Beruflich Dokumente
Kultur Dokumente
0y, R.Lebe
~ 0780Dover, NJ
9. -ERF~RMIN ORGNIZTIONNAMEAND
DDRES 1. DECR LASSEICTIOJDOWNGRAIN
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DTIC TAB 0
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Unannounced
Justification-
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165
isHCONTRACT
NO. DAAK1O-78-C-O
4
-.
GULF + WESTERN PROJECT NO. 30012
"I r
7.62 MM CARTRIDGE CASL FEASIBILITY STUDY
PREPARED BY R. L. Weber
F. W. Dietsch
January 12, 1981_ _ _ _ _ _ _ _
_ _ _
DATE __ _ _ _ _ _
CHECKED BY
81 3 30 052
Ii~3 052-**.-
UNCLASSIFIED
SECURITY CLASSIFICATION OF THIS PAGE (When Data Entered)
G&W Advanced Development & Engr. Center AREA & WORK UNIT NUMBERS
101 Chester Road
Swarthmore, PA 19081 Proj. No. 5786753
It. CONTROLLING OFFICE NAME AND ADDRESS 12. REPORT DATE
US ARMY ARRADCOM 12 Jan 81
DRDAR-SCM-M, FC&SCWSL 13. NUMBER OF PAGES
Dover, NJ 07801 112
14. MONITORING AGENCY NAME & ADDRESS(If different from Controlling Office) IS. SECURITY CLASS. (of this report)
UNCLASSIFIED
15sa.DECL ASSI FICATION/ DOWNGRADING
SCHEDULE N/
17. DISTRIBUTION STATEMENT (of the abstract entered In Block 20, If different from Report)
20. ABSTRACT (Coninue .,a.verse obbo Itn=ec"a. and Identify by block numbet)
This report describes a proposed 3-draw process utilizing the standard U.S. cup
on a modified Small Caliber Ammunition Modernization Program (SCAMP) Case Sub-
module at Lake City AAP to manufacture 7.62mm cartridge cases that would satis-
fy the U.S. NATO grain configuration requirements.
30012
I GN Advanced Development and Engineering Center
101 Chester Road * Swarthmore. Pennsylvania 1981
5 TABLE OF CONTENTS
I SECTION PAGE
1. SUMMARY ........... ............................. 1
2. INTRODUCTION ........... .......................... 2
3. OBJECTIVE ........... ............................ 3
4. PLAN ............ .............................. 4
i" 5. PROPOSED PROCESS ...............
6. TOOLING.DEVELOPMENT......
..............
..................
6
8
6.1 Equipment ........ ........................... 8
ILLUSTRATIONS
ii FIGURE NO. PAGE
1. DEVELOPMENT HISTORY................... 5
2.PROPOSED PROCESS..................... 7
3. TAPER TOOL MODULE .......... ........................ 9.
4. TAPER SIMULATOR AND TOOL MODULE .................. . 10
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No.30012
. -Advanced Development and Engineering Center
" "101 Chester Road * Swarthmor. Pennsylvania 19081
TABLE OF CONTENTS
(Continued)
3 1t
FIGURE NO. PAGE
5. INDUCTION TEST RIG SCHEMATIC ...... . .... ............... 14
6. INDUCTION TEST RIG .. .. .. .. . .. ... . .. .... . .... 15
7. QUENCH AND BLOW OFF CHAMBER. .. .. .. . .. .... . .. ..... 16
>1-i . 8. BODY ANNEAL INDUCTION COIL ...... ................... .. 25
9. DRAW PUNCH SLEEVE ....... ........................... 30
10. EQUIPMENT LAYOUT SCHEMATIC ..... .................... ... 32
IATTACHMENTS
ATTACHMENT NO.
1. TOOL DRAWINGS
2. COIL DRAWINGS
3. IN-PROCESS PART DEFINITIONS
4. DIMENSIONAL INSPECTION DATA
5. METALLURGICAL INSPECTION DATA
6. TEST FIRING DATA
$ 7. VOID TEST DATA
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Advanced Development
and Engineering Center
G N 101Chester Road * Swarthmor,. Pennsylvania 19081
1. SUMMARY
This document reports the activities and results of a program carried
out by the Advanced Development and Engineering Center of GULF + WESTERN
to develop a process to manufacture 7.62 mm cartridge cases on SCAMP equipment.
