design and manufacturing of ISO 30 tool pocket by using CNC machining centre

1. INSTITUTE OF AERONAUTICAL ENGINEERING COLLEGE,
HYDERABAD
2016
DESIGN AND MANUFACTURING OF ISO
30 TOOL POCKET BY USING CNC
MACHINING CENTRE
MINI PROJECT
H Y D E R A B A D

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DESIGN AND MANUFACTURING OF ISO 30
TOOL POCKET BY USING CNC MACHINING
CENTRE
A PROJECT WORK
Submitted in fulfillment of the award of Degree of Bachelor of Technology
In Mechanical engineering
Submitted
By
CH SAGAR 13955A0305
T KRISHNA MURTHY 13955A0303
M SUDHEER 13955A0309
M VARMA 13955A0310
Under the Supervision of
C LABESH KUMAR (Assistant Professor)
T VANAJA SRINIVAS (Assistant Professor)
Department of Mechanical engineering
INSTITUTE OF AERONAUTICAL ENGINEERING
(Autonomous)
DUNDIGAL – 500 043, HYDERABAD, TELANGANA STATE
DEC, 2015

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INSTITUTE OF AERONAUTICAL ENGINEERING
(Autonomous)
DUNDIGAL – 500 043, HYDERABAD, TELANGANA
Department of Mechanical engineering
CERTIFICATE
This is to certify that the work embodies in this dissertation entitled
‘DESIGN AND MANUFACTURING OF ISO 30 TOOL POCKET BY
USING CNC MACHINING CENTRE’ is a bonafide being carried at “HMT
lmtd” submitted by ‘T KRISHNA MURTHY, CH SAGAR, M SUDHEER,
M VARMA’ Roll Nos. – ‘13955A0303, 13955A0305, 13955A0309,
13955A0310’ for partial fulfillment of the requirement for the award of
‘Bachelor of Technology in Mechanical Engineering discipline to Institute
of Aeronautical Engineering, Dundigal, Hyderabad, Telangana State,
during the academic year 2015-2016 is a record of bonafide piece of work,
undertaken by him/her the supervision of the undersigned.
Approved and Supervised by
Signature
(C LABESH KUMAR)
MECH, Assistant professor
Signature
T VANAJA SREENIVAS
MECH, Assistant professor
Forwardedby
(Dr. LV NARASIMHA PRASAD) (Prof VVSH PRASAD)
PRINCIPAL HOD of Mechanicalengineering
EXTERNAL EXAMINAR
Signature

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INSTITUTE OF AERONAUTICAL ENGINEERING
(Autonomous)
DUNDIGAL – 500 043, HYDERABAD, TELANGANA
Department of Mechanical engineering
DECLARATION
We ‘T KRISHNA MURTHY, CH SAGAR, M SUDHEER,
M VARMA’, are students of ‘Bachelor of Technology in Mechanical
Engineering’, session: 2015 - 2016, Institute of Aeronautical Engineering,
Dundigal, Hyderabad, Telangana State, hereby declare that the work presented
in this project work entitled ‘DESIGN AND MANUFACTURING OF ISO 30
TOOL POCKET BY USING CNC MACHINING CENTRE’ is the outcome
of our own bona fide work and is correct to the best of our knowledge and this
work has been undertaken taking care of engineering ethics. It contains no
material previously published or written by another neither person nor material
which has been accepted for the award of any other degree or diploma of the
university or other institute of higher learning, except where due
acknowledgment has been made in the text.
T KRISHNA MURHTY 13955A0303
CH SAGAR 13955A0305
M SUDHEER 13955A0309
M VARMA 13955A0310
Date:

