Turning Manufacturing Process: Workbook April 2007 MT11055 - NX 5

Turning Manufacturing Process
Workbook
April 2007
MT11055 NX 5
Publication Number
mt11055_w NX 5
Proprietary & Restricted Rights Notice
This software and related documentation are proprietary to UGS PLM

Software.
Copyright 2007 UGS PLM Software. All Rights Reserved.
All trademarks belong to their respective holders.
Turning Manufacturing Process Workbook
mt11055_w NX 5
Contents
The manufacturing process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Process planning sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

The finished program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Replay the finished program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 2
Machining environment and spindle setup . . . . . . . . . . . . . . . . . . . 3-1
Define machining environment and spindle setup . . . . . . . . . . . . . . . . . 3- 2
Define tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Create and define tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 2
Define the geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Define part boundaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 2
Define blank geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Define the Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 2
Define the IPW at spindle 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Define blank geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 2
Create a facing operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Create the operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 2
Create a centerline spotdrill operation . . . . . . . . . . . . . . . . . . . . . . 9-1
Create the operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 2
Create a centerline drill operation . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Create the operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 2
Create a rough OD operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Create a groove OD operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
UGS Corp., All Rights Reserved
Contents
Create a rough bore ID operation . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

Create the Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 2
Create a finish bore ID operation . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
Create a groove ID operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
Create a finish OD operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
Create a facing operation on the back side . . . . . . . . . . . . . . . . . . 17-1
Create a groove face operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1
Create a thread OD operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1
Postprocess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
Postprocess the program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20- 2
Shop documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-1
Create and save a tool list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21- 2
mt11055_w NX 5
The manufacturing process
This project allows you to practice many of the Turning concepts you learned
in the student manual. Its purpose is to guide you through the general
workflow process. This project assumes you are familiar with basic Turning
functionality, and therefore does not give detailed step-by-step instructions. If
necessary, you can refer back to the Student Manual for details.
In this project, you will create a two-spindle Turning program. You will define
the spindle setup and reference the in-process workpiece (IPW) at the second
spindle. You will create a program that cuts one end of the part (1), transfers
the part to the other spindle, and then cuts the other end of the part (2). You
will verify your program by visualizing the material removal as you create
the operations. Finally, you will Post Process and create shop documentation.
mt11055_w NX 5
Lesson
Process planning sheet
The following process plan represents the manufacturing of the part. Included
are the operation number, work center designation, operation description,
operation name, and tool description. A definition of these items follows:
Operation Number is the sequential order in which a process is performed.
Work Center is the particular work area in which the operation is

performed.
Description is the detailed description of the operation that is to be

performed.
Operation Name is the actual name of the operation used to machine

the specific feature or task.
Tool is the description of the tool used to machine the specific feature.
Operation
Number
Work Center
Description
Operation
Name
Tool
FACING
OD_80_L
Piston
100.00
CNC
Mill-Turn
Horizontal
Mill-Turn,
Side 1, Mach.
No. 1450,
Tape No.
12345_A
100.10
Finish right
face of part
100.20
Centerline
CENTERspotdrill right LINE
end of part
SPOTDRILL
SPOTDRILLING
TOOL
100.30
Centerline
peckdrill
through part
DRILLING
TOOL
CENTERLINE
PECKDRILL
1-1
Process planning sheet
1
100.50
Rough the
outside
diameter
Groove
outside
diameter
ROUGH
TURN OD
100.60
Rough
bore inside
diameter
ROUGH
BORE ID
100.65
Groove inside GROOVE ID

