UNITED STATES ARTILLERY AMMUNITION The original of this book is in the Cornell University Library. There are no known copyright restrictions in the United States on the use of the text. http://www.archive.org/details/cu31924012809632 ""''ejl States artillery ammunition; 3 to 3 1924 012 809 632 UNITED STATES ARTILLERY AMMUNITION MUNITIONS BOOKS COMPILED BY THE EDITORIAL STAFF OF THE AMERICAN MACHINIST Manufacture of Artillery Ammunition, 759 pages, 6x9, 648 Illustrations $6.00 Shrapnel and Other War Material, 92 pages, 8% x 113.^, Fully Illustrated . ... $1.50 United States Artillery Ammunition, 97 pages, 8% x lli-^, Fully Illustrated . .. $2.00 UNITED STATES ARTILLERY AMMUNITION 3 TO 6 IN. SHRAPNEL SHELLS 3 TO 6 IN. HIGH EXPLOSIVE SHELLS AND THEIR CARTRIDGE CASES BY ETHAN VIALL Managing Editor American Machinist, Member American Society op Mechanical Engineers, Member Franklin Institute First Edition McGRAW-HILL BOOK COMPANY, Inc. 239 WEST 39TH STREET. NEW YORK LONDON: HILL PUBLISHING CO., Ltd. 6 & 8 BOUVERIE ST., E. C. 1917 ,r:y^- :\ *•<». #' ^ ^^,..,.^ Copyright, 1917, by the McGraw-Hill Book Company, Inc. FOREWORD No'organization could have been better fitted than the Avicrican Machinist for the task of col- lecting and presenting the manufacturing methods of our arsenals. The average reader does not realize the enormous amount of detail involved in a task of this kind. The American Machinist has in this work demonstrated its public spirit and patriotism. HOWARD E. COFFIN, Chairman of INIuxitions Committee, Council of National Defense. PREFACE The purpose of publishing this material at the present time is' to give shop men, engineers and manufacturers an accurate knowledge of the sizes, tools, shop work and gages for the more commonly used United States shells and cartridge cases. While a large part of the detail work con- nected with the gathering of the material in- corporated in this book has fallen to my share, it is to the staff of the American Machinist as a whole that the real credit belongs, as each mem- ber stood ready at all times to do his part and more. ETHAN VIALL. New York, July, 1917. Vll CONTEISTS Page Foreword . • . v Preface vii I 3 IN. Common Shrapnel 1 II 3 IN. Common Shells (High Explosive) 26 III 3 IN. Naval Shells 48 IV 3 . 8 TO 6 IN. Shrapnel and High Explosive Shells 56 V 6 IN. Naval Shells 62 VI 3 TO 6 IN. Cartridge Cases 71 Index " 95 IX The United States 3-in. common shrapnel, familiarly known as a 15-pounder, carries a charge of 338 hexagon- shaped lead balls, 0.5 in. at their largest diameter and 0.45 in. at the flats. Back of the balls is a charge of 1180 grains of shrapnel powder. Screwed into the front end of the projectile is a combination fuse communicating with the powder chamber SMto.or- --A •8.0lt0.0S—; »| End. View showing Case when) Tracer is Used "P^^nis fiirgmg is used for 5 common shrapnel i'FA hiqh-lxplosive shmiiiinil 5'Ehrhardt- hi^h-explosm shrapnel ' FIG. 1. DIMENSIONED FORGING FOR 3-IN. COMMON SHRAPNEL, guncotton also acts as an aid to ignition. The fuse may be set for time explosion, or it will explode on impact. The dimensions of the ease forging are given in Fig. 1. These forgings must be thoroughly an- nealed and pass the follow- ing physical tests : Elastic limit, 60,000 lb.; tensile strength, 95,000 lb.; elong- ation, not less than 15 per cent. ; contraction not less e.3 tO.03 -5.5d"tO.OZ"--- ^^'.20 per inch US. Standard Thread 1 ' ,£U pBrincn (/.o.o/anauru imtf uu ^ \ 0-l2"Drill after ^ Assembling Head Stamp mth 0062 (£) Letters and g rigures ■■- Lot N^^"'^of Shrapnel -—- Case, Purchase Order; Date of Issue ofPO-Criscal YearUind Initials of tianufacturer The Stamping prescribed may be siampecrinun Band, if also stamped on Base within the Grvove, in Lieu of Stamping in front finish/ Outside.Rough Inside except inhere marked/ " GiVeffie lewder Chamber a heavy Coat ofnon-aad Paint rOROCD alloy srta 6reat care should be talcen to remove allBurrs sharp Machine from Solid or Hollow Comers and Scale. Eccentnaty not overaOl" forged Steel ±0.01" . . Base of Shrapnel -5cores-JS„^inch when Tracer is Used Modification of Rear of Projectila for use in 3" Howitzer T -o.45^r 0.04R. ■0.35' . aosfit 5^° Detail of Grooves ■"--A FIG. 2. DIMENSIONED FINISHED CASE PressMetalof Fuse into Notch, for Lodging Waterproof (CoverGroove- MATRIX Resin and pure white /'commercial Napthalene Center of /Gravity .STOPPER, Dry fibrous 6un Cotton. Roll tightly info a Cylinder and press dov/n until it rests on Shoulder of Dig ohraam and is about I Inch long. \Watei'proof Cover U--/74-'->|<-C*'>j<- U — HEAD Fll.LER'-\ ^Slightly moisten these , r^'"-. Joints with Cosmolene ^' 8.Z' -I0.84-- _Base of Slirapnel when Tracer IS used. 4.8 h~,BAS£ CHARGE ' "h Stirapnel Powder I 10% of each Lot mill be — ?4 fitted with Tracer FIG. 3. DETAILS OF COMPLETE PROJECTILE through a small tube, the shrapnel powder being held in place by means of a small plug of dry guncotton. This ^Copyright, 1917, Hill Publishing- Co. than 30 per cent. The only requirement as to chemical composition is that neither the sulphur nor phosphoruB content shall exceed 0.045 per cent. [1] FIGS. 4 TO 11. VARIOUS OPERATIONS ON 3-IN. COMMON SHRAPNEL CASES Fig. 4 — Centering in drilling machine. Pig. 5 — Turn body on latlie. Pig. 6 — Finisii outside (without tracer supporf) J!^s 7 — Finish outside (with tracer support). Pig. 8 — Finish interior on automatic. Fig. 9 — Turning the bands Fig 10 — Hydraulic testing apparatus. Fig. 11 — Tapping for head. ' Former used on Grinding machine. Fl = Former No. 1. Pig. 12. STANDARD LATHE F2 = Former No. 2. H = High speed steel. TOOLS FOR GENERAL, SHOP USE C = Carbon steel. [3] OPERATION 1. CENTERING Transformation — Pig. 13. Machine Used — Drilling machine, Pig. 4. Number of Operators per Machine — One. Work-Hold- ing Devices — Arbor, Fig. 14. Tool-Holding Devices — Drill chuck. Cutting Tools — No. 42 combination center drill. Cut Data — 350 r.p.m. Production — 1200 per 8 hr. Note — A little red lead is used "where drilled. OPERATION 2. TURN BODY Transformation — Fig. 15. Machine Used — Le Blond 17-in. lathe, Pig. 5. Number of Machines per Operator — Three. Work-Holding Devices — Centering chuck. Fig. 16. Cutting Tools — Left-hand turning tool. Fig. 12. Number of Cuts — One. Cut Data — 50 ft. surface speed; 60 r.p.m.; 0.040-in. feed. Aver- age Life of Tool Between Grindings — 15 to 20 cases. Gages — Length from base to bourrelet. Fig. 17; combination maxi- mum and minimum snap. Pig. 18; maximum, rear of band ring, Fig. 19; minimum rear of band ring. Fig. 20. Production — 250 per 8 hr. Note — Speed given is maximum, as lower speed is used on harder cases. OPERATION 3. FINISH OUTSIDE (CASE WITHOUT TRACER SUPPORT) Transformation — Fig. 21. Machine Used — Potter & John- ston automatic, Pig. 6. Number of Machines per Operator — mhaut Night Tracer Support FIG. 13 Two. Tool-Holding Devices — Facing-tool holder, formmg-tool holder, tool post. Cutting Tools — Pacing tool. Fig. 22; form tool. Pig. 23; knurl. Pig. 24. Cut Data — 40 to 70 surface speed; 56 to 90 r.p.m.; fast speed and feed used for knurl and end work. Coolant — Zurn cutting oil. Special Fixtures — Internal split collet; bushing for collet. Fig. 25. Ga:ges — Maximum and minimum width of band seat, Pig. 26; position of crimping grooves. Pig. 27; combination snap, diameter of band seat. Pig. 28; thickness of base and test piece. Pig. 29; position and width of band seat. Pig. 30. Production — 300 per 8 hr. OPERATION 3 -A. FINISH OUTSIDE (CASE WITH TRACER SUPPORT) Transformation — Fig. 31. Machine Used — Pig. 7. Cutting Tools — Pacing tool. Fig. 32. Gages — Combination sheet gage. Fig. 33. Note — This operation is exactly the same as operation 3, except for different facing tool and one gage. OPERATION 4. FINISH INTERIOR (AND BOURRELET WHEN CASES ARE FINISHED AT FRANKPORD ARSENAL) Transformation — Pig. 34. Machine Used — Potter & John- ston automatic. Pigs. 8 and 9. Number of Machines per Oper- WthHight TracerSup^ Bushing OZ'R-. tool STEEL(Harden) ■^ & OSezWTap Body /'mach.steel X- Sfd/.75'Deep^ >{075" I Oi',DrilU I J^;.. I Deep Y'-l-S Stamp Name of Shrapnel, L-. Part, Operation, Place of I Manufacture, and Date-Year ^" OPERATION I F16.I4 Screws MACH. STEEL (Case Harden) FIG. 19 MACH.STEEL Countersunk Head, (Case Harden) Bronze Screws FIG. 20 OPERATION 2 [4] ator — Two. Work-Holding- Devices — Split chuck. Tool-Hold- ing Devices — Rough boring bar; finish boring bar; tool holder for rough bourrelet, Pig. 35; tool post. Cutting Tools — Rough diaphragm-seat cutter, Fig. 36; rough boring tool, Pig. 36; rough facing tool. Pig. 36; finish diaphragm-seat cutter, Pig. 36; finish boring tool. Pig. 36; finish facing tool, Pig. 36; cham- fering tool. Pig. 36; rough outside beveling tool. Pig. 37; turn- ing tool for bourrelet. Pig. 35; square-nose lathe tool. Pig. 12; finish beveling tool. Pig. 37; No. 