side of the column may be opened for inspection and oiling of the internal
mechanism with the column. The other side of the column contains levers, handles,
etc. for operating the machine.
4.3.8 Tool head
The tool head of a shaper holds the tool rigidly, provides vertical and angular
feed movement of the tool and allows the tool to have an automatic relief during its
return stroke. The vertical slide of the swivel base which is held on a circular seat on
the ram. The swivel base is graduated in degrees, so that the vertical slide may be set
perpendicular to the work surface or at any desired angle. By rotating the down feed

29. 23
screw handle, the vertical slide carrying the tool executes down feed or angular feed
movement while machining vertical or angular surface.
The amount of feed or depthof cut may be adjusted by a micrometer dial on
the top of the down feed screw. Apron consisting of by a screw. by releasing the
clamping screw, the apron may be swivelled upon the apron swivel pin either towards
left or towards right with respect to the vertical slide. This arrangement is necessary to
provide relief to the tool while making vertical or angular cuts. The two vertical walls
on the apron called clapper box houses the clapper block which is connected to it by
means of hinge pin. The tool post dismounted upon the clapper block.
On the forward cutting stroke the clapper block fits securely to the clapper box
to make a rigid tool on the work lifts the block –out of the clapper box a sufficient
amount preventing the tool cutting edge form dragging and consequent wear. The
work surface is also prevented from any damage due to dragging.
Figure 4.4 Components of tool head
1) Down feed screw micrometre dial. 2) Down feed Screed. 3) Vertical Slide. 4)
Apron. 5) Apron clamping bolt. 6) Clapper Block. 7) Tool post 8) Washer. 9) Apron
swivel pin. 10) Swivel base.

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4.4 Operations performed on shaper machine
There are four types of operations performed in a shaper machine and those are:
 Horizontal cutting
 Vertical cutting
 Inclined cutting
 Irregular cutting
Figure 4.5The four operations performed on shaper
4.4.1 Horizontal cutting:
Horizontal surfaces are machined by moving the work mounted on the
machine table at a cross direction with respect to the ram movement.
The clapper box can be set vertical or slightly inclined towards the uncut
surface this arrangement enables the tool to lift automatically during the return stroke
the tool will not drag on the machined surface.

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4.4.2 Vertical cutting:
A vertical cut is made while machining the end of a workpiece, squaring up a
block or machining a shoulder the feed is given to the tool by rotating the down feed
screw of the vertical slide the table is not moved vertically for this purpose the apron
is swivelled away from the vertical surface being machined.
4.4.3 Inclined cutting:
An angular cut is done at any angle other than a right angle to the horizontal or
thevertical plane the work is set on the table and the vertical slide of the tooth head is
swivelled to the required angle either towards right from the vertical position.
4.4.4 Irregular cutting:
A round nose tool is used for this operation for a shallow cut the apron may be
set vertical but if the curve is quite sharp, the apron in swivelled towards the right or
left away from the surface to be cut.
4.5 Specification of shaper machine:
The size of a shaper is determined by the maximum length of stroke or cut it
can make. The usual size ranges from 175 to 900 mm. The length of stroke indicates,
in addition to the general size of the machine, the size of a cube that can be held and
planed I the shaper. Thus in a 250 mm shaper the length of stroke may be adjusted
from 0 to 250 mm, the cross feed adjusted of the table will be 250 mm and the
extreme bottom position of the cross rail will permit the table to accommodate a work
piece 250 mm high.The length of stroke of a shaper merely indicates the overall size
of the shaper other particulars, such as the type of drive : belt or individual motor
drive, power input, floor space required, weight of the machine, cutting to return
stroke ratio, number and amount of feed etc. are also sometimes necessary.

32. 26
The specification of shaper machine depends upon the following:
i. The maximum length of stroke rams.
ii. Types of the drive (crank, gear and hydraulic type).
iii. Power input of the machine.
iv. Floor space required to establish the machine
v. Weight of the machine in tonne.
vi. Feed
vii. Cutting to return stroke ratio.
viii. Angular movement of the table.
4.6 Application of Shaper Machine
The most common use is to machine straight, flat surfaces, but with ingenuity and
some accessories a wide range of work can be done. Other examples of its use are:
i. Keyways in the boss of a pulley or gear can be machined without resorting to
a dedicated broaching setup.
ii. Dovetail slides
iii. Internal splines
iv. To make gear teeth
v. Keyway cutting in blind holes
vi. Cam drums with tool paths of the type that in CNC milling terms would
require 4- or axis contouring or turn-mill cylindrical interpolation.
vii. it is even possible to obviate wire EDM work in some cases
4.7 Advantages of shaper machine:
The shaper machine has the following advantages:
i. The single point tool used which is expensive or we can say low tooling cost.
ii. The cutting stroke having a definite stopping point.
iii. The work can be held easily in the shaper machine.
iv. The set up is very quick and easy and also can be readily changed from one
job to another job.

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4.8 Disadvantages of shaper machine:
The shaper machine has the following disadvantages:
i. By nature, it is a slow machine because of its straight-line forward and returns
strokes the single point cutting tool requires several strokes to complete a
work. (they are slow)
ii. The cutting speed is not usually very high speeds of reciprocating motion due
to the high inertia force developed in the motion of the units and components
of the machine.

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5 Conclusion
A shaper is a type of machine tool uses linear relative motionbetween the work
piece and a single-point cutting tool tomachine a linear tool path. Shapers are mainly
classified asstandard, horizontal, universal, vertical, geared, crank,hydraulic, contour
and travelling head, with a horizontalarrangement most common. The vertical shaper
isessentially the same thing as a slotter, although technically adistinction can be made
if one defines a true vertical shaperas a machine whose slide can be moved from the
vertical.Small shaper machine have been successfully made tooperate by hand power.
As size increases, the mass of theshaper machine and its power requirements increase
and itbecomes necessary to use a motor or other supply ofmechanical power.
Also we know that Pneumatic Shaping machine is very cheap as compared to
hydraulic shaping machine. The range of the cutting thickness can be increased by
arranging a high pressure compressor and this machine is advantageous to small sheet
metal cutting industries as they do not have rely on the expensive hydraulic shaping
machine.
In this project we have discussed the different types of shaper machine, their
working principles, applications, advantages, limitations, and disadvantages of
pneumatic shaper machine.

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Reference
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Volume 8, Issue 2 PP. 49-56.
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