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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

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