2i^ geometric tap. Cut Data f^-(}e):Zl -1.625"- o.zf^ 5.tZ5" >l HIGH SPUD STEEL ^ (nnishXtaomarden) ^ no. 32 \l '04DrilL OM^"^ K ■■>(U25 FIG. 33 OPERATION 3A — 50 ft. surface speed; 60 r.p.m. working speed; 35 r.p.m. tap- ping speed; 20 ft. surface speed. Coolant — Zurn oil. Gages — Maximum and minimum depth of diaphragm seat. Pig. 38; combination maximum and minimum diameter diaphragm seat. Pig. 39; combination maximum and minimum diameter rear of thread. Pig. 40; combination length of case. Pig. 41; com- bination maximum and minimum outside diameter and taper of mouth. Fig. 42; combination snap, bourrelet diameter. Pig. 28; maximum ring, bourrelet diameter. Fig. 43; minimum ring, bourrelet diameter. Pig. 44; maximum thread, plug, Pig. 45; minimum thread, plug. Pig. 45; maximum and minimum diam- eter, powder chamber. Fig. 46. Production — 180 per 8 hr. Note — Powder chamber is machined by forgers. OPERATION 5. ASSEMBLE BAND Note — This is exactly the same as for the 3-in. common steel shell, except that only 1000-lb. pressure is used, on account of the thinner wall of the case. OPERATION 6. HYDRAULIC TEST Number of Operators — One. Description of Operation — Operator places case in fixture, mouth down, pours a cup of water in top of fixture over end of case, turns on 1000-lb. hydraulic pressure and watches "water and case for bubbles or jets. Apparatus and Equipment Used — Special fixture, Fig. 47; pressure pump. Production — 1200 per 8 hr. OPERATION 7. TURN BANDS Transformation — Pig. 48. Machine Used — Pig. 9. Gages — Finished band profile and position, Pig. 49. Note — Operation same as for 3-in. common steel shell. OPERATION 8. TAP FOR NIGHT TRACER Transformation — Pig. 50. Machine Used — Warner & Swasey turret lathe. Pig. 51. Number of Operators per Machine — One Tool-Holding Devices — Tap holder, drill holder, recessing-tool holder, Pig. 52. Cutting Tools — Drill, reamer, Pig. 53; recessing tool. Pig. 54; tap. Pig. 55. Cut Data — 334 r.p.m. machinery speed; 58 r.p.m. tapping speed. Coolant — Zurn oil. Gages — Combination depth. Fig. 56; maximum and minimum thread, plug. Pig. 57. Production — 185 per 8 hr. K --4.0-- — -» ,ao'_ k— -/j-'-^K -as- aT5^<0.75^ — 225"- ^ Steel Setscrew ■>f6lS'^0.6& ,4,0s"Mo/es.aS°Deep itrff -i- z:3 MACHINE STEEL Finish/ taOOS" Head MACHINE STEEL FinishftQOOS" Cap MACHINE STEEL Fmish/iQOOS" Locknut MACHINE STEEL Finish/ i 0.005" Shank ^-isefaf--^ f<- -325-- V r\Q.zz -: H \<—-S2S- a4570tOOOO"-aOO5" Vft*^ HI6H-SPEED STEEL Finish /tO.OOS" Grind Cuffing Edge Facing Tool Dof and Dash for Angle on 'f\IO^ifbffer & Johnson Aufo... ^/qi '0j05"r: i5° 'aoTR:" '^"0°S9 Tool for Cleveland Automatic Machine 2.0-- FIS.E£ 90°.;>\a/\c- ,0.005"/?. Detail of Knurls o.o5">i\<-as°>i Counferborei.J,f^-'\ \'0I6 --H MACHINESTEEL Finish/ taOl" Stamp Number on each Piece Bushing for Collet on P 8c J. Automatic Fie. 25 ams HIGH-SPEED STEEL Fihi Finish/ iabd5"and Harckn ^-"■l-^s'-—^ ^025^^ soeeh}' •0002". m§*0004"Wj4\ ■'^■o.o8-:^,:^y^^Sfg^'U'R. U — ass'!-—X— a/-—i\<-...045"--A -^tfA k- ■--.-■mfdi} -- -'^. ->J Tool for RoHer 8c Johnson Automatic fis.es JiLU Finish/ tOOl and Harden HIGH-SPEED STEEL Knurling Tool FlG■.^4 Finish/ ±0.005 and Harden SAW STEEL Band Seat Width and Depth Fie. 26 OPERATION 3 [5] The forgings shall be free cutting and readily ma- chined. The machinability will be determined by turn- ing the body of the forgings, as received, from the drawing diameter to a diameter of 3.063 in. on an engine lathe. This turning will be done at an average rate of 14 shells per hour per lathe, and at this speed the tool consumption shall not exceed one tool for each 20 shells turned at this rate. For the purpose of the test for physical qualities and for phosphorus and sulphur content the forgings will be separated into lots of 3000 each. From each lot of 2000 the inspector will select six forgings for physical test, provided that additional forgings may be selected, if is shoMTi in Fig. 3. This last weighs approximately 15 lb., divided as follows : Lb. Balls (238) 5.71 Matrix 0.43 Head filler 0.07 Diaphragm 0.48 Base charge 0.17 Fuse 1.28 Total weight 15 ±0.15 The efficiency equals 38 per cent., and the velocity. of the balls must be not less than 260 ft. per sec. The night tracer referred to is a small device placed on 10 per cent, of the projectiles, for use at night. As the shell is fired, the tracer leaves a trail of fire behind it, commencing a few seconds after it leaves the muzzle Lb. 5.89 Band 0.15 0.02 Head 0.7 Retainer . 0.01 Tube (including- tube) inner 0.09 / [<•— a/5->t<- — 0.5- -^ ■^^ ->fc-— (3/i---->i<-- cr-— H ' ^55° 1 Enlarged View -2.0'- 5MV STEEL (Harden) O.?SDri7/0^ 0.4 R f,FJni.-ih'a0.005" <\ FI6.E7 S fe ts *S0SZ5°^- 0.625' ■Diamond Knurl ^^^ ~??'5~ QK'k r'Qrsi^ TOOL STEEL raU=4 F!nishjmi" Y^-,.o"->\ '0.375 Stamp Nome of Shrapnel, Part, Operafion, —^ -J Dimension gaged, Place of Manufacture s S: Date (Year) ■ll.d'- TOOL STEEL nnislifc/.mi Harden <5 ^ — 1 XO.s\ 3;?i FI6.29 DRILL ROD Finisiif tO.Ol' Oaging Point Finisfi fg& Harden 005 Rl Stamp Name of Shrapnel, Part, 6age, Dimensions gaged, Place of Manufacture 6b Date ('Year) t^ACHINE STEEL i 006''A |<- "Ui 'Case Harden Gaging Surfaces ±J^ mf 045^ Y0.0Z PART A B C BAND SEAT EST ?.se 1.45 BODY 2.98 2.965 1.5 BOURRELET 2.99 2985 1.5 REAR OF BAND 2.985 2.975 1.5 Fie. 28 T-' 'K 0.25 R ^, 0.201 Drill: I V-0.55"--^ W ' SAW STEEL -1.2- -JO ■^0.5* ->)< 10"-— > ±- <0.I25 OPERATION 5 Fie.30 necessary, to obtain not less than one forging from each lot of forgings as heat-treated. Two specimens for physi- cal test will be taken from each sample forging from such parts of the forging as, in the judgment of the inspec- tor, will best indicate the uniformity of physical qualities .throughout. The contractor shall furnish the inspector with an analysis of each heat of steel used, which may be verified by the inspector if he so desires. Forgings must be homogeneous in structure and free from pipes and cracks. Forgings in which these defects develop during machining will be replaced by the con- tractor. The interior of the forgings must be smooth and free from scale, and machining must be resorted to in or- der to produce this result, in case smoothness is not ob- tained by forging under the press. A finished shrapnel case with all dimensions is illus- trated in Fig. 2, and a completely assembled projectile of the gun and making it possible to follow the flight easily. This device will be described in detail elsewhere. The sequence of operations from the centering of the case forging to the final crimping on of the waterproof cover is as follows : 1. Centering 2. Turn body 3. Finish outside (ca.'^e without tracer support) 3-A. Finish outside (case with tracer support) 4. Finish interior (and bourrelet when cases are finished at Prankford Arsenal) 5. Assemble band 6. Hydraulic test 7. Turn bands 8. Tap for night tracer Head (Bar Stock) 1. Machine without thread and countersink 2. Countersink 3. Turn threads 9. Mill notches 4. Crimp in washer 5. Wash in hot soda watei 6. Paint inside 7. Insert retainer and fill with resin 8. Face off resin [6] Diaphragm (Forging) 1. Drill and oounterbore 2. Heat-treatment 3. Remove scale from oounterbore 4. Grind base 5. Paint base 6. Assemble tube Locking Pins (Bar Stock) 1. Machine Assembling 1. Wash case in hot soda water 2. Paint interior 3-A. Assemble tube and diaphragm 3-B. Pill case 3-C, Compress balls 4. Cut out surplus resin 5. Moisten threads with cosmoline, assemble head to case and insert inner tube 6. Pin head to case ^^^>;^^^?^/<^///^^^^^^^ Tr~fr -0.01' FIG. 35 OZlS'Tap.Sht.:^^^ □ □ 1^ . = /img/!m-E.S}¥~^, A/m^Z^^I>^(i> „ -A ^-10° ^."^ Tmshg-hm^i 0.375 \i W,-jio.S'/'""'^ Mouth of Case Facing Blade Stamp name of shrak^l.S">\ anc^d/am. of cutter Diaphragm Seat Cutter p , tOOjxl .__>.,„,. wsggEro|i / TOOL STEEL (harden) □QDl f,0.625^.j00S\^>^zl^iff) 10"^^ STEEL — — -^^-^ '4:- .S ^J '<^io° K^ !