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USAMC ltr, 14 Jan 1972

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 AMCP-706-249

AMC PAMPHLEi »706-249

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RESEARCH AND DEVELOPMENT

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ENGINEERING DESIGN HANDBOO

AMMUNITION SERIES
SECTION B, MANUFACTURE OF METAL
COMPONENTS OF ARTILLERY AMMUNITION

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HEADQUARTERS, uJl^^M'tfi>lTt%ÄMTfcfif^ JULY 1964

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HEADQUARTERS
UNITED STATES ARMY MATERIEL COMMAND
WASHINGTON, D. C. 20315

31 July 1964

AMCP 706-249, Section 6, Manufacture of Metallic Components

of Artillery Ammunition, forming part of the Ammunition Series of
the Army Materiel Command Engineering Design Handbook Series,
is published for the information and guidance of all concerned.

(AMCRD)

FOR THE COMMANDER:

OFFICIAL: SELWYN D. SMITH, JR.

Major General, USA
Chief of Staff

(&i4-^
Colonel, GS
Chief, Admiiiistrative Office

DISTRIBUTION: Special
 PREFACE

This handbook is the last of six handbooks on artillery ammuni-

tion and forms a part of the Engineering Design Handbook Series of
the Army Materiel Command- Information concerning the other
handbooks on artillery ammunition, together with the Table of Con-
tents, Glossary and Index, will be found in AMCP 706-244, Section
1, Artillery Ammunition- -General.

The material for this series was prepared by the Technical

Writing Service of the McGraw-Hill Book Co. , based on technical
information and data furnished principally by Picatinny Arsenal.
Final preparation for publication was accomplished by the Engi-
neering Handbook Office of Duke University, Prime Contractor to
the Army Research Office-Durham for the Engineering Design
Handbook Series.

Agencies of the Department of Defense, having need for Hand-

books, may submit requisitions or official requests directly to
Publications and Reproduction Agency, Letterkenny Army Depot,
Chambersburg, Pennsylvania 17201. Contractors should submit
such requisitions or requests to their contracting officers.

Comments and suggestions on this handbook are welcome and

should be addressed to Army Research Office-Durham, Box CM,
Duke Station, Durham, North Carolina 27706.
 TABLE OF CONTENTS
Section 6 - Manufacture of Metallic Components of Artillery Ammunition

Page Paragraphs
Introduction 6-1 6-1 to 6-10
Forging of HE Shell 6-4 6-11 to 6-33
Machining of HE Shell 6-14 6-34 to 6-56
Cold Extrusion of HE Shell 6-21 6-57 to 6-68
Compromise Method of Shell Forming (Hot Cup,
Cold Draw) 6-25 6-69 to 6-70
Manufacture of High Explosive Plastic Shell 6-26 6-71 to 6-77
Manufacture of Armor-Piercing Shot and Caps 6-29 6-78 to 6-86
The Manufacture of Hypervelocity Armor-Piercing
(HVAP) Shot 6-35 6-87 to 6-91
The Manufacture of Tungsten-Carbide Cores 6-36 6-92 to 6-95
The Manufacture of Brass Cartridge Cases 6-37 6-96 to 6-103
The Manufacture of Steel Cartridge Cases 6-41 6-104 to 6-122
The Manufacture of Trapezoidal-Wrapped Steel
Cartridge Cases 6-46 6-123 to 6-131
The Manufacture of Perforated Cartridge Cases 6-48 6-132 to 6-133
References and Bibliography 6-49,-50

111
 MANUFACTURE ÜF
SECTION

6
METALLIC COMPONENTS OF ARTILLERY AMMUNITION
INTRODUCTION

6-1. Objectives in Design. Design of compo- to render withdrawal easy. A method of manu-
nents of artillery ammunition seeks to accom- facturing cartridge cases by spiral wrapping of
plish objectives set forth in requirements of sheet steel is also coming into increased use.
service. Design and the expedients of available
6-4. Progress in Manufacturing Techniques.
material and manufacturing methods must be
Use is being made of the techniques of powder
correlated to minimize drain on stockpiles and
metallurgy for the manufacture of rotating
man-hours in times of emergency. Principal
bands and other parts that lend themselves to
metals employed for a round of artillery are
this method. Use of cold extrusion methods
(1) steel for the shell, (2) brass for the cart-
promises a superior shell body, having the
ridge case, and (3) copper for the rotating
required physical (including fragmentation)
band. Steel is also employed successfully for
characteristics, from a slug which exceeds the
certain types of cartridge cases.
weight of the finished carcass by only a few
6-2. Reasons for Use of Steel and Brass. The percent. However, throughout the period in-
low cost of steel and its ready adaptability to cluding the First and Second World Wars, a
a wide variety of specifications, especially few changes which could be regarded as radical
those for strength and hardness, virtually rule departures from pre-existing practice took
out any other material from consideration, as place. Cartridge case manufacture is still more
far as the shell is concerned. Cartridge brass, or less unchanged, although the labor of hand-
despite its higher cost, owes its traditional ling components has been greatly reduced. A
employment chiefly to the ease with which it noteworthy forward step in the case of high-
may be drawn into a thin-walled case, its re- explosive shell was the forge finish of the
sistance to corrosion, and its successful per- cavity. This saved much expensive machining.
formance of the function of obturation.
6-5. Casting Versus Forging of Steel Shells has
attracted the attention of many ordnance en-
6-3. Selection of Manipulative Techniques.
gineers. The principal resistance to casting
Means employed to cause metals to assume the
high-explosive shells arises from a justifiable
desired form include (1) casting in a mold;
skepticism about the integrity of the finished
(2) squeezing and drawing, either hot or cold;
article. Cast steel, except under high hydro-
and (3) machining. Selection of one or more
static heads, is especially prone to blowholes
of these techniques, in an appropriate sequence,
on account of its relatively high melting point,
is governed by considerations of both cost and
as compared with cast iron. Centrifugal cast-
adaptability. Thus, while it would be possible to
ing has been proposed but never seriously
machine a large shell out of a solid bar, it is
considered. Tank hulls, however, were suc-
cheaper to forge hot and finish on the lathe.
cessfully cast during World War II and the
Similarly the easiest way to make a cartridge
possibility of casting high-explosive shell with
case is (1) to blank out a disk from rolled
the aid of shell molds cannot be overlooked.
strip, (2) to cup it and, (3) by successive draws
and intermediate anneals, to extend the metal 6-6. Influence of Hot Versus Cold Work on
into a long, cylindrical thin-walled container Steel. In hot-forging, as distinct from cold-
having the necessary combination of plasticity working, the temperature of the steel always
and resilience to expand with the gun tube at exceeds the critical range. Hence, the micro-
the instant of firing, and to retreat sufficiently structure of the steel is austenitic. No amount

6-1
of deformation while in this condition injures
the steel in any way; on the contrary, it im-
proves it. Cold-worked steel can always be
distinguished from hot-forged stock, under the tj. so -
microscope, by the appearance of the grains. «> 10
"\
Cold-working tends to elongate the grains ^
whereas hot work breaks up the large crystals, !$ SO
^
which tend to form at elevated temperatures, 5 so
into a fine grain of normal polyhedral pattern.
However, if steel is subjected to tension while
at forging heat, the amount of elongation to
which it can be subjected without cracking de-
pends upon the cleanliness of the steel. Dirty "• 30

steel (including high-sulfur steel), if ex- C

tended sufficiently under the rolls, may exhibit
cracks. O S 10 10 JO *0 SO to 70 to to 91
Reduction by cold working, percent
6-7. Hot Work Produces Satisfactory Shell. The
familiar pierce-and-draw process of manufac- Figure 6-1. Stress-strain curves of cold -
turing steel shells subjects the steel to far less worked, low-carbon steel
risk of cracking from overextension than the
rolling down in the mill. Manufacture of shell
forgings by hot work is an eminently satis-
factory method. It does entail, of course, the
machining of the exterior of the forging and the
removal of a considerable quantity of steel.
The latter is conserved by circulation through
the open-hearth furnances as scrap.

6-8. Influence of Cold Work on Physical Prop-

erties of Steel. The principal results of cold
work are a considerable increase in tensile
strength and a large loss in ductility. Yield
strength increases as the cross section is de-
creased. With reductions of 30 to 70 percent,
it is at least 90 percent of the tensile strength;
and for greater reductions, yield strength and
tensile strength may for all practical purposes
be the same. Figure 6-1 shows the stress-
strain curves of cold-worked, low-carbon steel.
Figure 6-2 shows the influence of carbon con-
tent on the gain in tensile strength arising
from cold work.

6-9. Extrusion for Shell Manufacture. Steel,

especially low-carbon steel, can, it is now
known, be made to flow under sufficient pres-
sure into the form of an artillery shell or
cartridge case and to acquire, in the process,
the required physical properties. Under favor- 10 20 30 40 50 60 70 80 90
able circumstances pressures of over 200 Reduction ofarea in drafting ,per cerrt
tons—many times in excess of the yield strength
of the steel — may be applied without fear of Figure 6-2. Effect of cold working on the
rupture. Also, deep-drawing operations charac - tensile strength of carbon steel, gain in
teristic of cartridge case manufacture may be tensile strength versus area reduction

6-2
carried out to the extent of a 55 percent reduc- cated. Further, there appears to be a remark-
tion, an amount far in excess of normal limits. ably low percentage loss of steel in cold ex-
trusion. For example, a 75-mm shell weighing
6-10. Advantages of Extrusion over Forging. 8.9 pounds starts with a 9.22-pound slug. The
Among the advantages claimed for extrusion are key to successful operation lies in the proper
(1) the enhancement of physical properties, by application of zinc phosphate to the surface of
cold-work, beyond the requirements of the the shot-blasted and pickled slug and successive
specifications for steel shell; (2) the elimina- squeezes. The metal phosphate acts as a "host"
tion of heating facilities for forging and heat to the sodium stearate soap lubricant to avoid
treatment; (3) the avoidance of a resort to sticking and tearing of the component against
critical alloys. Manganese content is greatly the extrusion tools.
reduced, savings up to 50 percent being indi-

6-3
 FORGING OF HE SHELL

6-11. Steel Used Early in World War H. Shells sistance of the steel. In general, as far as
were forged from a steel known as X-1340, steel for shells is concerned, high sulfur con-
which had the following composition: carbon, tent was believed (1) to contribute to non-
0.35 to 0.45 percent; manganese, 1.35 to 1.65 uniformity in quality; (2) to be responsible for
percent; phosphorus, 0.45 percent maximum; transverse weakness and red shortness, giving
sulfur, 0.075 to 0.15 percent. These are rela- rise to longitudinal cracks at the open end of
tively high percentages of manganese and sul- the shell; and (3) to occasional surface defects.
fur. High manganese content was originally in- High sulfur content does, however, promote
tended to secure the required physical proper- free machining. But above all other considera-
ties (on cooling from forging temperature) tions, the presence of large quantities of high
without subsequent heat treatment, manganese sulfur shell-steel scrap (crop ends, scrap
being a hardener. The amount by which 0.01 forgings, lathe chips, etc.) was a menace to the
percent manganese increases the tensile quality of other steels in the mill whose sulfur
strength varies with the carbon content from contents were normal.
100 to 500 psi. The increase in the yield
strength is somewhat more than this, 50,000 6-13. Steels Used After World War II. Steel
psi, accompanied by good ductility, being easily which replaced the older X-1340 had the fol-
lowing composition: carbon, 0.60 percent max-
attained with manganese in excess of 1.0 per-
imum; silicon, 0.15 to 0.35 percent; manganese,
cent, provided the cooling is rapid and uniform.
1.00 percent maximum; sulfur, 0.06 percent
While the physical requirements were met in
maximum. Maximum percentages of residual
the smaller shells, difficulty was experienced
ingredients were given as follows: nickel, 0.35
with the 155-mm on account of the higher ratio
percent; chromium, 0.30 percent; copper, 0.25
of volume to heat-robbing surface. This ac-
percent; together with the proviso that the sum
counts for the decision of the Ordnance De-
partment to adopt a steel with lower manga- of the percentages of nickel, chromium and
copper must not exceed 0.50. This steel had
nese content and to obtain the required me-
no noticeable influence on the amount of work
chanical properties by heat treatment. This
required in the forge shop. There was a notice-
action also saved considerable quantities of able absence of any tendency to crack, espe-
manganese, which was in short supply, and cially at the open end of the forging. The work
simplified the work of the forge by eliminating
of the machine shop, however, was increased.
air-blast cooling; however, the work in the
machine shop was increased. 6-14. Prevailing Shell Steel Specifications. The
chemical requirements of shell steels, as of
6-12. Objections to High Sulfur Content. Re- 17 February 1953, are shown in table 6-1.
duction of the manganese content of the steel
would have necessitated a reduction in the sul- Grades WDSS 1 and 2 are used for the most
fur in any event, since there is a limit to the part for 60-mm and 81-mm mortar shell forg-
amount of sulfur with which manganese will ings; also for the 57-mm recoilless gun shell.
combine to form manganese sulfide and thus The other grades cover all calibers from
rid the steel of the more objectionable iron 37-mm to over 155-mm, in which the yield
sulfide. Lower percentages of sulfur were de- strengths vary from 60,000 psi to 80,000 psi.
sirable, however, for other reasons. First, All shell steel is made by the basic open-
manganese sulfide is almost completely in-1 hearth process to fine grain practice, silicon
soluble in solid iron. Consequently, when the 0.15 to 0.30 percent. Bessemer steel never has
iron solidifies manganese sulfide is present in been acceptable lor shell bodies because of its
the mass of metal as discrete particles. These low notch toughness, especially at subzero
particles, if present in large quantities, as a temperatures. The current specification for hot-
result of excessive sulfur, may have a dele- forged artillery shell is identified as MIL-S-
terious effect on the ductility and impact re- 10520C (ORO).

