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Turning Manufacturing Process

WorkbookApril 2007

MT11055 — NX 5

Publication Number

mt11055_w NX 5

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Proprietary & Restricted Rights Notice

This software and related documentation are proprietary to UGS PLMSoftware.

Copyright 2007 UGS PLM Software. All Rights Reserved.

All trademarks belong to their respective holders.

2 T urning Manufacturing Process — Workbook mt11055_w NX 5

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Contents

The manufacturing process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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 Turning Manufacturing Process — Workbook 3

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Co n t e n t s

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

4 Turning Manufacturing Process — Workbook ©UGS Corp., All Rights Reserved mt11055_w NX 5

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The manufacturing process

This project allows you to practice many of the Turning concepts you learnedin the student manual. Its purpose is to guide you through the generalworkflow 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 definethe spindle setup and reference the in-process workpiece (IPW) at the secondspindle. You will create a program that cuts one end of the part (1), transfersthe part to the other spindle, and then cuts the other end of the part (2). Youwill verify your program by visualizing the material removal as you createthe operations. Finally, you will Post Process and create shop documentation.

©UGS Corp., All Rights Reserved Turning Manufacturing Process — Workbook 5

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Lesson

1 Process planning sheet

The following process plan represents the manufacturing of the part. Includedare 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 isperformed.

• Description is the detailed description of the operation that is to beperformed.

• Operation Name is the actual name of the operation used to machinethe 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

Piston

100.00 CNCMill-Turn

HorizontalMill-Turn,Side 1, Mach.No. 1450,

Tape No.12345_A

100.10 Finish rightface of part

FACING OD_80_L

100.20 Centerlinespotdrill rightend of part

CENTER-LINESPOTDRILL

SPOT-DRILLINGTOOL

100.30 Centerlinepeckdrillthrough part

CENTER-LINEPECKDRILL

DRILLINGTOOL

©UGS Corp., All Rights Reserved Turning Manufacturing Process — Workbook 1-1

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P r o c es s p l a n n in g s h e et

100.50 Rough theoutsidediameter

ROUGHTURN OD

OD_80_L

100.55 Grooveoutsidediameter

GROOVE OD OD_GROOVE_L

100.60 Roughbore insidediameter

ROUGHBORE ID

ID_80_L

100.65 Groove insidediameter

GROOVE ID ID_GROOVE_L

100.67 Finishthe insidediameter

FINISHBORE ID

ID_55_L

100.70 Finishoutsidediameter

FINISHTURN OD

OD_80_L

200.10 Change tospindle 2 andfinish left faceof part

FACING 1 OD_80_L

200.20 Groove leftface of part

GROOVEFACE

FACE_GROOVE_

200.30 Threadoutsidediameter

THREAD OD OD_THREAD_L

300 Inspection Inspect

1st articlefeaturesmachinedin operationnumbers 100thru 1010

400 Manual

Deburr Clean

deburr and

clean partper customer specs

500 Inspection Finalinspectionof all features

1-2 Turning Manufacturing Process — Workbook ©UGS Corp., All Rights Reserved mt11055_w NX 5

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Lesson

2 The finished program

You will begin by replaying the finished program. This will give you anoverview of the program you will be creating in this project.


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2

Th e fi n i s h e d p r o g r a m

Replay the finished program

Step 1: Open tmp_piston_mfg_demo_1 from the workbook_partsdirectory 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.


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Lesson

3 Machining environment andspindle setup

Before you define part geometry, blank geometry, specify tools, or createoperations, you must define the machining environment and the spindlesetup. Spindle1 has already been defined for you. You will define Spindle2.


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3

M a c h in i n g e n v i ro n m e n t a n d s p i n d l e s e t u p

Define machining environment and spindle setup

Step 1: Open tmp_piston_mfg_asmb_1 from the workbook_partsdirectory.

Step 2: Rename the part ***_piston_mfg_asmb_1, where *** representsyour initials.

Step 3: Display the Geometry View of the Operation Navigator and expandthe objects.

Step 4: Double-click MCS_SPINDLE in the Operation Navigator and clickCSYS Dialog next to Specify MCS. Notice that the origin of theMCS defining this spindle is centered on the left face of the part.

Only the first spindle has been defined.

Step 5: Create an MCS defining the second spindle. Be sure you position itcentered on the left face of the part.