«■■-■ -3.125' ->l|| Mouth of Case 5; Boring 5lade men speed STEEL >l V^a/25'' Fmish/to.0/,l1anlen FIG. 37 OPERATION A B FIRST 8M asf nmsHEO dB' t.rr ->l Stamp'nameofshrapnd.part. openifion. d/mension gaqed.place '(y&ir) , MACH. STEEL ^^— ^^-^-»±l-> Finist, Xtaoir O.J85xl.5"SteelPin.'Mi <----IO.B' 5ra cket CASriRON ±0.06' Bottom Plate rORiED STEEL Rnish/aOZ" FIG. 47 FORCEP STEEL finish ftOM' as'ksysteel Rod Details on Cross Bar Cross Bar Drill and counterbore for O.SZWStdfllisterhead Screw, -t^OSS Fie. B6 stamp Name of Shrapnel, fbrt. Gage, Dimensions gaged, Place of Manufacture and Date (Year) Qll^^ y- J, - 3.5^- — -H ■ COLD-DMWH STEEL (Case Harden) Finish/taor FI6.57 OPERATION 8 -J \<-0.035 H- -iT- 1 HI6H-SPEED STEEL . (Harden) Finish J torn Finish Cutting .Edges Jjt Fie.5' [8] FIGS. 59 TO 64. VARIOUS OPERATIONS OX THE HEAD Fig. 59 — Machining tlie head. Fig. 60 — Countersinking head. Fig. 61 — Crimping in washer. Fig, 62 — inserting retainer and filling with resin. Fig. 63 — Facing off resin. Fig. 64 — Notching head [9] shown in Figs. 6 and 7, differs principally in that in The method of assembling and turning the copper the latter case a larger place has to be left ou the rotating bands is described in the article on the 3-in. end for the tracer support, a special tool being used. common steel, or high-explosive, shell. The making of Finishing the interior. Fig. 8, is done on both Potter the band is also described in the article. & Johnston and Cleveland machines, as shop conditions Standard cutting tools, which are used for all regular at the time or as the sizes of the various shells dictate. operations, are charted in Fig. 13 and will be designated Crimping Groove, MACM STEE^ (,,• nmsh/iOOl'CaseHQrclen "' Body Thrdcperin ^''' MACH STEEL St^mp-nameofmachimand finish /tMQ,^seH,rcten size.placeofmanufticfvrvand riZiA" COLO DHAVifi STEEL _. . date(y,„r) p,^ 74 ^eli Finish fm^ Fin, pcrew (Compief-errim lianlen) it'^' 'inishftOOl" l4USSfa7hrr/pfrdll^S^ liaS'Sfeel I'm Max DIam of Fuze Spn of Fuze Seat Threaa [10] individually only by their common names, siTch as left- hand lathe tool. The dimensions and shape of the various tools can be quickly obtained by reference to the chart. Work on the Head Details of the head are illustrated in Fig. 58. This is machined from bar stock on automatic machines, as shown in Fig. 59, each operator tending three machines. The end of the bar is drilled, bored, counterbored, reamed, grooved, faced and tapped for the fuse. At the same time the outside is formed with a circle tool. The tap used is of the collapsing type, oil being forced to the work from the rear. As can be seen, ample provision is made for supplying all the tools with oil. Owing to the size of the piece, the number of operations and the accuracy zstaoos- ■>! ''Drik ^1118'Rea m ^ , aiSS'LS i,„^i -J om'Crlll' <■ -—ZZ5"- -, aizs'R- k szs'taos' a^l'W-Aas%'i4ussk. Uaoe'^ J Hole MACH. sr£SL FinishJ(tO.OI'Case harden ^^^^^ Stamp Name of Shrapnel, Part,Openjtioh. Dimensions gaged. Place ofManuHacture, .and Dafe( Karl J&- tf K-C .'\l)2S'Ream OOSh. npf 'Stfil Pin Drive _Cr ami) 'J§. A \ FOROED STEEL FinishJ + OOl' FIG. 101 [111 The washer is made of thin sheet metal and is placed in the head, and the edges are crimped down into the grooves of the head with a double roller tool, as shown in Fig. 60, details of the tool being given in Fig. 96. After the head has been thoroughly washed in Jiot soda water, the inside is painted by hand ; then the short piece of tube, or retainer, is put in place and melted resin is poured in, as sIio-^to in Fig. 62. The resin is allowed to cool, and then the head is placed in a special screw chuck and the resin faced off, as shown in Fig. 63, details of the chuck being given in Fig. 101. The tool used is a standard left-hand facing tool. The purpose of milling notches in the head is to provide means for locking the fuse securely after it is screwed into the mouth of the case, metal on the fuse being forced into these notches with a punch and hammer. The notch milling is illustrated in Fig. 64, the fixture being a rather simple one, but answering the purpose perfeetlj''. Head (Bae Stock) operation 1. machine without thread and countersink Transformation — Fig. 65. Machine Used — Gridley or Cleve- land automatic, Fig. 59. Number of Machines per Operator — Three. Work-Holding Devices — Split chuck. Tool-Holdiiig Devices — Circular form-tool holder, cutoff-tool holder, drill holder, rough-tool holder, combination groove-tool and reamer holder, tap holder and adapter. Cutting Tools — Circular form tool. Fig. 66; cutoff tool. Fig. 67; twist drill, Fig. 68; roughing tool. Fig. 69; set (2) grooving tools, Fig. 70; facing tool, Fig. 71; combination counterbore and reamer. Pig. 72; tap, Pig. 73 Cut Data — 50 ft. surface speed. Coolant — Zurn oil. Special Fixtures — Stop, Fig. 74. Gages — Maximum thread, plug. Pig. 75; minimum thread, plug. Fig. 76; diameter and length of thread (operation 1), Fig. 77; length over all, Fig. 78; length of shoulder (operation 1), Fig. 79; depth of groove, Fig. 80; maximum and minimum inner diameter of crimp wall. Fig. 81; outer diameter and depth of crimp wall, Fig. 82; diameter of small end, Fig. 83; diameter of large end. Fig. 84. Production —115 per 8 hr. OPERATION 2. COUNTERSINK Transformation — Fig. 85. Machine Used — Brown & Sharpe turret lathe. Fig. 60. Number of Operators per Machine — One. Work-Holding Devices — Special chuck. Fig. 86. Tool-Holding Devices — Tool holder, Fig. 87. Cutting Tools — Beveling tool, Fig. 88. Cut Data — 210 r.p.m. Gages — Diameter of fuse-seat bevel. Pig. 89; minimum diameter of fuse seat and fuse-seat thread, Fig. 76. Production — 800 per 8 hr. OJS"-0.000, ' "^niisterhead Screw , „ „ „ » -0.75 Ream ^...^j?,...>, 4 Threads per Inch, U 5 5i'd Lefr Hand rmishftaOl" Locking Nut \,<:>i.0.7S Ream \*-l.62S°^l.6SS^ MO'mVs.perhUSSrforlatlxlHB F0R6EDSTEEL \<-—'- SSS'-'—X, l^-!S',6 ■• '• ■• " ■' Engine Lathes Fmshf±O.OI' COLD -DRAWN STEEL Fm!shfiO.Ol" UOS'M ^°'^^ LdKiking Nut for 3-incK Shrapnel Heads :^-.^^i«?i^ Left Hand: t<-/(7"lfl7J'(t=,<-^- Br OXUffTlisterheadStUScreiv^ us standard Threads Finish ftaOl' Case Harden MACHINE STEEL Chuckscrew ->I/J« ■aoor llTh'ds.perlnch.US.Sfd. mCHINE STEEL: FTn!sh/iO.OI,' Case-Marden Chucksacewivftic .Boae-Plu^'' FmishftaOl' Harden TOOL STEEL Stof>, F1S.86 -■5.55'-- 0.575 TaflSfU FwrA-0.437 -0.000 *0.00i Two A-as" -0.000" *q.ooe" a6\<—LS-->] 0.6 -T*- 33a -S- 4 057S'07S sta Steet Setscrem ■-■aisR <2(?ir->lK-i riash/it ^^ ZiOm'0.5"Filfsterhead Steel Screws [<-0.S"->\ Stomp Name of Shrapnel, Part, Dimension gaged, 'Case Harden Place cff t^anufacfure, and Date (Year) FIS.89 N Z5^-- -.->|<.- -S.5'r- -->l k- .-6.0'- — >) FIQtST h- -..5£-r..._„ .>, ^ 4. % 0-f^y-anZ '■•rr V. \ OPERATION Z HIGH-SPEED STEEL Finish ftO.OI' Harden Chamfering Tool FI6.88 HIGH-SPEED STEEL Finish ftO.Ol" Harden Bfiveling Tool [12] FIG. 94 ^''' ■^ ^ 1 j r^ 1 = i m 'A 1 ^^ 1 — aa Assembled Views D.lt"Dnlt 0.5"rapStxi,Lh TOOL STEEL {harden) Roller U. /'-J , TOOL STEEL (fiarden) Roller Pin rinish/tOOl" LH ■5.7/5 ■|(o) 1 tf//^-' u • > FIG 96 OPERATION 4 MAZH. STEEL (Case harden) Body AlZSlo.S'Steel hnOnx \.... X t^ y^ 1 Sfamp^nameoT I „ shrapnel, partf k- /5^ Mgagedlmensms 5 ---'j;- '^ gaged, place of ^ manutacfure, and dak,^eiir} iR- rooz. srf£i nnish/toortlarden FIG. 97 OPERATION 3. TURN THREAD Transformation — Pig. 90. Machine Used — Brown & Sharpe turret lathe. Number of Operators per Machine — One. Worlt- Holding Devices — Special chuclc, Fig. 86. Tool-Holding De- vices — Chamfering-tool holder, holder for circular thread cutter. Cutting Tools — Forming tool, Fig. 91; chamfering tool. Fig. 88; circular thread cutter. Fig. 92. Cut Data — 200 ft. surface speed. Coolant — Dard oil, jjut on with brush, gages — Maximum thread, ring. Fig. 93; minimum thread, ring. Fig. 93; diameter length of finished thread. Fig. 77; maximum and minimum length oi: shoulder, Fig. 79. Production — 250 per 8 hr. Note — This is a thread-chasing operation, as can be seen from the illustration. OPERATION 9. MILL, NOTCHES Transformation — Pig. 102. Machine Used — Brown & Sharpe miller. Fig. 64. Number of Operators per Machine — One. Tool- Holding Devices — Arbor, Fig. 103. Cutting Tools — Milling cutter. Cut Data — Cutter runs 370 r.p.m. Special Fixtures — Fig. 104. Production — 1400 per 8 hr. ■rOZS" az5->\ H-iizs-U >, - ■__-ggg^|: J ' L .I '■ForOJZ5^0.IZ5'0.45 long. Steel Key --as'^- ■>l ^a/25 TOOL STEEL Arbor FinishftO.OI Stamp Name of Machine, Place of Manufacture and DatefYear} OneA^.5" ,^ FourA'075 ' ,k- 1.0 -H ^ |<-/57i-->( FI&I02 Finish J iO.OI Case Harden MACHINE STEEL Bushing FI6.I03 Finish /i 0.0/" (Mse Harden MACHINE STEEL .OBDrill 14- Th'ds.per JnckUSStU: MACHINE5TEEL FinishfiOOl" Spindle \StH0.6iS' Nut COLD -DRAWN STEEL finish/'OOl" l,0S7S!la75^5feel Bh-Drive TOOL STEEL , FinishfiO.05' Harden -;j' V .■■asSfd.Th-d asm' ^^aizs^ §, „.o„ O.ii S'Wam- Q57S /?. ..^^ .-.woo - -KmMO ^S^>^Sig) c mo5' "yr • \J"'^-cic ■0.005' ^fsiW Stud *ro.oBiW ' ~ *0.000„ -0.005 15"Diam.Cll1ter-^- ■^!:^ ' m>*-l.875'\i'- ^Ji.FimshJiO.01 Lever u. o " BRONZE FinishfiOOl' ^ ^ MACHINE STEEL §^ Finish mOl'Case Harden "^ \ /.0.3I^W■Stee^ f^n-Drive ^ ' \^.'87W^......-kf^ Headless Steel[ Screw Base " \<-z6"^ir'a3ll"(i)TapStda37S%ep — jjj '^■TaUe of Milling Machine Stop STEEL MUSIC WIRE T y Height ■«C=^ 6 Coils Fnlsh/mS Spring Soto ^(ii)„^^,fc ^ ^-l te a — Xhj zS-l VI I -^ o .1 ■ ^■^O.SS'Sm^i?^ 6,QW"(ifil.0'StdFiliskrhead Steel Scmtis ,/> BRONZE FinishpaOl" COLD-DRAW STEEL F16.i04 Gib OPERATION 9 -aor fSTEi Pivot Stud [1.3] OPERATION 4. CRIMP IN WASHER Transformation — Fig-. 