6-4
 Table 6-1

Carbon Manganese Phosphorus Sulfur Silicon

Steel no. percent percent percent percent percent

WDSS 1 0.14-0.20 1.00-1.30 0.040 max. 0.08-0.13 0.10 max.

WDSS 2 0.28-0.34 0.60-0.90 0.040 max. 0.050 max. 0.15-0.30
WDSS 3 0.60 max. 1.00 max. 0.040 max. 0.050 max. 0.15-0.30
WDSS 5 0.65 max. 1.00 max. 0.040 max. 0.050 max. 0.15-0.30
WDSS 6 0.55 max. 1.00 max. 0.040 max. 0.050 max. 0.15-0.30
WDSS 7 0.65 max. 1.30 max. 0.040 max. 0.050 max. 0.15-0.30

In the above steels, incidental elements shall not exceed the following: nickel, 0.25 per-
cent; chromium, 0.20 percent; copper, 0.50 percent; molybdenum, 0.06 percent.

6-15. Shapes From Which Shell Forgings Are shown were standardized at a time when the
Made. The modern hot-forged shell blank starts Ordnance Department purchased shell forgings
as a billet, parted off from round stock or from prime contractors. Later on, when shell
square stock with rounded corners. In the machiners purchased shell forgings directly
familiar pierce-and-draw process, the square- from the forge plants, no fixed outside dimen-
stock type has the advantage (more fully dis- sions existed. In consequence the same shell
cussed elsewhere) of imposing less severe duty forger made shell forgings to different dimen-
on the punch, since lateral movement of the sions at various times, or even at the same
steel takes place as the die pot is filled, thus time, if he had orders from several shell
limiting the extent of rearward extrusion. machiners. The desirability of saving weight
caused changes in these dimensions to the
6-16. Specifications. Military specification for point where they lost their original signifi-
shell steel covering the compositions shown in cance. Cavity sizes, of course, persisted, since
the table above are the following. the cavity was finished in the forge, apart
Federal. QQ-M-151 — Metals: GeneralSpec- from the small amount of material removed
ification for Inspection of. by shot blasting.
Military. MIL-M-11266 — Macroetch Test
and Macrographs of Steel Bars; MIL-M-12286 — 6-18. Billet Separation. The great majority of
Macroetch Test and Macrographs for Resul- shells are forged from single or double slugs
furized Steel Bars, Billets and Blooms. parted off from the main billet or bar. Sepa-
Standard. Military, MIL-STD-129-Marking ration may be effected in various ways, es-
of Shipments. pecially by (1) shearing, (2) sawing, or (3)
flame cutting; (4) "nick and break" was also
These specifications (1) cover the quality of the widely used. The first three do not permit
steel; (2) indicate permissible variations for effective inspection of the separated surfaces
check analysis; and (3) deal with the matters of for secondary pipes, cracks and holes. Break-
internal soundness, (4) extent of the discard ing does, but slivers'and rough breaks occasion-
from the top and bottom of the ingot, (5) identi- ally mask holes and cracks. Moreover, steel
fication by heat number, and (6) surface con- breaks at times with a loose sliver which is
dition. They also exhibit permissible variations not easily detected if it lies flat against the
from size and straightness; and deal with sam- broken surface. Such a sliver would end up as
pling, inspection, and test procedures. Notes a sliver in the cavity and be detected on shot
are also appended on preparation for delivery blasting, causing rejection of the forging.
and ordering data.
For shearing, the bar must be heated to at
6-17. Shapes and Dimensions of Shell Forgings. least 80°F to avoid shearing cracks. Even so,
Figure 6-3 gives information on the shape and if the slugs are not delivered to the furnace
dimensions of forgings for 75-mm, 90-mm, and within a few hours or days at the most, cracks
105-mm shell. These data were laid down for may develop unless the steel has been heated
World War II manufacture. The dimensions to 200°F. Among the methods available for

410670 O -57 - 2 6-5

 . MAX.
H
MIN.
RIDGES AT 180°PERMITTED
r-E^ WHEN FORGING IS MADE
BY UPSETTER METHOD.
CONTOUR MAY VARY BETWEEN THAT SHOWN
BY FULL LINE AND THAT SHOWN BY DOTTED LINE.

A TOLERANCE OFHQ" IS PERMITTED

ON THE DIAMETER AT ANY PORTION
OF THE INTERIOR CAVITY

SIZE A B C D E F G H 1 J K L M N 0 P Q
75mm 13.125 11.35 5.51 -20 5.48r20 L36 1.11 I.OS 1.4 1.06 2.133.28:0624 .8 .47 8° .1 +.02
90mm 14.0 1230, 6.30- 6.11720 2J5 1.43 1.5 1.25 2.55 392:08 4 .8 6° .1 ?02S
105mm 19.0 15.5 8.45-20 8.80:2C 225 1-65 1.30 2.0 200 3r3Q 4.55:10 18 1.25 .5 8° ,25 1025
155mm 26.50 23.0 10.42:25 10.10:25 2.80 I.9C 1.58 3.0 250 4.84 6.6O10 43 1.75 1 8° 25*035
DIMENSIONS OF SHELL FORGINGS
Figure 6-3. Dimensions of shell forgings
separation of the slugs from the bar, shearing appreciable cooling effect. A thin skin only is
is the cheapest. However, shearing of rounds affected in the second or so of contact between
is limited to 3 inches diameter, although some- high-pressure water and the steel. Reheating
what larger squares are sheared. Nicking and of the thin, cooled skin by the heat in the body
breaking is the cheapest method for large of the slug is rapid.
shells. Sawing and flame cutting give square
ends that make it easier to set the slug upright 6-20. Shell Forging. The apparently simple
on the rotary hearth of the heating furnace. process of forging a shell from a heated slug
is actually beset by many pitfalls. Modern
6-19. Billet Scale and Descaling. Shell steel techniques have grown out of extensive develop-
bars, when delivered to the forge, are covered ment. Earlier and more direct methods cen-
with a light scale and occasionally with rust. tered about forcing a punch into a round slug
The amount of scale formed and its nature vary previously raised to forging heat and placed in
with furnace heating time, temperature, and the a die or "pot" which it fitted loosely. The metal
composition of the shell steel and of the fur- rises around the punch, much after the fashion
nace atmosphere. Scale is abrasive and ruins of drawing on a heavy steel glove. The load on
tools and dies. A nonretentive scale is desired, the punch under these circumstances is very
that is, one that can readily be knocked off in severe, and its life is short. The surface of the
its entirety. Scale on a round slug can be punch deteriorates rapidly, giving rise to rough
cracked off with an end squeeze; another method cavities which have to be machined. "Wash"
employs serrated rolls. Water jets driven by heating of the slugs (hasty heating causing steep
high pressure (2,500 psi) are effective without temperature gradients from the hot exterior to

6-6
the cooler interior) forces the punch to run to 6-22. The One-Shot Method. Figure 6-4 illus-
the side, producing "thick-and-thin" forgings, trates diagrammatically the progressive stages
difficult to machine and wasteful of steel. in the one-shot piercing process that is cred-
ited with producing smooth, satin-like cavities.
Punches are now made of alloy steel and are The profile of the piercing punch must, of
lubricated. The load on the piercing press is course, be that of the cavity in the shell. Since
reduced by performing the forging process in the ordinary high-explosive shell has a fairly
two steps. First a cup is formed in the press; large length-to-cavity diameter ratio, the pierc-
this cup is then mounted on a mandrel and ing punch is much longer and more slender than
pushed through a series of ring dies of gradu- the punch required for the more familiar
ally diminishing size to draw out the body of double-ope ration sequence of pierce and draw.
the forging. Provision of a retreating base in the die averts
the limitations encountered when shells were
Possibly the most significant change between pierced in one go.
the two World Wars has been the use of round-
cornered squares in place of rounds for the In the one-shot process, friction between the
slugs. The load on the punch is reduced, since exterior of the slug and the die tends to hold
lateral flow of the steel to fill the die reduces the forging against the die walls, while the
the amount of backward extrusion, as well as punch makes its way into the interior of the
the work required to change the shape of the slug, extending it as the base of the die drops
slug to that of a cup. when the thrust upon it exceeds a predeter-
mined adjustable value. Slug temperatures must
6-21. Objectives in Shell Forging. The effort to be high and heating should be uniform if "run-
produce accurate, minimum-weight shell forg- out" of the long and relatively slender punch is
ings arises from the necessity of saving steel. to be avoided. A modification of the one-shot
During a war, shells are manufactured in astro- process calls for the use of a second press
nomical quantities, and demand on steel capac- where the bottom of the forging is set.
ity is correspondingly heavy. The return of
scrap and chips to the mills reduces the load on Figure 6-5 is a diagrammatic cross-section
the blast furnace, and is a necessary part of the through a "one-shot" press. The piercing
material requirement of the open hearth. Trans- punches are fastened to a turntable which is
portation is another factor. Tools need be con- indexed 90° after each piercing operation. This
served. Power used in the machine shop is less gives the punches a chance to cool off and to
if only a thin roughing cut has to be made. be lubricated for the subsequent operation.
Weight may be saved at the outside diameter, After the first turn through a right angle, the
also on the length and on thickness at the base. punch which has just been at work is sprayed
But enough metal has to be left to make sure with oil. Another quarter turn and it is im-
that a high percentage of forgings will "clean mersed in oil. A third quarter turn and it is
up" during rough turning without leaving any in the inspection position. The means whereby
black spots. the base of the die (marked "resistance pin")
descends as the pressure upon it exceeds a
Several distinct improvements have been suc- predetermined pressure are clearly in evi-
cessful: (1) the so-called French extrusion dence. This relief pressure is adapted to the
process, in which a plunger moving downwards variable resistance of shell steel at forging
within a cylindrical die extrudes the slug over heat to change of shape; and to variations in
a punch which sits upright with its nose within the frictional resistance of the interior of the
the die; (2) use of mechanically operated die with wear. Punches in this operation have
presses, such as bulldozers and upsetters; (3) to be carefully guided, as indicated by the ex-
application of cross rolls (familiar in the man- tensive punch guide on top of the die.
ufacture of seamless tube) to the extension of
the cup produced by the piercing press; (4) the 6-23. Hydraulic Piercing for Subsequent Draw-
"one-shot" process, in which the base of the ing. In the process described .in the preceding
die drops downwards under a controllable pres- paragraph, the entire action takes place in the
sure, thus minimizing rearward extrusion of the piercing die unless a second operation to set
steel and relieving the load on the punch. the bottom of the forging is used. The greatest

6-7
 REDUCTION IN LENGTH FURTHER SLIGHT BASE RETRACTION BASE RETRACTION
SHOWS BILLET HAS REDUCTION IN HAS COMMENCED HAS CONTINUED
BUMPED UP AT TOP LENGTH SHOWS
IN THE DIE MORE BUMP UP
IN TOP OF DIE

Figure 6-4. Progressive stages of one-shot piercing method

part of high-explosive shell manufactured dur- pressure of the punch until friction between
ing World War II, however, was forged in two die and slug takes hold and lateral displace-
major operations, the "pierce" and the "draw". ment supervenes. Finally the excess metal in
Many minor variations of the piercing or "cup- the die extrudes rearward toward the end of
ping" operation appeared. Sometimes the die the piercing stroke.
pot was inverted, the punch entering from
below, partly to facilitate the removal of scale The maximum square is determined by the
but principally to secure concentric entry of consideration that the steel displaced from
the punch. If a cylindrical or prismatic slug is the cavity by the punch must be sufficient to
placed in a tapered die set upright, it tends to fill the four segments between the billet and
rest against one side of the die, causing eccen- the die; otherwise the forging would not fill
tric entry of the punch. There is less liklihood the die. If S is the measure of the side of the
of this happening in the case of an inverted square and r the radius of the corner, then for
die. Figure 6-6 shows the arrangement of the equality between the area of the original round
tools of a hydraulic press for inverted piercing. cornered square and the final annulus

6-24. Round Versus Square Slugs. During World S2 = 3.222rS * 2.45 r2 = 1.375d2
War II the use of round stock for shell slugs
was restricted, on account of its higher cost 6-25. Drawing After Piercing. Figure 6-7 ex-
as compared with round-cornered square bil- hibits a typical draw bench with solid ring
lets. But there is less rearward extrusion, dies. As previously indicated, the forge work
that is, flow of metal in the direction opposite required to produce a shell is divided between
to that of punch travel. In fact, in the early use the piercing press and a subsequent draw. The
of the round-cornered square it was hoped to drawing operation m»y be carried out on a
avoid rearward extrusion (with its consequent mandrel which pushes the cup through a series
erosion of punch and die) by making the area of ring dies of successively smaller diameter.
of the original square equal to that of the final Instead of solid rings, rollers may be used; or
annulus. Actually the slug is shortened by the humped rolls may be employed for the purpose,

6-8
 The cavity is merely shot-blasted, and little
metal is removed in the process.

6-26. The French Extrusion Method of forging

shell foreshadows the modern techniques of
cold extrusion which will be described later.
The principle is illustrated in figure 6-9. A
slug, raised to forging heat, is placed in the
die (B). The punch (C) then moves forward to
PREFILL TANK
cause flow through the annular space between
the die (B) and the mandrel (A), the action being
PREFILL VALVE continued until the desired base thickness of
the forging is secured. The process can be
readily carried out on a bulldozer. This simple
MAIN RAM
method of forging high explosive shell attracted
less attention during World War II than it
MAIN CYLINDER. merited, partly on account of the uncertainty
concerning the outside diameter of the forging.
WEDGE
,WEDGE CYLINDER
Some care is necessary in the adjustment of
CYLINDERS
the relative axial position of the die (B) and the
TOP mandrel (A), and consequently of the charac-
CROSSHEADXJ teristics of the annular orifice between them,
to ensure satisfactory performance.

