The Logbook and

Evaluation
No. Process

Quality
Control/Health
and safety

Details

Problems

Images

No problems N/A
were
encountered
.

N/A

Created the
activity log

Created the activity log on

Google drive to ensure that
the table and data will not be
lost in the future.
Produced a list of possible
projects in a list so that i
could keep track of what I
needed to sketch.

No problems N/A
were
encountered
.

N/A

Produced an
ideas list of
possible
projects

No problems N/A
were
encountered
.

N/A

Refined the
list to three
potential
projects

The refining process was

mainly based on the size of
the potential project at the
end of the day. i.e. Could it fit
in my school bag or not?

No problems N/A
were
encountered
.

N/A

Defined the
Product
Specification The product specification for
s
the pen was completed

No problems Use:
were
Vernier Caliper
encountered (Measurements)
.

Used the
lathe to face
off and turn
down the
This gives the rod a datum
alumimium point and makes it easier to
rod
taper.
No problems Use:
were
Vernier Caliper
encountered (Measurements)
.

Drilled the
pilot hole
(Prototype)

This guides the full size bit to

ensure a straight hole.
This is to accommodate the
ink cartridge

Drilled the
main section
on the pen's
body
(Prototype)

The drill bit

was too
small to drill
the whole
section. So
after half
way I flipped
the pen and
carried on
drilling.

Use:
Vernier Caliper
(Measurements)

10

11

Measured the ink cartridge.

No problems Use:
were
Vernier Caliper
encountered (Measurements)
.

Measure stock aluminium

with the vernier

No problems Use:
were
Vernier Caliper
encountered (Measurements)
.

Cutting off the bad side of

the aluminium bar.

No problems
were
encountered
.

Use vernier
caliper and a
hand saw or
cold cut saw.
Wear PPE
goggles and
engineering
jacket.

Facing off the fresh cut face

to make a datum point for
future measurements
references.

No problems
were
encountered
.

Use vernier
caliper. Wear
PPE goggles
and engineering
jacket.

Measuring.

Choosing the
stock

Rough cut

Face off

12

13

14

15

Measure the height of the

aluminium bar with the
vernier caliper and use a
desk scribe to mark the cut
point. Use the faced off side
datum point on a flat bed to
get accurate measurements.

No problems
were
encountered
.

Use vernier
caliper. Wear
PPE goggles
and engineering
jacket.

Face off the second face so

that the rod can be center
punched.

No problems
were
encountered
.

Use vernier
caliper. Wear
PPE goggles
and engineering
jacket.

Center punch the aluminium

rod so that the drill bit will be
automatically centered when
drilling occurs

No problems
were
encountered
.

Use vernier
caliper. Wear
PPE goggles
and engineering
jacket.

Drill the main body to the

specifications of the ink
cartridge.

The drill bits

weren't long
enough to
drill the
whole length
of the body.
This meant
that I had to
drill from
each side to
make up for
the short drill
bit.

Use vernier
caliper. Wear
PPE goggles
and engineering
jacket.

Rough length

Face off
second face.

Centre
punch

Drill main
body

The ink cartridge has a step

which means that I needed
to switch the drill bit half way
through the drilling process

16

17

18

Drill the ink

cartridge nib
hole.

The drill bits

weren't long
enough to
drill the
whole length
of the body.
This meant
that I had to
drill from
each side to
make up for
the short drill
bit.

Use vernier
caliper. Wear
PPE goggles
and engineering
jacket.

Face off both ends of the

No problems
aluminium bar in preparation were
for the tapered end
encountered
.

Use vernier
caliper. Wear
PPE goggles
and engineering
jacket.

make steps gradually getting No problems

deeper towards the tip. This were
will form the taper.
encountered
.

Use vernier
caliper. Wear
PPE goggles
and engineering
jacket.

Face off

Steps

19

20

21

22

This is what makes the taper No problems

smooth and visually
were
pleasing.
encountered
.

Use vernier
caliper, files,
Wear PPE
goggles and
engineering
jacket.

repeat the last two steps

until you have a smooth
taper.

No problems
were
encountered
.

Use vernier
caliper. Wear
PPE goggles
and engineering
jacket.

Use 60 grade abrasive wet

and dry abrasive paper to
make the tooling lines less
visible.

No problems
were
encountered
.

Use vernier
caliper. Wear
PPE goggles
and engineering
jacket.

Use 600 grade abrasive wet

and dry abrasive paper to
make the tooling lines
almost disappear .

No problems
were
encountered
.

Use vernier
caliper. Wear
PPE goggles
and engineering
jacket.

Filing

Rinse and
repeat

Sanding

Sanding Part
2

23

24

Tap pens body with a M7

Tap

No problems
were
encountered
.

Wear PPE
goggles and
engineering
jacket.

Die the cap with an M7 die

No problems
were
encountered
.

Wear PPE
goggles and
engineering
jacket.

Tap body

Cap die
Turn down the body and cap No problems
so that they are flush with
were
each other
encountered
.

25

Keep hands
away from the
chuck.
Wear PPE
goggles and
engineering
jacket.

26

27

Use the knurling tool to

engrave the cross hatch
pattern into the body.

No problems
were
encountered
.

Keep hands
away from the
chuck.
Wear PPE
goggles and
engineering
jacket.

Sand down the scuff marks

created by the chuck. Use
the hand file then switch to
the sandpaper followed by
the Brasso. This gives the
pen a smooth and shiny
finish.

No problems
were
encountered
.

Keep hands
away from the
chuck.
Wear PPE
goggles and
engineering
jacket.

Knurl the grip

Sand down
the scuff
marks

The Evaluation
The product does its job well. The knurled metal finish enables the user to keep a firm grip
over long periods of time. The main difficulties were encountered when creating the
cartridge chamber the measurements have to be precise to the Nth degree. The Die and
Tapping stage was fairly easy, providing the right equipment was at hand. There was
difficulty finding die set one two and three, so I had to settle for one and three until the
whole set was found.
What was successful.
The knurling process was a success and aided in the grip of the pen. Not only does it look
cool, it functions as a grip that make the pen easy to hold even when the pen is wet due to
sweat or spillages. The facing off was another success and a key part of the project in
terms of making the pen look professional.
What went wrong
There was no drill bit long enough to drill the whole ink cartridge chamber. I improvised a
solution by drilling the aluminium bar twice once from each end. However, it was tricky
and if I misplaced either the drill bit or workpiece (i.e. if either was not centred correctly)
then the holes would do one of two things. A: Not meet each other, or. B: Form a crooked
connection.
I overcame this challenge by carefully triple-checking the workpiece and bit every time I
performed any machining.