lAB3

Lab 3 (Virtual)

INTRODUCTION
In this lab 3, you will use a combination of software and machine to produce to functional twist ball-
point pen, starting with a raw acrylic stock and component kit. There are two parts to this lab, with each
part spanning over two lab periods. In Part I of the lab, you will focus on designing the pen body and
generating the CNC code to machine out your pen based on your design. In Part II of the lab, you will
learn how to set up work coordinates and cutting tool on a CNC lathe, perform turning operation on the
CNC lathe to cut out your designed pen body, polish surfaces and assemble components to produce your
complete pen.

The instruction provided in this handout will focus on Part I of the lab – pen design and code. You will
be using the computer-aided design (CAD) portion of an industrially used computer-aided
manufacturing (CAM) software, called Mastercam, to design your pen, including one upper barrel and
one lower barrel of the pen. Once the design is accomplished, you will create toolpaths (rough cut and
finish cut) for the pen barrels. Both upper and lower barrels will be cut in one continuous toolpath for
each pass, starting with the lower and finishing with the upper. You will also use Mastercam to specify
tool types and cutting parameters, including feed rate, spindle speed and depth of cut. There is a
simulation feature in Mastercam that you can use to verify the accuracy of your design, CNC code, and
cutting tool/parameter setup.

Each student is required to design his/her own pen and produce one completed pen at the end of Lab 3.
Although individual work and products are expected, students will be working in pairs during the
machining portion of the lab with each pair sharing one CNC lathe. Therefore, teamwork is still an
essential part of the lab to ensure lab goals and deliverables are accomplished within the designated lab
time. (cancelled due to current states)

OBJECTIVES
1. Analyze components of the provided “Funline” Designer Twist Ball Point pen kit.
1. Identify the dimension requirements of matching components/pen features.
2. Use precision measuring tools to measure dimensions of all components in the pen kit.
2. Create a design for the matching upper and lower barrels of the pen using the CAD feature of
Mastercam software.
3. Set up proper cutting tool and cutting parameters in Mastercam.
4. Create accurate toolpaths for both rough and finish cuts for the pen body using Mastercam.
5. Generate CNC code for the pen machining operation using Mastercam.
6. Simulate and verify the accuracy of design and CNC code to produce the final pen within

dimensional and machine/tool constraints using the simulation feature within Mastercam and
CNCBase for proLIGHT 3000 Turning Center software.

INTRODUCTION (MODIFIED)

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By this time, you should have already completed your pen design in Mastercam, created
toolpaths for both rough cut and finish cut, and generated and successfully verified a working CNC
program for the turning operation for your pen. You are now ready to move to Part II of the Pen lab.
During this second portion of the Lab, (since we didn’t have a chance to go to the work shop) you will
virtually learn how to set up work coordinates and cutting tool on a CNC lathe, perform turning
operation on the CNC lathe to cut out your designed pen body, polish surfaces and assemble
components to produce your complete pen.
You are expected to view a series of video clips which illustrate a step-by-step process to prepare
and finish your pen. Finally each student will prepare a detailed lab report reflecting both hands-on and
virtual experiences encountered in Parts I & II of the Pen Lab.

OBJECTIVES (MODIFIED)
1. Set up work coordinates on the CNC lathe.
2. Select and configure cutting tools.
3. Familiarize with key features in the CNCBase for proLIGHT 3000 Turning Center software,
including code writing/editing, tool setup, stock setup, axis and spindle controls, program
verification, and program execution.
4. Identify basic components of the ProLIGHT 3000 CNC Lathe.
5. Start, home and jog the ProLIGHT 3000 CNC Lathe.
6. Explain the turning process on the ProLIGHT 3000 CNC Lathe to produce the pen body based
on your previous pen design and CNC code posted from Mastercam software.
7. Describe the challenges and precautions during the surface finishing and assembly stages of
your pen to ensure high product quality.