6-27. Progressive Piercing on the Upsetter.

The origin of the force that does the work in
FOUR POSITION
"TURRET forging a shell from a slug is a matter of little
-STOPS moment, granted that adequate force is avail-
•FOUR PUNCHES able. A hydraulic press produces a steady
thrust, but a crank and flywheel combination
produces a variable thrust. The thrust may be
as great near the dead center as the several
parts of the machine will withstand, but it de-
clines rapidly toward crank positions at right
angles to the dead center.

Given a sufficiently powerful press, the job of

forging a shell should apparently be completed
XDIE CLOSING
GEAR at one heavy stroke; nevertheless, a series of
operations is necessary, if for no other reason
COLUMN• •RESISTANCE PIN than that the energy capacity of the system per
revolution of the flywheel is a limiting factor.
The sequence is best interpreted by reference
BOTTOM CROSSHEAD BASE CYLINDER
to figure 6-10, entitled "Upsetter Forging With
Figure 6-5. One-shot press a Collar." In brief, the bar, one end of which
has been heated while the other serves as a
as shown in figure 6-8. While the shape of the tong hold, is pushed against a stock gage and
piercing punch is determined by the experience gripped by the closing dies. In the first push
of the tool designer, the profile of the draw- (not shown in the diagram) the punch upsets the
bench mandrel must, of course, be that of the end of the bar and splinters the scale. There-
cavity in the shell. Likewise the diameter of after, the stock is pushed forward to the gage
the last ring die is determined by the diameter a second time after turning through 90°. Sub-
of the shell, that is, it must not be less than sequent events may be followed from the dia-
this. Actually, of course, sufficient metal must gram. After each thrust of the pitman carrying
be left on the outside to "clean up" on machining. the head in which the punches are mounted, the

6-9
 Figure 6-6. Hydraulic press tools

6-10
 DRAW RING DRAW RING DRAW RING DRAW RING
NO. 4 NO.3 NO.2 NO. I

-± EQ
y>>m>>>>jsr#iEtt
STRIPPER ASSEMBLY P^»^/<I

■^RING HOLDERS
: ( )
HIP iiijuimiifiA v J > > i J i 11 111 J J i r cd
Figure 6-7. Draw bench

MANDREL RELEASE

DRIVE SHAFT

PUSHER RAM

Figure 6-8. Cross rolling mill

6-11
split die opens, one half moving under toggle
action to enable the operator to transfer the
stock from one impression to the next below.
In this way the final form of the forging is
reached. Round or square stock may be used
in the upsetter. The latter has the advantage of >
being readily gripped in the dies, despite rea-
sonable variations in size.

6-28. The Effect of Water Sprays on Hot Forg-

ings lies in the extent to which the hot forging
is cooled. With modern shell steels, no injury
B=>
results as long as the outer layers remain
above the critical temperature; however, if
3-
surface cooling is continued until the tempera-
ture falls to the "blue heat" (around 700°F), >
the deformability of the steel becomes low;
steel tends to fracture at this temperature like
cast iron. Ordinarily this does not happen.
Even the hydraulic descaling of the slug with
o E3-
cold water under a pressure of 2,500 psi ap- Figure 6-10. Upsetter forging
pears to have no injurious effects. In any case,
even if fine hair-like cracks should form on
the outside of the forging, any injury from
water would be removed in rough turning.

Cracks in the cavity would be more serious,

both because of the greater difficulty of ob-
servation and on account of the small amount
of metal removed by shot blasting. Careful
investigation, in cases where water was freely
sprayed in the cavity for periods in excess of
normal, failed to reveal any cracks from this
cause.

6-29. Economics of Shell Forging. The cost of

producing a usable shell forging is the sum of.
many minor and a few major items. These in-
clude the cost of the steel, freight, unloading,
billet separation, transportation to furnace,
heating, descaling, forging, cooling, inspection,
hospitalization, and loading. Coupled with these
costs are those for supplies, such as fuel,
CONICAL refractories, material for tools, packings, lu-
SECTION brication, overhead in the form of interest,
OF DIE depreciation of buildings and equipment, in-
surance, taxes, management and other forms
of indirect labor; all of these must also be
included in cost appraisal.
In making an appraisal of the different tech-
niques of forging shell, the method which
proves most economical for one size of shell
may not be the cheapest for another. For ex-
Figure 6-9. French extrusion process ample a 75-mm HE shell forging is most

6-12
economically made on the upsetter; the up- 1. Inspection for Soundness.
setter, however, is the most expensive method Soundness of base
of making the 105-mm. Seams and slivers
Scoring or roughness of cavity
6-30. Comparative Study of Shell Forging Meth- Scale pits
ods. Certain considerations other than cost Gas pockets or blisters
enter into the selection of equipment to forge Torn cavity
shell. These are (1) what type of equipment is Tear drops
best adapted to rapid conversion on the out- Cracks in nose end after nosing
break of war; (2) what forging equipment should 2. Inspection for Adherence to Dimensions.
be immediately available, without conversion, Outside diameter
if urgent necessity should arise; (3) the degree Diameter of cavity
of skill required in any given method, since a Length of shell (clean metal)
process than can be operated by unskilled labor Thickness of base
has the advantage of a quick start. Eccentricity
Ovality
An ASME study on "The Forging of H.E. Steel Length of taper in cavity
Shells" tabulates the various items of cost Ballooning of cavity (double nose)
entering into the manufacture of 720,000 shells
by various methods, for four different sizes of
6-32. Inspection Before Heating. The principal
shells, namely, 75-mm, 90-mm, 105-mm, and
defects encountered in the slug are (1) un-
155-mm. The figures relate to 1943. In the
soundness of the center caused by pipe; and
final analysis no large differences, with one or
(2) surface seams and laps. Pipe is an unusual
two exceptions, exist among the various meth-
extension of the cavity which forms under the
ods. Total cost divided by number of shells
results in the following average dollar values upper crust as the ingot cools and shrinks. This
defect is usually removed by cropping in the
of the four shell sizes:
mill; but incomplete removal may cause un-
sound cores and basal porosity. Shells are pro-
For the 75-mm shell forging,
tected against premature detonation from this
577,500/720,000 = $0.81
cause by a rolled steel plate, welded to the
90-mm shell forging,
base. Experiments to determine the possibility
877,800/720,000 = $1.22
that basal porosity will cause detonation within
105-mm shell forging,
the gun tube indicate that the risk is very small.
1,188,600/720,000 = $1.65
It is, however, a chance that cannot be taken.
155-mm shell forging,
Pipe is detected by sawing and macroetching
3,443,000/720,000 = $4.78
the ends, and sometimes the middle, of the bar.
Billets 5 by 5 inches, or larger, are particu-
Slug weights for these shell sizes were, ap-
larly subject to unsoundness, hence the ends of
proximately, 19, 30, 42, and 128 pounds, re-
each slug are usually examined.
spectively. The costs per pound of forged shell
are:
6-33. Inspection After Forging. Inspection after
4.3 cents for the 75-mm forging is done before the forging has cooled.
4.1 cents for the 90-mm The principal checks are made for concentricity
3.9 cents for the 105-mm and thickness of base. This is followed by a
3.7 cents for the 155-mm cold inspection prior to machining. "Teardrops"
and "torn cavities" arise from the same cause.
Certain items, such as real estate and build-
The melting point of the steel skin in the cavity
ings, taxes, burden, overhead, and other more
or less fixed expenses, are not included in is lowered by the addition of the carbon in the
these figures. graphite lubricant used on the punch, and may
liquefy in flakes or globules which weld them-
6-31. Inspection of Shell Forgings. Forgings selves to the wall of the cavity. The bond is
are inspected for soundness and adherence to not secure. The shot blast sometimes removes
dimensions. Inspection procedures fall into the the flakes and the tear drops may be chiseled
following categories: out.

430670 O -
6-13
 MACHINING OF HE SHELL

6-34. Sequence of Operations in the Machining centricity than rotation of either shell or drill
of Shells. The following operations are nor- alone.
mally performed on the shell after it comes
from the forge:
1. Shot blasting of cavity 6-36. Rough Machining the Outside of the Shell.
2. Cutting to length (See figure 6-11.) Rough machining is carried
3. Centering out on a special, single-purpose lathe, designed
4. Rough machining to mount an optimum number of carbide cutting
5. Heating for nosing tools working simultaneously. The shell is
6. Nosing gripped internally by the expanding pads of a
7. Heat treatment heavy arbor, while its base rides in the live
8. Testing for hardness center of the tailstock. The greater the number
9. Shot blasting of tools, with given feed and depth of cut, the
10. Nose boring tighter must be the grip between arbor and
11. Finish turning of body shell.
12. Removing boss
13. Finishing of base 6-37. Nosing. The open end of the rough-
14. Rough turning of band seat machined shell is closed in and the ogive
15. Finishing of band seat (including waving formed by a large vertical press capable of
or knurling) exerting pressures of 150 to 400 tons. The
16. Nose tapping body of the shell is well supported by a chuck
17. Bourrelet finishing during the operation. Fuze thread diameter is
18. Nose notching the same for all high-explosive shell, from
19. Cleaning of band seat 75-mm to 240-mm; therefore, the open end of
20. Banding the largest shell must be deformed about three
21. Band turning times as much as the smaller calibers to pro-
22. Degreasing duce the same size fuze hole. As a result,
23. Fastening of base plate 155-mm shell and up are hot-nosed, while the
24. Painting 75-mm to 105-mm can be cold-nosed.
25. Checking for dimensions after each op-
eration 6-38. Heat Treating. The critical temperature
of shell steel lies between 1,400 and 1,450°F.
6-35. Preparation for Machining. After shot- All portions of the nosed shell forging must be
blasting the cavity to remove scale, the excess heated above this critical temperature and
length is cut from the mouth of the forging and quenched. In order to achieve maximum hard-
a centering hole for the tailstock center is ness prior to tempering, coupled with a mimi-
drilled in the base. The cutting-off operation mum of distortion, the cooling rate of the in-
is usually done by sawing or by flame-cutting side and outside, during quenching, must be as
on a cradle of slowly revolving rollers. The near the same as practical. In order to make
torch is placed inside the shell, so that the sure that the critical temperature has been
flash is thrown to the outside where it is re- reached, the temperature is brought up to about
moved in rough turning. For 155-mm shell and 1,500 to 1,525°F. For quenching, oil is pre-
above, flame cutting is more economical than ferred to water, which is more drastic in its
sawing. Since the cavity of the shell is not cooling action and hence more liable to produce
machined, it is necessary to locate all machin- cracks. The quench is followed by tempering,
ing operations therefrom. The centering hole is that is, reheating the shell to some tempera-
drilled while the forging is mounted on an arbor ture below the critical range to soften and
which rotates counter to drill rotation. This ar- toughen the steel. Tempering temperatures
rangement gives a better guarantee of con- usually range from 1,000 to 1,250°F.

6-14
 Fu» CniaKt fiM
HaMMTM. Ian

RMSCO «MO

Figure 6-11. Lathe for rough turning

6-39. Testing for Hardness. The temperature permissible Brinell hardness is established by
at which shells are tempered is determined consideration of machining difficulties. Un-
primarily by the necessity for meeting speci- satisfactory shells are returned to the heat-
fications for physical properties. The higher treating department.
the temperature, the softer the steel and the
lower the tensile strength. There is an ap- 6-40. Shot Blasting. After heat treatment, the
proximate relation between tensile strength and cavity is cleaned by shot blasting in order to
hardness (tensile strength = 480 x Brinell hard- remove any scale formed during heat treat-
ness). Therefore, after tempering, the shell is ment, thus preparing the cavity for painting.
Brinell-tested for hardness. The lowest per-
missible Brinell hardness is determined by the 6-41. Finish Machining. (See figure 6-12.) To
minimum tensile stress specified; the highest prepare the shell for finish machining, the nose

6-15
of the shell is bored, reamed, and faced to lathe may be coupled with the finishing opera-
provide a surface for chucking. The shell is tion on the base.
mounted in the finishing lathe between an ex-
panding driver head, which grips the nose bore, 6-43. Machining the Band Groove. Grooves
and the tailstock center, on which the boss in with radial side walls can be machined by a
the base of the shell rides. forming tool, which leaves circumferential
ridges in the bottom of the groove and finish-
Because of its effect on exterior ballistics, machines a portion of the shell adjacent to one
close tolerances are specified for surface side of the groove. These ridges are later con-
roughness. The maximum roughness permitted verted into sharp projections by knurling roll-
by the Ordnance Department is 250 micro- ers with hardened teeth. Grooves with undercut
inches. sides and wavy ribs require somewhat different
treatment. The groove is first opened up with a
The machining setup is similar to that used for radial feed to the depth of the top of the ridges.
rough machining (paragraph 6-34), although a Clearance is then cut at the sides of the rec-
lighter lathe may be used. tangular groove. Undercutting of the sides of
the groove and machining of the wavy ribs by a
6-42. Finishing the Base. After completing waving tool may be done simultaneously.
finish-turning of the shell, the boss on the
base is removed. It may be sheared off; sawn 6-44. Nose Tapping. Cutting the thread in the
by a metal saw, or abrasive wheel; or cut off nose of the shell to receive the fuze is most
in the lathe. An end mill is also occasionally frequently done with collapsible tapping heads.
employed. The removal of the boss in the However, milling cutters may be used. These

Figure €-12. Tooling setup for turning

6-16
 v..
enter the bore, are then advanced to cut, and thin-walled shell, welded overlay bands are
are traversed axially through a distance equal often used.
to the pitch of the thread, while the shell ro-
tates once. Tapping may be done on a standard 6-49. Band Turning. After having been set, the
tapping machine; a multistation machine may rotating band is machined to the specified size
also be used. and shape. Bands without grooves may be fin-
ished with a single point tool; those with grooves
6-45. Finishing the Bourrelet. In order to are usually finished on a lathe with a form tool.
maintain the close tolerances of bourrelet Milling with a profiled cutter is also practiced.
diameter in mass production with unskilled Since gilding metal is comparatively soft, it
help, the bourrelet is usually finished by tends to spread beyond the confines of the
centerless grinding, although many machiners groove during the banding operation; hence
prefer a shallow cut in the lathe with a very trimming tools must be provided in the machin-
fine feed. ing set-up.