94. Machine Used — Drilling machine, fig. 61. Number of Operators per Machine — One. Work- Holding Devices — Special chuck. Tool-Holding Devices — Crimping-tool holder. Tools — Crimping tool, Fig. 96. Cut Data — 260 r.p.m. Gages — Depth of disk, Pig. 97. Production— 1400 per 8 hr. OPERATION 5. WASH IN HOT SODA WATER Number of Operators — One. Description of Operation — Operator puts 40 heads into a dipping basket and sets it in cleaning solution; when grease is off, the heads are rinsed in hot water; if not too greasy, about 2 min. is enough time for cleaning. Apparatus and Equipment Used — One tank of boiling Wyandotte metal-cleaner solution; one tank of boiling water; metal dipping baskets. Production — 2500 per day. OPERATION 6. PAINT INSIDE Transformation — Pig. 98. Number of Operators — One. Apparatus and Equipment Used — Brush and pot of asphaltum varnish. Production — 1200 per day. OPERATION 7. INSERT RETAINER AND FILL WITH RESIN Transformation — Pig. 99. Description of Operation — Oper- ator placesi head, small end down, on plate, then puts in retainer and pours in melted resin. Fig. 62. Apparatus and Equipment Used — Metal plate, furnace and kettle, pouring ladle. Production — 1200 per 8 hr. OPERATION 8. FACE OFF RESIN Transformation — Pig. 100. Machine Used — Small lathe. Fig. 63. Number of Operators per Machine — One. Work-Holding Devices — Special screw chuck, Fig. 101. Cutting Tools — Left- hand facing tool. Cut Data — 220 r.p.m. Production — 1200 per 8 hr. Diaphragm (Forging) operation 1. drill and countbrborb Transformation — Fig. 106. Machine Used — Turret lathe. Number of Operators per Machine — One. Work-Holding De- vices — Special screw chuck. Fig. 107. Tool-Holding Devices Drill holder and bushing, countersink holder and bushing, counterbore holder and bushing. Cutting Tools — Twist drill; countersink. Fig. 108; counterbore. Fig. 109. Gages — Maxi- mum diameter, ring. Pig. 110; minimum diameter, ring. Fig. Ill; maximum and minimum diameter counterbore, plug. Pig. 112; depth of counterbore. Pig. 113. Production — 400 per 8 hr. Note — These are forgings, trimmed outside in a die, and only have to be drilled and counterbored. OPERATION 2. HEAT-TREATMENT Number of Operators — One. Description of Operation — Diaphragms are kept in furnace until temperature reaches 1600 deg. P., then taken out and placed in cottonseed-oil bath to harden; next, are rumbled in hot soda water to remove scale, and are then drawn to 900 deg. P. in saltpeter bath. Apparatus and Equipment Used — Furnace; perforated copper bask.et, 24 in. long, 15 in. wide, 12 in. deep; rumbling device. Production — 4800 per 8 hr. OPERATION 3. REMOVE SCALE FROM COUNTERBORE Machine Used — Drilling machine. Tool-Holding Devices — Drill chuck. Cutting Tools — Twist drill, ground to suit. Pro- duction — 1400 per 8 hr. OPERATION 4. GRIND BASE Transformation — Pig. 114. Machine Used — Diamond-disk grinder. Fig. 115. Number of Operators per Machine — One. Note — Operator holds piece on disk until a flat seat is ground on the bottom; one operator generally grinds, paints and assembles with a total of from 800 to 1000 per day. OPERATION 5. PAINT BASE Transformation — Fig. 116. Description of Operation — Operator applies asphaltum varnish to base with a brush. Production — See grinding note- OPBRATION 6. ASSEMBLE TUBE Transformation — Fig. 117. Description of Operation — Oper- ator presses tube into diaphragm, as shown in Pig. 118. Apparatus and Equipment Used- — Fixture, Pig. 119. Gages — Length, Figs. 120 and 121. Production — See grinding note. 6ive bottom of diaphragm' a Diaphragm tieavy coat of non-add paint fORGED srcfL taoos' FIG. 105 ,„ ■<--l.25'-^- O.SI2%)TapSlilTi^_ \i-0.2Z" | 1. — "^ 1 1 ..4\^:O0r2,ys':-. — ^ ■^(^Sf— ^^sl— ^^ A .,„ 1 k FIG. 106 D( ■ 1.5" --:U US MIDVALE EXTRA HieHSPfED STEEL Harden & Grind tO.Oi" FIG. 108 \i-—l.2'-— -' I |<- I.OS ■^ FIG. 109 Stamp: name ofs/jrapnei,part, operation, p/ace ofmanufiicture and date (year) o.m"(§- Tapsni. — , — u "cj-jV;"";" stamp: name of stirapnel, part, „„,.M'. t ■ •>Ji?<(K- ■S™-'5cre»v name and size of iafhe '^ WM'n^M^ Sfii-Steel Filistert,eadScrem. fJatftUnt 'sS'Mrfrass LocJ< ^^,"^'"'"''"3^ Screws Usedin Warner &S«asey ttand Turret Lathe l-Steel Key ^^^^ nPF-„..T,nM . Body OPERATION I FIG. 107 ->i«#- &>«<- l>M"nHsterimd ' ^^ I .'Standard Scren FIG, no stamp: name ofshrapnel,part operation, dimension ^aaed, place ofmantmctor^,anddafe(year} 0.25-^ . , om'stit^f 1 / H H i ^V'T ' ^ 1- m ! i 1 :a; i»»y u i^-l 5jW fj/)7*<5S ALL MATERIAL TOOL STEEL EXCEPT WHERE OTHERtnSE NOTED O rmiStl /±O.Ol"hARDEN ■A V-tj.S' FIG. Ill Stamp: mmeoFsltrapnel part; gage, d/menshfKaaget place ofmanufyctvre aw r date (year) Assembled Views Plate MACH. STEEL FIG. 113 M r m J1ACH. STEEL l-ai2s'xa28' ' ileadiess/fyot Point Pin l-O.I2S'kii2S ,„„.,.^ Steel Sel Screir [14] Locking Pins operation 1. machine (bar stock) Transformation — Pig. 122. Machine Used — Brown & Sharpe automatic. Number of Machines per Operator — Three. Cut- ting Tools — Cutoff and form tool, Fig. 123. Coolant — Zurn oil. Gages — Length, Fig, 124. Production — 2500 per 8 hr. Work on the Diaphragm Since a diaphragm is forged and then trimmed in a die, the amount of machining work needed is small. It is held in a special chuck. Fig. 107, in a turret lathe and drilled and counterbored. Following the heat-treatment, which is given in detail under the proper heading, the base is ground on a disk grinder in order that it may- seat properly in the case. Eemoving scale from the counterbore is simply a scraping operation, and an old twist drill, ground to suit, is used in a drilling machine. The base is next painted, and the center tube is pressed in with the special fixture. Fig. 119. The work on locking- pins, central tubes, inner tubes and retainers is all simple. A '^ <«/?-> 55' '■•■.:■ ■: «5i Y 1 — Usr l— J Stvimp'naineof'machine.kindof steei.placeorrnanuf^cturectna eta fe (year) Wom"„ S.I Stama:nomeorshrapnel, parf^amensionsgaqe^f, place ofmanufactune and FIG. 114 F1G.I15 FIC-.[[6,0P.5 OPERATION 4 Drive antfpeen after assembling head to case .STECL Unish/tOMS' , Locking Pin FIG.I2E leUSSmThrd.perin HIGH SPEED STEEL finish /t0.005' FIG. 123 HACH. STEEL fjnisfy/tOOI'iaseHan/en FIG.IE4 - 0.6Z5"rapStd. 062Sx!ns'Std Steel Selsat* (Ie7(m2'- ' OtterDn '^1.125'' -Washer Assembled f/hispyiaOl Case Harden ll437Xp*i'Sfd.SieeiSetScreir/ Test Piece COLD DRAWN STECL Rnish /taOl'CaseHarden A ' 6.35S"forS"Cmm(mShrapnel FIG. 121 OPERATION 6 e" Plate MACH. STEEL rinish/tO.Ol' [15] It 01 R. -534taOI- -zt^ 'J^aoz' C/i -125" >|<— - ■aifms' 005 " o.i75"i0.ooi" SEAMLESS DRAWN BRASS TUBING One A-60° ^-0.625 ■■ " '90° " -0.4' -US' -a45"->\ -it F16,1E5 — ><-ox'>^ c Ib^fc |< 70^:-- ■-075'-\ SAW STEEL y- '0I5R L -1.5- -H |«375' COLD- DRAWN STEEL FinishftQoC Case Harden ns. m HI6H-SPEED STEEL \y finish Gaging Surfaces fa , _ -sm'm. —'-^ o.iz5^ Fie. 129 )^= stamp Name of Shrapnel, Part, Dimension ga^ed, Place of Manufacture and Date(Year) FinishJtWOS i harden \ finish Cutting ; Edgefg \ <^04Z5^ 0JZ5-- ^3S V«/JiH 'rn'oriii ■^ __i. A i i J X i I ^-0.125'R. ♦ < - -z.o"-— .._ ---> FIS.I28 0.m"(§'..V:.:-'>^ OPERATION 1 MACHINE STEEL FinishftO.Ol" Case Harden F1S.I30 Tube (In^nee) OPERATION 1. MACHINE Transformation — Fig. 131. Machine Used — Brown & Sharpe automatic. Number of Machines per Operator — Three. Tool- Holding Devices — Four tool holders. Cutting Tools — Two countersinks, Fig. 126; two belling tools, Fig. 132; chamfering tool. Fig. 133; cutoff tool. Fig. 134. Cut Data — 2400 r.p.m. Coolant — Lard oil. Gages — Overall length, Fig. 135; maximum and minimum diameter of bell, Fig. 135. Production — 4200 per 8 hr. Note — Seamless copper tubing is used. Tube (CEJfTEAL) OPERATION 1. MACHINE Transformation — Fig. 125. Machine Used — Brown & Sharpe automatic. Number of Machines per Operator — Three. Tool- Holding Devices — Four tool holders. Cutting Tools — Two countersinks. Fig. 126; two belling tools. Fig. 127; cutoff tool, chamfering tool, Fig. 128. Cut Data — 2400 r.p.m. Coolant — Lard oil. Gages — Overall length. Fig. 129; maximum and minimum diameter of bell. Fig. 130. Production — 2500 per 8 hr. Note — Seamless brass tubing is used. Stamp Name of Shrapnel. Part, Size, Place of Manufacture and DatefYear) m07R ^-/7j'-v ff i Corner -1.3 >i COLD -DRAWN STEEL Finish fiO.01, Case Harden F16.132 Stamp Name of Machine, kind of Steel Place of Manufacture and Date (Year) .A Stamp Place of Manufacture and DateCYear) 3Thds.per Inch, U.SStH. // W ^Finish fyms^- Harden FI6.153 "T \kl .FI6.I?' Stamp Name of Shrapnel, Part, Dimensions gaged, Place of Manufacture and DatefYear) Finish fW.01" '--.,i'A^ Fie. 134 ,..ito MACHINE STEEL Finish ft QOl" Case Harden^ Fie, 135 [16] Retainer Seamless Drawn Brass Tub/net aose"T?}id<±o.oi" ^ Stampi name oTmachine.kind |i ji ofsreeLplaceofmanuTacfure IN*' bnddafefyear) ^ ■A^\ '<-I.IZS 'IZUSSfdnrU. per in. 1 "''"-fn'^^i%V?W% '^rS7aSXa&. rmish/gtMOi nG.I38 rureaniiVate (year) FIG. 136 MISM-SPEED STEEL (Harden) rinish/g±O.OI" FIG. 137 OPERATION t ^ Utf/' ''V07"Drill z ...0.125 If T n «azf rmishft 0. 