Sample pen geometry

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TOOLS/EQUIPMENT/MATERIALS
1. Pen kit 9. 9” Band saw
2. One acrylic pen blank round 10. 10” Bench drill press
3. Caliper and/or ruler 11. 6” Bench grinder
4. Spacer bushings 12. Vise
5. One 7mm-diameter mandrel (8” for 13. Engraver
mounting workpiece on lathe) 14. ProLIGHT Turning Center
6. One 6-inch mandrel (for mounting 15. Mastercam X9 software
workpiece on drill press)
16. CNCBase for proLight 3000 Turning
7. Super glue
Center software
8. Sand papers 17.Polishing kit

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SAFETY AT TURNING CENTER

Like any other machine tool, the ProLIGHT Turning Center can be dangerous if you don’t follow
some basic rules of safety. Here are some common safety rules for using any machine tool.
a) Wear Safety Glasses. Operating any power tool can cause material to be thrown into your eyes.
b) Know the Emergency Stop Procedure. There are two standard methods:
i. Pushing the EMERGENCY STOP button on the front of the Turning Center.
ii. Simultaneously pressing the Control and Space Bar on the keyboard.
c) Dress Properly. Loose shirt tails or sleeves, rings, watches and dangling jewelry, as well as long hair
can get caught in machinery.
d) The system runs on Electricity. The Turning Center should be plugged into a three-hole grounded
receptacle and should never be operated in a damp or wet location.
e) Keep the Safety Shield in Place. The safety shield should be closed whenever the Turning Center is
operating to prevent flying debris.
f) Check Lathe Components. Always examine the bed saddle and cross slide to be sure they are free of
shavings and particles from previous operations. Remove such debris from the lathe to avoid possible
binding of components which may result in possible damage to the lathe, work piece or the operator.
g) Use the right tool. Select the type of cutting tool best suited the operation. Don’t force a tool or
attachment to do a job it wasn’t designed to do. Select the feed rate and depth of cut that is best suited
to the design, construction, and purpose of the cutting tool. It is always better to take too light a cut
than a cut that is too heavy.
h) Mount the cutting tool properly. Each cutter used in the turning operation must be sharp and tightly
inserted in its holder. The cutting edge of the tool must be on the centerline or just below the center of
the axis of rotation of the lathe.
i) Before running a part program on a CNC Turning Center:
i. Verify the part program on the computer and make sure the machine is properly initialized.
ii. Ensure your stock has sufficient length to work with according to your CNC program.
iii. Make sure you know how to stop the Turning Center in an emergency.
j) Never start the Turning Center Without Your Instructor’s Permission! Your instructor must check your
setup every time you use the Turning Center.
k) Secure the work piece. The work piece can be held in a chuck or a collet.
l) Remove all tool and wrenches. Items left in the work area can cause damage to the Turning Center or
injury to the operator.
m) Set a proper spindle rotation speed. The Turning Center is equipped with an electronically controlled
spindle motor to produce a range of spindle rotation speeds. Speed can be set with the control software
or by using an S code in the NC program.
n) Never make physical adjustments while the Turning Center is running. Only feed rates and spindle
speeds can be adjusted during operation.
o) Use a brush to remove chips after the Turning Center has completely stopped. Chip build-up or other
debris can interfere with the safe operation of the Turning Center. Using a brush prevents getting chip
splinters in your hand.

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LAB PROCEDURE
I. Prepare pen stock:
1. Recall the previously recorded values for the exact length of the upper and lower pen barrels
(remember that they must match the exact lengths of the metal tubes). Mark the proper lengths
on the original acrylic stock.
2. Using the bandsaw, cut the original acrylic stock into two sections: one for the upper barrel and
one for the lower barrel. Make sure to cut each section with some extra length to accommodate
for any non-straight cut resulted on the bandsaw. You can shorten the barrel lengths later, but
you cannot re-add the material if they are cut short. You will use the lathe to straighten the stock
ends next.
3. Facing the stock ends:
a. The proLIGHT 300 CNC lathe should already be ON at this time. If not, turn on the CNC
lathe controller (black) box using the red power switch.
b. Start the CNCBase for proLIGHT 3000 Turning Center software on the computer
connected to the lathe.
c. Familiarize with various components of the lathe (see Figure 1) and CNCBase software
features.
d. Home the machine:
i. Pull out the Emergency Stop button, if not already out.
ii. From the Setup menu on the CNCBase software screen, select Set/Check Home
or “Ctrl-H”. A dialog window appears as shown in Figure 2.
iii. Select the Home button. The machine will move to the end of each axis until it finds the
corresponding limit switch to reset the machine position (in machine coordinate system)
to zero.
Emergency Tool turret
Stop button Safety shield

