Objective
This activity aims to introduce students to the process of keyway cutting using a shaper machine. Students will learn how to align, secure, and machine a straight internal keyway on the previously fabricated flange. The focus will be on proper workholding, tool setup, and accurate stroke adjustment.
Materials and Equipment
The following materials and tools are essential for successfully completing this activity. Ensure they are available, complete, and in proper working condition before starting.
- Finished Flange with Bore
- Shaper Machine
- Shaping Tool
- Vise
- Vernier Caliper
- Safety Goggles
Procedure
Workpiece Preparation and Setup
- Ensure that the flange has been bored to the final diameter and that its internal bore is clean and free from burrs.
- Mount the flange securely in the vise on the shaper table, ensuring that the bore is oriented vertically and that the workpiece is firmly clamped.
- Use parallels or blocks if needed to raise the workpiece and ensure the bore is aligned with the tool stroke path.
- Visually confirm that the flange bore is square with respect to the shaper ram's travel.
Tool Setup and Stroke Adjustment
- Mount the internal shaping tool to the tool holder of the shaper.
- Adjust the stroke length to slightly exceed the depth of the bore.
- Position the tool to align with the centerline of the bore for keyway placement.
- Use manual jog or slow power strokes to check for tool clearance and alignment before beginning full-speed shaping.
Keyway Cutting
- Begin shaping using light passes. After each stroke, advance the tool slightly using the vertical feed or cross-slide feed.
- Periodically retract and clear chips from the bore to avoid tool jamming.
- Continue shaping until the desired keyway depth and width are achieved, based on the specified dimensions.
- Measure the keyway dimensions using a vernier caliper or depth gauge.
Finishing and Inspection
- Deburr the edges of the keyway to remove sharp corners or raised metal.
- Clean the workpiece and remove it from the vise.
- Inspect the keyway for dimensional accuracy and surface finish.
- Test-fit the intended key into the slot to ensure a proper fit.