6-46. Nose Notching. Staking notches are re- 6-50. Washing and Degreasing. High-explosive
quired in some shells but not in all. These shells are painted to protect them against rust.
notches may be cut by various means, the most The surface is prepared by washing and de-
common being milling. One or several milling greasing. This consists of an alkaline wash,
cutters may be used. If several are used the followed by a rinse and an acid wash. The alka-
cutters rotate continuously, the shell being line solution dissolves the grease. It is not
pushed up against a stop governing the proper allowed to dry on the shell because the salts
depth of cut. may react with the explosive in the cavity, and
for this reason is removed by flowing water in
6-47. Cleaning the Band Seat. The presence of the rinse tank. For the acid wash, the solutions
chips or other trash may interfere with the which are used contain phosphoric acid, which
proper seating of the band. The seat is there- (1) produces a surface to which paint adheres
fore cleaned thoroughly with a steam jet, or by exceptionally well, and (2) forms a complex
wiping with a rag which has been wet with phosphate coating which protects the steel
carbon tetrachloride. A very thin layer of oil against rusting.
or grease does not interfere with tight banding.
6-51. Fastening the Base Plate. Since pre-
6-48. Banding. The proper mounting of the mature explosion may result from cracks,
driving band on the shell is of considerable sponginess, pipe, or holes in the base of the
importance, since the tightness of the band shell, a rolled steel plate is mounted on the
affects the ballistics of the shell. The band, finished base of the shell. This base plate may
made of gilding metal, copper, or iron, should be (1) welded on; (2) caulked with a lead ring;
fill the band groove completely, without clear- or (3) peened in place. The preferred method
ance; and exert pressure against the shell both in this country is resistance welding, either
radially and against the sides of the groove. with the wheel or the cam-operated, recipro-
Banding is commonly done on a multicylinder cating type of spot welding electrode.
hydraulic press (figure 6-13), or a toggle joint
press (figure 6-14) known as a tire-setter, in 6-52. Methods of Weight Control. For various
which a number of jaws are thrust radially reasons, including tool wear, variation in the
inward against the band, squeezing it into size of the forge-finished cavity, lubrication,
place. Banding may be done cold on shell up to and (in large shells) temperature during the
and including 240-mm. For larger sizes the nosing operation, the weight of the shell would
band is heated to around 1,500°F before appli- vary beyond prescribed limits if means of
cation to the shell. In general it must be set weight control were not used. Among available
sufficiently hard so that when the pressure is methods of control are (1) the adaptation of the
released, and in the case of hot banding the outside diameter of that region of the rough-
band is cool, the shell springs back more than turned shell which undergoes deformation dur-
the band. If this condition is not fulfilled the ing nosing; (2) adjustment of the distance
band will be loose. Shell may also be banded between base and nosing die; (3) alteration of
by forcing through a die (figure 6-15). For the thickness of the base within prescribed

6-17
 rout? CYLINDER
RECIPROCATING
PUMP

Figure 6-13. Hydraulic banding press and pump

tolerances; and (4) reduction of wall thickness pressed into the shell while at rest; while in
by removing metal from the cavity. As a last the second, the stamps are mounted in the
resort, (5) a thin cut may be taken from the circumference of a wheel which rolls them in,
center section of the ogive. This procedure is as in a knurling operation.
not recommended.
6-54. HoBpitalization. In the course of manu-
8-53. Marking. The Ordnance Department re- facture a few shells slip through which will not
quires that all shells be stamped before paint- pass inspection. If the body is oversize, the
ing, in accordance with precise instructions as shell can be remounted in the lathe for re-
to which items are to be marked, on what part machining. Likewise, the ogive may be re-
of the shell the stamp is to be placed, and the profiled. Other hospitalization operations in-
size of letters and numerals. Two methods are clude refacing the nose and retapping. A faulty
in common use. In the first the stamps are center may cause the shell to "run out," that

6-18
 _J

Figure 6-14. Toggle joint banding machine

BREAK SHARP CORNERS finish may be improved by the application oi
a fast moving abrasive band.
/VENTRANCE
' ANGLE 6-55. Painting. Except for the rotating band
(sintered iron excepted) and the threads in the
nose, all parts of the shell must be painted
prior to shipment. Spraying is almost uni-
versally used. The paint applied to the cavity
has an asphalt base and is acid proof. The
U 4.2I7"--0005DIA. RELIEF band is covered by a protector which may also
l5«V""ANGLE
B.O" DIA.-
support the shell during the operation. The
threads are closed off by a plug which may
Figure 6-15. Banding die serve to suspend the shell.
is, fail to clean up and show forging scale 6-56. Inspection. During manufacture the shell
after machining. The faulty center may be is inspected both by the manufacturer and by
welded up and redrilled. During nosing, non- Government inspectors. The manufacturer in-
uniform lubrication may cause the nose near spects at frequent intervals, such as after the
the tip to be thicker on one side than on the forgings have been received, after rough-turn-
other. This may be corrected by machining out ing, and after nosing; while Government in-
the irregularity with a boring bar and skiving spection is limited to three points in the pro-
tool. If heat treatment is unsatisfactory, it may duction line: (1) before application of the band
be repeated. Debanding and rebanding is an- and base plate; (2) before painting-, and (3)
other function of the shell hospital. Surface after painting.

6-19
The principal function of inspection is to check erties are made, and the base plate struck a
on size and shape. For this purpose gages — sharp blow with hammer and chisel to be sure
wherever possible, of the "yo" and "not go" that it is secure. Finish is checked by corn-
type — are provided. Visual inspection of the parison with a standard block or by means of
shell is mandatory at frequent intervals; con- a measuring device. Paint coverage, both out-
centricity is checked, tests of physical prop- side and inside, is examined visually.

6-20
 COLD EXTRUSION OF HE SHELL

6-57. Cold Extrusion of Shell. A process for depression or "dimple" on top. This dimple
cold-forming shell by extrusion has recently centers the slug with respect to the punch in
been developed in this country. By the use of the next operation. The sized slug is 5.115
extremely high pressures, steel slugs are ex- inches in diameter over the upper cylindrical
truded into finished shell with a minimum of portion; and 5.77 inches in overall length.
machining operations and waste material. The Before moving to the next operation, the slug
process consists of the following operations: is again phosphate coated and lubricated as
1. Preparing the slug described in the preceding paragraph.
2. Sizing the slug
3. First extrusion — first hit 6-60. Extrusion. (See figures 6-16c through
4. First anneal 6-16f.) The first extrusion operation is carried
5. First extrusion — second hit out on a 1,500-ton press; the actual pressure
6. Second anneal required is 1,100 tons. The press has a 36-inch
7. Second extrusion stroke, and a 48-by-48 inch bed. It is powered
8. Third extrusion by two 200 horsepower motors. Maximum oil
9. Extrusion to length line pressure is 2,460 psi. The bar, after this
10. Expansion of the bourrelet and drawing "first hit," has a cylindrical cavity 3.320
through inches in diameter and 4.08 inches deep. The
11. Nosing outer diameter has increased to 5.123 inches,
12. Stress relief anneal except where it tapers to the nose. The over-
13. Machining all length has been increased from 5.77 inches
14. Inspection and marking in the sized slug to about 7.4 inches. Following
washing and drying, the component is inspected
The following paragraphs describe the cold for seams which, if they occur, are ground out.
forming of the 105-mm HE shell as practiced If the seams are too deep, the piece is dis-
by the Mullins Manufacturing Corporation. The carded. The steel is then annealed at 1,450°F
procedures followed by other manufacturers to remove the effects of strain hardening. After
for machining this size or other sizes of shell annealing, the piece is again phosphate coated
may differ in detail, but the overall process and lubricated. A "second hit" deepens the cav-
is the same. ity, cabbages the nose, and further extends the
piece to about 7.9 inches, without change in the
6-58. The Preparation of the Slug. (See figure exterior diameter. A third extrusion pushes
6-16a.) A slug 4 11/16 inches long is sawn the rounded nose of the punch deep into the
from a 5-inch diameter C-1012 steel bar. Each tapered lower extremity, lengthens the body to
slug is chamfered, on both ends simultaneously, 8.8 inches, and develops the boat-tail. The
in a deburring machine, and the sawn faces are annealing, pickling, phosphate coating, and lu-
buffed to a smooth finish. The slug is washed brication are repeated, and the second and third
in a solution of sodium orthosilicate and dried extrusions are performed at pressures of 650
in a hot air circulator. In preparation for the tons and 580 tons, respectively.
next operation, the slug is then (1) pickled in
sulfuric acid, (2) rinsed, (3) phosphate coated, 6-61. Extrusion to Length. (See figure 6-17.)
(4) rinsed again, (5) neutralized, (6) lubricated, Up to this point the operations on the slug are
and (7) dried. comparable, in many ways, to hot forging; but
at this point the action becomes less familiar.
6-59. Sizing the Slug. (See figure 6-16b.) The Extrusion to length, cold, is not done on a
slug is sized under a pressure of 900 tons by a draw bench. The piece is forced to flow through
punch in a die. This produces a reduced lower the annular space between the nose of the ex-
end in the shape of a conical frustum, designed truding punch and the die, so that the shell
to center the piece in the next die; and a shallow "runs ahead" of the punch. This action may be

430670 O - 57 - 4
6-21
 SIZE SLUG
PRESSURE REQ'D.-900 TONS
B

IST HIT-IST EXTRUDE 2MDHIT-IST EXTRUDE

PRESSURE REQ'D.-IIOO TONS PRESSURE REQ'D.-SOO TONS
C D

2ND EXTRUDE
PRESSURE REQ'D-650 TONS 3RD EXTRUDE
E PRESSURE REQ'D-580 TONS
F

Figure 6-16. Slug

6-22
likened to any extrusion process in which a 6-63. Nosing. (See figure 6-19.) This operation,
plunger forces the metal through a formed die. similar to the cold-nosing of hot-forged shell,
The cylindrical enlargement of the punch body is conducted in a 500-ton mechanical press.
acts as the plunger; the annular space between The shell sits in a lower, retaining die, while
the nose of the punch and the restricted region the nosing die descends upon it and forms the
of the die constitutes the formed die. This op- ogive. Enough metal must be gathered in the
eration requires the usual coating and lubri- process to render nose reaming and tapping
cating preparation of the component. In addi- possible. The shell is then washed, rinsed,
tion, a lubricant consisting of molybdenum dried, and given a stress relief anneal at a
sulphide and oil is smeared on the shoulder of temperature of 850°F.
the piece at the press. The total pressure re-
quired for extruding to length is 650 tons. The
shell, as it comes from the press, has been
^ ^ V V
extended to a length of 15.16 inches; its ex-
ternal diameter reduced to 4.09 inches; and the
inner to 3.185 inches.

