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    SHAPER DUO

    Hexalobular Socket

    Hexalobular Socket

    Hexagon Socket

    Hexagon Socket

    Square Socket

    Square Socket

    • Now available for Hexalobular(6-lobe) Socket
    • Perfect fit for back spinde of Swiss machine
    • Achieves good corner edge sharpness
    • Less tool pressure than Rotary-Broaching
    • Easy to adjust for correct dimension
    • Economical double-ended insert bar (Except for Hexalobular)

    Comparison Chart of Hexalobular Socket Machining

      Tool Pressure Cycle Time Tool Cost High speed spindle Program  
    Shaper Duo
    Shaper Duo
    Not necessary Simple
    • No high speed spindle needed
    • A lot less cycle time
    End milling Necessary Complicated
    • Need high speed spindle
    • Time consuming process
    • Small diameter endmill driven by high-speed spindle is popular way to create Hexalobular(6-lobe) socket.
      It has some flexibility but needs high speed spindle unit and it is a time consuming process.
    • SHAPER DUO can make Hexalobular(6-lobe) socket faster and simpler.

    Comparison Chart of HEX Socket Machining

      Tool Pressure Cycle Time Flexibility Tool Cost  
    Shaper Duo
    Shaper Duo

    *Can be off-set by
    over-wrapping operation
    • Less tool pressure-especially on small diameter parts
    • One size can cover several socket sizes
    Broach Tool
    • Need to have tools for each socket size
    • Rotary-broach is an efficient way for Hexagon socket.
      But tool pressure is too much and often times it pushes part too hard.
    • SHAPER DUO system enables less tool pressure process and provides better tolerance with less cost.

    Process Chart

    ① Center drilling

    ① Center drilling

    Make a center hole which is smaller than pilot hole drill.

    ② Drilling (Pilot hole)

    ② Drilling (Pilot hole)

    Select a drill with same or smaller (0~-0.1mm) dia. as AF and machine a bit deeper because burrs may cause chipping on shaper insert

    ③ Shaper tool

    ③ Shaper tool

    Machine socket rotating 60 degrees 6 times

    ④ Chamfering

    ④ Chamfering

    Chamfer with the same pilot hole drill as ①

    ⑤ Deburring

    ⑤ Deburring

    Finish and deburr with the same drill as in process ②

    ☆Reduce cutting conditions due to heavy interruption

    SHAPER DUO Process Chart -Hexalobular-

    Socket Size Tool Pilot bore
    Dia.
     
    (mm)
    Starting “X”
    position
     
    (mm)
    Number of passes Estimated cycle time *
    Final “X”
    position
    (mm)
    Roughing
    pass
    0.025mm
    Finishing
    pass
    0.005mm
    ISO10664
    Stadard depth of Hexalobular hole
    (mm)
    Whole
    process
    ①-⑤
    Process④
    Shaper
    T6 SSP050N25T06 1.15 1.14 1.75 13 1 1.82 51 sec 23.2 sec
    T7 SSP050N31T07 1.38 1.35 2.06 15 1 2.44 59 sec 28.2 sec
    T8 SSP050N36T08 1.62 1.59 2.40 17 1 3.05 67 sec 33.8 sec
    T10 SSP050N41T10 1.92 1.89 2.80 19 1 3.56 75 sec 39.5 sec
    T15 SSP050N43T15 2.30 2.29 3.35 22 1 3.81 84 sec 46.2 sec
    T20 SSP050N46T20 2.71 2.69 3.95 26 1 4.07 94 sec 55.4 sec
    T25 SSP050N50T25 3.13 3.09 4.50 29 1 4.45 105 sec 63.8 sec
    T27 SSP050N55T27 3.52 3.51 5.07 32 1 4.70 115 sec 71.8 sec
    T30 SSP050N55T30 3.91 3.89 5.60 35 1 4.95 125 sec 80.2 sec

    *Using Carbide drill
    *Shaper cutting conditions
    Feed : 3000 mm/min DOC : 0.025 mm (Roughing), 0.005 mm (Finishing)

    SHAPER DUO Process Chart -Hexagonal-

    HEX
    Standard
    Tool Pilot bore
    Dia.
     
    (mm)
    Starting “X”
    position
     
    (mm)
    Number of passes Estimated cycle time *
    Final “X”
    position
    (mm)
    Roughing
    pass
    0.025mm
    Finishing
    pass
    0.005mm
    ISO 2936
    standard depth of Hex hole
    (mm)
    Whole
    process
    ①-⑤
    Process④
    Shaper
    HEX 1.5 SSP020N1130H 1.5 1.47 1.73 6 1 2 39 sec 14 sec
    HEX 2.0 SSP020N1430H 2.0 1.95 2.31 8 1 2.5 44 sec 16 sec
    HEX 2.5 SSP030N1940H 2.5 2.48 2.89 9 1 3 50 sec 20 sec
    HEX 3.0 SSP030N1940H 3.0 2.95 3.46 11 1 3.5 55 sec 23 sec
    HEX 4.0 SSP040N2450H 4.0 3.96 4.62 14 1 5 73 sec 33 sec
    HEX 5.0 SSP050N3260H 5.0 4.96 5.77 17 1 6 90 sec 46 sec
    HEX 6.0 SSP060N42120H 6.0 5.97 6.93 20 1 8 117 sec 63 sec
    HEX 8.0 SSP080N62160H 8.0 7.98 9.24 26 1 10 155 sec 92 sec