01 f/^^^ oTmanufaBure kid FIG. 139 dale (year) Eetainer operation 1. machine Transformation — Fig. 136. Machine Used — Brown & Sharpe automatic. Number of Machines per Operator — Three. Cut- ting Tools — Cutoff tool, Fig. 137; chamfering tool, Pig. 138. Gages — Length, Fig. 139. Production — 2500 per 8 hr. Note — Brass tubing used. Washer operation 1. punch (sheet steel) Transformation — Fig. 140. Machine Used — Cranlc press. Number of Operators per Machine — One. Punches and Punch Holders — Punch, Fig. 141. Dies and Die Holders — Die, Fig. 142. Lubricant — Machine oil. Production — 8000 per 8 hr. Note — This completes the washer. WW ■A\>-omi'%f 1 B ■orR. .rm g\7 ForZ.95'&5'Com.5hrapnel\-0.zA ^ ForSS'AJ'&e'Com Shrapnel A'039'^ . n^- 1 Washer e H- 10'- H ' H 4.ZS- H FIG. 140 ■■-ii.z'K-wsWi.BS'HaQ'U- ^^^ 3 aiOfReam. STEEL(Harden) FlnishftaOOS' «> Assembled Views •e 0.1% £I3I"R. ^ . TOOLSTCElA^" k*0.000' ^i I i»|>A4 jt ^-^.^ Forming : " ■ -■- — •' '^-nnnp' nfii^ni--uuuo , „ fi , n\''^'aen i ■/ ClOlWSteelBn. \;~ff99-^-0.S3A |^0fJ'|<.g7rf Drive and Bend !<■■-;■ 2/7" -H 2H „ ^,o» ForZ95 ayCom.Shrapnel K-ai8 ,^'05i' ■■A*.099'-^ H---Z.II5"——A 'Harden ForYeAT&e'Com'.ShrapnsJk-azl^'m' Fore95%3'Con^ FIS. 141 Fo r38:4T&6'Com. Shrapnel K-OiinS. fkam. >WS^ '^iiReam !5ft Wis'-- a. "Kj a575'Taf>Stk ~f ■>\09 H-l.85-y^-I.S5--^a65V- t< -525'- »1 _. F0R6ED STEELfinishJitlJOOf 3, 0.375\0m'Std. Sq. Head SetscrBWS Punch Holder SHEET STEELtO.Or Guide k.-M"-H<— -tf5-"-.->|< l.85"—-^-a9"->\ SHEET STEEL ±0.01' a375"XI.2sn'ap Bolts Stripper ■->l o.iiionii-<-\ h- "t„ ■Aosz^^-% ^% MACHNESTEEL Finish'J ±0.005" Guide Support [17] FIGS. 144 TO 149. VARIOUS BULLET-MAKING AND POWDER-LOADING OPERATIONS pie- 144 — Casting ingots. Fig. 145 — Extruding tlie wire. Pig. 146 — Special ball-forming machine. Pig. 147 — Press and ^" wire reels. Fig. 148 — Roll feed and tumbler. Fig. 149 — Powder-loading machines. 118] The lead balls used in shrapnel are both round and six-sided, as shown in Fig. 153, and are made in prac- ticjally the same way, only different dies being used. DIMENSIONS s SIZE 1RAPNEL DRAWING NO. PIECE MARK \{pjeraces O/ii'riats Z95"- 7S-Z-4I- 41 F 5" 15-2 -4 4F 5' 75-2-137 I37r ■ 3" 75 -2 -ISI 151 G i" 75-2 -152 75 fi D 0.54"t0.005 3.8" 75-2-145 I4SBI 4.7" 75-2-147 147 A 5" F.A. 3574 6" 75-4-12 12 a 6" 75-7-37 37CI 7' KA. 3578 COMPOSITION OF BALLS ^^^^^"-y Making Balls operation 1. casting ingots Transformation — Pig. 143. Number of Operators — One Description of Operation — Operator pours melted mixture of 7 parts lead and 1 part antimony into mold and allows it to cool for 3 or 4 min., then inverts mold and allows ingot to drop out, the shrinkage being sufficient for ample clearance. Apparatus and Equipment Used — Rockwell melting furnace, ladles, tongs and water-cooled mold. Fig. 144. Production — 43 per day per mold. OPERATION 2. EXTRUDING THE WIRE Transformation — Pig. 150. Machine Used — Waterbury- Parrel 700-ton hydraulic press. Pig. 145. Number of Machines per Operator — One. Dies and I3ie Holders — Pig. 151. Pressure Required— About 650 tons total. Production — 75 per day. Note — A spool of wire usually consists of five extruded ingots, or about 500 lb. OPERATION 3. PORMING BALLS ON SPECIAL MACHINE Transformation — Pig. 153. Machine Used — Special Water- bury-Parrel machine, Pigs. 146 and 154. Number of Machines per Operator — Pour. Tools — Shearing ring punch, Pig. 155; forming punch and die. Pig. 156; shearing punch and die. Pig. 157; transfer plate. Pig. 158. Cut Data — 68 strokes per minute. Production — 30,000 per day. Note — 500 lb. of wire makes about 380 lb. of balls; the balls for 3-in. shells run 41 to the pound; for 4.7-in. shells, 32 to the pound; and for 6-in., 22.90 to the pound. OPERATION 3 -A. PORMING BALLS ON A AND RUMBLING PUNCH PRESS PIG. 152. BALL DIMENSIONS Transformation — Pig. 159. Machine Used-^Waterbury- Parrel crank press, Pigs. 147 and 148. Number of Operators per Machine — Ttvo. Punches and Dies — Fig. 160. Production — 200,000 per day. Note — 500 to 600 lb. of balls are rumbled at a turn to remove fins left by dies; this operation takes about 15 min.; press runs 80 strokes per minute and takes 12 ■wires at once. fr ^V «=s ->, ytOJSS' ->^A-oos -US' ■->+<-- -Z6l'-- -1.48"- -A **■ ^■*'' TWL STEEL (H(,nJe^ ,,^1^-0.15' Shearing Ring Punch Finish J jjfllfe Transfer Plate Bushing Of^H.K FIG. 155 ..>, ^^.g2^' oo3U\^..aes" Cutoff For'i 7 Shells Wire is 0.370 'Siam. « 6" ' "■ " 0410' FI6.I50 3.IES' ^?.'^JC' Us75-"->l u,.+../3»..H l)«3?k--//2'--->l •■Hareen&grind^OU^f.- 22S-. ->! TOOLSTEEL FinisilJ Shearing Die- '0.ii'R Section A-B FIS. 154 '[19] Commonly, however, the hexagon balls are made on the special machines and the spherical ones on the press. The mix for the halls is melted in large pots and cast into ingots. A furnace and a mold are shown in Fig. 1-44. The mold in the foreground is water cooled and so made as to be swung over on trunnions, allowing the cooled ingot to drop out. As shown in Fig. 145, the wire from which the balls are made is extruded in a hydraulic press. As the wire issues from the die, it is carried down through a trough of water. At the farther end of the trough it runs over a large grooved pulley carried in a "floating" frame. From this pulley the wire is run back toward the press and is automatically wound on a reel. Friction drive is used in the reel-turning mechanism, adjusted so that the wire will be closely wound, but not pulled so hard as to sever it. In making balls on the type of machine shown in Fig. 146 a reel of wire is placed in the bracket and fed into the machine. A cam-operated slide cuts the wire off into short slugs, which are carried over and fed into a rotating disk. This disk carries the slug between two forming punches, which compress and form the lead into a ball. As the disk again indexes, the ball is carried to the next set of dies, where the flash is trimmed off. An extra punch in a slide removes all lead particles that might cling to the dies and cause trouble as the disk indexes to the different positions. FIG. 163 OPERATION 2. G, Pour in 4 Oz. melted Resin FI6.164 Eie. 167 "Where the balls are made on a punch press, as shown in Figs. 147 and 148, twelve are made at each stroke of the press. The 12 reels are carried on a slanting frame in such a way that any individual reel may be removed and replaced without disturbing the others. This is especially necessary, as it is impossible to empty the reels all at once on account of varying lengths of wire. After the balls are formed in the press, they drop into a tumbling barrel placed close to the machine, as shown at the back in Fig. 148. The balls are tumbled in this to remove the flash, the rubbing together accom- plishing the desired result. After the case has been washed in hot soda water, the interior is painted and then is ready for assembling and for receiving the balls. The standard shop directions for this operation are as follows : Make sure that the diaphragm seats very firmly on the shoulder; pour in 0.25 oz. powdered resin to seal joints and shalie down well to fill all cracks. The powdered resin becomes plastic when the melted resin is poured in. Put in one layer of balls (18) and pour in 0.4 oz. of melted resin. Put in 108 balls and settle by it pressure of 6 tons. Pour in 2.25 oz. of melted pure white commercial naphthalene. Put in sufficient number of balls to bring the "weight to 12.625 lb. Drive down with mallet and pour in 4 oz. of melted resin. After the mass has thoroughly cooled, face off matrix so that the depth from end of case shall be 0.35 in. to allo"w for screw- ing in of head, which should bear down hard on matrix. Final Operations Assembling operation 1. wash case in hot soda water Number of Operators — One. Description of Operation — Operator places case in solution until grease is cut oft, then rinses in hot water and drains it. Apparatus and Equipment Used — Tongs, Pig. 161; tank of Wyandotte metal-cleaner solu- tion; tank of hot water. Production — 350 per day. OPERATION 2. PAINT INTERIOR Transformation — Fig. 162. Number of Operators — One. Description of Operation — Operator chucks case and applies the paint inside so as not to d.aut) up the threads; machine runs 140 r.p.m. Apparatus and Equipment Used — Small special machine. Pig. 163; pot of asphaltum varnish; long-handled brush. Production — 1000 per day. OPERATIONS 3-A, 3-B AND 3-C. ASSEMBLE TUBE AND DIAPHRAGM, FILL CASE, COMPRESS BALLS Transformation-pFigs. 