Muhammad Zia

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INTERNSHIP REPORT (SMALL ARMS AND AMMUNITION)

Now small arms and ammunition department is further subdivided in to

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1-Modular Plant 2-C-08 3-C-09 4-A-54 5-D-02

We will try to disuss them in detail

MODULAR PLANT :
In modular plant bullet case plus bullet is made we will discuss all the processes one by one First of all brass plates are brought to the Modular Plant from Brass mills so that Bullet case can be made

BRASS PLATES

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The process starts with a brass disk stamped from strips of metal. Then, through a series of stages, the brass is extruded or drawn into a cylindrical shape. In the extrusion process the brass is squeezed through a die under tremendous pressure. This is repeated two or three times typically. In the more traditional draw process, the case is progressively stretched longer, in 3 to 5 stages, using a series of high-pressure rams forcing the brass into a form die. While extrusion may be more common today, RWS, which makes some of the most uniform brass in the world, still uses the draw process: It starts with cup drawing after the bands have been punched out. RWS cases are drawn in three stages and after each draw they are annealed, pickled, rinsed and subjected to further quality improvement measures. This achieves specific hardening of the brass cases and increases their resistance to extraordinary stresses.

Now I would like to discuss various Steps in bullet manufacturing . You can see from the figure that there are various stages through which bullet case is manufactured

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After the cases are extruded or drawn to max length, the cases are trimmed and the neck/shoulder are formed. Then the extractor groove (on rimless cases) is formed or machined, and the primer pocket is created in the base. One way to form the primer pocket is to use a hardened steel plug called a bunter. In the photos below you see the

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KMLS100 for bullet cupping

stages for forming a 20mm cannon case (courtesy OldAmmo.com), along with bunters used for Lake City rifle brass. This illustrates the draw process (as opposed to extrusion). The process of draw-forming rifle brass is that same as for this 20mm shell, just on a smaller scale.

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River Valley Ordnance explains: When a case is being made, it is drawn to its final draw length, with the diameter being slightly smaller than needed. At this point in its life, the head of the draw is slightly rounded, and there are no provisions for a primer. So the final drawn cases are trimmed to length, then run into the head bunter. A punch, ground to the intended contours for the inside of the case, pushes the draw into a cylindrical die and holds it in place while another punch rams into the case from the other end, mashing the bottom flat. That secondary ram holds the headstamp bunter punch.

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The headstamp bunter punch has a protrusion on the end to make the primer pocket, and has raised lettering around the face to form the headstamp writing. This is, of course, all a mirror image of the finished case head. Small cases, such as 5.5645, can be headed with a single strike. Larger cases, like 7.6251 and 50 BMG, need to be struck once to form a dent for the primer pocket, then a second strike to finish the pocket, flatten the head, and

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imprint the writing. This second strike works the brass to harden it so it will support the pressure of firing.

SWAGING A BULLET

1 Swaging is a cold forming process, which means that it involves shaping metal without heating to soften or melt it. The appropriate amount of material to be swaged (measured in grains) is placed in a die. A die is a harder metal container with a cavity (an empty space) shaped like the bullet without the back end. The die is part of a larger stationary object or is held in place on a platform. 2 A metal punch that fits into the open end of the die is forced into the die to the appropriate depth. As the punch forces the bullet metal into the die cavity, the material takes the shape of the cavity. The pressure can come from a manual or hydraulic press, from repeated hammer blows, or from a threaded punch that is screwed on. Excess metal is squeezed out of bleed holes. 3 The punch is removed from the die and the bullet is pushed or pulled out of the cavity. Any imperfections are removed by cutting or filing. 4 Multiple swaging steps can be used to insert partitions, to create a bullet out of multiple materials, and to further define the shape of the bullet. Sometimes several steps are necessary to add features such as a hollow point.

The bullet jacket

Some bullets have jackets of harder metal surrounding a softer core.

5 A coin-shaped piece of jacket metal is punched out of a strip or a sheet. The punch is usually a round metal cylinder that is pushed through the jacket material into a depression in a table. Some punches are rounded so that the piece of metal is shaped like a cup. Sometimes, tubing is used instead of a coin or a cup of metal. 6 If the jacket material is too hard to be formed easily, it can be annealed. Annealing is heating the metal, often with a gas flame, to soften it and make it more workable. 7 The jacket material is then placed in a die or over a punch and the punch is forced into the die. There may be several different punches and dies used to form specific features in the jacket. One of usual steps is to make sure that jacket is of uniform thickness. The thickness is typically 0.03-0.07 in (0.08-0.17 cm). Some bullets have a thin jacket electroplated onto the core.

C08:

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In C08 there are variety of equipments like CNC machines and JIG BAR machines also there is a variety of Milling and grinding machines

Jig-Boring Machine :
a metal-cutting machine for finishing holes, planes, and slots with a highly precise location of centers or surfaces without the use of special attachments for tool alignment. Jig-boring machines are used for boring, drilling, counter-sinking, reaming, milling, and other types of finishing in individual and small-scale production during the manufacture of cutting and measuring tools, jigs, dies, and key components of machines and instruments. Devices with stable and adjustable end gauges and indicator sensing units are used on jig-boring machines for precise measurements; also used are lead screws with dials and a vernier, which are equipped with error-elimination compensators, and graduated shafts with optical measuring instruments. There are two types of these machine tools: double-sided (gantry) machines with a one-movement table and opensided (single-sided, overhanging) machines with a two-movement table. In open-sided machines the spindle head moves only vertically; in the double-sided machines it moves horizon-tally along the crosspiece, which can travel in a vertical direction. The manufactured article and the cutting tool on the jig-boring machine are moved relative to one another along orthogonal coordinates (with linear displacement accuracy to 2 microns) and polar coordinates (with angular displacement accuracy to 5 seconds of arc). Sturdy construction is a feature of jig-boring machines, which have smooth drive motions and accurate balancing of fast-rotating parts (to reduce vibration). The machines are installed in insulated areas in which a constant temperature of 20C is maintained. Jig-boring machines are operated by highly skilled workers.