Spindle speed
control

Cross slide

Tailstock

3-Jaw Chuck Lathe bed

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Figure 1. ProLIGHT 3000 Turning Center

Figure 2. Machine homing Figure 3. Spindle setup

e. Mount the workpiece:

i. On CNCBase software, use the Jog Keypad to jog the tool up and out of the way.
ii. Push the Emergency Stop button in. Do this every time before opening the safety
shield. Now, open up the safety shield.
iii. There are three square openings around the surface of chuck, find the one with
“0” mark. Insert the chuck key into the opening with “0” mark to loosen the
chuck jaws.
iv. Insert the pen barrel that requires facing (with the facing surface exposed outside
of the chuck), leaving about 0.5” of stock inside the jaws. Secure the stock by
tightening up the jaws with the chuck key.
v. When done, remove all tools and wrenches that you might have left inside the
machine to prevent machine damage and injury to the operator.
f. Face the stock ends:
i. First, make sure that the tool is clear from the stock.
ii. From Setup menu, select Spindle to set up the speed. Set spindle speed to be
between 800 and 1200 RPM. See Figure 3.
iii. To turn on the spindle, click Spindle On, and click Done to exit.
iv. Jog the tool in –Z direction (tool is still above the stock), until it’s approximately
aligned with the right end surface of the stock.
v. Slowly jog the tool down in –X direction into to the stock and face off the first
layer of the right end surface. Note that this is a turning operation, so you only
need to jog the tool down to just pass the radius of the stock. Jog tool up in the +X
direction to above the stock after the first layer is removed.
vi. With tool still clear from the stock, slowly jog tool in –Z direction by 0.01”
distance to start facing off the next layer.
vii. Repeat steps v and vi above until the exact length of the pen barrel is achieved.
viii. Turn OFF the spindle when done.
ix. Repeat the facing process for the second pen barrel as necessary.

4. Insert inner metal tubes: the metal inner tubes will need to be glued to the inside of the acrylic
pen barrels before the machining process.
a. Obtain some sand papers and sand the outside surfaces of both metal tubes to facilitate glue
adhesion.

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b. Apply a thin layer of glue around the upper metal tube. Insert the metal tube inside the upper
acrylic pen barrel. Immediately push the tube through and flush down the ends. The glue
gets settled very fast, so you want to do this quickly.
c. Repeat the process for the lower metal tube and the lower acrylic pen barrel. Try not to stain
the acrylic surfaces with glue.
II. Set up the proLIGHT 3000 CNC lathe:
1. Define cutting tool: you will use a diamond-shaped cutting tool to turn the pen from the original
acrylic stock. You will follow the same tool library setup process as done during Part I of this lab
to define cutting tool parameters.
a. Select Tools from the main menu bar  select Setup Library. Set up Tool 01 parameters as
shown in Figure 4. Click Apply and OK when finished.

Figure 4. Tool setup Figure 5. Tool selection

b. Select Tools from the main menu bar  choose Select Tool option. The Select Tool for Use
dialog box appears as shown in Figure 5. Select T01 from the drop down tool list, then click
Select Tool.

2. Configure and home tool turret: Once you have defined tools to be used by the turret, you must
identify where the tools are located in the turret.
a. From the Tools dropdown menu, select Configure Turret. A Configure Turret window will
appear, as shown in Figure 6. Select Tool 01 from Station 1, and click OK to exit.
b. Home turret: from the main Tools dropdown menu, select Operate Turret option. An
Operate Turret window will appear as shown in Figure 7. Click the Home icon to home the
turret. When the turret reaches the home position, a black dot appears in the circle on the
Homed button. Click Done to exit the Operate Turret dialog box.