■^ ^ ^ -v vv
FINAL NOSE REDUCE

^> 's. ^^jy^A PRESSURE REQ'D.-400 TONS

Figure 6-19. Final nose reduce

6-64. Machining Operations. After the cold-
forming operations, the following machining
s: VV V V ^"X is done: (1) the nose is bored, faced, and
^ EXTRUDE TO LENGTH chamfered in preparation for threading; (2) the
PRESSURE REQ'D.-650 TONS
band seat is cut and knurled; (3) the bourrelet
Figure 6-17. Slug, extrude to length is ground; (4) the rotating band is pressed
into the seat; (5) the band is turned and
6-62. Expanding the Bourrelet and Drawing trimmed; (6) the staking notches are cut; and
Through. (See figure 6-18.) The previous op- (7) the base plate is welded on. These various
eration left the carcass with a boat-tail and a machining operations are similar to those al-
body which tapered by a few thousandths of an ready described for hot-forged shell (para-
inch toward the expanded lip left by the ex- graphs 6-34 through 6-56). The small number
trusion die. It is necessary to expand the body and relative simplicity of the machining opera-
to produce the bourrelet. This is accomplished tions on the cold-formed shell, as compared
by thrusting a punch of appropriate profile into with a hot-forged carcass, is impressive.
the cavity of the shell. While the shell remains
on the punch, the bourrelet is sized and the 6-65. Laboratory Tests. From each lot of
flared lip of the shell is straightened by drawing 20,000 shells, two are picked at random, and
through a die. The expansion of the bourrelet tests carried out on the steel of the shell body
requires about 175 tons; the subsequent sizing, and on the gilding metal. The yield point of the
about 125. steel is in the neighborhood of 73,000 psi; the
elongation 18 percent; and the reduction of area
about 64 percent. Typical results of tests on
the band give tensile strengths of about 38,000
^ ^ ^ ^ \ V ^ v X psi with a 20 percent elongation, and somewhat
greater than this with a 21 percent elongation.
Each shell used for these laboratory tests is
also checked for hardness. Rockwell B hard-
ness numbers range from about 86 to 96.
^ v ^ v ^ ^ v^:
k* EXPAND BOURRELET 6-66. Inspection in Process of Manufacture.
PRESSURE REQ'D.-75 TONS After the slug has been sawn from the bar,
Figure 6-18. Expand bourrelet there is a 100 percent inspection for weight;

6-23
and one slug from the first bar cut of each new a. Use of Strategic Material. Cold extrusion
heat is macroetched and tested for hardness. requires a steel with a low manganese content.
Following sizing, every 150th shell is given a Since manganese is a strategic material, this
profile check. After each of the first three represents an advantage over forging, which
squeezes, the shape and base thickness of the requires a high manganese steel.
shell are determined; also the size of the boat- b. Use of Steel Making Facilities. The cold
tail. After extrusion to length, body diameter is extrusion process uses a billet which is much
checked with a snap gage; also overall length; closer to the weight of the finished shell than
and lip thickness with a ball point micrometer. that used for forging. The scrap resulting from
Since surface defects may show up after ex- the forging process must be reprocessed. This
pansion to swell the bourrelet, every 15th shell represents an additional load on the steel mak-
is inspected visually. After nosing, the bour- ing facilities. This advantage of cold extrusion
relet diameter, body diameter, nose diameter, may be offset if the percentage of rejects from
eccentricity of the nose, inside diameter of the the production line is greater than the per-
nose, thickness of the base, and the size of the centage resulting from forging.
boat-tail are gaged. Visual inspection for de-
fects, with the aid of a light to view the cavity, The steel required for cold forging demands
is extensive, reaching 100 percent at two points. must be much freer from nonmetallic inclu-
After boring, facing, and chamfering the nose, sions and, since physical properties are ob-
the diameter of the bored hole, overall length, tained by work hardening, must have a more
nose diameter, and angle of chamfer are gaged. carefully controlled composition than that
After the machining of the band seat, there is a which is needed for forging. It is not known
100 percent check of the width of the band seat, whether or not our present facilities could
its diameter, the diameter of the recess at the supply the tremendous amounts of this high
rear of the band seat, and the position and angle quality steel which would be needed during
of the boat-tail with respect to the band seat. wartime.
After grinding, a snap gage is applied to the c. Machining Operations. Cold extrusion
bourrelet. After threading, the thread gage is eliminates rough machining and finish machin-
used in every 5th shell. Gages are also pro- ing of the body of the shell, as well as bourrelet
vided for inspection of the rotating band and its finishing. The remaining machine work is light,
position on the shell. The final inspection, which compared with these two operations.
follows the welding of the base plate, includes d. Total Number of Operations. Although
the application of a "Multichek Gage" to the the cold extrusion process eliminates several
shell diameter at seven points, from nose to of the machining operations required by forg-
rear bourrelet. After painting, the shells are ing, it requires eight press operations as com-
given a 100 percent visual inspection, both pared with three for forging. In addition, cold
inside and out. All shells are then passed extrusion requires a rather complex lubri-
through the forward bourrelet ring gage. In cation operation before each press operation.
combination with previous inspection measure- Hot forging requires that the shell be brought
ments, this last-mentioned inspection serves to forging temperature before each press op-
as a check on the thickness of the paint. eration; however, cold-forged shell must be
heat-treated several times during the forming
operation in order to maintain required physical
6-67. Government Inspection and Marking. Fol- properties. In all, approximately twenty-five
lowing final inspection by the plant, Government operations are required for cold extrusion
inspectors pass upon batches of 83 shells on a versus twenty-two for forging.
pallet. Shells released from inspection are e. Cost of Plant. Because of the extremely
marked, then washed, bonderized and dried, heavy, high-pressure extrusion presses re-
the cavity brushed out and painted in readiness quired, the cost of a plant for cold extruding
for packing. of shell is considerably greater than that for
a forging operation. A further disadvantage
6-68. Comparison of Hot Forging with Cold is that heavy-press time is usually at a pre-
Extrusion of Shell. mium in time of war.

6-24
 COMPROMISE METHOD OF SHELL FORMING (HOT CUP, COLD DRAW)

6-69. Compromise Method of Shell Forming. while at the same time eliminating this major
The principal advantage of cold forming is that disadvantage, has been proposed. This method
the weight of the completed shell is within a would employ hot forming to make the first
few ounces of the weight of the slug from which draws and cold forming for the subsequent
it is formed. By contrast, the weight loss re- operations.
sulting from the extensive machining which ac-
companies the hot-forging process may run as 6-70. Difficulties Involved. The difficulties in-
high as 50 percent. The principal disadvantage volved in this process are that (1) an extremely
of cold forming is that the 1,500-ton presses even heating of the billet is required to prevent
required for the first extrusion process are run-out of the punch, and that (2) some means
extremely expensive and at present are not must be provided to either prevent the forma-
readily available. tion of scale or to eliminate it completely after
it has formed. Large scale testing of this com-
A compromise method of forming, which would promise method is now under way at Frankford
make use of the advantages of cold forming Arsenal.

6-25
 MANUFACTURE OF HIGH-EXPLOSIVE PLASTIC SHELL

6-71. Introduction. The following paragraphs

describe the manufacture of the 75-mm shell,
HEP, M349, as practiced by the Chamberlain
Corporation. Procedures followed for other
shell or by other manufacturers may differ in
detail, but the basic process is the same.

The M349 includes three components: (1) a

shell body fitted with a rotating band, (2) a base
plug, and (3) a gasket (figure 6-20). The base
section in the neighborhood of the rotating band
is relatively heavy. The side wall tapers from
the base to about a tenth of an inch at the nose.
The base is threaded to receive the plug.

6-72. Development. The HEP shell has an un-

usual profile which is poorly adapted to stand-
ard forging cold-forming techniques. The in-
terior protuberance, required to accommodate
the rotating band, makes it impossible to with-
draw a forming punch. Machining of the cavity
would be a difficult operation. Quite early in
the experimental work on this shell, trouble
was experienced with loose rotating bands
caused by the difficulty in seating the band on
the thin wall. Attempts were made to make the
band an integral part of the shell body; failing'
that, a welded overlay of copper was used.

6-73. Experiments With a Two-Piece Body. At

first, the body of the HEP shell was made in
two parts. The nose was a cold drawn ogive
made from cold rolled 1030 steel. This was
then brazed to the body. As chamber pressures
were increased to secure higher muzzle veloc-
ities, the shell tended to bulge at the brazed
joint. Thickening the shell in this region was
tried and abandoned because of reduction in the
effectiveness of the round. Heat treatment to
harden the steel in the neighborhood of the joint
was out of the question, since it would have
destroyed the brazed joint. A single-piece, thin
walled shell appeared to be the only answer.

6-74. Present Manufacturing Method. The pro-

cess starts with a disk shaped blank, or "slug," Figure 6-20. HEP shell
of fine grained, spheroidized, mild steel (FS
1030). The blank is cleaned, phosphate-coated,
and lubricated. Figure 6-21 shows the sequence

6-26
 1ST DRAW

2ND DRAW
DISC
3 RD DRAW
4 TH DRAW

5 TH DRAW 6 TH DRAW TRIM NECK FINISH

Figure 6-21. HEP fabrication
of the draws. Note that the thickness in the nubbin is moved in on the cross slide, working
original cup is largely maintained in the draws. the hot wall of the shell around the profile of
The punches have reduced noses which draw the the mandrel to a tit on the nose. The tit is re-
body into the thin-walled extension of the lower moved in the finish grind.
region of the tube. After each of these opera-
tions, the component is annealed at 1,250°F, 6-76. Finishing. Following these shaping op-
just below the lower limit of the critical range, erations, (1) the shell is ground to meet sur-
for 45 minutes. The spheroidized structure is face finish requirements; (2) the base is faced
retained while the hardness, induced by cold and recessed; (3) the band is welded to the
work, is removed. body; (4) the band, which is to be pre-engraved,
is broached; (5) the base is tapped; (6) the shell
6-75. Cutting Off the Base. After the final is tested hydrostatically and with air; and (7) it
draw the piece is again annealed and given one is cleaned, phosphate-coated, and painted, out-
more draw. The base, closing the tube, is cut side and in. After loading, the base plug which
off, leaving an open ended "can" which is carries the fuze is screwed into the shell base.
trimmed to length. The open mouth is closed The copper gasket between plug and body
into an ogive as follows: (1) the thin walled guarantees tightness.
end is nosed, leaving a smaller open mouth;
(2) a mandrel is inserted in the shell, and bears 6-77. Hardness Testing. Because of the method
upon the partially closed nose; (3) the shell is of functioning of the HEP shell, it is important
rotated in a lathe and an oxyacetylene torch is that the hardness be accurately controlled.
played upon the partially formed ogive until Figure 6-22 exhibits the results of a typical
welding heat is reached. A stellite-sheathed Rockwell B hardness check.

6-27
 ROCKWELL PATTERNS
« 327
ELONGATION 11% (IN 2") ELONGATION 14% (IN 2")
YIELD POINT 58,000 P.S.I. YIELD POINT 99,000 RS.I.
ULTIMATE 70,770 P.S.I. ULTIMATE 71,890 P.S.I.
Figure 6-22. Typical hardness check

6-28
 MANUFACTURE OF ARMOR-PIERCING SHOT AND CAPS

6-78. Introduction. Armor-piercing shot may internal defects, including segregations, pipe,
take a variety of forms. They may be made (1) checks, and flakes.
with or without a cavity," (2) ogival- or trun-
cated-nosed, (3) capped or uncapped. Any com- 6-80. Manufacturing Techniques. Figure 6-23
bination of these choices is also possible. shows the first sequence of operations on the
bar stock. Each operation is performed by one
The following paragraphs describe the manu- spindle of an automatic screw machine, index-
facture of the 37-mm AP shot, M51, as prac- ing 105 pieces per hour and running at 258
ticed by the National Pneumatic Company. The rpm. The machined bodies are fed into a
processes which this capped monobloc shot go centerless grinder which brings the bourrelet
through are applicable to other types of shot to limits of 1.4475 — 1.4485 inches; and the
also. Differences in size and shape of shot will region in rear of the band seat to 1.436 —1.439
modify the procedures, but they will remain inches. The nose is then profiled on a six-
basically the same. A major difference exists station screw machine. The sequence is shown
in the case of shell with cavities —in this case in figure 6-24. The shot is then degreased and
the rough forging must first be made by the a number stamped on the base to identify the
pierce-and-draw process—but these shell are lot and, if necessary, the heat from which each
at present obsolescent. shot was made.
6-81. Heat Treatment. The shot are heated in
6-79. Steel Specifications. WD-4150 electric a radiant-tube, reducing-atmosphere furnace.
furnace steel, manufactured to Ordnance speci- The atmosphere, fed from a separate genera-
fication 57-107-D (with the exception that the ting unit at a temperature of 1,580°F, flows
carbon range is 0.52 to 0.57 percent) is used from the discharge end of the furnace forward
for this shot. The structure must be at least to the loading end, where the gases burn, pre-
50 percent lamellar pearlite. The composition heating the shot in the process. The shot are
of this steel is given as: carbon, 0.52 to 0.57 oil quenched at 140 to 180°F. They are then
percent; manganese, 0.60 to 0.90 percent; phos- placed in a batch-type furnace, where they are
phorus, 0.025 percent; sulfur, 0.025 percent tempered for four hours at 325°F. After tem-
minimum; silicon, 0.15 percent minimum; pering, the shot are allowed to stand for 72
chromium, 0.80 to 1.10 percent; molybdenum,
hours, after which they are hot-and-cold water
0.20 to 0.30 percent. Jominy tests are required tested to determine whether or not they will
in order to ensure hardenability to the speci-
crack. One shot from each heat is cut through
fied 79 to 82 Rockwell A. The steel is melted
the center (as shown in figure 6-25) and checked
in 50-ton Heroult electric furnaces and poured
for hardness at the points indicated; 79 to 82
into 16 1/2 in. square, big end up, molds,
Rockwell A is required. The microstructure of
fitted with hot tops. After slow cooling to avoid
the hardened shot consists of highly refined
checks and flakes, the ingots are stripped, re- martensite. Following the hot-and-cold treat-
heated, and rolled down to 4-inch square bil-
ment, the shot are air-blast dried, inspected
lets. Following slow cooling, the billets are
for surface defects, and shot blasted prepara-
pickled, surface conditioned, then reheated and
tory to matching with caps.
rolled down to rounds 1 and 17/32 inches in
diameter. These are annealed to reduce the 6-82. Specifications of Steel for the Caps. The
hardness to 183 to 212 Brinell, and machined composition of the steel for the caps is: car-
to diametral limits of 1.453 to 1.459 inches. bon, 0.90 to 1.00 percent; silicon, 0.40 to 0.65
A sample is taken from the top of each ingot percent; tungsten, 3.75 to 4.25 percent; sulfur,
after it is rolled into the 4-inch square billets. 0.025 percent maximum; manganese, 0.45 to
Disks, cut from the samples, are hydrochloric- 0.65 percent; chromium, 0.70 to 0.90 percent;
acid etched and then examined, by both mill vanadium, 0.30 to 0.40 percent; phosphorus,
and U. S. Army Ordnance inspectors, for 0.025 percent maximum.