The program was funded by ARRADCOM under Contract Number DAAK1O-78-C-0165,
which followed G+W Proposal Number 15506A.
The program plan was based on a tentative process mutually arrived at
by ARRADCOM and G+W in which the critical tasks were: (a)developing a
three-draw process from the specified standard U.S. cup using one inter-draw
anneal; and, (b)developing an induction anneal system to satisfy the U.S. -
4
N.A.T.O. grain specifications.
All development work was carried out at the G+W Folcroft facility using
G+W press simulators and a specially designed induction anneal test rig.
: I Although this equipment is manually operated, the various operations of the
SCAMP equipment are closely simulated in terms of metalforming and heating
4 functions.
The program was successful in accomplishing its objectives and culminated
in the supply of a small quantity of cartridge cases to. ARRADCOM for evaluation
and test firing.
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~No. 30012
i.Advapced Development and Enginering Center__
I.
2. INTRODUCTION
{ Over the last decade, G+W has been responsible for the conception and
development of high speed rotary ammunition systems as part of an extensive
modernization program carried out under the auspices of the P.B.M. office
of ARRADCOM.
Tq The systems are now installed at L.C.A.A.P. and are producing 5.56 mm
caliber ammunition. The systems were designed to be compatible with conversion
to produce other caliber sizes. However, it was also recognized that some
addition to, or modification of, the basic equipment may be necessary to
accommodate differences in processes appropriate to other calibers.
G+W has supplied systems to overseas customers which produce 7.62 mm
as well as 5.56 mn ammunition and, in doing so, has developed suitable
processes. However, the U.S. - N.A.T.O. requirements define a specific grain
structure and ARRADCOM also stipulated that the standard U.S. cup must be
used. These factors introduced complications of process beyond those already
developed.
G+W Proposal Number 15506 resulted in ARRADCOM placing a contract to
i develop a process which would fulfill the requirements and be compatible
with SCAMP equipment.
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No. 30012
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3. OBJECTIVE
at process
establish a to produce
per minute.
The objective
ram, M80 of the
cartridge cases SCAMPto sub-module
on a was
program 1200 parts
i . _7,62
with submission of: (a) 1,000
Program completion would be recognized
Number 10521997 with applicable grain
acceptable 7.62 mm cases to Drawing
report.
specification and, (b) a final technical
the effect of voids
.i "A contract modification added a test to evaluate
on the performance of the anneal
(missing parts) in the transport chain
i Il system.
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II
The plan which was prepared and generally followed is outlined below:
1. Identify differences between the proposed 7.62 mm process and the
current 5.56 mm SCAMP process, then develop the proposed process and
define the methods of showing compliance with the product specifi-
cation.
2. Design and procure the necessary developmental tooling and equip-
ament, including an induction anneal system.
3. Set up simulators, tool modules, induction anneal system and
processing equipment.
o V 4. Develop tooling and induction anneal process to obtain required
dimensional and metallurgical properties.
5. Perform measurements of in-process dimensions, head hardness, hardness
gradient and grain structure to define in-process part characteristics.
6. Produce a small batch of finished parts for Government evaluation
I "and process approval.
7. Produce 1,000 parts to be test-fired by the Government.
8. Develop final recommended process flow diagrams and in-process part
4
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F 5. PROPOSED PROCESS
Referring to Figure 2, the ARRADCOM stipulation was that the process
Ssi,ould use the standard U.S. cup, Drawing Number 10522459. It was
r I considered that the geometry of this cup, with consequent high area reduction
th'ough the final draw, mandated a three-draw process.
SgraiThe second consideration was that, in order to attain the specified
grain structure, an anneal would have to be performed between second draw
and final draw.
S IThe third consideration was the addition of a pre-pocket operation
prior to heading so as to have a reliable primer pocket condition and adequate
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30012
~No.