diameter
100.67
Finish
the inside
diameter
Finish
outside
diameter
100.55
100.70
200.10
200.20
200.30
300
400
500
1-2
Change to
spindle 2 and
finish left face
of part
Groove left
face of part
Thread
outside
diameter
Inspection
Inspect
1st article
features
machined
in operation
numbers 100
thru 1010
Manual
deburr and
Deburr Clean clean part
per customer
specs
Inspection
Final
inspection
of all features
OD_80_L
GROOVE OD OD_GROOVE
_L
FINISH
BORE ID
ID_80_L
ID_GROOVE
_L
ID_55_L
FINISH
TURN OD
OD_80_L
FACING 1
OD_80_L
GROOVE
FACE_GROOVE_L
FACE
THREAD OD OD_THREAD_L
mt11055_w NX 5
Lesson
The finished program
You will begin by replaying the finished program. This will give you an
overview of the program you will be creating in this project.
2-1
The finished program
Replay the finished program
2-2
Step 1:
Open tmp_piston_mfg_demo_1 from the workbook_parts

directory and go into the Manufacturing application.
Step 2:
Visualize the program using 2D Material Removal.
Step 3:
Look at the finished program in the Geometry View.
Step 4:
Close the part.
mt11055_w NX 5
Lesson
Machining environment and

spindle setup
3
Before you define part geometry, blank geometry, specify tools, or create
operations, you must define the machining environment and the spindle
setup. Spindle1 has already been defined for you. You will define Spindle2.
3-1
Machining environment and spindle setup
Define machining environment and spindle setup

Step 1:
Open tmp_piston_mfg_asmb_1 from the workbook_parts

directory.
Step 2:
Rename the part ***_piston_mfg_asmb_1, where *** represents

your initials.
Step 3:
Display the Geometry View of the Operation Navigator and expand

the objects.
Step 4:
Double-click MCS_SPINDLE in the Operation Navigator and click

CSYS Dialog next to Specify MCS. Notice that the origin of the
MCS defining this spindle is centered on the left face of the part.
Only the first spindle has been defined.

Step 5:
3-2
Create an MCS defining the second spindle. Be sure you position it

centered on the left face of the part.
mt11055_w NX 5
Machining environment and spindle setup
Step 6:
Rename the objects as illustrated below. This way, it will be easy

to tell which workpiece is associated with which spindle.
3-3
Lesson
Define tools
Tools must be created or retrieved from the library. The tools required to
machine this part are identified in the Process Planning Sheet.
4-1
Define tools
Create and define tools

Step 1:
Create a carrier called TURRET that uses the X/Y Plane.
Step 2:
Create 12 pockets called FACE_1 through FACE_12.
Step 3:
Create the tools identified in the Process Planning Sheet and put
them in the appropriate FACE.
The Machine Tool View of the Operation Navigator should be
organized as illustrated below.
Step 4:
Modify the tools as follows:

Set the (D) Diameter of the DRILLING_TOOL to 0.600.
Set the (IW) Insert Width of the FACE_GROOVE_L tool to
0.150.
Set the (IW) Insert Width of the ID_GROOVE_L tool to 0.100.
Set the Size of the ID_80_L and ID_55_L tools to Inscr. Circle
(IC) 0.250.
Set the (IW) Insert Width of the OD_GROOVE_L tool to 0.100.
4-2
mt11055_w NX 5
Lesson
Define the geometry
You will define part boundaries at each spindle.
5-1
Define the geometry
Define part boundaries

Step 1:
Double-click to edit the WORKPIECE_1 object in the Operation

Navigator and define the part geometry at Spindle 1 by selecting
the body.
Step 2:
Double-click to edit the WORKPIECE_2 object in the Operation

Navigator and define the part geometry at Spindle 2 by selecting
the body.
Step 3:
Make Layer 1 Invisible.
Step 4:
Display the part boundary in the TURN_WORKPIECE objects

for both spindles.
5-2
mt11055_w NX 5
Lesson
Define blank geometry
Blank geometry representing the original bar stock must be defined at

Spindle 1.
6-1
Define the Geometry

Step 1:
Double-click to edit the TURN_WORKPIECE_1 object in the

Operation Navigator and define the blank boundary as bar stock
using the following values:
Length = 3.500
Diameter = 3.200
Mounting Position Base Point: X = 0.250, Y = 0.000, Z = 0.000
Step 2:
Be sure to use At Headstock for the point location.
6-2
mt11055_w NX 5
Lesson
Define the IPW at spindle 2
The blank geometry at Spindle 2 will be defined by the in-process workpiece