6-29
 37% A.P.SHELL-SH0T-M'5I
llTOPERATION a SPINDLE CONOMATIC
OPERATION \POSlTIOH\ TOOLS
C/6204T-33-B

1 ROUGH FA C€% 0074 FEE D

7
^TP fsPOT DRILL.0074FEED
SUPPORT
ROUGH FORM.002 FEED

.495 DRILL.0074 FEED

SUPPORT

FINISH FACE.0074 FEED

BREAKDOWN TOOL
.OOfFEEV

KNURL.0O2 FEED
SUPPORT

FINISH DRIL LJ0074 FEED

FORM TOOL.002 FEED
SUPPORT

FORM TOOL.002 FEED

CHAMFER TOOL
SUPPORT

FORM CUT OFF TOOL

8 .002 FEED

Figure 6-23. Preliminary operations, AP shell

6-30
 37 % A. P. SHELL-SHOT-M-5t
2~OPERATION NEW BRITAIN MODEL 61
OPERATION POSITION TOOLS

J. INSERTAND
~EJECT 6

C/6 204-7-/
—>
I FOtfAf N0SE.00S4FEED

^J

-3>
_NO WO#K
I

OlßZO+TfrA
3 ROUGH FORM.OOl&FEED

C/620AT/i-A
4 FINISH SKIVE001*FEED

■7
~,> <

_/V0 WO#X
-^
5
Figure 6-24. Nose forming

6-31
 37% APSHELL- C4P-M-5/
I V. OPERATION 6 S PIN OLE CONOMAT\C
OPERATION G3HZH2 TOOLS
C/6202-7ÄI

1
I^SPOT DRILL
.004E>"FEED

«£/*202-7*62
/i Dtf/Z. LrSPECIAL GROUND
2 .0046V55D
FO#M TOOL
AAJX-^AI C/Ä202-72 .OO/8" FEED
GI6202T-II FO#M 700L
r .OOlS" FEED
l&DRIL L-SPECIAL GROUND
C/6202-7-3 004 6* FEED
G/62 02-7/9
UNDERCUTTING TOOL
-•4c/6202-7/4 .0 0 2" FEED
ROUGH REAMER
C/6202-T67 BREAKDOWN TOOb.OOI&FEED
G/6202-76
ROUGH FORM TOOL
5 OOO4"FEED
FINISH REAMER
^C/620 2-7-/4 004E> FEED
C/6202-7-7 FOffM TOOL
00 23" FEED
FINISH REAMER
76202-7/05 ,004€>" FEED
C/6202-7-8 FORM TOOL
7 OO23 FEED
REVOLVING SUPPORT
C/6204-79 .0023" FEED
C/6202-7-2/
8 CUTOFF
0023" F££D

Figure 6-26. Cap operations

6-32
All bars must be thoroughly annealed to 240 a cap is cut as shown in figure 6-27 and
Brinell maximum. They are turned and ground checked for hardness at the points indicated.
within limits of 1.431 inches and 1.435 inches. After hardening the caps are cleaned, drained,
A disk is cut from one bar of each heat and rinsed, and blown dry. After drying the caps
checked for surface decarburization and struc- are shot blasted.
ture.

6-83. Machining Operations. Figure 6-26 shows

the sequence of machining operations on the
cap. These are carried out on an 8-spindle
automatic screw machine which indexes 85
pieces an hour at a spindle speed of 168 rpm.
On an automatic lathe, the cap is then faced off
at the point where it is cut off from the bar in
the screw machine. It is then notched at two
points, 180° apart, and threaded for the wind-
shield.

6-84. Heat Treatment. The caps are heated in

an induction furnace to approximately 1,625°F
and oil quenched at 140 to 180°F. Periodically

Figure 6-27. Cap profile

6-85. Matching and Soldering. After shot blast-
ing, each cap is matched with a shot body upon
which it must spin perfectly without excessive
clearance. The cap remains on the body until
ready for soldering. This is done by placing
the bodies and the caps in an oven at 385°F.
The caps are fluxed and tinned, the body is
inserted in the cap and rotated slightly to cen-
ter it, and the solder is allowed to set. The
capped shot is then washed, the excess solder
is trimmed off, and the shot checked for con-
centricity of the cap threads with the bourrelet
and the tracer hole. A magnaflux test is ap-
plied to check for cracks.

6-86. Finishing Operations. The capped shot

are washed, and buffed with a wire buffer. The
shot are then banded and the band is machined.
Care must be taken to clean the copper out of
the relief groove and to see that the tracer
hole is clean. The finished shot are given a
final wash prior to inspection, which includes
gaging of the band, relief groove, body diam-
Figure 6-25. AP shot profile eter, depth of tracer hole, and weight. The

6-33
bands are then stencilled with the Government masked and «the shot are sprayed with lacquer
lot number and the manufacturer's lot number and infrared dried. After drying the thread
and type. The band and the threads which en- protectors are removed and the shot are packed
gage the windshield on the nose of the cap are with their windshields, for shipment.

6-34
 THE MANUFACTURE OF HYPERVELOCITY ARMOR-PIERCING (HVAP) SHOT

6-87. Components. The HVAP shot is made up 6-89. The Base. The base is a steel forging
of a tungsten carbide core, a steel-banded made from FS1314, FS1010, FS1020, orFS1315.
aluminum body, an aluminum nose piece, a It closes the rear end of the body of the shot,
steel base, and an aluminum windshield. These to which it is screwed and staked. The outside
parts are assembled to provide a light projec- of the base is machined with a groove for the
tile with an extremely hard dense core which rotating band and for the attachment of the
is highly effective against armor plate. cartridge case. A tapered recess in the rear of
the base provides a tolerance in machining to
6-88. The Body. The body of the shot is a hol- enable the weight of the shot to be held within
low, aluminum-alloy cylinder, approximately specified limits. A hole in the bottom of this
two diameters long. A bourrelct of seamless recess permits the attachment of a tracer.
steel tubing is pressed on the forward end of
the aluminum body, and machined to ride on
the lands of the rifling of the gun and prevent 6-90. Windshield. The windshield is a thin
balloting. The forward portion, just beyond the walled, die-cast, aluminum-alloy cone which
bourrelet, is threaded to receive the aluminum- is screwed to the body. It streamlines the
base alloy windshield, and the same size of shot and locates the center of gravity of the
thread is provided at the rear of the body for projectile to the rear of the center of buoyancy,
the attachment of the steel base. The outer sur- in the interest of stability in flight.
face of the body is finish machined and the
interior is bored out to a diameter slightly
under 2 inches, to within 1 inch of the front end. 6-91. Assembly. This aluminum nosepiece,
This forward portion is threaded internally for which engages the point of the tungsten car-
the installation of the nose piece, an aluminum- bide core, is screwed up and tightened to 150
alloy die casting in which the point of the pound-inches of torque. The core is then in-
tungsten carbide core rests. serted and the base screwed and staked.

6-35
 THE MANUFACTURE OF TUNGSTEN CARBIDE CORES

6-92. Introduction. Tungsten carbide cores are the carbide, or carbides, and blending the
presently used in both HVAP and HVAPDS shot. mixture by ball milling. This can be done
Although they are quite expensive, no satis- either wet or dry.
factory substitute has been found as of this
date. Their manufacture, similar to the pro- 6-95. Compacting and Sintering. Prepared pow-
cess followed for the production of commercial ders are formed into shape for use either by
tungsten carbide, is described in the following cold pressing, followed by sintering; or by hot
paragraphs. pressing, during which the pressing and sinter-
ing are done simultaneously. The material is
6-93. Tungsten Carbide. Of the two tungsten pressed into hard steel molds, at pressures of
carbides, only the monocarbide is used for from 5 to 30 tons per square inch, depending
manufacturing cemented carbides. This is pre- on the size and shape. Sintering is performed
pared either by heating a mixture of tungsten at 1,400 to 1,500°C. (2,550 to 2,730°F) for from
powder or tungsten oxide, with a calculated 30 to 60 minutes, in a protective atmosphere of
amount of carbon powder in a hydrogen atmos- hydrogen, containing sufficient carbon to pre-
phere, containing carbon; or by heating tung- vent decarburization; or in a vacuum. During
sten powder or oxide in a carburizing atmos- the sintering operation, the material goes
phere. The carbon powder may be lampblack through a plastic stage as a result of the for-
or sugar carbon. mation of a eutectic, between the cobalt and the
carbides, at approximately 1,350°C (2,460°F),
6-94. Milling and Blending. After the carbide thus wetting the carbide particles that do not
has been formed, it is carefully crushed, milled dissolve. This eutectic becomes the cementing
and screened. Compositions of the various com- material, surface tension drawing the particles
mercial grades are prepared by selecting meas- together. After cooling, the sintered product
ured quantities of the binder metal (cobalt) and has its final properties.

6-36
 THE MANUFACTURE OF BRASS CARTRIDGE CASES

6-96. Introduction. The following paragraphs' and a head whose thickness is approximately
describe the manufacture of the 120-mm brass the same as that of the original disk. The out-
cartridge case, M24, as practiced by the Chase side diameter is uniform at 7.004 inches. The
Brass and Copper Company. While the methods first of these draws takes a 250-ton hydraulic
used by other manufacturers may differ in press; the second calls for 200 tons; while the
detail, the process described may be con- third and fourth require 100 tons. The case is
sidered typical. edged between the third and fourth draws, in-
stead of merely after the final draw, to re-
The cartridge brass is 70 percent copper and move the "ears" or uneven mouth which are
30 percent zinc. It is rolled to a thickness of thought to be caused by "thick and thin," or
0.820 to 0.835 inch, and annealed to a grain eccentricity of the original cup. This causes
size of 0.075 to 0.150 mm. The upper and the metal to tend to draw out more in one
lower surfaces of the rolled strip are scalped, place than another. Considerable force is nec-
leaving a finished thickness of 0.790 to 0.805 essary to strip the draw from the punch; if not
inch. The strip is blanked to disks, which are cut off, the points of the ears would burr over.
then cupped and drawn four times, with inter-
mediate washing, annealing, pickling, trimming, 6-99. Heading. (See figure 6-30.) In order to
and lubrication. The job is completed by head- form the head of the case and to secure the
ing, saltpeter annealing, tapering, machining, desired physical properties, i.e., a hardening
and final edging. For the drawing operations, induced by cold work, the metal in the closed
highly polished tungsten carbide dies are used, end of the draw is upset in a powerful hydraulic
and are dry-soap lubricated. Heading, which press. Two steps, each requiring a maximum
proved troublesome because of tool breakage, thrust of 2,700 tons, are used. The heading
is performed by means of a two-piece die, tools consist of the punch, a built-up 'post' or
with a ring shrunk around an insert. Care is support within the case, and a die around the
to be taken in handling the case to avoid dents head to control its shape as the punch squeezes
and the consequent risk of excessive folding the metal radially outwards. The post consists
during tapering. A chrome flash is used on the of 15 spacers, held together with a tie rod.
tapering dies to avoid deposit of brass film. A built-up support, rather than a solid post, is
used because of the relative ease with which
6-97. Blanking and Cupping. (See figure 6-28.) these spacers can be heat treated to obtain the
The blanks are sheared in a knuckle-joint toughness and strength required to support the
mechanical press from strip 14 inches wide. heavy punch load, as well as the flexibility in
Twelve to thirteen disks, 12.18 inches in diam- adjusting the height of the post. The die is sup-
eter and 0.80 inch thick, are cut from each ported by a shrink fit ring.
strip, giving a scrap loss of about 40 percent.
The disk is then pushed through a die by a 6-100. Tapering. (See figure 6-30.) In prepa-
punch to form a cup 8.260 inches in diameter ration for tapering, a vent hole is drilled in
and about 5 1/8 inches long. This cupping op- the head in order to release the air which
eration reduces the thickness of the metal in would otherwise be trapped inside the case by
the bottom of the cup very slightly, while draw- the liquid saltpeter used for the semi-anneal
ing it down to 0.613 around the lip. prior to tapering. In order to help guarantee
success in the tapering operation, the mouth of
6-98. Drawing. (See figures 6-28 and 6-29.) the case is chamfered inside and out. The edge
After having been annealed and pickled, the must be free of burrs, dents, and chatter marks
cup is drawn out in four successive operations which might start a crease. In the manufacture
and two "edgings," or mouth trimmings, to a of this case, tapering is the most troublesome
closed-end tube 32 3/16 inches long, with side operation. The case is thrust into the tapering
walls which taper to a thickness of 0.042 inch die by a 150-ton hydraulic press, and removed

6-37
 .120

263

348

.633 •-.200

645

SECOND REDRAW

Figure 6-28. Cartridge case process drawing

035
.32j£ AFTER SECOND EDGE.