Ii Avancd Dvelomen andEnqneerlnil Center
0 Swarhmore. Pennsylvania 19081
Development and EngLn "Advanced
101 Chester Road
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CUP
I FIRST I DRAW I
SECOND DRAW
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I HEAD TURN
PIERCE
QUENCH, LUBE
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FIRST TAPER
SECOND TA'PR, PLUG
FINAL TRIM
FINISHED CASE
Si7
No"30012
W Advanced Development and Engineering Center
101 Chester Road * Swarthmom. Pennsylvania 1081
6. TOOLING DEVELOPMENT
Following the process selection described in Section 5, tentative
in-process part specifications were generated. Using these as a basis,
tooling was designed and fabricated to accomplish all operations. as The
development program began with these designs which were modified the
i
program progressed.
jThe development was an iterative process involving minor changes of
tooling design and in-process part specifications to achieve the desired
j final case characteristics. Some of the detail effects of tool design
changes will be briefly discussed.
6.1 Equipment
All development work was carried out using SCAMP tool modules
Vl and simulators.
A tool module is an assembly which contains all the tools necessary
to perform a particular metal-working operation. By virtue of the design,
tool adjustment is precisely controlled within the module and the whole
Iassembly can be quickly installed in the SCAMP rotary presses. It can
also be installed and used in a simulator, which is a single-station machine
I designed to duplicate the essential features (displacement, for example) of
a rotary press.
The original reason for the tool module/simulator concept was to
facilitate off-line tool check-out but it is also eminently suitable for
tooling and process development, as in this program.
Experience has shown that there is good correlation between simu-
lator and rotary press process performance so that the results of this program
Scan be expected to be valid in predicting the effects of sub-module conversion.
A typical tool module is shown in Figure 3, and is shown installed
in the appropriate simulator in Figure 4..
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30012
, Advanced Development and Engineering Center
101 Cheslor Road * Swarthmore. Pennsylvania 19081
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7. ANNEALING DEVELOPMENT
7.1 Equipment
To properly conduct all the various annealing tests that had to
be performed, a test rig was designed and constructed, see Figures 5, and 6.
This facility has all the necessary instrumentation required to monitor and
"A control all known annealing process parameters. Power, chain speed, water
temperature and pressure, time until quench, and coil dimensions are all
adjustable to allow a thorough evaluation of the pertinent variables so that
the process could be optimized. A brief description of each of the compon-
to select the voltage, and sufficient capacitance in 220, 440, and 800 volt
banks to vary the frequency. With this arrangement, a wide range of coil
sizes and configurations can be efficiently tuned.
7.1.3 Control Panel
I._ The control panel has all the necessary switches, indicator
lights and buttons that are required to operate the inverter and heat
station. Two analog meters monitor voltage and frequencyand a digital
meter monitors power output. The panel also has the controls needed to
operate the recirculating water system, the quench chamber, compressed air
for the blow-off chamber, and the chain drive motor.
[i 7.1.4 Quench and Blow-off Chamber
The quench and blow-off chamber, see Figure 7, is built
out of aluminum plate with acrylic windows in the front and back to allow
- visual inspection of the quenching process. The entire unit is mounted on
13
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moveable slides so that it can be moved toward or away from the coil. In
i this manner, the time required for full quenching can be varied to
provide the optimum effect.
7 The quench chamber consists of a series of square-pattern
ray nozzles arranged such that the cases are cooled quickly and uniformly.
The blow-off chamber uses a series of wide-angle, flat-pattern air nozzles
providing compressed air to dry the cases. All the nozzles are mounted in
manifolds with a flexible connector so that they may be repositioned easily
to accomodate the various annealing operations.
first chain has stainless steel pins on which the second draw parts are
placed for the interdraw anneal operation. The second chain has beryllium
copper clips which engage the extractor groove and is used for the body anneal,
stress relief, and neck and mouth anneal operations. In both cases, part
spacing is 0.75 inch and chain speed is 15 inches per second.
17
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G4'iiflNo. 30012
Advanced
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per second
With the 0.75 inch spacing and 15 inches
1200 parts per mirute.
j chain speed, the simulated production rate was
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Advanced Development and Engineering Center
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"7.4 Void Test
Five tests were performed to evaluate the effects of voids
(missing cases) on the ability of the annealing system to correctly heat
treat the 7.62 mm cases. The five tests were performed in compliance with
contract DAAK1O-78-C-0165 modification P00001, and are repeated here for
the convenience of the reader:
A. All twenty-four stations filled. Hardness data to be used
as base line for Test B and D.
11
on the chain. Anneal coil power setting to be the same as
used in Test Condition B.
