A shaping machine is another essential tool that ought to be in every workplace, just like other machine tools. It is intended to provide workpieces with flat, vertical, and horizontal surfaces with the appropriate forms. To cut in curves, various angles, and other forms, use a shaping tool.
Samuel Bentham created the shaper machine during the period from 1791 to 1793. Shapers were widely used in industrial settings from the mid-1800s through the 1900s. In the industrial sector, the predominant machine tools, such as grinding, milling, and broaching machines, have significantly assumed the functions previously performed by shapers.
Well, in this reading, we’ll explore what a shaping machine is, its parts, diagram, types, classifications, and how it works. We’ll also explore its advantages and disadvantages.
Let’s get started!
What is A Shaping Machine?
A shaping machine, also known as a shaper, is a type of machine tool that moves the workpiece in a linear relative motion along a linear toolpath using a single-point cutting tool. The machine creates a cut that is comparable to what a lathe does. The machine is designed to give desired shapes to a surface that is either vertical, horizontal, or flat.
Shaping machine tools are used to create curves, angles, and many other shapes. They feature a disc that rotate the tool resulting to a forward and backward movement. Also, the tool is rigid enough to give shape to a hard surfaces like metal and wood by removing the unwanted material.
Shaping machine works in a reciprocating motion, the workpiece are fixed in position on the machine table while the cutting tool moves to take the cut. This reciprocating movement is known as a forward and backward strokes. The forward stroke take the cut while the backward movement restores the position withing any cutting action.
Applications
The shaper machine can be used for any of the following applications:
- Creating smooth and curved surfaces on metal parts.
- Crafting engine parts and brake drums for use in automobiles.
- Producing slots, grooves, and keyways in metal parts.
- Producing dies and tooling for a wide range of sectors.
- Making gear teeth, both internal and external.
- Machining intricate profiles and shapes from steel and aluminium.
- Restoring or fixing metal surfaces that have been worn or damaged.
- Fabricating specialized components for custom machinery.
- Creating chamfers and notches in engineering parts.
- Manufacturing mechanical components with a high degree of precision, such as dovetail slides.
Related: What is Milling Machine? its Diagram & How it Works
Shaping Machine Parts
The various component of shaping machine include base, column, cross-rail, saddle, table ram and tool head.
Base
Just like other machine tools, the base is designed to take the entire load of the shaping machine. It is bolted on the floor of workshops. The base is made of cast iron in order to resist vibration and to take the compressive load.
Column
The column is cast iron mounted on the base. It is provided with accurate machine guideways on the top on which the ram reciprocates. Some guideways are also provided on the front vertical face for the cross-rail movement. All ram-driving mechanism is enclosed in the column.
Cross-rail
The shaping machine part is mounted on the ground vertical guideways of the column. It features two parallel guideways on its top perpendicular to the ram axis, this is called a saddle. It helps to move the table crosswise direction with the help of a feed screw.
A cross-rail allows the table to be raised and lowered at a required size the workpiece will accommodate. This is done by the rotating elevating screw that causes the cross rail to slide up and down on the vertical face of the column.
Saddle
A saddle is mounted on the cross rail to hold the table firmly on its top. The crosswise movement of the saddle causes the table to also move crosswise direction if the cross-feed screw is rotated.
Table
A table is mounted on the saddle, it moves crosswise by rotating the cross-feed rod and vertically by rotating the elevating screw. The table is made of cast iron, in the shape of a box with an accurate top and side surface. These surfaces feature t-slots for holding the workpiece.
In a universal shaping machine, the table is designed to swivel on a horizontal axis and its upper part is tilted up or down. In heavy shaper, the front face of the table is supported by an adjusted table to offer more rigidity.
Ram
A ram is a reciprocating member that holds a shaping tool. It is in the form of a semi-cylindrical and ribbed inside which makes it more rigid. It holds the screwed shaft for altering the position of the ram with respect to the work.
Tool head
the tool head is designed to firmly hold a cutting tool and offers both vertical and angular movement to the tool. This movement is done by a down-feed screw handle. The tool head also allows the tool to have automatic relief during the return stroke of the ram.
the head tool consists of an apron, a clapper box, and a clapper block; the apron contains the clapper box and tool post, clamped on the vertical slide by the screw. The apron is swiveled upon the apron swivel pin in the direction of right or left. The clapper box houses the clapper block using a hinge pin. A tool post is mounted on the clapper block.
Diagram
Types of Shaping Machine
Below are the various kinds of shaper:
Hydraulic Shaping Machine
The hydraulic system in these types of shaper machines facilitates the reciprocating motion of the ram. It operates using high-pressure oil as its primary medium. The hydraulic circuit for the shaper machine facilitates this process through a comprehensible system.
The ram is connected to the piston rod end. The high-pressure oil initially exerts force on one side of the piston. Subsequently, the opposing side activates the piston’s reciprocating motion, which is then transmitted to the ram.
The primary advantages of this type of shaping machine include a constant cutting speed and a consistent ram drive force. The machine operates silently throughout the entire cutting process, from start to finish, without producing any noise.
Universal-Type Shaping Machine
Shaper machines feature vertical and horizontal movements, along with the capability for the table to move along an inclined axis and swivel on its axis. The workpiece secured in the vice is capable of adjustment across various planes.
Horizontal Type Shaping Machine
The ram operates in a reciprocating motion within these specific types of shaper machines. The reciprocation of the ram maintains the tool’s position along a horizontal axis. The horizontal shapers are employed for shaping external grooves, keyways, and comparable features.