FOURTH REDRAW
.054
20^ AFTER FIRST EDGE-

THIRD REDRAW
Figure 6-29. Cartridge case process drawing

6-38
 .509 .597

092 094

HEADING HEADING DRILL VENT HOLE

FIRST BLOW SECOND BLOW

TAPERED DIMENSIONS ARE TAPER

THOSE OF THE FINISHED CASE

33—
00
16-

.443 .630 .293

OTHER MACHINED DIMENSIONS ARE

THOSE OF THE FINISHED CASE
MACHINED HEAD
Figure 6-30. Cartridge case process drawing
by a 25-ton knockout. This case has three dif- contour cutter, which chamfers the inside and
ferent diametral tapers. Accordingly, to sim- outside in one operation. Stamping, by means of
plify grinding and reduce toolmaking costs, the a drop hammer, concludes the machining se-
die is made in five sections. Metal properties quence. It is done after final inspection and
required for successful tapering are (1) a identifies the case as to manufacturer, year of
mouth soft enough to withstand reduction; (2) a manufacture, lot number, and the name and
body which is strong enough to resist the thrust designation of the component.
of the tapering punch and sufficiently rigid to
prevent the formation of pleats. Adequate lu- 6-102. Annealing Operations. Reducing-atmos-
brication, to promote the flow of metal in the phere, gas fired furnaces are used for the
die, must be present. process anneals. Temperatures are held at
1,250°F on all draws except the last, which is
6-101. Head Machining and Stamping. (See fig- 1,150°F. Total time in the furnace is 70 min-
ure 6-30.) The case is firmly clamped in a utes for the cup and 60 minutes for the draws.
collet chuck and the head is machined in three When it is necessary to soften only a portion
operations. The hydraulic knockout used to re- of the case, saltpeter anneals are used. The
move these cases from the tapering die tends case, after heading, is immersed for 2 min-
to distort the head, hence, the customary prac- utes, mouth down, to a depth of 14 to 14 1/2
tice of machining the head prior to tapering is inches. In the mouth anneal, the saltpeter is
not followed. The case is finished to length by a held at around 875°F; only about 5 inches of

6-39
the case are immersed. After stamping, the exterior surfaces of the case. If no change in
finished case is given a low-temperature, color of pieces of red and blue litmus paper
stress-relief anneal, at about 530°F, to relieve occurs, after 30 seconds of application to the
the locked-in stresses which have been held surfaces, they are assumed to be neutral. A
responsible for season cracking. test for cold shuts (fold-ins), at the interior
radius of the head, is carried out on one case
6-103. Inspection Procedures. Plant inspectors per lot. A radial section is cut from the base,
have a schedule of dimensional checks which polished, and nitric-acid etched. The excess
are made at various stages of manufacture. acid is washed off and the specimen immersed
in ammonium persulfate to accentuate the grain.
Government inspection, in addition to checks of Microscopic examination then determines the
size and shape, involves certain physical and depth of the cold shut. This may not extend
chemical tests. Under exposure to certain at- beyond tangents drawn to the interior of the
mospheres, cartridge brass will "season crack" base and the sidewall, so that they intersect.
if residual stresses are present. In order to Rockwell B hardness should vary from 35 near
determine whether the stress-relief anneal has the mouth to 88 in the region of the head, with
removed these locked-in stresses, two cases an intermediate value of 64 at 23.5 inches up
from each lot of 5,000 are cleaned in nitric from the head.
acid, rinsed, and immersed in a solution of
mercurous nitrate. After vaporizing the excess Proving ground tests require that
moisture, a mercury deposit is left on the 1. The case must enter the chamber of the
case. Any crack, which under normal condi- gun freely.
tions would have appeared in five years, will 2. No flutes or cracks shall appear after
develop under this test. A litmus-paper test firing.
is performed to determine the presence of 3. Obturation must be satisfactory.
residual acids or bases on the interior or 4. Extraction must be easy.

6-40
 THE MANUFACTURE OF DRAWN STEEL CARTRIDGE CASES

6-104. Steel for Cartridge Cases. Most steel tools during the cold-working operations broke
artillery cartridge cases have the following through the lubricating films and caused ex-
composition: cessive friction. A layer of soap is easy to
apply, remains intact during the forming and
Percent drawing operations, and can be removed with
Carbon 0.25 to 0.35 hot water.
Manganese 0.60 to 0.90
Phosphorous 0.040 max. 6-107. Precup and Cup. (See figure 6-31.) The
Sulfur 0.045 max. first drawing operation in the manufacture of
Silicon 0.10 max. the steel cartridge case is the cup which forms
the head and first few inches of the sidewall.
The carbon content is determined by the phys- This was formerly done in one operation, but
ical properties required in the lower sidewall. the common occurrence of fracture of the cup,
The steel is spheroidized before the cupping especially when 0.30 percent carbon steel was
and precupping operations, in order to increase used, caused operation to be divided into two
the amount of deformation the steel will stand stages. Following the first of these, the "pre-
without fracture. The cold work to which the cup," an inspection determines whether there
case is subjected during manufacture increases is any sign of a rupture or potential rupture.
the hardness, the ultimate strength, and the If none is observed, the precup is placed in the
yield strength so much that it is necessary to cupping die and the punch carries the com-
process anneal. The recrystallization tempera- ponent through the die, ironing out the sidewalls.
ture at which the effects of prior cold working Finished cups are inspected for evidence of
are completely eliminated is approximately "tool loading," that is, the incipient or actual
1,050°F. welding of steel particles from the cup to the
die, punch, or stripper fingers. This may be
6-105. Steel Blanks. (See figure 6-31.) The caused by an inadequate soapcoat, which leaves
steel cartridge case starts as a precut disk or bare spots.
blank of the prescribed dimensions. The ideal
blank would be smooth on both sides and free 6-108. Process Anneal. The cold work on the
from all surface imperfections. Since such cup distorts the ferrite grains and greatly in-
perfection is impossible, surface defects are creases the strength and hardness of the steel,
classified as those which iron out and those while at the same time drastically reducing the
which do not. Among the latter are notches, ductility of the steel. Before any further work
which, during the drawing operations, may be- can be done the cup must be annealed by heat-
come stress raisers. Disks having surface ing above the recrystallizing temperature (that
blemishes may be salvaged by grinding. is, by heating to around 1,150°F and holding at
this temperature for five minutes). Until re-
6-106. Preparation for Cupping. The blanks cently no attempt was made to control the at-
are (1) rinsed to remove soap which may have mosphere of the annealing furnace, thus avoid-
been picked up from the conveyor workholders; ing the formation of scale. Hence it has been
(2) washed in an alkali cleaning solution to necessary to "pickle" the cups in order to re-
remove oil and dirt; (3) given a rinse with move the scale. While the use of a controlled
trisodium phosphate to remove the cleaner and atmosphere does not entirely obviate the ne-
promote uniform soap coating; and (4) soap- cessity of pickling, the amount of scale formed
coated. This is done in one continuous opera- is considerably reduced; as is the pickling
tion. Many lubricants, such as oils, greases, time. Capital investment in a controlled-atmos-
and graphitized compounds have been tried as phere furnace is about 50 percent greater than
lubricants for the drawing operations, but it in an air-atmosphere furnace, and there is still
has been found that the intense pressures of the some uncertainty about the ultimate advantage

6-41
 Figure 6-31. Progressive drawing of forming and machining operations required to manufacture
a typical steel cartridge case, from the blank to the finished case
of scale control. Since the presence of soapy 6-110. Trimming. Between draws the mouth
film on the components during annealing would of the case is trimmed to eliminate "dead
produce hard scale deposits, which would be metal," which develops because, during the
difficult to remove in the pickling bath, the cups draw, the outer surface of the case elongates
are thoroughly washed to remove all soao prior more than the inner surface. Hence the lines
to annealing. of grain flow curve inward near the lip of the
case and show end grain on the inside of the
6-109. Drawing. Prior to drawing (figure 6-31), case. This weakens the steel, and may cause
the cups are phosphate coated and then soap- circumferential rupture. Another purpose of
coated. The phosphate acts as a host to the the trim, particularly after the final draw,
soap, which is used as a lubricant to prevent and before and after tapering, is to secure
metal-to-metal contact during the drawing op- uniformity in the length of the sidewall. Trim-
erations; the latter progressively reduce the ming is done both by a nibbling operation, which
thickness and length of the sidewall. The num- shears the surplus metal in a series of strokes
ber of draws required depends on the total re- of a cutter while the case is mounted on a
duction in wall thickness from cup to finished mandrel; and by a rotary trim before the
case. Each draw is designed to produce a re- taper. The rotary trim produces a burr-free
duction of approximately 40 percent, which is edge; the shearing action of the nibble trim
the maximum that can be sustained without produces burrs which necessitate a mouth
causing excessive variation in the thickness, ream to prevent scratching of the chrome
or a fracture, of the sidewall. Consecutive plating of the punch during the subsequent
draws may be made without intermediate lu- draw. If the steel is process annealed, there
brication if the total reduction is limited to is very little risk of trouble except in the
70 percent. case of consecutive drawing.

6-42
6-111. Prehead and Final Head. (See figure hardened and tempered. The induction coil
6-31.) Cold-worked steel is much more "notch raises the case to a temperature of 1,700 to
sensitive" than brass; therefore, all stress 1,800°F. This is followed by a quench with
raisers must be eliminated, especially from large volumes of water, preferably applied to
the internal radius of the head. Actual cold both inside and outside of the case.
shuts in this area may be tolerated in brass
cases, but in a steel cartridge case, ballistic 6-114. Magnetic Hardness Test. To check on
failure could result. The steel cartridge case the heat treating, all cases are tested for hard-
is headed in two operations. The preheading ness in a magnetic hardness comparator. A
operation, by gathering metal at the center of standard case of known hardness is mounted
the head and at the periphery, redistributes the in one induction coil while the case under test
metal in the head of the case to facilitate the is inserted in a similar coil. The standard coil
formation of the primer boss and the flange and the test coil form two arms of a Wheat-
during the final heading operation. Preheading stone bridge. If the magnetic characteristics
is done by a heavy squeeze in a hydraulic or (dependent upon hardness) of the case under
knuckle-type press between a stationary post test differ from the standard, the bridge will
and a die mounted on the face of the ram of the be unbalanced and an output voltage will appear.
press. Final heading forms the flange of the
case and the primer boss, and shapes the en- 6-115. Heat Treatment in Preparation for
tire interior of the head. Heading is a critical Tapering. The cold work in the final draw
operation, since roughness of the internal ra- raises the hardness of the case to around
dius of the head may raise the stress in the 96 Rockwell B, but at the same time materially
steel during firing to a point where the head reduces the amount of deformation the steel
separates from the body. can withstand as a result of further cold work.
Since the tapering of the cartridge case im-
6-112. Piercing the Primer Hole. Using a poses severe strains on the steel of the side-
mechanical press, the primer hole is pierced wall, heat treatment is required. To obtain
in the boss of the cartridge case. Piercing at maximum increase in percentage elongation
this stage makes it possible to finish-machine without appreciable loss of hardness, a tem-
the primer pocket during the machining of the perature between 1,000 and 1,050°F is re-
head. Formerly, the primer hole was pierced quired. If the temperature is allowed to rise
after the taper trim. This necessitated the use to 1,050°F, recrystallization takes place and
of air vent tubes in the salt pot used for the the steel loses much of its hardness and yield
taper stress relief. These air vent tubes per- strength. The case is therefore immersed, up
mitted the escape of the air from the inside of to the region that was hardened by induction
the case when the cases were dipped, mouth heating, in a salt pot at 1,020°F. It is held
down, into the molten salt; the trapped air es- there, mouth down, for a period of four or five
capes through the primer hole. Following the seconds.
piercing operation the case is passed through a
combination wash and pickle machine, where 6-116. Tapering. (See figure 6-31.) Following
the soapcoat, phosphate coating, and incidental the low-temperature stress relieving operation,
rust are removed and the case is thoroughly pickling for the removal of scale, and the ap-
dried preparatory to heat treatment of the plication of a coat of soap to the outside for
sidewall. lubrication, the case is tapered. This operation
develops the final contour of the body section
6-113. Sidewall Heat Treatment. The amount of by forcing the case into a tapered die in a
elastic recovery of the cartridge case after vertical hydraulic press. Not all cases suc-
firing depends primarily on the elastic limit of cessfully withstand this treatment. Among the
the steel in the side walls. If the elastic limit resultant defects are (1) "fluting," a waviness
is low, there will be more plastic deformation of the sidewall arising from inadequate stress
and consequently a smaller recovery. Since it relief, failure of the soapy lubricant, or the
is difficult to develop the requisite mechanical plugging of the air relief vents in the die; (2)
properties in the sidewalls of the steel case, "wrinkles," an aggravated form of fluting; (3)
especially the critical region near the head, by collapse of the body of the case, often caused
cold work alone, this portion is induction by a ragged mouth giving rise to high localized