    *Pilot bore diameter is same or smaller(0-0.1mm) as AF
    *Using Carbide drill
    *Shaper cutting conditions
    Feed : 3000 mm/min DOC : 0.025 mm (Roughing), 0.005 mm (Finishing)

    Recommended Cutting Conditions

    Feed : 3000 mm/min (120 IPM)
    DOC : Roughing ??? 0.025 mm (.0010") + Finishing ??? 0.005 mm (.0002")

    Recommended Cutting Conditions

    Insert Bar -Hexalobular-

    Insert Bar -Hexalobular-

    Item Number Socket Size Hexalobular Socket Ds
    (mm)
    L2
    (mm)
    α
    (mm)
    β
    (mm)
    f
    (mm)
    Pilot Bore Dia
    (mm)
    Coated Carbide
    # A
    (mm)
    B
    (mm)
    TM4
    SSP050N25T06 T6 6 1.75 1.27 Ø5 2.5 1.08 1.09 2.4 Ø1.15 ●*
    SSP050N31T07 T7 - - - Ø5 3.1 1.27 1.29 2.4 Ø1.38 ●*
    SSP050N36T08 T8 8 2.4 1.75 Ø5 3.6 1.48 1.50 2.4 Ø1.62 ●*
    SSP050N41T10 T10 10 2.8 2.05 Ø5 4.1 1.67 1.70 2.4 Ø1.92 ●*
    SSP050N43T15 T15 15 3.35 2.4 Ø5 4.3 2.04 2.10 2.4 Ø2.30 ●*
    SSP050N46T20 T20 20 3.95 2.85 Ø5 4.6 2.41 2.50 2.4 Ø2.71 ●*
    SSP050N50T25 T25 25 4.5 3.25 Ø5 5.0 2.78 2.90 2.4 Ø3.13 ●*
    SSP050N55T27 T27 - - - Ø5 5.5 3.15 3.30 2.4 Ø3.52 ●*
    SSP050N55T30 T30 30 5.6 4.05 Ø5 5.5 3.52 3.70 2.4 Ø3.91 ●*

    ● : Stock
    *To be released in December 2016.

    Insert Bar -Hexagon-

    Insert Bar -Hexagon-

    Item Number Base AF
    (mm)
    HEX Standard
    size range
    (mm)
    AF range Ds
    (mm)
    L1
    (mm)
    L2
    (mm)
    h1
    (mm)
    α
    (mm)
    β
    (mm)
    f
    (mm)
    Coated Carbide
    (Inch) (mm) TM4
    SSP020N1130H HEX 1.5 HEX 1.5 - 2.0 .055 - .078 1.4 - 2.0 Ø2 50 3.0 1.8 1.1 0.8 0.40
    SSP020N1430H HEX 2.0 HEX 2.0 - 2.5 .075 - .102 1.9 - 2.6 Ø2 50 3.0 1.8 1.4 1.1 0.55
    SSP030N1940H HEX 3.0 HEX 2.5 - 3.5 .095 - .141 2.4 - 3.6 Ø3 50 4.0 2.8 1.9 1.6 0.8
    SSP040N2450H HEX 4.0 HEX 3.5 - 4.5 .134 - .181 3.4 - 4.6 Ø4 60 5.0 3.8 2.4 2.6 1.3
    SSP050N3260H HEX 5.0 HEX 4.5 - 6.0 .174 - .244 4.4 - 6.2 Ø5 70 6.0 4.8 3.2 3.4 1.70
    SSP060N42120H HEX 6.0 HEX 6.0 - 8.0 .233 - .322 5.9 - 8.2 Ø6 80 12.0 5.6 4.2 4.0 2.00
    SSP080N62160H HEX 8.0 HEX 8.0 - 12.0 .311 - .480 7.9 - 12.2 Ø8 80 16.0 7.6 6.2 4.7 2.35

    ● : Stock

    Insert Bar -Square-

    Insert Bar -Square-

    Item Number Base AF
    (mm)
    AF range Ds
    (mm)
    L1
    (mm)
    L2
    (mm)
    h1
    (mm)
    α
    (mm)
    β
    (mm)
    f
    (mm)
    Coated Carbide
    (Inch) (mm) TM4
    SSP020N1740S 2.0 .075 - .090 1.9 - 2.3 Ø2.0 50 4.0 1.8 1.70 1.60 0.70
    SSP025N1940S 2.5 .087 - .102 2.2 - 2.6 Ø2.5 50 4.0 2.3 1.95 1.80 0.65
    SSP030N2260S 3.0 .099 - .118 2.5 - 3.0 Ø3.0 50 6.0 2.8 2.20 2.05 0.65
    SSP035N2760S 3.5 .115 - .145 2.9 - 3.7 Ø3.5 60 6.0 3.3 2.70 2.25 0.60
    SSP040N3380S 4.0 .142 - .181 3.6 - 4.6 Ø4.0 60 8.0 3.8 3.35 3.05 1.15
    SSP050N39100S 5.0 .178 - .212 4.5 - 5.4 Ø5.0 70 10.0 4.8 3.90 3.95 1.55
    SSP060N47120S 6.0 .209 - .259 5.3 - 6.6 Ø6.0 80 12.0 5.6 4.75 4.50 1.70
    SSP080N58160S 8.0 .256 - .318 6.5 - 8.1 Ø8.0 80 16.0 7.6 5.80 5.50 1.70

    ● : Stock

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