Figure 6. Configure turret window Figure 7. Operate turret window

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3. Mount the pen assembly:

a. Use the Jog Keypad to jog the tool up and out of the way.
b. Assemble the pen barrels and spacer bushings onto the provided 8”-mandrel as shown in
Figure 8.
1 center
bushing

3 spacer
bushings Lock nut

Live center

2 spacer
bushings
Figure 8. Setting the pen assembly on CNC lathe

c. Insert the left end of the pen assembly into the chuck jaws and secure it. Make sure that
only the mandrel portion is inside the chuck and the 3 left bushings rest against the
chuck jaws surface.
d. Use the provided knurled lock nut to secure the pen assembly in place on the mandrel setup.
Do not run the lock nut all the way to the end of the threaded section as you do not
want the pen barrels to rotate during the machining operation.
e. Adjust the live center to rest against the right end of the mandrel, and lock the live center in
place. Again, it is critical that the pen barrels do not rotate during the turning
operation.
f. When done, remove all tools and wrenches that you might have left inside the machine to
prevent machine damage and injury to the operator.

4. Set up work coordinates (X, Z) for the CNC lathe.

a. Set the Z-origin (or the Z-zero point): to be located on the right end surface of the acrylic
stock.
i. Switch to Slow jog mode on the Jog Control panel, and select Step B (0.01”) as
shown in Figure 9.

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0.003

Figure 9. Jog control panel Figure 10. Setting Z-zero point

ii. Slowly jog the tool tip close to the right edge of the stock, but slightly to the right of
the stock surface.
iii. Obtain a paper strip and measure its thickness using a caliper. Record the paper
thickness for later use.
iv. Insert the piece of paper between the tool and the stock’s right surface. SLOWLY jog
the tool towards the stock surface until the paper can just be pulled out between the
stock and the tool tip (you should feel some resistance between the paper and the stock
as you get close). Use caution as the tool approaches the workpiece to avoid tool
crashing into the workpiece.
v. From Setup menu, select Set Position. Set the Z coordinate to be the same as the paper
thickness. For example, if your paper thickness is 0.003”, then the current Z-coordinate
is 0.003”, meaning that the right surface of the stock is the Z-zero point. See Figure 10.
Click OK to accept and exit.
b. Set the X-origin (or the X-zero point): to be located at the center of the acrylic stock.
i. Using Continuous jog mode, move the tool up in the + X direction to be clear of stock.
Then jog the tool over to approximately mid-length of the stock (still above stock).
ii. Insert a small piece of paper with a known thickness (you may use the same piece paper
as earlier) between the tool and the stock’s top surface. SLOWLY (Step mode B or
0.01”) jog the tool towards the stock surface until the paper can just be pulled out
between the stock and the tool tip (you should feel some resistance between the paper and
the stock as you get close). Use caution as the tool approaches the workpiece to avoid
tool crashing into the workpiece.
iii. Measure the diameter of your acrylic stock using a caliper. Calculate the stock radius and
write it down to use in the next step.
iv. From Setup menu, select Set 0.003” = 0.313”. See Figure 11.
Position. Set the X coordinate to be Click OK to accept and exit.
stock radius + paper thickness.
Remember to only set the X-
coordinate this time and DO NOT
CHANGE the Z-coordinate in
this step. For example, if your
paper thickness is 0.003”, stock
diameter is 0.62”and you want to
set the X-origin to be at the center
of the stock, then you should set the
current X-position to be 0.310” +

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Figure 11. Setting X-zero point

5. Verify for your CNC program: You need to graphically simulate your CNC code and verify its
accuracy before actually executing the code on the CNC lathe.
a. From the File menu, open the CNC program file that you had previously generated and
edited from Mastercamyou’re your pen design.
b. From the Setup menu, select Verify Settings. Adjust the settings as previously done during
Part I of this lab. Refer to Figures 12a-c for guidance. Note the following:
i. For Length dimension: enter the full length of the pen assembly setup on the lathe,
including the 3 left spacer bushings, the upper pen barrel, the center spacer
bushing, and the lower pen barrel.
ii. For Diameter: enter the outside diameter of the original acrylic stock.
iii. For Origin: enter the same calculated length dimension as in (i) for Z, and “0” for X.
That means the work origin is set at the very right end surface of the acrylic stock (Z-
zero) and at the center of the stock (X-zero).
iv. For Initial Tool Position: allow the initial tool position to be slightly outside of the stock
towards the upper right. To do this, add 0.2” to the calculated length dimension as in
(i) for Z, and enter 1.0 for X (i.e. 1” above stock center).