(IPW) referenced from the first workspace.
7-1
Define the IPW at spindle 2

Step 1:
Double-click to edit the TURN_WORKPIECE_2 object in the

Operation Navigator and define the blank geometry by choosing
From Workspace and specifying corresponding Reference (1) and
Target (2) points. Be sure to select Flip Direction so that the
vectors display as illustrated below.
7-2
mt11055_w NX 5
Lesson
Create a facing operation
The following phases of the turning manufacturing process pertain to the

creation of operations, generation of tool paths, and verification of material
removal. You will repeat these three phases for each operation you create
until you have completed the program.
You will create an operation that faces the end of the part using a Linear Zig
cutting motion.
8-1
Create a facing operation
Create the operation

Step 1:
Create a FACING operation at Spindle 1 using the following:

Program: PROGRAM
Tool: OD_80_L
Geometry: TURN_WORKPIECE_1
Method: LATHE_ROUGH
Step 2:
Define an Axial trim plane that constrains the cut region in such a
way that only the right end of the part is faced.
Step 3:
Specify a Start point at the approximate screen position illustrated

below using a Direct motion. Use the same location for the Return
Point.
Step 4:
Specify Additional Profiling.
Step 5:
Generate the tool path.
Step 6:
Verify using 2D Material Removal.
8-2
mt11055_w NX 5
Lesson
Create a centerline spotdrill

operation
Before drilling the centerline of the part, you must first create a Centerline
Spotdrill operation.
9-1
Create a centerline spotdrill operation

Step 1:
Create a CENTERLINE_SPOTDRILL operation at Spindle 1

using the following:
Program: PROGRAM
Tool: SPOTDRILLING_TOOL
Method: LATHE_CENTERLINE
Step 2:
Specify a Return Point at the approximate screen positions

illustrated below using a Direct motion.
Step 3:
9-2
mt11055_w NX 5
Lesson
10 Create a centerline drill operation
You will create a Centerline Drill operation that uses a breakchip motion to
drill completely through the center of the part.
10
10-1
Create a centerline drill operation

Step 1:
Create a CENTERLINE_PECKDRILL operation at Spindle 1

using the following:
Program: PROGRAM
Tool: DRILLING_TOOL
Method: LATHE_CENTERLINE
Step 2:
Define a Total Depth that drills completely through the blank

material.
Step 3:
Specify a constant chip removal increment of 1.0.
Step 4:
Specify a Return Point at the approximate screen position

illustrated below using a Direct motion.
Step 5:
Step 6:
10
10-2
mt11055_w NX 5
11
Lesson
11 Create a rough OD operation
You will create an operation that roughs the outside diameter of the part
using a linear zig motion.
11-1
Create a rough OD operation
11

Step 1:
Create a ROUGH_TURN_OD operation at Spindle 1 using the

following:
Program: PROGRAM
Tool: OD_80_L
Method: LATHE_ROUGH
11-2
Step 2:
Define an Axial trim plane at -0.050.
Step 3:
Omit the Reversal Mode so that the tool does not cut into the
neckdown areas.
Step 4:

Point.
Step 5:
Step 6:
mt11055_w NX 5
Lesson
12 Create a groove OD operation
12
You will create an operation that cuts the outside diameter groove using
a Plunge Zig motion.
12-1
Create a groove OD operation

Step 1:
Create a GROOVE_OD operation at Spindle 1 using the following:

Program: PROGRAM
Tool: OD_GROOVE_L
Method: LATHE_GROOVE
12
12-2
Step 2:
Specify a constant 75% stepover.
Step 3:
Define two trim points at the ends of the vertical lines to constrain
the cut region to the groove.
Step 4:

Point.
Step 5:
Step 6:
Verify using 2D Material Removal
mt11055_w NX 5
Lesson
13 Create a rough bore ID operation

13
You will create an operation that rough bores the inside diameter using
a Linear Zig motion.
13-1
Create a rough bore ID operation
Create the Operation