164 and 164-A. Number of Oper- ators — Two. Description of Operation — First operator puts in diaphragm and tube, making sure the diaphragm seats firmly; then he pours in % oz. po^tvdered resin; next, he places a layer of IS balls on the diaphragm and pours in 0.4 oz. of melted resin; 108 balls are put in and pressed down by second operator with 6 tons' pressure; 2% oz. of melted pure white commercial naphthalene is poured in; sulHcient balls are next added to bring weight to 12.625 lb.; these balls are driven down with mallet, and 4 oz. of melted resin is poured in. Apparatus and Equipment Used — Watson-Stillman hydraulic press. Fig. 165; scale. Pig. 166; melting pots for resin and naphthalene, Pig. 167; mallet. Production — 340 per 8-hr. day. OPERATION 4. CUT OUT SURPLUS RESIN Transformation — Fig. 168. Machine Used — Small lathe, Pig. 169. Number of Operators per Machine — One. Work- Holding Devices — Special chuck, Pig. 170. Tool-Holding Devices — Shank for cutter. Fig. 171. Cutting Tools — Resin cutter. Fig. 172. Cut Data — 250 r.p.m. Gages — Depth, Pig. 173. Production — 1000 per 8 hr. Stamp Name of Shrapnel, Part, Place of Manufacture and DafefYear) FI6.169 One Om^d-S Drill Rod, Drive ITh'ds. per Inch, " OSSfd I „ ! J ■;,^-\a5"Drill \<-I.Z5"^-l.75"--^ ' ' ' Stamp Name of Shrapnel, fbrf, OneA'tm ForiOi. '• "'Zan « 2.95" u -5.0- Hame and Size of flachin ■MACHINE STEEL Finish fiO.Ol" FI&.I70 ion. .5 X -o.ooz''^\ ^0.05''>\^ '^ TOOL STEEL^, FinishfiQOI FI6.I7I 'V.3lz"(i)"Force MACHINE STEEL FinishfiaOl' - Case Harden », Stamp Name of Shrapnel, Part Place of Manufacture and Date (Year) TOOL STEEL FinlshftO.OZ' Harden For Z35 Shrapnel A-im, ■■s.o"„ - -.-z.eu' •' i8„ " •"3.Z88„ - 4.7. V ^-4.004 •• 6.0 " --4^9 For O.SIZ'(§fil.Z5"Std. Steel Setscrew^ FI0.172 ■45- o tSL_ Y '^ <-a3 ''U ■0125*0.6 Steel Pin Drive Stamp Name of Shrapnel, Fart, Dimension gaged, -fg^ Place of t^anufaciure and Date (Yeary OPERATION 4 [21] Fie. 173 OPERATION 5. MOISTEN THREADS OF HEAD "WITH COSMOLINE, ASSEMBLE HEAD TO CASE AND INSERT INNER TUBE Transformation — Fig. 174. Number of Operators — One. Description of Operation — Operator brushes a little cosmoline on threads of head, places case in bench holding block and screws head into place, Fig. 175; he tlien put s in inner tube and hammers it in place with hammer and special punch. Fig. 176. Apparatus and Equipment Used — Holding block; wrench, Fig. 177; punch, Fig. 178; hammer. Production — 515 per day. OPERATION 6. PIN HEAD TO CASE Transformation — Pig. 179. Machine Used — Small drilling machine. Fig. 180. Number of Operators per Machine — One. Tool-Holding Devices — Drill chuck. Cutting Tools — No. 31 twist drill. Special Fixtures — Fixture to hold case, Fig. 187. Production — 600 per 8 hr. Note — Pins are supplied of correct size and are driven in by hand. OPERATION 7. TURN BOURRELET (WHEN CASES ARE FINISHED BY OUTSIDE CONTRACT) Transformation — Pig. 182. Machine Used — Le Blond 17-in. lathe. Number of Operators per Machine — One. Work-Hold- ing Devices — Special chuck. Fig. 184; steadyrest. Cutting Tools — Left-hand lathe tool. Cut Data — 50 ft. surface speed. Special Fixtures — Split bushing; form and form follower. Fig. 183. Gages — Maximum diameter, ring, Fig. 43; minimum diameter, ring. Fig. 44; diameter, nose thread, plug, Fig. 45. Production — 180 per 8 hr. In all cases where two parts are screwed together it is the practice to put on enough cosmoline to coat the threads. This is simply slushed on with a small brush. With the threads moistened with cosmoline, the head is screwed into the case, using the special wrench and holding block shown in Fig. 175. Following this the same operator forces in the inner tube with a punch and hammer, as shown in Pig. 176, the two transformations A and B, Fig. 174, showing what is done. Details of both the wrench and punch are given in Figs. 177 and 178. The pinning of the head to the case is done by one operator who first drills the two holes in a small drilling machine, using a special holding fixture as shown in Fig. 180, the details being given in Fig. 181. After drilling the holes he drives in small pins, which are bought in quantities for the purpose. No accurate spacing of the pin-holes is necessary, the operator drilling them approximately opposite each other. The turning of the bourrelet indicated in operation 7, is only done where the cases are finished by outside contractors, as when they are machined at the arsenal the bourrelet is finished along with the point. The grooving for the waterproof cover is done in a lathe, the shell being held in a special screw chuck. Fig. 187, in conjunction with a revolving tail center. Fig. 189, the cutting tool used being shown in Fig. 188. Painting of the outside is done by chucking the shell in a lathe and applying the paint in broad bands with a brush, the operator after a little practice judging the width of the bands with his eye. On large shells they are held in a vertical position on a rotating fixture, the operator using pointers on an upright piece to indicate the width of the bands until accustomed to his work. A '035 Punch STECL (Harden Point) nnish/tOOl" for? 95 "ancfS "Shrapnel '•■ S.e/t7"-6" ■• FIG. 178 Bushing MACH. STEEL (Case Harden) i'S4J. B-3.rfbr473hrapnel A-li: K. B-5.5 •• 6" .1 Cap MACH STEEL ^-^-^75\l ForOSJSxllfsfd Fillsterhead Steel Screws MACHINE STEEL Fie. 181 OPERATION 6 Body (Black)— 1 Gal.: Lampblack, dry I lb. Linseed oil, raw A sal Texene A &al Japan drier ts gra-J Copal varnish -h gal Cast Iron (Light Olive Green) — 1 Gal.. French yellow ocher, in oil 7 J4 lb- Lemon chrome yellow, in oil 1^ oz. Chrome green, in oil 6 oz. Lampblack, in oil -> ^2. Linseed oil, raw tV S^\ Texene Vs gal Japan drier fz gal. Copal varnish sV gal. Powder (Vermilion) — 1 Gal.. Deepfast vermilion, in oil 2 lb. Red lead, dry 7 lb. Whiting, dry 4 % lb. Linseed oil, raw % gal- Japan drier -lis gal. Priming Coat (Red) — 1 Gal.: Red lead, dry ^9 J?. Whiting, dry 4 lb. Linseed oil, raw % gal. Japan drier i^ gal. Explosive D (Deep Yellow) — 1 Gal.: French yellow ocher in oil 7% lb. English Venetian red, in oil 3 oz. Lemon chrome yellow ^Vi lb. Linseed oil, raw % gal. Texene ft gal. Japan drier s^a gal. Copal varnish A gal. Cast Steel (Warm Gray) — 1 Gal.. White lead, in oil 8 lb. Whiting, dry ^Y? VS: French yellow ocher, in oil % lb. Lampblack, in oil % oz. Lemon chrome yellow, in oil 1 oz. Linseed oil, raw A gal. Texene A gal. Japan drier -h gal. Copal varnish rs gal. Forged Steel (Blue Gray) — 1 Gal.. White lead, in oil 7 lb. Whiting, dry 5 lb. Lampblack, in oil 3 oz Linseed oil, raw < % gal. Texene ft gal. Japan drier -h gal. Copal varnish rs gal. \^a75>i \<—l25-^- 1.0->^ tZS- ->|< /rj-— >t<- -LES---. I 1 1/ For Q5IE (§) Filisterhead 5tU Sefecrevrs k-^ -- Q Q l^°'-_OS"Bolf__ _ , ''-For^Q^BoH- "Tfao^U^ FI6.I8Z Split Bushing MACHINE STEEL FinhhfiO.01 Body CASTIRON Fmishf±O.Ol" Groove, for Faceplate of Lathe to suit Chuck Stam Name of Shrapnel, Part Place of Manufacture and Date (Year) K-IJ75->i<— 25-- ->i MACHINE STEEL Finish f iO.005 Harden -5 Form Yof Closing Ring '1ACHINE STEEL Finishftaor n6.l83 M5'Drill,05%eB i 1 iT^- to t ' ' '^*= Jaw CAST IRON ^ FinishJiaOl" 1 A-(a"--i?„r'y'-—'- ^1^^0-05" ----> |fl«3t<- Steel Pins, Drive ...Jq^^ ;- &o'ms--— - *| Harden End, ■> 05>-I.O->¥-I.O-H \. ,'J- 5 ^-J.r^^ nc'^D^uJf ^^ .!. TOOL STEEL FmishJiaOOS Form Follower ■025 SPRING STEEL FinishfiCOf Expansion Spring FI6.I84 OPERATION 7 A-Z98 for 5-inch Common Shrapnel A'Z.955'" 2.95-inch Shrapnel [23] The powder charge is loaded in the machine shown m Fig. 14!). The shells are placed in rotating holders, and a funnel is swung over them. The powder eliarge is then poured into the funnel and runs down through the center tube into the powder chamber. A second operator then takes the shell and pokes a small wad of gun cotton down into the center tube to hold the powder in place. Following the loading, the shells go to a gang of three men, who put on the fuse. The first brushes cosmoline on the threads and partly screws in the fuse. The next man sets the shell in a bench chuck, Fig. 195, screws down the fuse and locks it in place with punch and hammer. The third man places the fuse setter over the fuse and sets it to the safety point. From this gang the shell goes to the crimping machine, Fig. 19^". The operator paints the cover groove, slips a brass waterproof cover in the holder, places the shell in the fixture and starts the machine. The disk roller revolves around the head and securely crimps the cover in place. Following this the edges of the cover and the junction with the shell are painted by hand with asphal- tum varnish in order that the joint may be water-tight. OPERATION 8. GROOVE FOR WATERPROOF COVER Transformation — Pig. 185. Machine Used — Le Blond 17-ln. latlie, Pig. 186. Number of Operators per Machine — One. Work-Holding Devices — Special screw chuck, Fig. 187. Cut- ting Tools — Special lathe tool, Fig. 188. Cut Data — 50 ft. sur- face speed. Special Fixtures — Revolving center. Fig. 189. Gages — Position, scratch gage, Pig. 190; position gage, Fig. 191. Production — 600 per S hr. OPERATION 9. PAINT OUTSIDE Transformation — Pig. 192. Number of Operators — -One. Description of Operation — Operator chucks butt end of case in small lathe and applies paint "with "wide brushes. Apparatus