1. Six voids evenly spaced throughout the twenty-four station
positions on the chain. Anneal coil power to be adjusted
to the base line hardness data established in Test Condition A.
E. Six consecutive voids out of the. twenty-four station positions
on the chain. The anneal coil power settings to be the same
as used in Test Condition 0.
Each test was run five times and six samples were taken from each
test. The 1/2 and 1-1/2 inch points were checked for hardness on each of
I the 150 test pieces. To obtain results that reflected the worst possible
condition, the samples were taken from the positions immediately adjacent
I to the voids. For example, in test (C), three groupings of 24 cases were
run with a void of four missing cases in the middle of each group. Therefore,
- if each set was numbered 1 to 24, the cases in the position of 11 to 14 were
15 were ,I
removed to act as the void, and the cases in the positions of 10 and
removed from each group as the test samples.
The results are summarized in Attachment 7, with the hardnesses
given for each test being the average of 30 cases.
24
kk "" C No. 30012
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' Advnnced Development and Engineering Center 1n 30012
101 CheJtr Road * Swarthmore. Pnnty-vnla 19081
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30012
1 j Advanced Development and Engineering Center
101 Chester Road * Swarthmore. Pennsytvanis 19061
j- 9.1 Dimensional
Measurements are made on the in-process parts and on the
finished cases. The resulting data is included in Attachment 4.
1l 9.2 Metallurgical
Measurements of external surface hardness and internal head hardness,
together with typical microphotographs of grain structure are included as
I" Attachment 5.
II
27
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No. 3012 !
Advanced Development and Engineoring Center
1
I 101 Chester Road * Swarthmore, Pennsylvania 1901
Inc. for test firing. They were loaded to M80 high pressure test specifi-
cations and fired in a pressure barrel No deficiencies were noted in the
LThe subsequenttestinspection.
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On Advanced Development and Engineering Center
101 Chester Road * Swarthmoro, Pennsylvania 19081
11.1 Tooling
SCAMP tool modules were used-throughout. Relative to 5.56 mm
production, the additional draw operation was accomplished by using a
standard first draw module and equipping it with second draw tooling;
the pre-pocket tooling was installed in a standard header module.
The only change made in the tool module area related to non-
metalworking components involved draw punch alignment. Test series A and
B had shown some difficulty in maintaining wall thickness variation
tolerance of the final draw part. Investigation showed this to be caused
by punch-to-die misalignment. This, in turn, resulted from the restricted
length of the punch shank-to-gland-to holder engagement and the clearances
involved, which induced the misalignment when the retaining nut was tightened.
This condition was corrected by installing a re-designed sleeve
which maximized engagement length. This modification is shown in Figure 9.
It may be noted that the sensitivity to misalignment is not
present in the existing G+W 7.62 mm two-draw process which uses a cup with
greater height: diameter ratio.
_11.2
1 Basic Equipment
Relative to the 5.56 mm SCAMP case sub-modules operating at
29
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No. 30012
*1
5/16 X 24 U.N.F.
2 PLACES
2.500
MATERIAL
PRE-HEAT TREATED
4130 Rc28 - 32 or Equivalent
30
i4
11.3 Layout
A possible equipment layout is shown schematically in Figure 10.
In practical terms, location of the two additional presses could
be most effectively provided for by excavation of the existing pit. The
pit does have one "spare" station, so that excavation would be limited to
zJ extension by one station upstream.
