A comprehensive engineering model for the design,manufacture and assembly of helical carpenter shapers

Abstract

Currently, straight cutting-edge carpenter shapers are widely used in the production process. The manner of contact between this traditional type of shaper and the workpiece is a piecewise continuous curve. One drawback of shapers of this type is that the noise generated during the cutting process tends to be very loud. In order to overcome this problem, the current paper takes the thickness of the cutter into account and employs the concept of equidistant lines and surfaces to develop a new carpenter shaper that comprises a helical cutting edge on a cylindrical shank surface. The geometric shape of the blade surface that is mounted in the groove of the cutter shank is first derived. The contact curve of the proposed carpenter shaper with the workpiece is shown to be continuous. In order to establish a geometric model that facilitates the simple production of a carpenter helical shaping cutter, this paper presents a new design approach, which constructs an equidistant and equivalent involute helical surface model and a corresponding planar unwinding torus model. The carpenter shaper thus obtained is proven to be successful in reducing the noise levels of the cutting process. The contact style of the shaper also offers the additional advantages of higher cutting efficiency, lower energy consumption and longer tool-life. A numerical example is presented to illustrate the effectiveness of the proposed modelling approach. The results indicate that the proposed carpenter helical shaping (CHS) cutter model is accurate, efficient and comprehensive. The model is sufficiently accurate that it can be used as a guideline for the design, manufacture and assembly of robust, reliable and silent wooden shapers.

Keywords

helical cutting edges equidistance transformation carpenter helical shaping cutter involute helical surface helix curve

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