and Equipment Used — Pot of black paint, pot of yellow paint, two brushes. Production — 800 per day. Note — Machine runs 250 r.p.m. OPERATION 10. LOAD POWDER CHARGE Transformation — Fig. 193. Number of Operators — Three (two loaders and a trucker). Description of Operation — Cases are placed in the revolving fixtures shown, and 1180 gr. shrapnel powder is poured in through the funnels; next, a wad of gun cotton is pushed down tlirough the tube to retain the pow^der and assist ignition; powder is measured by means of the little dipper shown on the bench; the cases rotate about 200 r.p.m. as the powder runs in through a /j-in. opening in the funnels. Apparatus and Equipment Used — Loading fix- tures. Fig. 149; measuring dipper; trucks. Production — 2200 per day per gang. OPERATION 11. BRUSH COSMOLINE ON FUSE THREADS Number of Operators — One (three in gang). Production — 1200 per day. -- — - .. , succession. Note — Three men do operations 11, 12 and 13 in OPERATION 12. SCREW IN FUSE AND LOCK Transformation — Pig. 194. Number of Operators — One (in gang of three). Apparatus and Equipment Used — Bench chuck, wrench, punch and hammer, as shown in Fig. 195. Pro* duction — 1200 per day. ■■ astaos'- ■>{ ril Oil Grooves 0./%'de,x005"aeep,x/.5"/onQ -r^as K OMSH: ''i^'» Sy '^ § 's ^-T 'o.n ■0.29" MACH. SrCCL (Case Harden) O.ZS'kanS'Std fleadless Setscreiv A '2.4"fprZ.gs"& 3 "Com. Shrap. A -255"- 3" H.E.Shrapne/ '^ FIG. 189 Ba//s held in Retainer'' - O.igT'k') Hardened Ball Retainer ^^^\<--i.4S''->\ Stamp :name ofshrapnef. part -m- FIG. 186 oyk ^^-^ -^lSspofrace \ -5.I2S Y Harden ->| HIGH Sfen sm^^t tool" FIG. 188 I '-/fini )j<- QJ- ■ ^0.15-^ Oroove Crimping and Lubricating Groove, FORdED STEEL Stamp with 0.06d'(jg) letters 8c figures, tot no. of sfietl, purchase order, date of issue of p.o (fiscal year) and initials of ^K manufacturer \ r< \-- 5.0^0.1 to Center of Oravify —>\ —--y-9.7ri0.!"- yoiuwe Cavity Empty IZ.S8 Cu In. " Fuse in Place 1849 '■ •• Withwt Fuse 2Z4 " With '• no IHotclKS equally spaced. Press metal of fuse into notches for locking 15 Scores per Inch, 0.15'Deea Scores inhdsperlnch,tl.S.Std Left Hand Moisten Thds slightly with Cosmoline —-5.23±0.r- ■- -ii.e'io.1"- ^=3fmp vfiih 0.062 Q letters & figures, FA. lot no & ammunition lot na The stamping prescribed may he rolled in on hand if also stamped en base nithin the groove in lieu of stamping in front of band Finish Oufsidkf taOl" Rough Inside except where marked fi Coat Inside mfh Non-acid Paint FIG. 2. DETAILS OF COMPLETE PROJECTILE [26] PIG. 3. CENTERING BASE OP PORGING IN A LATHE PITTED WITH CROSS-SLIDE TURRET PIG. 4. ROUGH-TURNING THE NOSE OP THE CASE ON A LATHE PIG. 5. ROUGH-TURNING BODY, USING A SPECIAL DRIVER AND CENTER PIG. 6. PINISHING THE BASE ON A CLEVELAND AUTOMATIC SCREW MACHINE PIG. 7. ROUGH-FORMING AND PINISHING THE POINT PIG. 8. PINISHING THE BODY, WITH CASE HELD AND BOURRBLET ON AN AUTOMATIC BETWEEN SPECIAL CENTERS FIG. 9. NOTCHING THE BASE ON A HAND MILLER FITTED WITH SPECIAL FIXTURE PIG. 10. SORING THE INTERIOR ON A LATHE USING COMMON BORING TOOL [27] v//// /////////////////mm ^' W///////////////// ///. FI6.II HIGH SPEZD STEEL {Harden) Fini5hj:taor \1^ I ■ , _,.,--' ^ MACHINE STEEL I , // J L. ,w^...^ (CaseHarden)Fini5hJ±0.0l'r-'-' "^ '^^ '-^ 0.575"X0.875"Stil Steel SetscrewsVi 3— H -SSl'MaAr Wrl It"- ^°}.'^^ Harden ^-^^-■-^^- ---^■■P°'%^■o.l^5"■ / /V/>7. - j,l gn-// Min.(Size l^ijsefhisEdaeforWarp6(iqe 1 'l^ax^Radiusof Band Minus Jd' Thi5EdgemusTbeground5trdlgfif-~-,,\Tobearon I Max.RadiusofBourrelet c^i' ' / 7;-'' J ""'^''^^''^■^ W- dos"- >(*""""_'.:.: ;:-:v6'=;-^v„-;/'; ->«-/./i->' s/nrsrfa Finishj+o.oos" Depth of Cavi+y Rod and Warp Gage '^^O.lfD FIG.I2 •<--- - Zl" y — - S/llV ST££L Fini5hJ±0.005 Cross Bar (Depth of Cavity Rod) OPERATION I FIG. 14 "■■45' ■"'^Section A-A I] h ---g'io./"- Assembled Views A =3.S7S' B'3.l "s'fi.fShrapne/ A =3.875''B=3./':3"Common ,, A=l.d75 B'505," Z.95"Shrapnel -A Body TOOL STEEL (Fbrae) Fmish/tO.OS'^ H-O.8t0.002 MarkO/'/- Case Holder MACH. STEEL (Case Harden) r®~ir „ Finish/taOS" (2«"HK 0.2S'K0.57S"Stc/./1eadle5S Stee/ Set Screw '■^■■J aS^pSfc/.Tor I.4SM r^0.6"hoJdinq ■^ 'iRr* ^"'^'^ ^ ■fS^^-ZOUS.Std.nri/3. J ^ perir, p^^^ nolding Screw tool steel TOOL STEEL(flarden) /1orc/en*-o.OJ rinish/tO.O/" Ba//s fie/c/in ffeta/ner by Two Set Mar/rs (1 ' ^ '^\<-az5'hoo2" Sg Race Ring JV ^"O'- STEEL =i5 Marc/entaot no. 20 Ball Retainer ., BRONZE rinjshf-tO.OI" 25 0.25"Steel Bolls OPERATION 1. ROUGH-FACE BASE Transformation — Fig. 11. Machine Usea — Prentice upright drilling inachine. Number of Operators per Machine — One. Work-Holding Devices — Table knee clamp, Fig. 12-A; bed- plate center, Fig. 12-B. Cutting Tools — Facing cutter with inserted blades, Figs. 12-C and 13. Cut Data — Spindle runs 65 r.p.m. Coolant — None. Average Life of Tool Between Grindings — About Va day. Gages — Depth of cavity. Fig. 14. Production — 400 per 8 hr. Note — Operator must face base close to the maximum limit to allow for finish. OPERATION 2. CENTER Transformation — Fig. 15. Machine Used — Reed 18-in. lathe. Fig. 3. Number of Operators per Machine — One. Work- Tn.i? w^^i.tP®^'??^"^''''^!'"'^^'; three-jaw universal chuck. T^Sh^^ "^i. Devices^Turret toolholder; Fig. 16. Cutting F?5 7^ iS"^^''=.'^"A'"l'"^ , tool. Pig, 16-A; centering reamer, f ,-f» nf T^^„, S"5 Data—ITO r.p.m. Coolant— None. Average ProdSctio°n-!o'oTe?"8°hr'."'''"^'-^'^°"' ' '^'^^'^- Gages-None. OPERATION 3. ROUGH-TURN POINTS l«tV?p''''Ffi°a"'''M°V^'^iA''- Machine Used— Le Blond 17-in. lathe. Fig 4. Number of Operators per Machine— One. Work- ?ent^.'?^ 5r,"^l?T,'?"^'=T.''°? =^"^1 centers; red lead on tail center Tool-Holding Devices— Toolpost. Cutting Tools— un entirr™nnF„t°°^ dumber of Cuts-Cuts off scale Ind cleans •^M^^J tJ '?*^-..'^"*^ R?'^— ^^ '■■P-'"- Coolant— None. Gages — None. Production — 200 per 8 hr vj^sco [28] tracers. The weight of the complete projectile is divided as follows: Shell (empty), steel. Band, copper Fuse Base cover (complete) Trinitrotoluol Total weight 15 Lb. 12.355 0.15 1.38 0.215 0.9 ±0.15 LIST OP OPERATIONS ON THE CASE Rough-face base Center Rough-turn point Rough-turn body Finish-machine base Finish point Finish-turn body Notch base Bore interior Rough base-cover groove Finish base-cover groove Assemble band Turn band on lathe ■A. Turn band on special machine Resize threads and counterbore; inspect all over Sandblast Hydraulic test mm^2z^^^^ ^^/.m'^'/:'/^////^/^^.^^ ;^ Fie. 15 ..J l-lf^' A' OPERATION 2 __ ffl ~T^-f\ - L.. l— |tr-A^; j> --■ r — -~ ^ Y- 1 ■ ■5.0 >- 0IZ5>. aiOl Drill- "S ; -JaS5C J _i Wi-q"-* ■ Case Harden 6agmg Surfaces PART A B c Band Seat 1 87 !.S6 14} Bodi fm 7%^ ft Bourrekf 71^ ?m 1.5 Rear of Band zms i.m ■If SAW STE^L rmSsh/iQQl" Harden FIS.44 '////W/////y/A ' • ////////^//'//'/7. FIG. I7.0R3 FIG. 18 fl'^^jeu.S.StH.Threac/s 075 R eam. ' siV perm. 0.5l2l{) TapStH. Assembled Views ->\061S^- rinish/tO-Ol" FIG. 19 ai2S>\^ k -Af-aoez ^-/'>, S jeuS.Sti/.Thri/ perm Adjusting Screw MACti. srcCL (Case Harden) '^^ /\ = 1 1^^^ £ Stamp-name of shell, gage^ d/menslons aage place ofmani/fdcrure and date (year) ■3.07 Max.:- 0. 06'-i\ U'* ^" ''"^^ Harden Gaging SurKice S'^ MACn. [STEEL /_ . FJnishQtO.Ol" FI6. 2! [29] The rough-facing of the base is done in a drilling machine fitted with a special cutter and holding fixture, as shown in Fig. 12. The point of the cawe rests on a centering block, and the body is held in a clamping de- vice. The amount faced off the base is determined by the depth of the cavity, a depth gage being used to indicate this. The tool head is fitted with high-speed steel cutters that are easily reground when dull. "When centering the base, the inside edge is first trued up with a single rough- ing tool; and then the centering reamer and counterbore is run in as shown in Figs. 3 and 16. Eoughing the point consists mainly in turning it to approximate shape, care being taken to get under the scale all around. It will be observed that the case here is held on the tail center, yet no mention has been made of the centering of the point. This will be understood standard high- when it is explained that the point is centered by the com- pany that makes the forgings, in order to rough down the outside concentric with the cavity. The body is roughed off in a lathe as shown in Fig. 5, the point being held and driven by a special chuck. Fig. 19; and the base is held on a revolving center, Fig. 30. A speed turning tool is used for the cut. OPERATION 4. ROUGH-TURN BODY Transformation — Pig-. IS. Machine Used — Le Blond 17^in. lathe, Fig. 5. Number of Machines per Operator — Two. Work- Holding Devices — Special drive chuck, Fig. 19; revolving plug center. Tool-Holding Devices — Tool post. Cutting Tools — Lathe turning tool. Number of Cuts — One. Cut Data — 0.040 in. feed, tIb to % in. cut, 60 ft. surface speed, 70 r.p.m. Coolant — None. Average Life of Tool Between