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ACKNOWLEDGEMENT
We express our deep sense of gratitude and indebtedness to
Prof. VVSH PRASAD, HOD MECHANICAL DEPARTMENT, IARE, HYDERABAD.
For giving us opportunity to carry out this project. With immense pleasure we express our
deep sense of gratitude and respect to Mr. C LABESH KUMAR, Assistant Professor,
T VANAJA SRINIVAS, Assistant professor who was guiding us by giving his valuable
suggestions, constructive criticism and encouragement, which helped us to keep our spirits
high and to deal with problems. His meticulous methodology, critical assessment and warm
encouragement made it possible for me to bring the work in its present shape.
We are sincerely thankful to all other members of FACULTY OF
MECHANICAL, IARE, HYDERABAD for giving us time to time support in doing this
project. We express a word of thanks to our friends for their constant support, suggestions
and encouragement during preparation of this project.
Finally, we thank God for giving us the loving siblings and affectionate
parents, who blessed us with everything all throughout our life. Our gratitude to them cannot
be expressed in words. To them we owe our wonderful today and a dream filled tomorrow.

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.COMPANY PROFILE
 When HMT was founded in 1953, it dedicated itself to a clear objective: empowering
the emergence of Indian Industry. With the virtue of being founded on a strong
technical base, HMT donned the role of a one-of-its kind precision engineering
company. HMT leveraged its technical know-how, acquired from world leaders in
machine tools, to arm a wide spectrum of industries with vital manufacturing
machinery and solutions. Strongly supported by excellent R&D prowess, a highly-
skilled workforce and as many as nine exclusive machine tool units across the
country, HMT contributed enormously to the precision engineering arena.
 HMT Machine Tools’ expertise in machine tools has been honed to a point that it can
design and develop any kind of machine. From simple lathes to multi-station transfer
lines, from stand-along CNC machines to flexible manufacturing systems, leading to
factory automation, HMT Machine Tools’ Products cover general purpose machines,
special purpose machines and CNC machines to meet the application needs of every
engineering industry. To date, over 100,000 machine tools on par with international
standards in quality and performance, manufacture by HMT, are in use all over India.
The Company also manufactures sheet fed offset printing machines in single, two,
four, and five colours, programmable paper guillotines, ball screws, and CNC Control
Systems.
 HMT’s pioneering spirit and cutting-edge marketing abilities enable it to showcase its
products and services to a worldwide clientele. The establishment of HMT
(International) Limited leveraged the Company’s international trading experience.
HMT(I) markets the products through a global network that extends over 40 countries
to service its customers worldwide. HMT(I) has a diverse clientele with more than
18,000 machines in over 70 countries including the developed ones.

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ABSTRACT
The mini project work entitled “‘DESIGN AND MANUFACTURING OF
ISO 30 TOOL POCKET BY USING CNC MACHINING CENTRE’”
This work consist of ISO 30 pocket Design and Manufacturing. The Pocket is used
for clamping and unclamping of the tool holder. The detail design has been carried out using
Catia Software with all Dimensions. The Manufacturing of this pocket is done using Casting
process. This Casting process involves Pattern Making, Mould box preparation, Melting and
Pouring. Machining is performed on CNC Machining centre. The material used for this
pocket making is Aluminum.
An ISO 30 pockets is a standard spindle taper which is used to universally. ISO
standards for “international standard organization”. For the machining of any job on the
modern day CNC machines, we require different tools for different operations. All these have
to be clamped and unclamped the machining part which is spindle in many cases.

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CONTENTS
CERTIFICATE II
DECLARATION III
ACKNOWLEDGEMENT IV
COMPANY PROFILE V
ABSTRACT VI
1) Introduction to ISO 30 pockets 9
2) Introduction to CNC 10
3) Why taper is required 14
4) Design of ISO 30 pockets 15
a) 2D DIMESNIONS 15
b) 3D DIMENSIONS 16
5) Manufacturing process ofISO 30 pocket 17
6) Tools used in the manufacturing of ISO 30 pockets 19
a) Shoulder mill
b) End mill cutter 20
c) Drill bit 21
d) Boring bar 21
7) Working of ISO 30 pocket 22
8) Application of ISO 30 tool pocket 23
9) Advantages of ISO 30 pocket 24
10) Conclusion 26
11) REFERENCES 27

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INTRODUCTION TO ISO 30 POCKETS
An ISO 30 pockets is a standard spindle taper which is used universally. ISO standards for
International Standard organization which standardizes such complex tool structures so that
they could be used in any standard problems.
We require different tools for different operations. All these have to be clamped to the
machining part which is spindle in many cases. So for making it easy to clamp and unclamp
these many tools time, the part of that tool should be clamped is made taper. It slips even
after clamping.
An ISO 30 pockets is a standard spindle taper which is used to universally. ISO standards for
“International standardization for organization”. For the machining of any job on the modern
day CNC machines, we require different tools for different operations. All these have to be
clamped and unclamped the machining part which is spindle in many cases.