1 "The details of the sub-module changes, such as drive re-arrangement,
I< provision of transport system supports and utilities are properly the subject
1 Iof a study beyond the scope of this contract.
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Se101 Chester Road * Swarthmore. Pennsylvanla 1.081
-Key
1. Cup Feeder
2. Initial Draw Press
3. Second Draw Press
j 4. Final Draw Press
, 5. Pre-Pocket Press
6. Header Press
7. Head-Turn Press
j 8. Pierce Press
9. First Taper Press
! j 10. Second Taper Press
11.. Trim Press
12. Eject-Transfer Turret
13. Eject-Transfer Turret
14. Eject-Transfer Turret
15. Eject-Transfer Turret
16. Eject-Transfer Turret
1 17. Eject-Transfer Turret
18. Eject-Transfer Turre~t
1 19. Drive Motor,
20. Drive'Motor
21. Drive Motor
22. Re-Spacer
1 I23. Re-Spacer
24. Re-Spacer
25. Re-Spacer
j 26. Re-Spacer
27. Interdraw Anneal Station
28. Body Anneal Station
29. Stress Relief Anneal, Neck & Mouth Anneal, & Clean Station
IL
FIGURE 10 EQUIPMENT LAYOUT SCHEMATIC
(Continued)
.33
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Advanced Development and Engineering Center
101 Choster Road * Swarthmors. Pennsylvania 19081
mI
12. CONCLUSIONS
The program has demonstrated the feasibility of producing 7.62 mm
j M80 cartridge cases to U.S. N.A.T.O. specifications on a SCAMP sub-module
at 1200 parts per minute.
. -j All final case dimensional and metallurgical specifications can be
fulfilled without exception.
NA critical factor in the process was the successful development of
induction heating to stimulate re-crystallization and grain growth with
a continuous work-piece flow in less than 5 seconds.
SAll tools are compatible with existing tool modules and sub-module
presses and their fabrication requires only normal techniques.
" I Because of the stipulated use of the standard U.S. cup and incorporation
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Advanced Development and Engineerinl Center
101Choster Road Swarthmor, Ponnsylvanla 19W1
-First Draw
J Punch 11831351
Bottom Die 11831578
Middle Die 11831579
Top Die 11831360
" Stripper 11831361
Retainer 11831362
Second Draw
Punch 11831364
Bottom Die 11831365
Middle Die 11831366
Top Die 11831367
Stripper 11831368
Retainer 11831369
Third Draw
Punch 11831371
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No. 30012
S-Advanced Development and Engineering Center
101 Chester Road * Swarthmore. Pennsylvanla 19081
Pocket
Stem 11831379
I Bunter 11831381
I Head
Stem 11831384
Bunter 11831385
i- Pocket/Head
Die 11831380
S- Retainer Nut 11831382
L
Head Turn
I Mandrel 11831387
Form Tool 11831388
Stripper 11831389
"' Guide Roller Pin 11831390
Plug 11831391
I Guide Holder 11831392
Guide Roller Assembly 11831393
i
Pierce
Punch 11831395
Guide Punch 11831396
J Stem 11831397
Stripper 11831398
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No. 30012
1~ O3 \\'Advanced Development and Engineering Center 101Chester Road *Swarthmore. Pennsylvania 1W081
First Taper
Body Die 11831400
1 Shoulder Die 11831 401
Mandrel 11831 402
I Second Taper
.1Body Die 11831 403
Shoulder Die 11831404
Mandrel 11831405
V First/Second Taper
Mandrel Seat 11831406
Sleeve 11831407
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RE"CEIV
SH. P. WMIME- LABORA T ORYY "" " NO0V 319bu
3114 Scarboro Road Street, Maryland 21154 (301) 838-6550
30 October 1980
(HPWLI 2483)
11 Gcntlemen:
In accordance with your Purchase Order No. 78625-02, H.P. White Laboratory,
~1 Inc. conducted firing tests of twenty (20) expernental 7.62nm brass cartridge cases.
forA propellent loading was developed which would produce the pressures specified
for the caliber 7.62mn, I80 High Pressure Test (proof) cartridge. The cases were
primed and loaded in accordance with that loading and the cartridges fired in a
pressure barrel configured to determine peak chamber pressures in copper units of
pressure (CUP). Table I is a sumnary of the attached data record of these firings.
;i D
Subsequent to these tests the spent cases were examined for evidence of
cracks,bulging, distortion, prbier leakage, etc. No deficiencies were noted.
The spent cases are being returned via United Parcel Service under separate
cover. Should you have any questions regarding this matter or if we may be of
any further service, please do not hesitate to contact us.
S_'Very truly yours,.
'D.R. u
ii' DRD/lt
enclosures
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FIRING RECORD
H. P. WHITE LABORATORY, INC. JOB NO. 2483
3.14 Scarhoro Road, Strect,_ taryland 21154
Ammunition: 7.62 handloads
I C~,1~ll X: - ___________Used . __ __ carviu No.:
Primer: M 100 Loader: Lo No.:
Powder: gr. IMR 4475 1On:
Seating Depth:
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