Step 1:
Create a ROUGH_BORE_ID operation at Spindle 1 using the

following:
Program: PROGRAM
Tool: ID_80_L
Method: LATHE_ROUGH
13
13-2
Step 2:
Specify a constant cut depth of 0.030.
Step 3:

Point.
Step 4:
Step 5:
mt11055_w NX 5
Lesson
14 Create a finish bore ID operation
You will create an operation that finish bores the inside diameter.
14
14-1
Create a finish bore ID operation

Step 1:
Create a FINISH_BORE_ID operation at Spindle 1 using the

following:
Program: PROGRAM
Tool: ID_55_L
Method: LATHE_FINISH
Step 2:
Define an Axial trim plane at the corner of the chamfer.
Step 3:
Define a Radial trim plane at the bottom of the groove.
Step 4:

Point.
14
14-2
mt11055_w NX 5
Create a finish bore ID operation
Step 5:
Step 6:
14
14-3
14
Lesson
15 Create a groove ID operation
You will create an operation that cuts the inside diameter groove using a
Plunge Alternate motion.
15
15-1
Create a groove ID operation

Step 1:
Create a GROOVE_ID operation at Spindle 1 using the following:

Program: PROGRAM
Tool: ID_GROOVE_L
Step 2:
Specify a Plunge Alternate cutting motion.
Step 3:
Step 4:
Define two trim points at the ends of the vertical lines to constrain
the cut region to the groove.
Step 5:
Specify a Start and Return Point at the approximate screen

position illustrated below.
Step 6:
Step 7:
15
15-2
mt11055_w NX 5
Lesson
16 Create a finish OD operation
You will create a Finish OD operation that finishes the outside diameter
using the Machine all Regions parameter.
16
16-1
Create a finish OD operation

Step 1:
Create a FINISH_TURN_OD operation at Spindle 1 using the

following:
Program: PROGRAM
Tool: OD_80_L
Geometry:TURN_WORKPIECE_1
Method: LATHE_FINISH
Step 2:
Omit the reversals.
Step 3:
Machine all of the regions.
Step 4:
Define an Axial Trim Plane at 0.050.
Step 5:
Specify a Return Point at the approximate screen position

illustrated below.
Step 6:
Step 7:
16
16-2
mt11055_w NX 5
Create a finish OD operation
So far, your program should look like this in the Geometry View of the
Operation Navigator.
16
16-3
16
Lesson
17 Create a facing operation on

the back side
You will create an operation that faces the back side of the part using a Linear
Zig motion. This operation requires the part to be transferred to Spindle 2.
17
17-1
Create a facing operation on the back side

Step 1:
Create a FACING operation at Spindle 2 using the following:

Program: PROGRAM
Tool: OD_80_L
Method: LATHE_ROUGH
Step 2:
Specify an additional profiling pass.
Step 3:
Choose Cutting and clear the Undercut check box.
Step 4:

below. Use the same location for the Return Point.
Step 5:
Step 6:
17
17-2
mt11055_w NX 5
Lesson
18 Create a groove face operation
You will create an operation that cuts the face groove using a Plunge
Alternate motion.
18
18-1
Create a groove face operation

Step 1:
Create a GROOVE_FACE operation at Spindle 2 using the

following:
Program: PROGRAM
Tool: FACE_GROOVE_L
18
18-2
Step 2:
Specify a Plunge Alternate cutting motion.
Step 3:
Step 4:

below. Use the same location for the Return Point.
Step 5:
Step 6:
mt11055_w NX 5
Lesson
19 Create a thread OD operation
You will create an operation at spindle 2 that threads the outside diameter
of the part.
19
19-1
Create a thread OD operation

Step 1:
Create a THREAD_OD operation at Spindle 2 using the following:

Program: PROGRAM
Tool: OD_THREAD_L
Method: LATHE_THREAD
Step 2:
Define the Thread Geometry as illustrated below.
Step 3:
Define a total cut depth of 0.035 and a constant cutting increment

of 0.005 using a tolerance of 0.001 and a thread angle of 180
degrees.
Step 4:
19
19-2
mt11055_w NX 5
Create a thread OD operation
Step 5:
Your final program should look like this in the Geometry View.
Step 6:
Save and close the part.
19
19-3
19
Lesson
20 Postprocess
You will postprocess the program.
20
20-1
Postprocess
Postprocess the program

