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

Select a pilot hole drill which is bigger dia. than AF.

②  Drilling (Pilot hole)

②  Drilling (Pilot hole)

Select a drill with same dia. as AF and machine a bit deeper because burrs may cause chipping on shaper insert

③ Chamfering

③ Chamfering

Chamfer with the same pilot hole drill as

① (Chamfer can be done at same time as ①).

④ Shaper tool

④ Shaper tool

Machine HEX portion rotating 60 degrees 6 times

⑤ Chamfering

⑤ Chamfering

Finish and deburr with the same drill as in process②

☆Reduce cutting conditions due to heavy interruption

SHAPER DUO Process Chart -Hexalobular-

Socket Size Tool Pilot bore
Dia.
 
(mm)
Total DOC
/side
 
(mm)
Number of passes Estimated cycle time *
Total pass
/side
Roughing
pass
0.025mm
Finishing
pass
0.010mm
ISO10664
Stadard depth of Hexalobular hole
(mm)
Whole
process
①-⑤
Process④
Shaper
T6 SSP050N25T06 1.15 0.3 13 12 1 1.82 51 sec 23.2 sec
T7 SSP050N31T07 1.38 0.34 15 14 1 2.44 59 sec 28.2 sec
T8 SSP050N36T08 1.62 0.39 17 16 1 3.05 67 sec 33.8 sec
T10 SSP050N41T10 1.92 0.44 19 18 1 3.56 75 sec 39.5 sec
T15 SSP050N43T15 2.3 0.525 22 21 1 3.81 84 sec 46.2 sec
T20 SSP050N46T20 2.71 0.62 26 25 1 4.07 94 sec 55.4 sec
T25 SSP050N50T25 3.13 0.685 29 28 1 4.45 105 sec 63.8 sec
T27 SSP050N55T27 3.52 0.775 32 31 1 4.70 115 sec 71.8 sec
T30 SSP050N55T30 3.91 0.845 35 34 1 4.95 125 sec 80.2 sec

*Using Carbide drill
*Shaper cutting conditions
Feed : 3000 mm/min DOC : 0.025 mm (Roughing), 0.010 mm (Finishing)

SHAPER DUO Process Chart -Hexagonal-

HEX
Standard
Tool Pilot bore
Dia.
 
(mm)
Total DOC
/side
 
(mm)
Number of passes Estimated cycle time *
Total pass
/side
Roughing
pass
0.025mm
Finishing
pass
0.010mm
ISO 2936
standard depth of Hex hole
(mm)
Whole
process
①-⑤
Process④
Shaper
HEX 1.5 SSP020N1130H 1.5 0.116 6 5 1 2 39 sec 14 sec
HEX 2.0 SSP020N1430H 2.0 0.155 7 6 1 2.5 44 sec 16 sec
HEX 2.5 SSP030N1940H 2.5 0.193 9 8 1 3 50 sec 20 sec
HEX 3.0 SSP030N1940H 3.0 0.232 10 9 1 3.5 55 sec 23 sec
HEX 4.0 SSP040N2450H 4.0 0.309 13 12 1 5 73 sec 33 sec
HEX 5.0 SSP050N3260H 5.0 0.387 17 16 1 6 90 sec 46 sec
HEX 6.0 SSP060N42120H 6.0 0.464 20 19 1 8 117 sec 63 sec
HEX 8.0 SSP080N62160H 8.0 0.619 26 25 1 10 155 sec 92 sec

*Pilot bore diameter is same as AF
*Using Carbide drill
*Shaper cutting conditions
Feed : 3000 mm/min DOC : 0.025 mm (Roughing), 0.010 mm (Finishing)

Recommended Cutting Conditions

Feed : 3000 mm/min (120 IPM)
DOC : Roughing ・・・ 0.025 mm (.0010") + Finishing ・・・ 0.010 mm (.0004")

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 1.2 1.09 0.5 Ø1.25 ●*
SSP050N31T07 T7 - - - Ø5 3.1 1.4 1.29 0.6 Ø1.48 ●*
SSP050N36T08 T8 8 2.4 1.75 Ø5 3.6 1.6 1.50 0.7 Ø1.72 ●*
SSP050N41T10 T10 10 2.8 2.05 Ø5 4.1 1.8 1.70 0.8 Ø2.02 ●*
SSP050N43T15 T15 15 3.35 2.4 Ø5 4.3 2.2 2.10 1.0 Ø2.40 ●*
SSP050N46T20 T20 20 3.95 2.85 Ø5 4.6 2.6 2.50 1.2 Ø2.81 ●*
SSP050N50T25 T25 25 4.5 3.25 Ø5 5.0 3.0 2.90 1.4 Ø3.23 ●*
SSP050N55T27 T27 - - - Ø5 5.5 3.4 3.30 1.6 Ø3.62 ●*
SSP050N55T30 T30 30 5.6 4.05 Ø5 5.5 3.8 3.70 1.8 Ø4.01 ●*

● : 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