SHAPIN

FABRICATION AND MACHINING TECHNIQUES

G
PRESENTED
BY :

OJASVITA
OSHMA
NAWIN
NITHIN
NUPUR
ACKNOWLEDGEMEN
T
This presentation on SHAPING
incorporates all our research on the topic
including the information that we
collected by the visit to the INDUSTRIAL
TRAINING INSTITUTE.

We bid our thanks to our esteemed

faculty Mr Sharan for his inevitable
guidance and support.

Any suggestions for the improvement of

our presentation will be whole-heartedly
accepted.
 FABRICATION AND
MACHINING
Fabrication applies to the building of
machines, structures and other equipment, by
cutting, shaping and assembling components
made from raw materials. It also involves the
metal preparation, welding and assembly
aspects.

Machining is one of the most important

material removal methods and is a collection
of material-working processes in which
power-driven machine tools, such as lathes,
milling machines, and drill presses are used
with a sharp cutting tool to mechanically cut
 SHAPING
Shaping is a material removal process
in which a cutting tool takes mass and
shapes a stationary object to produce
a sculpted or plane surface.

THE SHAPING
MACHINE
A shaping machine is used to machine
surfaces. It can cut curves, angles and
many other shapes. It is a popular
machine in a workshop because its
movement is very simple although it can
produce a variety of work.
 TYPES OF SHAPERS
1. According to the TYPE of mechanism used
2. According to the POSITION and TRAVEL of ram
3. According to the type of DESIGN of the table
4. According to the type of CUTTING STROCK
stroke
 CRANK SHAPER

• Single point cutting tool is given

reciprocating motion equal to
the length of the stroke.
• Bull gear is used to change the
motion of crank to circular
path.
•
 GEARED TYPE
• The reciprocating motion of the
ram in some type of shaper is
effected by mean or rack and
pinion.
• Speed and the direction in which
the machine will transverse
depend on the number of gears
in the gear train.
 HYDRAULIC SHAPER
• The reciprocating movement of
the ram is obtained by
hydraulic power. Piston speed
is changed according to the
amount of liquid delivered by
the pump.
• Advantages- constant speed,
flexibility of speed and feed
control, eliminates shock,
machine doesn’t make much
 HORIZONTAL SHAPER
• The ram holding the tool
reciprocates in a horizontal
axis.
• Horizontal shaper are mainly
used to produce flat surface.
 VERTICAL SHAPER
• The ram holding the tool
reciprocates in vertical axis.
• In some, vertical position of the
ram can be changed about 10
degree.
• Very convenient for machining
internal surfaces, keyways,
slots or grooves.
•
•
 TRAVELLING HEAD
SHAPER
• The ram carry the tool while it
reciprocates moves crosswise
• It is static on the basement while
the ram moves.
 UNIVERSAL SHAPER
• In addition to the two
movement, the table can be
tilted on an angle parallel to
thePUSH
ram. TYPE
• SHAPER
• •The metal is removed when

the ram is moved away from

the column.
 DRAW TYPE SHAPER
• the metal is removed when the
ram is moves towards the
column of the machine.
• The cutting pressure acts to take
a deep cut.
PRINCIPAL PARTS
 BASE
It is necessary for support
required for all machine tools.
The base may be bolted to the
floor or on the bench according
to the size. It is designed that
it can take up the entire load of
machine and the forces set up
by cutting tools. It is made of
cast iron.
 The column is a box like
thing which is mounted
upon the base. It encloses
the ram deriving
mechanism. Two
guideways are provided
on the top of the column
on which the ram
reciprocates. The front
vertical face serves the
guideways for the
crossrail. These all are
 CROSS RAIL
The cross rail is mounted on
the front vertical guide ways
of the columnIt has two
parallel guide ways that
perpendicular to the ram axis it
can be pulled up and down by
elevating screw.
 SADDLE
The saddle is mounted on the
cross rail which holds the table
firmly on top. Crosswise
movement of the saddle by
rotating the cross feed screw
by hand or by power
 TABLE
it is a box like casting having T-
slots both on the top and the
sides for clomping the work.
 RAM
The ram is the reciprocating member
of the shaper. This is semi cylindrical in
the form and heavily ribbed inside to
make it more rigid. It slides accurately
on well machined guide ways on the
top of the column. It houses a screwed
shaft for altering the position of the
ram with respect to the work. It holds
the tool head at the extreme forward
end.
 TOOL HEAD
The tool head of shaper holds
the tool rigidly, provides
vertical and angular feed
movement to the tool and
allows the tool to have an
automatic relief during its
return stroke
 Shaper
mechanism
In a shaper ,rotary movement of the drive is converted into
reciprocating
Movement by the mechanism contained within the coloumn of
the machine.
The ram holding the tool gets the reciprocating movement.
Task: to remove the
punched area
 The tools used to cut
the material

Tools used to adjust these

cutting tools
So that it is in contact with the
material
The shavings or
crap
Slotted Link Quick Return Shaper Drive Mechanism - The slotted link
quick returns mechanism.
Slotted link mechanism
Principle of mechanism

Slotted link mechanism is very common in mechanical shapers. The

mechanism is simple and compact. It converts the rotary motion of the
electric motor and gearbox into the reciprocating motion of the ram.

