Hydraulic Shaper by Er. Abhisek Bhattacharjee

Hydraulic liquid is pumped by a constant discharge pump into the direction control valve. It has four ports and three stages. If the pressure goes beyond desired limits, the same is released by the pressure relief valve. The liquid reaches the right side of the cylinder through the inlet E and outlet A of the valve. Due to the pressure of the liquid, the piston moves towards left. The tool head moves forward to perform the forward cutting stroke. The liquid on the left side of the piston is sent back to the reservoir through B and P. Due to the change of position of plunger inside the valve, the liquid reaches the left side of the cylinder through the inlet E and outlet B. Piston moves towards right. The tool head moves in the opposite direction and this movement is known as the return stroke. The liquid on the right side of the piston is sent back to the reservoir through A and P.

Quick Return of the Ram

Due to the change of stroke volume of the cylinder during forward and return stroke, the piston returns at a faster rate. The stroke volume of the cylinder during return stroke is comparatively smaller than during forward stroke due to the presence of the piston rod. So, the pressure increases automatically to push the piston and the tool head at a faster speed during return stroke.

Parts of Hydraulic shaper machine:

Fixed Double Acting Cylinder, – Fixed in RAM of Machine
spool-type DC valve,
spool shaft stroke adjusting lever,
pump,
pressure relief valve or Relief valve
return line with filter,
oil reservoir.

Advantages of Hydraulic Shaping machine

Does not make any noise and operates very quietly
Ability to stall against an obstruction without damage to the tool or the
Ability to change length and position of stroke or speed while the machine is running
The cutting and return speeds are practically constant throughout the stroke. This permits the cutting tool to work uniformly during the cutting stroke.
The reversal of the ram is obtained quickly without any shock as the oil on the other end of the cylinder provides a cushioning effect.
Offers great flexibility of speed and feed
Relief Valve ensures proper pressure supply hence machine overloading is avoided.
More strokes per minute can be achieved by consuming less time for reversal and return stroke.

Disadvantages of Hydraulic Shaping Machine:

Hydraulic shaper machine is more costlier than mechanical shaper
The stopping point of the cutting stroke in a hydraulic shaper can vary depending upon the assistance offered to cutting by the work material.
Leakage of oil poses a major problem in machine tools. When the amount of leakage increases the capacity of the unit reduces and the efficiency goes down.

Application Hydraulic Shaper machine :

To generate straight and flat surfaces
To smooth rough surfaces
To make internal splines
To make gear teeth
To make dovetail slides
To make keyways in pullies or gears

Hydraulic Circuit by Er. Abhisek Bhattacharjee

The basis for all hydraulic systems is expressed by Pascal's law which states that the pressure exerted anywhere upon an enclosed liquid is transmitted undiminished, in all directions, to the interior of the container. This principle allows large forces to be generated with relatively little effort. The purpose of a specific hydraulic system may vary, but all hydraulic systems work through the same basic concept. Defined simply, hydraulic systems function and perform tasks through using a fluid that is pressurized. Another way to put this is the pressurized fluid makes things work. The power of liquid fuel in hydraulics is significant and as a result, hydraulic are commonly used in heavy equipment. In a hydraulic system, pressure, applied to a contained fluid at any point, is transmitted undiminished. That pressurized fluid acts upon every part of the section of a containing vessel and creates force or power. Due to the use of this force, and depending on how it’s applied, operato...

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