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M a c h in i n g e n v i ro n m e n t a n d s p i n d l e s e t u p

Step 6: Rename the objects as illustrated below. This way, it will be easyto tell which workpiece is associated with which spindle.


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3

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Lesson

4 De fine tools

Tools must be created or retrieved from the library. The tools required tomachine this part are identified in the Process Planning Sheet.


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4

De fi n e t o o l s

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 putthem in the appropriate FACE.

The Machine Tool View of the Operation Navigator should beorganized 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 to0.150.

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.


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Lesson

5 De fine the geometry

You will define part boundaries at each spindle.


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5

De fi n e t h e g e o m e t r y

Define part boundaries

Step 1: Double-click to edit the WORKPIECE_1 object in the OperationNavigator and define the part geometry at Spindle 1 by selecting

the body.

Step 2: Double-click to edit the WORKPIECE_2 object in the OperationNavigator 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 objectsfor both spindles.


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Lesson

6 De fine blank geometry

Blank geometry representing the original bar stock must be defined atSpindle 1.


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6

De fi n e b l a n k g e o m e t r y

Define the Geometry

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


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Lesson

7 De fine 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.


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7

De fi n e t h e I P W a t s p i n d l e 2

Define blank geometry

Step 1: Double-click to edit the TURN_WORKPIECE_2 object in theOperation Navigator and define the blank geometry by choosing

From Workspace and specifying corresponding Reference (1) andTarget (2) points. Be sure to select Flip Direction so that the vectors display as illustrated below.


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Lesson

8 Create a facing operation

The following phases of the turning manufacturing process pertain to thecreation of operations, generation of tool paths, and verification of materialremoval. You will repeat these three phases for each operation you createuntil you have completed the program.

You will create an operation that faces the end of the part using a Linear Zig

cutting motion.


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8

Cr e a t e a f a c i n g o p e r a t i o n

Create the operation

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

Program: PROGRAM

Tool: OD_80_LGeometry: TURN_WORKPIECE_1Method: LATHE_ROUGH

Step 2: Define an Axial trim plane that constrains the cut region in such away that only the right end of the part is faced.

Step 3: Specify a Start point at the approximate screen position illustratedbelow using a Direct motion. Use the same location for the ReturnPoint.

Step 4: Specify Additional Profiling.

Step 5: Generate the tool path.

Step 6: Verify using 2D Material Removal.


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Lesson

9 Create a centerline spotdrilloperation

Before drilling the centerline of the part, you must first create a CenterlineSpotdrill operation.


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9

Cr e a t e a c e n t e r l i n e s p o t d r i l l o p e r a t i o n


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

Program: PROGRAMTool: SPOTDRILLING_TOOLGeometry: TURN_WORKPIECE_1Method: LATHE_CENTERLINE

Step 2: Specify a Return Point at the approximate screen positionsillustrated below using a Direct motion.



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Lesson

10 Create a centerline drill operation

You will create a Centerline Drill operation that uses a breakchip motion todrill completely through the center of the part.


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0

Cr e a t e a c e n t e r l i n e d r i l l o p e r a t i o n


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

Program: PROGRAMTool: DRILLING_TOOLGeometry: TURN_WORKPIECE_1Method: LATHE_CENTERLINE

Step 2: Define a Total Depth that drills completely through the blankmaterial.

Step 3: Specify a constant chip removal increment of 1.0.

Step 4: Specify a Return Point at the approximate screen positionillustrated below using a Direct motion.




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Lesson

11 Create a rough OD operation

You will create an operation that roughs the outside diameter of the partusing a linear zig motion.


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1

C r e a t e a r o u g h O D o p e r a t i o n


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

Program: PROGRAMTool: OD_80_LGeometry: TURN_WORKPIECE_1Method: LATHE_ROUGH

Step 2: Define an Axial trim plane at -0.050.

Step 3: Omit the Reversal Mode so that the tool does not cut into theneckdown areas.





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Lesson

12 Create a groove OD operation

You will create an operation that cuts the outside diameter groove using a Plunge Zig motion.


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2

C r e a t e a g r o o v e O D o p e r a t i o n


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

Program: PROGRAM

Tool: OD_GROOVE_LGeometry: TURN_WORKPIECE_1Method: LATHE_GROOVE

Step 2: Specify a constant 75% stepover.

