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Work holding

Work holding

Hi,
I have a Royal Shaper, which seems to be in reasonable condition. I have used it once or twice, but the results are not very good. I fitted a machine vise, then levelled the ways of the vise with a DTI using the table adjustments.
I fit a piece of metal into the vice, go over it once with the tool, turn it over and repeat. The metal is never parallel.Anything better than abou 5 thou is impossible. I have tried walloping the metal with a hide mallet, while it is in the vise, in order to make proper contact with the ways,still no good.
Any ideas please?
Jack

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Jack Rogerson
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Re: Work holding

Hello Jack,
I'm not sure which way you are getting an error or whether it is consistent. Consistency is very significant as it can be a very good clue as to where the problem lies.

Have you clocked the table &/or vice from the ram? That is what is doing the cutting so should be your reference. If the table slides are loose or worn, the table will tend to droop, using an outboard support may then lead to indeterminate results.

I am assuming, you have the jaws of the vice parallel to the ram so that they open and close perpendicular to the ram and the problem is that a job ends up tapered from end to end. You say 005, but over what length? The base of the vice between the jaws is only probably 3" wide so if your 005 taper is over, say 8", that's less then a thou per side across the width of the vice. It's not too hard to get that much from dirt, surface damage, and even bounce when knocking the work down as well as any slackness in the vice motion which will tend to lift the moving jaw upwards as you clamp it up.

If you could give a bit more detail about the geometry it might help define the source of the problem more definitively.

Rgds
Richard

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Re: Work holding

Jack/ Richard,
Richard is quite right in saying that you need to fill in more detail about your setup, sizes etc to get to the bottom of this problem.
Which way are you turning over, rolling over or end for end?

Another aspect of checking the accuracy of a shaper is to check the linearity of the ram motion. put a known parallel in the vice and DTI on the tool box. Set the parallel true over the full stroke and then look at the intermediate points.Ram slide wear will show that the tool does a bit of a banana shaped motion.
Whilst set up this way check to see if there is variation in the ram fit by trying to lever the toolbox upwards against its weight at both in and outstroke limits. When you are cutting the tool will tend to lift more at the outstroke end than at the instroke and you don't see that when just doing an initial unloaded check but that could contribute to your errors. Each error may only be small but if they all add together rather than cancel each other out you can get the problems you are experiencing.
Regards Bob D

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Bob Dodds
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Re: Work holding

Richard/Bob
The workpieces in question are quite small.no more than 4" long and 3" wide.It was turned over end for end.The vise jaws are parallel to the axis of the ram.
I did use a DTI, fixed to the ram, in order to get my vise true. However I didn't pay particular attention to the fact that the ram ways could be worn, just never thought of it at the time.As you might have guessed, I'm new to using shapers. I think the problem may possibly be with the vise, as, although it's quite large, it is only a lightweight affair. I will re-check the truth of the vise, and  as suggested look for wear on the ram.
Thank you for your help.
Jack

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Re: Work holding

Jack,
One remaining question: Which way is the taper? Along parallel with the ram or across the width of the part. And a subordinate question, is the taper always broadly the same and in the same direction?

When you are checking the ram, it may be just that the gibbs need a little adjustment.

When you check the vice, also try resting the DTI on top of the moving jaw while you tighten it onto someting - you may find it lifts. If it were to lift by 0025, then you flip the work end for end and do the same again, there's your 005" across the job for example.

Richard

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Re: Work holding

Richard,
I can't honestly answer your questions. I think I will have to go back and do some more tests. I will take more care this time to see exactly what is happening.
Thank you
Jack

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