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CNC Machines:
Modern computer numerical control (CNC) machine tools that have revolutionized the machining processes. In modern CNC systems, end-to-end component design is highly automated using computer-aided design (CAD) and computer-aided manufacturing (CAM) programs. The programs produce a computer file that is interpreted to extract the commands needed to operate a particular machine via a postprocessor, and then loaded into the CNC machines for production. Since any particular component might require the use of a number of different tools-drills, saws, etc., modern machines often combine multiple tools into a single "cell". In other cases, a number of different machines are used with an external controller and human or robotic operators that move the component from machine to machine. In either case, the complex series of steps needed to produce any part is highly automated and produces a part that closely matches the original CAD design.

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A CNC Turning Center.

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Siemens CNC panel.

CNC LATHE MACHINES: A metal lathe or

metalworking lathe is a large class of lathes designed for precisely machining relatively hard materials. They were originally designed to machine metals; however, with the advent of plastics and other materials,

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and with their inherent versatility, they are used in a wide range of applications, and a broad range of materials. In machining jargon, where the larger context is already understood, they are usually simply called lathes, or else referred to by more-specific subtype names (toolroom lathe, turret lathe, etc.). These rigid machine tools remove material from a rotating workpiece via the (typically linear) movements of various cutting tools, such as tool bits and drill bits.

Construction: The design of lathes can vary greatly depending on

the intended application; however, basic features are common to most types. These machines consist of (at the least) a headstock, bed, carriage, and tailstock. Better machines are solidly constructed with broad bearing surfaces (slides or ways) for stability, and manufactured with great precision. This helps ensure the components manufactured on the machines can meet the required tolerances and repeatability.

Center lathe with DRO and chuck guard. Size is 460 mm swing x 1000 mm between centers

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The headstock (H1) houses the main spindle (H4), speed change mechanism (H2,H3), and change gears (H10). The headstock is required to be made as robust as possible due to the cutting forces involved, which can distort a lightly built housing, and induce harmonic vibrations that will transfer through to the workpiece, reducing the quality of the finished workpiece. The main spindle is generally hollow to allow long bars to extend through to the work area. This reduces preparation and waste of material. The spindle runs in precision bearings and is fitted with some means of attaching workholding devices such as chucks or faceplates. This end of the spindle usually also has an included taper, frequently a Morse taper, to allow the insertion of tapers and centers. On older machines the spindle was directly driven by a flat belt pulley with lower speeds available by manipulating the bull gear. Later machines use a gear box driven by a dedicated electric motor. A fully geared head allows the operator to select speeds entirely through the gearbox.

Bed
The bed is a robust base that connects to the headstock and permits the carriage and tailstock to be aligned parallel with the axis of the spindle. This is facilitated by hardened and ground ways which restrain the carriage and tailstock in a set track. The carriage travels by means of a rack and pinion system, leadscrew of accurate pitch, or feedscrew. Types of beds include inverted "V" beds, flat beds, and combination "V" and flat beds. "V" and combination beds are used for precision and light duty work, while flat beds are used for heavy duty work.[citation needed] When a lathe is installed, the first step is to level it, which refers to making sure the bed is not twisted or bowed. There is no need to make the machine exactly horizontal, but it must be entirely untwisted to achieve accurate cutting geometry. A precision level is a useful tool for identifying and removing any twist. It is advisable also to use such a level along the bed to detect bending, in the case of a lathe with more than four mounting points. In both instances the level is used as a comparator rather than an absolute reference.

Feed and lead screws

The feedscrew (H8) is a long driveshaft that allows a series of gears to drive the carriage mechanisms. These gears are located in the apron of the carriage. Both the feedscrew and leadscrew (H7) are driven by either the change gears (on the quadrant) or an intermediate gearbox known as a quick change gearbox (H6) or Norton gearbox. These intermediate gears allow the correct ratio and direction to be set for cutting threads or worm gears. Tumbler gears (operated by H5) are provided between the spindle and gear train along with a quadrant plate that enables a gear train of the correct ratio and direction to be introduced. This provides a constant relationship between the number of turns the spindle makes, to the number of turns the leadscrew makes. This ratio allows screwthreads to be cut on the workpiece without the aid of a die.

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Some lathes have only one leadscrew that serves all carriage-moving purposes. For screw cutting, a half nut is engaged to be driven by the leadscrew's thread; and for general power feed, a key engages with a keyway cut into the leadscrew to drive a pinion along a rack that is mounted along the lathe bed. The leadscrew will be manufactured to either imperial or metric standards and will require a conversion ratio to be introduced to create thread forms from a different family. To accurately convert from one thread form to the other requires a 127-tooth gear, or on lathes not large enough to mount one, an approximation may be used. Multiples of 3 and 7 giving a ratio of 63:1 can be used to cut fairly loose threads. This conversion ratio is often built into the quick change gearboxes.

C-09:
In C-09 bullet belt is manufactured and also the packaging material is manufactured

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There are various steps through which bullet belt is manufactured first its strip are cut afterwads they are heated then phosphated afterwards jointed by a spring

A-54:

Just like Modular plant here also bullet is manufactured but here

it is of 9mm size I would like to show it digramatically

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Ammunition suppliers nationwide have reported a shortage of stock because of a dramatic increase in gun sales.

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An ammunition loader is filled with .40 caliber projectiles.

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A machine turns out .45 caliber cartridges.

A .40 caliber cartridge is measured for quality control.

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The rounds will be shipped to dealers across the country.

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