6-43
stress; (4) scoring by the tapering tools; and inspectors make the final acceptance gaging of
(S) stretcher strains, a pattern of Lueder's the case. Inspection before coating not only
lines sometimes observed on the surface of avoids damage to the coat, but in the event that
soft steel subjected to cold work. Stretcher a lot is rejected it obviates the need to remove
strains indicate that stress relieving has been the varnish or zinc plating before reprocessing.
overdone; the temperature has risen above Government intermediate inspection procedure
1,050°F, recrystalliaation of the steel has taken involves inspection of cartridge cases in sub-
place, and the hardness of the body may be lots of approximately 2,000 cases. Acceptability
below specifications. of each sublot is determined from an inspection
of about 100 cases from each. If the first sam-
6-117. Machining Operations on the Head and ples from a sublot contain more defects, of
on the Mouth. (See figure 6-31.) The cartridge any kind, than permitted by standard sampling
case is thoroughly washed and dried, so that it inspection tables, a second sample, twice the
can be held securely during machining. It is size of the first, is taken and inspected for the
then inspected and defective cases are rejected class of defects which were the cause of re-
before- machining. The head of the case, the sampling. If the defects of the second sample
flange, the shoulder, the primer hole, and the are too numerous, the entire sublot is rejected.
mouth of the case are finish machined on a
special lathe, which may be of one of two 6-120. Protective Coatings. Two types of pro-
types: (1) a single-spindle, center-drive lathe, tective coatings are used on steel cartridge
or (2) a multi-spindle machine. The single- cases, zinc, or phenolic varnish. Zinc is pre-
spindle machine is preferred because of lower scribed by the Navy and varnish by the Army.
initial cost and greater convenience. The cold- The cases are prepared by removing scale,
worked structure of a steel cartridge case formed during the mouth anneal, as well as
presents difficulties in machining. The material shop dirt and any traces of machining oil. The
is exceedingly tough and produces long, stringy varnish coat is uniformly applied by dipping.
chips which are hard to handle. Following After dipping, the coat is air dried prior to
machining, the cases are 100 percent inspected baking, in order to avoid thin or bare spots
for size and shape. The mouth of the case is resulting from flow of the varnish on first
then resized to the correct dimensions by hold- contact with the heat of the oven. The phenol
ing the case in a special fixture and forcing a formaldehyde resin varnish specified for this
sizing plug into the mouth to a depth of one service bakes by polymerization at a tempera-
inch. The case is tapered slightly undersize, ture of 400°F. The varnish case is tested by
and then resized after machining, in order to pouring 3 liters of Ottawa sand upon the in-
insure its passing the chamber gage inspection. clined sidewall through a vertical tube, 3 feet
long, located 1 inch from the case. The area
6-118. Mouth Anneal. The last production op- abraded must not exceed a specified limit.
eration on the case prior to application of the The baking at 400°F also serves as a low-
protective coating is a mouth anneal to in- temperature stress relief which protects against
crease the ductility of the steel. This is done rupture during firing, but does not appreciably
for two reasons: (1) unless relieved, the high lower physical properties. Cases which are to
yield and low percentage elongation character- be zinc plated are stress-relief annealed after
istic of cold work may cause the mouth to split the taper but before plating. Before zinc coat-
on firing; (2) if the case is attached to the shell ing, the case is cleaned electrolytically in an
by crimping, softening of the mouth is essential. alkaline bath. After rinsing, and an acid dip to
Every half hour, a mouth-annealed case is re- neutralize all traces of the alkali cleaner, the
moved from the production line and given a outside and inside of the case are plated to a
Rockwell test at five points in the annealed thickness of 0.00015 to 0.00020 inch.
zone to determine whether the hardness meets
specifications. 6,-121. Final Inspections. These are made both
by the manufacturer and by the Government.
6-119. Government Intermediate Inspection. The inspection by the manufacturer is pri-
After all manufacturing and washing operations marily visual. Scratches, cuts, dents, lamina-
have been completed in preparation for the ap- tions, and other blemishes cause the case to be
plication of the protective coat, Government set aside for possible salvage. The inspector

6-44
is also on the lookout for coating defects, in- failure means rejection of the lot without
cluding blisters, unevenness of varnish coat or further appeal.
zinc plate, and bare spots. A recheck of hard-
ness, in the magnetic comparator, is also made 6-122. Head Stamp and Packing. The head of
to make sure that no case slips through without the cartridge case is stamped by the manu-
being properly heat-treated. The final Govern- facturer with the lot number, the component,
ment inspection is similar to the intermediate the code designation of the manufacturer, and
(paragraph 6-119), except that this time 300 either the Ordnance bomb or the Navy anchor
samples are selected from a lot of not over to signify acceptance of the lot. Two percent
25;000 cases. Included in the Government's of the stamped heads are then checked with a
final inspection is a Rockwell hardness test special head thickness gage to insure that the
applied to 10 cases per lot; failure of 1 case stamping ridges are not excessive and that the
in the group is cause for rejection of the en- head has not been distorted. The finished cases
tire lot. The manufacturer may request that are then packed in corrugated paper cartons
a second group of 10 be selected. Another for shipment.

6-45
 THE MANUFACTURE OF TRAPEZOIDAL-WRAPPED STEEL CARTRIDGE CASES

6-123. Introduction. The following paragraphs

describe the manufacture of the trapezoidal-
wrapped steel cartridge case, 120-mm, M24E1,
as practiced by the Murray-Ohio Corporation.
The methods described are typical of the manu-
facture of this type of case.

In order that this type of cartridge case may

be the equivalent, in all respects, of the stand-
ard brass case, the following characteristics
must be maintained:
1. Stable dimensions, with emphasis on the
region of engagement with the gun, head en-
gagement, and datum diameter -i-<t
2. Uniform internal volume, to accommodate
the exact quantity of the charge
3. Good obturating quality Figure 6-32. Body layout
4. Free and uniform ejection
5. Resistance to weathering effects of the
elements.

6-124. The Body of the Case. This is made

from standard mill tolerance steel sheet (SAE
1008) sheared and trimmed to a trapezoidal the lap seam (in other words, a smooth closure
blank (figure 6-32). The blank is rolled into an on the outside of the case) indicates good work-
open-ended, tapered cylinder, and expanded by ability of the metal. Following expansion, the
hydraulic pressure against the walls of a die, bodies are tackwelded at the top and at the
and tack-welded at top and bottom. The wrapped bottom of the seam with a 1/4-inch long bead
sheet comes from the rolls rather loose, with to hold the case to its expanded size through
the upper and lower edges of the trapezoid the subsequent spinning operation, which turns
forming the mouth and the base, respectively, over the lower lip of the case to fit into the
so that there is a single wrap at the mouth and head.
several wraps at the base. Before wrapping, the
sheet is washed and varnished on both sides. 6-126. Spinning the Lower Lip. A six-jawed
Since the varnish has a tendency to age harden, collet chuck, carried by a lathe spindle, closes
the sheet is worked immediately after baking. the coiled body upon an expanding mandrel.
An air-operated pusher head, mounted on the
6-125. Rough Rolling and Expanding. The trap- lathe tail stock, is used to push the work into
ezoidal sheet is rough rolled in a specially the collet. A motor-driven mechanism on the
built machine. One end of the long lower edge lathe carriage causes a flanging roller to move
of the sheet is entered between the first and over a series of fixed paths, which progres-
second rolls. These are backed up by a third sively form the flange in a series of "passes."
roll, which turns the sheet around into a The collet is provided with an ejection arrange-
tapered cylinder. The "wrap-up" is then low- ment, which pushes the work forward as the
ered into a die over a rubber bladder. After collet opens and permits its ready removal
the die is sealed, hydraulic fluid pressure at from the spinning lathe. For some types of
15,000 psi presses the bladder against the in- cartridge case, the flanging may be done prior
terior of the case and expands the case against to expansion, instead of afterwards, as in this
the walls of the die. A well-defined offset at case.

6-46
6-127. Completion of the Assembly. The base, wrapped cases can be set up, in dispersed
or head, of the case Is burnt out from SAE 1545 areas, in a very short time. Since no heat
steel plate which is ground and machined, then treatment is required anywhere in the pro-
fastened to the body (figure 6-33). The several cess, the expensive furnaces, with their ex-
parts of the head assembly are enameled and acting controls, are eliminated. Hardness
baked to protect against corrosion and weather- checking is not necessary, and the highly
ing. qualified inspection personnel normally re-
quired for this service are not needed. In
6-128. Advantages of Wrap-Up Cases. Wrapped general, since the wrapped case is made from
cartridge cases date back to an 1869 U. S. standard rolled sheet, requiring little attention
patent. Apparently the problem of sealing led to avoid minor imperfections, the care which
to abandonment in favor of the drawn case, for is exercised to avoid tiny flaws or under-
which hydraulic press capacity had to be pro- surface imperfections (causing ballistic fail-
vided. The wrapped case does not require these ure) in the drawn case is unnecessary. Thus
presses. Recently, the development of the inspection costs are held to a minimum.
sheet-metal industry and the expansion of steel
sheet capacity has paved the way for the solu-
tion of the major problems of design and pro- 6-130. Performance. Experience in the Korean
duction. These are principally the flanging of war demonstrated the acceptability of the
the lower lip and the expansion and locking of wrapped case. The only malfunctions reported
concerned certain undesirable characteristics
RHEEM of the nitrocellulose lacquer coatings. This has
SPIRAL WRAPPED
-BODY since been corrected. The flexibility of this case
gives it an advantage over the drawn case, es-
pecially those drawn from steel. The spiral
seam, acting as an expansion joint, enables it to
fill the chamber without rupturing. The multi-
component construction of this case offers ad-
vantages in salvage. Since the base is fastened
to the body by simple threaded attachments,
battle salvage of the bases (which represent a
substantial portion of the manufacturing cost
of the complete case) is a definite possibility.
Being flat, they are easily shipped. The body
Figure 6-33. 120-mm case assembly could also be shipped flat, or merely regarded
as expendable.
the case itself. The other processes involved
in this method are not fundamentally complex. 6-131. Inspection. Body steel is checked for
thickness and hardness. After rough rolling,
6-129. Facilities. The initial cost of produc- the body is visually examined for flutes, and
tion-line machines for wrap-up cases is small to see that no leaf extends more than 1/8 inch
compared with that for cup-and-draw. They are above mating leaves. Bases are spot checked
not highly specialized, and are to be found in for blemishes after grinding. Government in-
many sheet-metal works. Less space is re- spection includes the normal size and shape
quired, hence production lines for trapezoidal- gage checks.

6-47
 THE MANUFACTURE OF PERFORATED CARTRIDGE CASES

6-132. Introduction. The manufacture of per-

forated cartridge cases (figure 6-34), used in
recoilless weapons, is similar to the method
used for the manufacture of any drawn case,
with the following exceptions.
1. The perforations are punched prior to the
final tapering.
2. After the final tapering, the inside of the
case is shot-blasted to insure a smooth in-
terior. Figure 6-34. Perforated cartridge case
3. The inspection procedure includes a check
for alinement of the perforations. case. The case rests in a shoe, or cradle,
during the punching operation to enable it to be
6-133. Perforating. In the earlier stages of indexed for successive rows of perforations.
development of this type of cartridge case, the A complete row of punches descends at a single
holes were drilled. This practice was too slow stroke and punches the holes through the die
for quantity production, and has since been buttons in a die holder on the anvil. A blast of
supplanted by multiple punching along the longi- air blows the chips out of the anvil through a
tudinal axis. The case is supported internally chip receiver pipe. An automatic indexing de-
by a sliding wedge and anvil, which are ex- vice then turns the case and moves it longi-
panded by air pressure after insertion in the tudinally in order to stagger the rows of holes.

6-48
 REFERENCES AND BIBLIOGRAPHY

1. Report on Shell Forging by the American Society of Mechanical Engineers, 31 December

1943.

2. Report on Finishing and Machining of H. E. Steel Shells by the American Society of Me-
chanical Engineers, 1 April 1946.

3. Description of Manufacture, Shell, H. E., 105 mm. Ml, by Extrusion Methods, Mullins
Manufacturing Corporation, Salem and Warren, Ohio.

4. Description of Manufacture, Shell, H. E. 57 mm, M306A1, Heckethorn Manufacturing and

Supply Company, Littleton, Colorado.

5. Description of Manufacture, Shell, H. E., 75 mm. T50E2, from Forgings, W. C. Norris

(manufacturer), Tulsa, Oklahoma.

6. Phase n Study, Shell, H. E., 76 mm., T64, by Cold Extrusion, Heintz Manufacturing Co.,
Philadelphia 20, Pennsylvania.

7. Description of Manufacture, Shell, H. E., 76 mm, T64, from Forgings, The Murray Com-
pany of Texas, Inc., Dallas, Texas.

8. Description of Manufacture, Shell, H. E., 90 mm., M71, from Forgings, The Murray Com-
pany of Texas, Dallas, Texas.

9. Description of Manufacture, Shell, H. E., 105 mm., Ml, from Forgings (with Appendix for
Shell, H. E., 105 mm., M323, from Forgings), The Yoder Company, Cleveland, Ohio.

10. Description of Manufacture, Shell, H. E., 105 mm., Ml, by Extrusion Methods, Mullins
Manufacturing Corporation, Salem and Warren, Ohio.

11. Description of Manufacture, Shell, H. E., 120 mm., M73, Frankford Arsenal, Philadelphia,
Pennsylvania.

12. Supplementary Report on Shell Forging (Large Caliber) by the American Society of Me-
chanical Engineers, 1 December 1945.

13. Description of Manufacture, Case, Cartridge, 75 mm., M31A1, 2 vols., vol. I, Frankford
Arsenal, Philadelphia, Pennsylvania.

14. Description of Manufacture, Case, Cartridge, 75 mm., M31A1, 2 vols., vol. II, Frankford
Arsenal, Philadelphia, Pennsylvania.

15. Description of Manufacture, Case, Cartridge, 76 mm., T19E1B1, Steel, Norris-Thermador

Corporation, Los Angeles 58, California.

16. Description of Manufacture, 105 mm. Steel Howitzer Cartridge Case, Employing Cold
Forming Methods using Cold Extrusion, Heintz Manufacturing Company, Philadelphia,
May 1950.

17. Description of Manufacture, Case, Cartridge, 105 mm., M32, 2 vols., vol. I, Frankford
Arsenal, Philadelphia, Pennsylvania.

6-49
 REFERENCES AND BIBLIOGRAPHY (cont)

18. Description of Manufacture, Case, Cartridge, 105 mm., M32, 2 vols., voL n, Frankford
Arsenal, Philadelphia, Pennsylvania.

19. Description of Manufacture, Case, Cartridge, Brass, 120 mm., M24, Chase Brass and
Copper Company, Waterbury, Connecticut.

20. Description of Manufacture, A. P. Shot, 37 mm., M51, National Pneumatic Company.

21. Meinel, William J., Cold Extrusion of Steel, Ordnance. September-October 1953.
22. Whitlock, George E., Cold Extrusion, Ordnance. January-February 1954.

23. Howley, Walter N., Hot Forging of Shells, Ordnance. September-October 1954.

24. Norris, K. T., The Steel Cartridge Case, Ordnance, May-June 1954.

25. King, William N., Steel Cartridge Cases, Ordnance, July-August 1954.

26. Gomez, R. R., The Spiral Wrapped Case, Ordnance, November-December 1954.

6-50 V. S. GOVERNMENT PRINTING OFFICE : 1957 O - 430670

8 79-536