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An ISO 30 pockets are used in tool magazine. The tool magazine is an arrangement of
multiple tools that allows a CNC machine to rapidly change from one machining operation to
the next. The tool rotate along the tool magazine and the required tool are taken near to the
AUTOMATIC TOOL CHANGER. Automatic tool changer to perform a no. of operation in a
single setting of the job.
An ISO 30 pockets manufacturing on different operations (shoulder milling, cutting, end
milling, grooving, drilling, tapping, and surface finishing). These all operations are done on
CNC machine.

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INTRODUCTION TO CNC
A computer numerical control (CNC) program is a step by step set of coded
instructions consisting of a alphabet letters and symbol in a language, which the machine tool
unit can understand. The information in these instructions represents magnitude, speed and
direction of the operation of the machine tool.
The term “CNC Machine” is typically used to refer to a device which uses a rotating cutting
tool which moves in 3 or more axes (X, Y and Z) to cut-out or carve parts in different types
of materials. The information on these pages will focus on what are typically referred to as
“CNC Routers” although it would be applicable to most CNC milling and engraving
machines too.
The image to the right shows a typical CNC setup with labels for some of the key
components and also an indicator showing the 3 axis of movement (X, Y and Z) and their
directions in relation to this particular machine. This is just one example and it should be
noted there are many other types, sizes, ratios and configurations of CNC too.

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Words type used in CNC programming
As stated, the programs are made of lines of codes and codes and codes are made up
of words. The following words may be contained in preparation of a program.
Address Meaning
N Address of the block
G Preparatory functions
X,Y,Z Positional data
F Feed
S Spindle speed
T Tool
M Miscellaneous functions
Preparatory functions (G)
Preparatory functions are denoted by G. These functions are linked to the movement
of machine axes. Codes which are generally used in the manufacturing of ISO 50 pockets
are listed below.
G – Code Meaning
G00 Rapid traverse
G01 Linear interpolation with feed rate
G02 Circular interpolation (clockwise)
G03 Circular interpolation (Ccw)
G53 Zero offset off
G54 Zero offset #1
G55 Zero offset #2
G56 Zero offset #3
G57 Zero offset #4

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G80 Canned cycle off
G81 Drilling to final depth canned cycle
G82 Spot facing with dwell time canned cycle
G83 Deep hole drilling canned cycle
G84 Tapping or thread cutting with balanced chuck canned cycle
G85 Reaming canned cycle
G86 Boring canned cycle
Why taper is required:
For the machining of any job on the modern day CNC machine, we require different
tools for different operations. All these have to be clamped and unclamped to the machining
part which is spindle in many cases. So for making it easy to clamp and unclamp these many
tools time and time, the part of the tool that should be clamped is made taper. But as the part
of the tool which should be clamped is taper, it slips after clamping.
The taper is the conical shaped area of the tool holder that enters the spindle when
changing the tool. An 8 degree taper automatically centers the tool into the spindle. The
taper is accurately ground to a tolerance of .0002” for both the taper tolerance and outside
diameter tolerance. Some tool holders like HSK have a shorter taper than BT or CAT
style.