(a) (b) (c)

Figure 12: Verify Settings – (a) View tab; (b) Stock tab; (c) Options tab

c. From the Program dropdown menu,

select Verify, or simply press F6 on
your keyboard. You may also use the

shortcut icon to get to the same

Verify Program window. See Figure
13.

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Figure 13. Verify program window

d. Check that the correct program is selected. Click Verify Program. The simulation should
start.
e. Ask your lab instructor to verify the final simulation of your CNC code before running it on
the lathe.

III. Machine the pen body:

1. Once all needed verification is done, manually jog the tool up, to the right, and clear of the
workpiece.
2. Before executing your CNC program, check that all safety precautions have been taken.
3. Ask your lab instructor to watch the initial tool movements with you when executing your
CNC code.
4. If anything should go wrong, IMMEDIATELY PRESS the EMERGENCY STOP button.
5. When ready, select the Run/Continue command from the Program Menu. The Run Program
dialog box will appear. Make sure that the Start Line box is set to line 1 of the program.
6. Click on the Run Program button to begin running your program. DO NOT TAKE YOUR
EYES OFF THE PART AND TOOL DURING THE MACHINING PROCESS.
7. After the program ended, press the Emergency Stop button before opening the safety shield
and remove the finished part.
8. Inspect the pen barrels:
a. Check for any incomplete or excess cuts along the pen barrels.
b. Check the fitting of the center band to the tenon portion of the upper pen barrel.
c. Measure the end diameters of both upper and lower pen barrels. Record the values and
compare to your design specifications.
d. Discuss any problems with your lab instructor and identify potential resolutions for the
problems.

IV. Polish the pen body:

1. Obtain a 6”-mandrel and a shared polishing kit for your pen.
2. Mount one pen barrel at a time onto a mandrel and secure it to the upright drill press.
3. Turn the drill spindle on at a low speed.
4. Start sanding the outside surfaces of your pen barrel to remove any scratches. Use a coarser
sand paper if larger material removal is desired, and a finer sand paper if only a fine amount of
material needs to be removed.
5. To bring out the final color of your pen, apply a small amount of polish to a small piece of
paper towel or clean rag and apply it against the rotating pen barrel. No need to polish the
tenon of the upper pen barrel as the center band will cover it.
6. Buffer the pen surface to bring out its final finish.

V. Assemble the pen:

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1. Line up all pen components according to Figure 14. Be careful not to scratch pen
surfaces.

Figure 14. Pen assembly

2. Press the cap cut (recessed end first) into the tapered end of the upper pen barrel. Use a
vice if necessary.

3. Apply a thin layer around the tenon portion of the upper pen barrel, slide the center band
(square end first) over the tenon. Push in. Let dry.

4. Insert the cap thread into the hole in the clip. Screw together tightly into the cap nut.

5. Press end tip into the tapered end of the lower pen barrel. Use the vice if necessary.

6. Scribe a line/ mark on the twist mechanism 13/16" line from the chrome end. Press (may
use a vice for this) with the brass end of the mechanism first into the opposite end of the lower
pen barrel to the line scribed. Leaving 13/16" exposed. This dimension is critical as it will
determine whether the pen will work properly at the end.

7. Twist the mechanism and lower pen barrel to check the retracting and extension of the
refill. Press the mechanism further in if necessary.

8. Insert refill into twist mechanism and screw to the end.

9. Engage and push the two pen barrels together.

10. Pen operates by twisting the barrels to extend or retract writing tip.

VI. Wrap up the lab:

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1. Shut down power to the CNC Lathe by pushing in the Emergency Stop, and turning off the red
switch to the black controller box.
2. Save if necessary any program used in CNCBase software.
3. Close the CNCBase software and log off the computer.
4. Use brush and vacuum to clean the ENTIRE lathe workstation and work benches.
5. Wipe down ALL tools with paper towel and WD-40 as necessary.
6. Organize and perform inventory all the hand tools used in the lab. Please report to your lab
instructor if an item is missing or damaged.

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