Step 3: Define two trim points at the ends of the vertical lines to constrainthe cut region to the groove.



Step 6: Verify using 2D Material Removal


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Lesson

13 Create a rough bore ID operation

You will create an operation that rough bores the inside diameter using a Linear Zig motion.


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3

C r e a t e a r o u g h b o r e I D o p e r a t i o n

Create the Operation

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

Program: PROGRAMTool: ID_80_LGeometry: TURN_WORKPIECE_1Method: LATHE_ROUGH

Step 2: Specify a constant cut depth of 0.030.





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Lesson

14 Create a finish bore ID operation

You will create an operation that finish bores the inside diameter.


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4

Cr e a t e a fi n i s h b o r e I D o p e r a t i o n


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

Program: PROGRAMTool: ID_55_LGeometry: TURN_WORKPIECE_1Method: 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.



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Cr e a t e a fi n i s h b o r e I D o p e r a t i o n




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4

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Lesson

15 Create a groove ID operation

You will create an operation that cuts the inside diameter groove using aPlunge Alternate motion.


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5

C r e at e a g r o o v e I D o p e r at i o n


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

Program: PROGRAM

Tool: ID_GROOVE_LGeometry: TURN_WORKPIECE_1Method: LATHE_GROOVE

Step 2: Specify a Plunge Alternate cutting motion.


Step 4: Define two trim points at the ends of the vertical lines to constrainthe cut region to the groove.

Step 5: Specify a Start and Return Point at the approximate screenposition illustrated below.




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Lesson

16 Create a finish OD operation

You will create a Finish OD operation that finishes the outside diameterusing the Machine all Regions parameter.


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6

Cr e a t e a fi n i s h O D o p e r a t i o n


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

Program: PROGRAMTool: OD_80_LGeometry:TURN_WORKPIECE_1Method: 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 positionillustrated below.




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Cr e a t e a fi n i s h O D o p e r a t i o n

So far, your program should look like this in the Geometry View of theOperation Navigator.


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6

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Lesson

17 Create a facing operation onthe back side

You will create an operation that faces the back side of the part using a LinearZig motion. This operation requires the part to be transferred to Spindle 2.


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7

C r e a t e a f a c i n g o p e r a t i o n o n t h e b a c k s i d e


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

Program: PROGRAM

Tool: OD_80_LGeometry: TURN_WORKPIECE_2Method: LATHE_ROUGH

Step 2: Specify an additional profiling pass.

Step 3: Choose Cutting and clear the Undercut check box.

Step 4: Specify a Start point at the approximate screen position illustratedbelow. Use the same location for the Return Point.




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Lesson

18 Create a groove face operation

You will create an operation that cuts the face groove using a Plunge Alternate motion.


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8

Cr e a t e a g r o o v e f a c e o p e r a t i o n


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

Program: PROGRAMTool: FACE_GROOVE_LGeometry: TURN_WORKPIECE_2Method: LATHE_GROOVE

Step 2: Specify a Plunge Alternate cutting motion.


Step 4: Specify a Start point at the approximate screen position illustratedbelow. Use the same location for the Return Point.




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Lesson

19 Create a thread OD operation

You will create an operation at spindle 2 that threads the outside diameterof the part.


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9

Cr e a t e a t h r e a d OD o p e r a t i o n


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

Program: PROGRAM

Tool: OD_THREAD_LGeometry: TURN_WORKPIECE_2Method: 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 incrementof 0.005 using a tolerance of 0.001 and a thread angle of 180degrees.



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Cr e a t e a t h r e a d OD o p e r a t i o n

Step 5: Your final program should look like this in the Geometry View.

Step 6: Save and close the part.


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9

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Lesson

20 Postprocess

You will postprocess the program.


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0

P o s t p r o c e s s

Postprocess the program

Step 1: Open tmp_piston_mfg_demo_1 from the workbook_partsdirectory.

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

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

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.


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Lesson

21 Shop documentation

You will create and save a tool list in text format.


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1

S h o p d o c u m e n t a t i o n

Create and save a tool list

Step 1: Open tmp_piston_mfg_demo_1 from the workbook_partsdirectory.

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

Step 3: Click Shop Documentation in the toolbar or chooseInformation→Shop 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 whichyou 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.

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