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DESIGNING OF ISO 30 POCKET
1) 2D DIMENSION
ISO Taper
(T)
Max. Dia.
(D)
D1 L
Collar Dia.
D2
Draw Bolt Thread
M
ISO-30 31.75 17.4 71 54 M-12
ISO-40 44.45 25.3 96 66.7 M-16
ISO-50 69.85 39.6 133 101.6 M-24

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2) 3D DIMENSIONS

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MANUFACTURING OF ISO 30 POCKETS
Metalcasting processes
Casting:-
casting is one of the oldest manufacturing process. It is the first step in making most
of the products.
Steps: -
Making mould cavity - Material is first liquefied by properly heating it in a suitable
furnace. - Liquid is poured into a prepared mould cavity - allowed to solidify - product is
taken out of the mould cavity, trimmed and made to shape.
We should concentrate on the following for successful casting operation:
(i) Preparation of moulds of patterns
(ii) Melting and pouring of the liquefied metal
(iii) Solidification and further cooling to room temperature
(iv) Defects and inspection
Steps in making sand castings
The six basic steps in making sand castings are, (i) Pattern making, (ii) Core making,
(iii) Moulding, (iv) Melting and pouring, (v) Cleaning
Pattern making - Pattern: Replica of the part to be cast and is used to prepare the mould
cavity. It is the physical model of the casting used to make the mould. Made of either wood
or metal.
The mould is made by packing some readily formed aggregate material, such as
moulding sand, surrounding the pattern. When the pattern is withdrawn, its imprint provides
the mould cavity. This cavity is filled with metal to become the casting. If the casting is to be
hollow, additional patterns called ‘cores’, are used to form these cavities.

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Core making Cores are placed into a mould cavity to form the interior surfaces of castings.
Thus the void space is filled with molten metal and eventually becomes the casting.
Moulding Moulding is nothing but the mould preparation activities for receiving molten
metal. Moulding usually involves: (i) preparing the consolidated sand mould around a pattern
held within a supporting metal frame, (ii) removing the pattern to leave the mould cavity with
cores. Mould cavity is the primary cavity. The mould cavity contains the liquid metal and it
acts as a negative of the desired product. The mould also contains secondary cavities for
pouring and channeling the liquid material in to the primary cavity and will act a reservoir, if
required.
Melting and Pouring The preparation of molten metal for casting is referred to simply as
melting. The molten metal is transferred to the pouring area where the moulds are filled.

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Cleaning Cleaning involves removal of sand, scale, and excess metal from the casting.
Burned-on sand and scale are removed to improve the surface appearance of the casting.
Excess metal, in the form of fins, wires, parting line fins, and gates, is removed.
Inspection of the casting for defects and general quality is performed.

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MANUFACTURING PROCESS ON MACHINE
1. FACING
2. TURNING
3. MILLING
4. SLOTTING
5. DRILILNG
6. SURFACE FINSHING
CNC PROGRAMMING FOR FOUR SIDE MILLING OF THESE COMPONENT
000 54
M06 T03
G90 G54 G00 X50 Y0 Z10
M03 S1000
G01 Z 2
G01 X0
G01 Y30
G01 Y30
G01 Z10
G01 X50
G01 Z3
G01 X0
G01 Y30
G01 Y30
G01 Z10
G01 X50
G01 Z50
M02;

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PROGRAMS
G00 Rapid positioning
G01 Linear inter rotation
G54 selection off set
G90 Absolute programming
M30 end of tape and main program end

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Tools usedin the manufacturing of ISO 30 pockets
a) Shoulder mill
• Shoulder mills generate two faces simultaneously which requires both
peripheral milling in combination with face milling.
• Shoulder milling can be done on plane surface, in grooves, in bores, etc.
and each different surface needs a suitable kind of shoulder mill.
b) End mill :
• End mill is also a rotary cutting tool but unlike reamer or hole mill which
cut in the sideways of a bore.
• End mill removes material in the axial direction (at the front tip of the
tool) generally end mills are used for enlarging the a small portion of the
bore so that the head of the LN-Key screw fits in and does not protrude
out of the surface.