Geared Type Shaping Machine
The rack and pinion mechanism is responsible for generating the reciprocating motion of the ram. The rack teeth are precisely machined directly beneath the interface where the ram engages with the spur gear. The number of gears in the gear train determines the machine’s speed and direction of motion. There is currently no industry-wide use of this specific type of shaper machine.
Vertical Type Shaping Machine
The ram in these types of shaper machines exhibits reciprocating motion within a vertical plane, with the table providing support for the workpiece. Vertical shapers can be operated manually, driven by a rack, powered by a screw mechanism, or utilize hydraulic power.
The workpiece is capable of movement in multiple directions, encompassing transverse, longitudinal, and rotational motions. This shaper is capable of machining internal surfaces, slots, and keyways.
Standard Type Shaping Machine
A shaper is classified as a standard or plain shaper when its table is capable of both vertical and horizontal movements to provide the feed. The manual shaping machine represents the oldest category of machinery used in different machine shops.
Crank Type Shaping Machine
The crank shaper is the most prevalent type, utilizing a single-point cutting tool to achieve a reciprocating motion that corresponds to the stroke length. The device converts the rotary motion generated by a larger component known as the bull gear.
The bull gear receives its power from an overhead line shaft or from an independent motor in the case of a belt drive configuration.
Draw Type Shaping Machines
In shaper machines, metal removal occurs as the ram moves in a reverse direction. The tool in this shaper is mounted in the tool head facing the opposite direction, resulting in the cutting action occurring when the ram moves in the opposite direction.
Travelling Head Shaping Machines
To give the required feed in this type of shaper, the ram that holds the tool travels diagonally during reciprocation. This machine is utilized for tasks that present significant challenges in hanging and feeding from a shaper’s table. The tool remains fixed at the base as the ram provides feeding and reciprocating motion.
Push Type Shaping Machines
Of all the various types of shapers, these are the most popular and flexible. As the ram moves away from the column, indicating that it is advancing the work, the material is being removed.
Related: What is Drilling Machine? its Diagram, Types and Specifications
How Does Shaping Machine Works?
A shaping machine works by fixing the workpiece on a table, with the cutting tool fixed on a ram that moves forward and backward in a slider (reciprocating movement) form. The forward strokes towards the workpiece take the cut, while the backward movement sets the ram for another cutting action.
A hydraulic shaper machine operates as a motor that drives a hydraulic pump to deliver oil at a constant pressure to the line. The piston connected to the ram is pushed by the oil, carrying the cutting tool as it moves toward the workpiece. The piston rod connects the piston and ram, allowing for the complete stroke. The length of the stroke depends on the position of the trip dogs, which can be adjusted by unclamping and moving them to the desired position.
The working of a shaping machine involves placing the workpiece on a table, setting the desired surface, and then performing its reciprocating action. The ram moves forward and backward to complete a stroke, cutting off the material while leaving the required shape. The forward stroke takes the cut, and the backward stroke sets the ram for another cutting action.
Difference Between Shaper and Planer Machine
All operations performed in planning machines can be executed in the shaping machine. The extended stroke length, increased dimensions, and enhanced rigidity allow planning machines to perform more substantial tasks on extensive projects and their elongated surfaces.
It generates planes and flat surfaces using a single-point cutting tool. Compared to a shaper machine, a planer machine is larger and more massive. The planer is capable of machining heavy workpieces, which cannot be accomplished on a shaper surface.
The significant difference between shaper and planer machine are presented in the table below:
| S.no | Shaper | Planer |
| 1 | In a shaper machine, work is held stationary, and the cutting tool on the ram is moved back and forth across the work. | In a planar machine, the tool is stationary, and the workpiece travels back and forth under the tool. |
| 2 | Shapers can be used for shaping much smaller jobs. | A planer is meant for larger jobs than can be undertaken on a shaper. Jobs as large as 6 meters wide and twice as long can be machined on a planer. |
| 3 | A shaper is a light machine. | A planer is a heavy-duty machine. |
| 4 | Shapers can employ light cuts and finer feed. | Planers can employ heavier cuts and coarse feed. |
| 5 | Shaper uses one cutting tool at a time. | Planer uses several tools to cut simultaneously. |
| 6 | The shaper is driven using a quick return mechanism. | The drive on the planer table is either by gears or by hydraulic means. |
| 7 | It is less rigid and less robust. | Due to the better rigidity of the planer machine, compared to that of a shaper, the planer can give more accuracy on machined surfaces. |
Related: What is Planer Machine? Its Diagram and How it Works
Advantages and Disadvantages of Shaping Machines
Advantages
- The shaper tool is cost-effective.
- Workpieces can be securely mounted on a shaper machine.
- The cutting stroke is designed to have a specific stopping point.
- The setup process is efficient and straightforward, facilitating a seamless transition between jobs.
- A bench vise serves the purpose of securely holding the workpiece in place during various tasks.
Disadvantages
- The process is slow due to the straight-line forward and backward movement for a stroke to be completed.
- The cutting speed is slow.
- Cutting tools might break during the cutting.
Conclusion
A shaper machine is a type of precision machining tool that is mainly used to create smooth, curved surfaces on metal or other material workpieces. It works by reciprocating a linear motion to remove material. The cutting tool is the main part of a shaper; it is positioned atop a ram that oscillates. A clamp holds the workpiece securely to a table. As the ram operates, the cutting tool removes material from the workpiece, shaping it as needed.