The slotted link mechanism gives the rain a higher velocity during the return
non cutting stroke than
The slotted link mechanism gives the rain a higher velocity during the return
non cutting stroke than during its forward cutting stroke thereby reducing the
time wasted during the return stroke. The bull gear is driven by a pinion which
is connected to the motor shaft through a gearbox with four, eight or more
speeds available. The bull wheel has a slot. The crank pin A is secured into
this slot; at the same time it can slide in the slotted crank B.
When the bull wheel rotates, the crank pin A also rotates and side by side
slides through the slot in the slotted crank B. This makes the slotted crank to
oscillate about its one end C. This oscillating motion of slotted crank (through
the link D) makes the ram to reciprocate. The intermediate link D is necessary
to accommodate the rise and fall of the crank.
The 'Whitworth' quick
return mechanism
converts rotary motion
into reciprocating motion,
but unlike the crank and
slider, the forward
reciprocating motion is at
a different rate to the
backward stroke. At the
bottom of the drive
arm, the peg only has to
move through a few
degrees to sweep the arm
from left to right, but it
takes the remainder
of the revolution to bring
the arm back. This
mechanism is most
commonly seen as the
drive for a shaping
machine.
 Shaper
vises :
A vise is a quick method of holding and
locating
Relatively small and regular shaped
work pieces.

It consist of base, table,screw,f ixed,and

movable
Jaws. the base has a projection or
tongue which
Fits into the slots of the machine table.
 Parallel
s:
When the height of the job is less than the height of the
jaws of the vise, parallels are used
To raise and seat the work piece above the vise jaws and
parallels with the wise bottom.
Parallels are square or rectangular bars of steel or cast
iron , hardened and ground with
opposites sides Parallel. they are available in different
heights…

Hold
downs:
Hold downs or grippers are used for holding thin pieces of
work in a shaper vise.
Hold downs are also used for holding work of smaller height
than the vises jaws where
Suitable parallels are not available.
Clamping work on the
table:
When the work piece is too large to be held a
visit must be fastened directly on
the shaper table. in holding work on the table
,clamping bolts should not be unduly
Tightened to produce distortion of the work.
Different methods are applied :

T-bolts and clamp:

T-bolts having tea heads are fitted in the t-slots
of the table. The length of the threaded
Portion is sufficiently long in order to
accommodate different heights of work.
Stop pins and toe dogs:

While holding thin work on the table stop

pins in conjuntion with toe dogs are used.
A toe dog is similar to that of a center
punch or a cold chisel.

The end of the to dogis slightly drilled so

that I end of the stop pin screw may fit into
it
A large number of stops pins dogs are
placed all round the work. when of the stop
pin
Is tightened ,the work is gripped down on
the table.
Stop and strip pins:
Work having sufficient thickness is held on the
table by strip and stop pins.

A strip is a long bar having a toungue with holes of

fitting the t-bolts

The stopping screws are then tightened from the

other end of the work so that
the work may be clamped between stop pins and
strip plate

V-block:
For holding round rods v-block are used. Work may
be supported on two
V-blocked at its two ends and is clamped to the
table by t-bolts and clamps
SHAPING OPERATIONS
The different operations which a
shaper can perform are as follows :

§Machining horizontal surface

§Machining vertical surface
§Machining angular surface
§Cutting slots, grooves and keyways
§Machining irregular surface
§Machining splines and cutting gears
 MACHINING HORIZONTAL
SURFACE
A shaper is mostly used to machine a
flat, true surface on a work piece
held in a vise or other holding
devices. After the work is properly
held on the table, a planing tool is
set on the tool post with minimum
overhang. The table is raised till
there is a clearance of 25 to 30 mm
between the work piece and the tool.
Proper cutting speed and feed is
then adjusted. Depth of cut is
adjusted by rotating the down feed
screw of the tool head. The amount
of depth of cut is adjusted by a
 MACHINING VERTICAL
SURFACE
A vertical cut is made while
machining the end of a work
piece, squaring up a block or
cutting shoulder. The work is
mounted in the vise or directly
on the table and the surface
to be machined is carefully
aligned with the axis of the
ram. A side cutting tool is set
on the tool post and the
position and length of the
stroke is adjusted. The
vertical slide is set exactly at
zero position and the apron is
swivelled in a direction away
 MACHINING ANGULAR
SURFACE
An angular cut is made at any
angle other than a right
angle to the horizontal or to
the vertical plane. The work
is set on the table and the
vertical slide of the tool head
is swivelled to the required
angle either towards left or
towards right from the
vertical position. The apron is
then further swivelled away
from the work so that the
tool will clear the work
during the return stroke. The
 CUTTING SLOTS,
GROOVES AND KEYWAYS
With the suitable tools shaper can
very conveniently machine slots
or grooves on a work or cut
external keyways on shafts and
internal keyways on pulleys or
gears. For cutting slots or
keyways a square nose tool
similar to a parting tool is
selected. External keyways are
cut on a shaft by first drilling a
hole at the blind end of the
keyway. Internal keyways are cut
by holding the tool on a special
tool holder so that the tool post
 MACHINING
IRREGULAR SURFACE
A shaper can also produce a contoured surface
that is a convex or concave surface or a
combination of any of the above surfaces. To
produce a small contoured surface of forming
tool is used. If the curve is sufficiently large,
power-cross feed is conjunction with manual
down feed is so adjusted that the tool will trace
the required contour. If the contour has too
many ups and downs both the feeds are
operated by hand. A round nose tool is selected
for machining irregular surfaces.
 MACHINING SPLINES
AND CUTTING GEARS
The work is mounted between two centres
and a spline is cut similar to the cutting of a
keyway. After the first spline is cut the work
is rotated through a predetermined amount
by using index-plate and index-pin. The
periphery of a gear blank is divided, and
equally spaced grooves are cut by using an
index-plate having proper whole circles.
While cutting gear a formed tool is used.
THANK
YOU