INSTITUTE OF AERONAUTICAL ENGINEERING COLLEGE, HYDERABAD

DESIGN AND MANUFACTURING OF ISO 30 TOOL POCKET BY USING CNC MACHINING

CENTRE

A PROJECT WORKSubmitted in fulfillment of the award of Degree of Bachelor of Technology

In Mechanical engineeringSubmitted

By

CH SAGAR 13955A0305T KRISHNA MURTHY 13955A0303M SUDHEER 13955A0309M VARMA 13955A0310

Under the Supervision of

C LABESH KUMAR (Assistant Professor) T VANAJA SRINIVAS (Assistant Professor)

Department of Mechanical engineeringINSTITUTE 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, TELANGANADepartment 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

SignatureT VANAJA SREENIVASMECH, Assistant professor

Forwarded by

(Dr. LV NARASIMHA PRASAD) (Prof VVSH PRASAD)PRINCIPAL HOD of Mechanical engineering

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 13955A0303CH SAGAR 13955A0305M SUDHEER 13955A0309M 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 15a) 2D DIMESNIONS 15b) 3D DIMENSIONS 16

5) Manufacturing process of ISO 30 pocket 17

6) Tools used in the manufacturing of ISO 30 pockets 19a) Shoulder millb) End mill cutter 20c) Drill bit 21d) 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.

D2Draw 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

Metal casting 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. FACING2. TURNING3. MILLING4. SLOTTING5. DRILILNG6. 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 used in 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 Tool Pockets Work

Tool holders have three main parts: the taper, the flange, and the collet pocket. Driven or "live" tooling is powered. Static tooling is 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 moved from 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 production and tool carrying capacity of the machine.

• It is very quickly.

• It reducing the nonproductive time.

• It is used to improve the capacity of the machine to the work with a no. of tools.

• It is also used to change worn out or broken tools.

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 with more force than is 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.

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• 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.

• 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 inserted axially from behind and the tool tapped out.

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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 can be carried out by using different material in the 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.

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