SARASWATI INSTITUTE OF TECHNOLOGY AND MANAGEMENT

A SEMINAR REPORT ON

STUDY OF MANUFACTURING OF AMMUNITION AND ITS COMPONENT

Presented By: VIKASH SHARMA SYED WASI UDDIN
M.E. 4th year

ORDNANCE FACTORY CAWNPORE(O.F.C.)

ABOUT OFC
Ordnance Factory Cawnpore was established before the independence of India in the year 1943.
Spread over an area of 104.10 Hectares. The factory manufacture a variety of products of ammunition items. The factory has implemented International Quality Management System Standard (ISO 9001:2000) in all spheres of its production activities.

 105mm IFG HE:

PRODUCTS

105 mm IFG HE ammunition is filled with high explosives (TNT). Specification/Characteristics:

a) b) c)

Mass of the filled shell Muzzle velocity Maximum range

16.97 kgs max 591 M/sec (normal charge) 710 M/sec (super charge) 17600 m (Variable range can be achieved by using different types of cartg cases such as normal charge and super charge)

 125 mm HE: 125 mm Ammunition is used with Tank T-72 as main gun ammunition. The main gun 125 mm is having smooth bored barrel. FUNCTION: The shell is designed for destroying enemy shelters, vehicles and personnel. SPECIFICATION/CHARACTERISTICS:
a) Mass of the filled shell with fuze and tail unit assy b) Filling type in shell standard c) Muzzle velocity at +15C d) Maximum range 23 kgs RDX/TNT (60:40) 850 M/s 5000 m

 155 mm Shell HE: The shell HE 107 is designed for firing at maximum 18 kms. range. It is often used for training/practice. FUNCTION: When the gun is fired, the shell is ejected out at varying muzzle velocity due to the gas pressure created by the burning of propellant. SPECIFICATION/CHARACTERISTICS:
a) b) c) d) e) f) Mass of the shell with fuze Mass of the shell without fuze Length of shell with fuze Length of shell without fuze Filling type, standard Filling mass 43.1 kgs 42.1 kgs 701 mm 604 mm TNT 6.6 kgs

Manufacturing of 105mm IFG HE Shell

1. Forging: Forging is a manufacturing process involving the shaping of metal using localized compressive forces While in manufacturing of 105mm IFG HE shell, a large piece of metal is divided into number of parts according to the required size.

2. Centering: Centering is a process in which a drilling operation is made at the pip of the forged part. In this process a hole is made at the center of the pip to locate the job in the tail-stock of the lathe machine.

3. Rough Turning: Forging provides a very rough shape to the raw material so in rough turning operation. The material is removed from the outer surface of the job. In this process outer diameter, cavity, profile as well as length are maintained.

4. Bottling: It is done by heating job in an induction coils above recrystallization temperature. In this a mark is made to the job up to which it is heated and then the heated part is given a bottled shape by the help of compressive forces. Heating and force are depends upon the diameter of shell.

5. Bore and Face Operation: The shape of shells is not cylindrical but more likely it is in bottle shape. Therefore it has rough surface at its face so, facing operation is performed on shell which cleans the face of shell and also maintains the diameter of shells. Boring operation is also performs at same time. 6. First Cut Operation: In 1st cut operation outer diameter, cavity and profile is maintained. Tool used for maintaining outer diameter of shell. Basically the diameter of shell is greater than the required diameter after this operation. In this operation only the outer surface material is removed from the shell.

7. Finish Body Operation: The above operations which were performed are the rough operation while the next operations including finish body operation are finished operation. In this operation only the outer diameter is maintained and thus we get the required diameter of shell.

8. Stamping:

In stamping, a stamp is made on each shell which contains the hardness, date, type etc. and all the important specifications of shell.

9. Cut Off Pip Operation: In this operation the pip which is made during forging is now removed from shell.

10. Facing Operation: In this process, the step which is obtained during cut off operation is removed out. Here length is not maintained and it is a finish operation.

11. Internal Blending Operation: In this operation, there is removal of metal from the inner surface of shell.

12. Run-Out and Weight: Run-out and weight is just an operation in which weight of each shell is measured. Further on roughness of shell is also measure during same operation. 13. Grooving Operation: In grooving, the metal is removed from shell in form of band so that a cooper band in placed over it.

14. Knurling operation: In knurling, we provide a grip to the grooved part so that copper band can place to shell tightly. 15. Crack Detection: We use ultrasonic testing (UT), very short ultrasonic pulsewaves with center frequencies ranging from 0.1-15 MHz and occasionally up to 50 MHz are launched into materials to detect internal flaws.

16. Shot Blasting: Shot blasting is done to remove out the dust and scraped part of shell from inner surface. Iron particles are used to clean the shell. 17. Finished Nose Chamfering: In chamfering the face of the shell is tapered to 18 degree with the vertical axis. It is performed to avoid Sharpe edges.

18. Threading Operation: Threading is the process of creating a screw thread. It is done in the inner face of shell according to the requirement.

19. Band Press Operation: In this operation, the extra copper band is removed out from the shell and turn is given to avoid Sharp edges.

20. Seam Weld Operation: Seam welding is a process that produces a weld at the faying surfaces of two similar metals.

21. Phosphating Operation:

Caustic soda (10 min) Cold Water (10 min) Hot Water (5min) Acid (10 min) Cold Water (10 min)

Phospho-dyne (20 min)

22. Varnishing: Varnishing is done at inner part of shell. This is same as painting operation. 23. Painting: Here the shell is painted out. Different type of shells has different color to paint. It is done at outer surface of shell.

24. Packing: Hence the shell which is passing out from many operations is now packed down. These are packed down with safety in a thermocol case.

25. Dispatch: Finally the shell which is packed is then dispatch to the other areas and supplied to the Indian army. Charge is filled at other Ordnance factories.

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