Step 1:

directory.
Step 2:
Click PROGRAM in the Program Order View of the Operation

Navigator.
Step 3:
Click Post Process in the toolbar or right-click and choose Post

Process..
Step 4:
Select an appropriate postprocessor from the Postprocessor list.
Step 5:
Click Browse for an Output File.
Step 6:
In the Look in: box, select a directory you can write to.
Step 7:
Key in ***_postprocessor_output in the File name: box where ***

represents your initials.
Step 8:
Click OK to accept the output specification.
Step 9:
Click OK to postprocess the tool paths.
Step 10: Close the part.
20
20-2
mt11055_w NX 5
21
Lesson
21 Shop documentation
You will create and save a tool list in text format.
21-1
Shop documentation
21
Create and save a tool list
21-2
Step 1:

directory.
Step 2:
Click PROGRAM in the Program Order View of the Operation

Navigator.
Step 3:
Click Shop Documentation in the toolbar or choose

InformationShop Documentation.
Step 4:
Choose Tool List (TEXT) from the Report Format list.
Step 5:
Click Browse for an Output File and specify a directory to which

you can write.
Step 6:
Click OK in the SHOP DOC Output Specification dialog box.
Step 7:
Click OK in the Shop Documentation dialog box.
Step 8:
Dismiss the Information window and close the part.
mt11055_w NX 5

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Turning Manufacturing Process

Proprietary & Restricted Rights Notice

This software and related documentation are proprietary to UGS PLM

Turning Manufacturing Process Workbook

The manufacturing process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Process planning sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Turning Manufacturing Process Workbook

Create a rough bore ID operation . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

Turning Manufacturing Process Workbook

UGS Corp., All Rights Reserved

The manufacturing process

UGS Corp., All Rights Reserved

Turning Manufacturing Process Workbook

Turning Manufacturing Process Workbook

UGS Corp., All Rights Reserved

Process planning sheet

Operation Number is the sequential order in which a process is performed.

Work Center is the particular work area in which the operation is

Description is the detailed description of the operation that is to be

Operation Name is the actual name of the operation used to machine

UGS Corp., All Rights Reserved

Turning Manufacturing Process Workbook

Process planning sheet

Groove inside GROOVE ID

Turning Manufacturing Process Workbook

UGS Corp., All Rights Reserved

The finished program

UGS Corp., All Rights Reserved

Turning Manufacturing Process Workbook

The finished program

Replay the finished program

Open tmp_piston_mfg_demo_1 from the workbook_parts

Visualize the program using 2D Material Removal.

Look at the finished program in the Geometry View.

Close the part.

Turning Manufacturing Process Workbook

UGS Corp., All Rights Reserved

Machining environment and

UGS Corp., All Rights Reserved

Turning Manufacturing Process Workbook

Machining environment and spindle setup

Define machining environment and spindle setup

Open tmp_piston_mfg_asmb_1 from the workbook_parts

Rename the part ***_piston_mfg_asmb_1, where *** represents

Display the Geometry View of the Operation Navigator and expand

Double-click MCS_SPINDLE in the Operation Navigator and click

Only the first spindle has been defined.

Create an MCS defining the second spindle. Be sure you position it

Turning Manufacturing Process Workbook

UGS Corp., All Rights Reserved

Machining environment and spindle setup

Rename the objects as illustrated below. This way, it will be easy

UGS Corp., All Rights Reserved

Turning Manufacturing Process Workbook

UGS Corp., All Rights Reserved

Turning Manufacturing Process Workbook

Create and define tools

Create a carrier called TURRET that uses the X/Y Plane.

Create 12 pockets called FACE_1 through FACE_12.

Modify the tools as follows:

Turning Manufacturing Process Workbook

UGS Corp., All Rights Reserved

Define the geometry

Rename the part _piston_mfg_asmb_1, where represents