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c) Drill:
• These are also called twist drills.
• Drills are generally used to make cylindrical holes in a work piece.
• Actually drill bits are available in different sizes. Depending on the size
of the hole required the corresponding drill bit is selected and is clamped
in to the drill.
• Bits are held in a tool called a drill, which rotates them and provides
torque and axial force required to create the hole.
d) Boring bar :
• Boring bars have three primary components although many differing
designs.
• The parts include the body, bar holder and dial screw (graduated micro
screw).
• These boring bars are clamped to the spindles for boring or they can also
be used for slotting purpose.

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How to ToolPocketsWork
Tool holders have three main parts: the taper, the flange, and the collet pocket. Driven or
"live" toolingis powered. Static toolingis not.
 The taper is the conically-shaped area of the tool holder that enters the spindle during
tool changing.
 The flange is the part of the tool holder to which the automatic tool changer is
attached when the tool holder is movedfrom the tool changer to the spindle.
 The collet pocket is the area into which the collet is inserted before being secured by
various types of collet nuts.
Some tool holders shrink-fit around the machine tool or cutting tool and remain firmly in
place. Others are optimized to the smallest size possible to allow for maximum clearances
during machining.
ISO 30 pockets Applications:
• To improve the productionand tool carryingcapacityof the machine.
• It is very quickly.
• It reducing the nonproductive time.
• It is usedto improve the capacity of the machine to the work with a no. of tools.
• It is also usedto change worn out or brokentools.
USE
• Tools with a tapered shank are inserted into a matching tapered socket and pushed
or twisted into place. They are then retained by friction. In some cases, the friction
fit needs to be made stronger, as with the use of a drawbar, essentially a long bolt
that holds the tool into the socket withmore force thanis possible by other means.
• Caution needs to be exercised in the usual drilling machine or lathe situation,
which provides no drawbar to pull the taper into engagement, if a tool is used
requiring a high torque but providing little axial resistance. An example would be
the use of a large diameter drill to slightly enlarge an existing hole. In this
situation, there may be considerable rotary loading. In contrast, the cutting action
will require very little thrust or feed force. Thrust helps to keep the taper seated
and provides essential frictional coupling.
• The tang is not engineered to withstand twisting forces which are sufficient to
cause the taper to slip, and will frequently break off in this situation. This will
allow the tool to spin in the female taper, which is likely to damage it. Morse taper
reamers are available to alleviate minor damage.
• Tapered shanks "stick" in a socket best when both the shank and the socket are
clean. Shanks can be wiped clean, but sockets, being deep and inaccessible, are
best cleaned with a specialized taper cleaning tool which is inserted, twisted, and
removed.

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• Tapered shank tools are removed from a socket using different approaches,
depending on the design of the socket. In drill presses and similar tools, the tool is
removed by inserting a wedge shaped block of metal called a "drift" into a
rectangular shaped cross hole through the socket and tapping it. As the cross
section of the drift gets larger when the drift is driven further in, the result is that
the drift, bearing against the foremost edge of the tang, pushes the tool out. In
many lathe tailstocks, the tool is removed by fully withdrawing the quill into the
tailstock, which brings the tool up against the end of the lead screw or an internal
stud, separating the taper and releasing the tool. Where the tool is retained by a
drawbar, as in some mill spindles, the drawbar is partially unthreaded with a
wrench and then tapped with a hammer, which separates the taper, at which point
the tool can be further unthreaded and removed. Some mill spindles have a captive
drawbar which ejects the tool when actively unscrewed past the loose stage; these
do not require tapping. For simple sockets with open access to the back end, a drift
punch is insertedaxially from behind and the tool tappedout.

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Conclusion
ISO 30 pocket tool have been casted by using Aluminium as a material which is
replica for original pocket tool. The pattern for making this Aluminium casting is made of
wood. After casting machine has been carried Horizontal machining centre with all
necessary all programming’s. The detail design has been carried out in Catia with all
Dimensions.
The same process canbe carriedout by using different material inthe future scope.

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References
 R.S.Khurmi “Design of Machine Elements”, Eurasnia publishing house 3 Pvt Ltd,
14th revised edition.
 R K Jayan “Production technology”, publishing house 3 pvt ltd, 14th revised edition.