Grindings — 15 pieces. Gages — Combination snap. Pig. 21. Production — 200 per 8 hr. OPERATION 5. FINISH-MACHINE BASE Transformation — Pig. 22. Machine Used — Cleveland 3% -in. automatic, Fig. 6. Number of Machines per Operator — Three. AVork-Holding Devices — Split collet chuck. Tool-Holding Devices — Holder for combination reamer and counterbore, Pig. Mo I d e r MACtI STEEL finishftOOl" r ^''xl"Sfit.SteglSetSavir ff.Zf>i 1<-/-H 04S7 force ^^'^; (cm Rernove affer '^ssernblinQ Stop Pin 0.125 '•0.75" Drill Retainer Washer ->] f-O.II" Retainer Collar O.Sx I 2S"Stil.Sfeel'SetSefscrew. Pivot Point O.IZ5''xll4"StvelPln.Vriye no. 24 "6 Coils -J l.87S"rreeHt. Retainer Spring OPERATION [30] , „ „ nB"Deep ,, 3-0.6m&)xZ.ZStc/. Co//arJieadStee/Sa-e)vs HSffM Z-OSy.S"'Std. Co//ar tteacf Sted Scretrs H K 0.23'^0.003 cramp fOReeO STCEL ±0.01" Z-0.S7s"x0.6S'stU Nead/ess Steel Setscrvirs. nat Point 'ZS"-OMof\<(!75S\ 4;i-a3'zW'f- FIG. 26 Tool Wedge rooLSTCCL , nnish/taoi ^ ^f45 >] f -azs _| 0,5Tap,?0Thds. K 1.875 ->\.perlnch,U.5.Sfd W 6* A 3. ~ sl : ! ^^-^«^> Y M ^ ^- ; ■; i i InyA i Pi^S^fe 11 a: One Q5"0.6ST'(ifStd Headless Steel Setscrews ■■az5hz&\%f TOOL STEELfPack Harden) Finish f ±0.005" Knurl Holder V^—-l.575'-->\ ^ ^"-^ -aoo3 Holder ■ /J-"- ■>i ae"U 5(7" 5famjo name ofprqjecfile,part, size, number of threads per inch,place of manufacture and datefyear) „._ „ TOOL STEEL finish/ i0.005i' Harden E -7.75"- \^-oj5-^-o.45->] is -^- -ass- '0.05R' '0.04 ^ ■ Stamp name of shell j place of manufacture and datefyear) -5.5- STtEL ^^^/ ■>\.U 0.lZi0.005-^- ^ HI6HrS/=rED STEEL F inish f± 0005',' H arden =*-4illllllll^^ 1.95"- >J HI6H-5PEED STEEL Finish f 1 0.005, Harden FI531 OPERATION 5 S -J' \' " Flat " Boring Bar A B NAME OF MACHINE II.SW.I I4.9i0.l FOR 3.25 CLEV. AUTO MACH. 6.Z5t0.l 9.65 ±0.1 FOR POTTER & JOHNSON Fie. 34 MACHINE STEEL Finish/ tO.OI" VO.I5"->Y-0.5-^O.I5>Y 0.2-- -M SA'N STEEL finish/ moos' FI6.37 ' fg.?m2'(g-'^\< , . Round:. _ \<--0.%'Maxr—H ^0.25" >] < 0.07 Max. ^0.4 ^^U 0.25 Drill-' ML 0.05-MIn> %.-..a54"Mia -J K -4.0 —■ U -;5.25''---y>^ |<-/,75--^<--/!5-->](375 C- /.5'V | J.£'5-',"z,->J lnch,U.S. Shank SAW STEEL Finish/ iO.005 'Harden Fie. 38 OPERATION 5 0.457W ■0.00.5" V—-5.25"-—- HI6H-SPEED STEEL Finish/ ±0.005' 6rind Cutting Edge Fie. 35 Finish/10.005 Locknut , One a5"'l.l25"Std5teel Sefscn J " OJil.375"" •• '• OSI5'il.O" " " Jm 0.5kl25"Std Filisferhead Screws HI6H-SPEE0 STCEL (Harder) Finish/ tool" Bourrelet Cutter 049^ K- ■.—4"Snug Plate , . r 0.3l2'(i)"xm"5tandard Counter\ i .„», jf^ ■sunkHeqd Steel Screws ' S ,X" ^ om§>iO.S"StandardCounter-\f^Jrl-^f 'X sunk Head SteelScretv 05[>- -40/"- -'^-^'l HIGH-SPEED STEEL {Harden) FinishJiiOOt" Cgivs Cutter Fie. 47 -J i — r-^ Q r Qfl5vQ •7375- -.— ->| ^■7.125"- ■- >} --475'-^-- ->r-»-1'§ 1^" -2'->^-l.937"m-^, ■ I k !8 Body "= MUCH STECLfinisfi/iOOr OS'XISTS'STandard Steel Setscrens ' 062S'!O.6255'Standard Steel Setscrms OllS'll IS' Steel Dowel Pins, Drive mX/1951," \-IS75-~ ■65^'- -6.05- ■ s h'-'i \^'-i.r- \ I J— ft ■:.>\ — -H OXliipStd 06'Deep\ fl HwrW ; /.#" ->l<06"4« Z.75"*0002'- , 1OOI..475'- ^ -4375" -- -0.45' ^ ^ i Hi \ ! 0625 Top.. '^Sfd. "" n Drill far f'0.625'Boh- Securing Bolts COLD-DRAWN STEEL Finish/tO.Ol" 0.625"Nufs to .J...-i Block i mCHSTEELFinish/tO.Ci OPERATION 6 [32] stamp Name of Shell, Gage, Dimensions gaged. Place of Manufacture and Date (Year) L- /M--W- /,i6'JU-lsf.-d<.-/p'-l \Straight ! ' j H 5.9S4-'- SAVI^TEEL (Harden) Finish f ±001" Fie. 48 0.IZ5- fr os RIG. 49 OPERATION 6 u ' Stamp Name of Shell; Part, Gage, DimensTons •^aged, Place of Manu facture and Date(Yearj 'Cade harden gagingS'urfaces mCHIttCSTffl Finish niOni' mCHIME STtEL,Fini5h gtO.oi' FIQ.50 Bourrelet Cutter Slide mcHiNE sTECL. Finish f*aoi' OASl'iif /Mis' Standard headless Steel Screw 027S- Body mCHiKE 5tEEL,Finishfi00l' ' OS'netls'Siandard Steel Setscrews FIG. 46 OPERATION 6 >ifl«5K- - -E2S'- - -OWSW- Ogive Cu-tter A 0.6' moo" -om" -SPEED StEEL.(Harden) 'Finish ftO.Ol' 23; tap holder, Fig. 24; tap-holder adapter, Fig. 25; cutoff tonl- holder. Fig. 26; form tool holder, Fig. 27; knurl holder. Fig. 28. Cutting Tools — Tap, Fig. 29; cutoff tool, Fig. 30; form tool for band seat and groove, Fig. 31; knurl. Fig. 32; counterbore, Fig. 33; boring tool. Fig. 34; facing tool, Fig. 35. Cut Data — 80 r.p.m. Coolant — Zurn cutting oil, %-in. diameter stream. Average Life of Tool Between Grindings — Tap, 3 or 4 days; forming tool, 1 day; reamer, 3 or 4 days; cutoff, i day; other tools, 2 days. Special Fixtures — Stop in pusher tube; pusher stop. Fig. 36. Gages — Depth of cavity, Fig. 14; position of band and grooves. Fig. 37; band-seat width and depth. Fig. 38; maximum ring, rear of band. Fig. 39; minimum ring, rear of band. Fig. 39; diameter and depth of fuse-flange seat, Fig. 40; maximum thread plug. Fig. 41; minimum diameter of thread and eccen- tric of counterbore. Fig. 42; combination snap-band seat. Fig. 43; position and width of band seat. Fig. 44. Production — 32 per 8 hr. per machine. OPERATION 6. FINISH, POINT Transformation — Fig. 45. Machine U&ed — Cleveland 3% -in. automatic. Pig. 7. Number of Machines per Operator — Two. Work-Holding Devices — Split chuck. Tool-Holding Devices — ■ Roughing toolholder. Pig. 46; finishing toolholder. Fig. 47. Cutting Tools — Tool for roughing ogive. Pig. 46; tool for roughing bourrelet. Pig. 46; tool for finishing ogive. Pig. 47; tool for finishing bourrelet. Fig. 47. Number of Cuts — Two, roughing and finishing. Cut Data — 50 ft. surface speed, 57 r.p.m. Coolant — Zurn cutting oil. Average Life ot Tool Between Grindings — 60 pieces. Special Fixtures — Pusher stop; sprmg stop. Gages — Profile, Fig. 48; maximum diameter of bourrelet ring. Fig. 49; minimum diameter of bourrelet ring. Fig. 49; combination, snap bourrelet diameter, Fig. 50. Pro- duction — 64 per 8 hr. per machine. OPERATION 7. FINISH-TURN BOD 7 Transformation — Pig. 51. Machine Used — Reed 18-in. Jathe, Fig. 8. Number of Operators per Machine — One. Work-Hold- ing Devices — Universal three-jaw chuck, with extension jaws. Cutting Tools — Lathe turning tool. Number of Cuts — One. Cut Data — 125 ft. surface speed; 150 r.p.m.; 0.045 in. depth of cut; 0.024 In. feed; total length of cut, Sy. in. Coolant — None. Average Lite of Tool Between Grindings — 20 pieces. Special Fixtures — Revolving center; center' plug in spindle. Gages — • Combination snap-body diameter. Fig. 52. Production — 200 per S hr, OPERATION 8. NOTCH BASE Transformation — Pig. 53. Machine Used — Brown & Sharpe hand miller. Fig. 9. Number of Operators per Machine — One. Work-Holding Devices — Fixture, Pig. 54. Tool-Holding De- vices — Arbor. Cutting Tools — Cutter, standard 60 deg.. 2.75 in. in diameter, 0.5 in. thick, 22 teeth. Number of Cuts — -Three. Cut Data — Cutter runs 370 r.p.m. Coolant — None. Gages — None. Production — 600 per 8 hr. [33] OJBiyoz'Standard k- Countersunk Head ' ~r BronzeScrews . 2S-— U .-^js'^ymu asTimmaor """^ 0m04iT(ifSfdPlvof Point Headless Steel Scriw ■*IMI<- - , COLD Omm STEEL FlnifhJtOOl" 03ie'(§'Nufs Rorier Bolt S4 0.87S"k- TOOLSTEEL(Harden) FinishJtaOOS' Stop Automatic machines like the one in Fig. 6 are used to operations are going on, the form tool for the band seat finish-machine the base. The interior is rough-bored, does its work, and the bottom of the groove is knurled counterbored, tapped and the end faced. While these with a knurling tool carried in the front tool block. FIG. 58. ROUGHING BASE-COVER GROOVE PIG. 59. FINISHING BASE-COVER GROOVE [34] MACHINE STEEL Finish f ±0.01" Case Harde n -6.0 ->t. & 0.125 Drill -1= 9^ 1-^ .-.ai f.lE5>\ Y MACHINE STEEL '^^^ * "'^ '-^ FIG. 55 r0.6B5 Cross Bar <^V,vA For ai75kz5"std. .{•ip' '^T c u J Cross Bar OPERATION 9 1^ :Q g5/?. ^j.'\j. Finish fiQ.Ol' Case Harden "^^ T"^^^ ^ O.ll5"0rill Rod -^a5f<- stamp name of shell, part, operation, place of manufacture and date (year) q^"/^. 0375 TapStd Square Head Steel Setscren -z^ TIT" '\4 ■f (' k 0875 etf ■,^: 0.59 ±0.005 M& -i.457L ■7 S" V.S!5\< Mforged steel Finishf±0.0l" fg 2.Z5"l^ax:- a i3*49>ir /^-•■ Stamp name of projectile, goge, dimensions g^ged, place of manufacture and date (fear) A 055' '~J -VA SAW STEEL Vv////.-:>,v//y.'y/ Taper 056Z'(§f 005-^\<, ZZ4Min. ^>t FinishfiO.OI Harden Fie. 66 ^_ , OZS' Square K 0.5^ Steel Key Y ','--.^ 005 ff.:. Force in Holder, snug in Cuiter^J\^'''^^^.s^ FI6.64 -^P ■0 Inch per foot f -r- -^—■^-^rm _i4_ ■5.Z5 0.05 R. 20. ■>| V-0.55 Holder MACHINE I STEEL I Finish/ma k- OPERATION lO om 0.15 37—7- .■• Jf -0 5.5"- ■ M ^^ , ,^ ^,..r) — \ *=— Lm^-^4i L ;," Q?-^ l-flJiflJ'SI ^ "■"."■/■^ ' -5 <^"^«^ ^^■^ " ------>j HIGH-SPEED STEEL nnishftaOl' Harden ySldper 5hank(shown in full) for Engine Lathe \ Straight Shankfshom in dot and dash) for Hand Scren Machine FIS.S5 io.5m ■ Drill Tap for0.5ls'(§)m7S"std. Hex. Head Steel Scren OPERATION 9. BORE INTERIOR Transformation — Pig. 55. Machine Used — Reed 18-in. lathe, Pig. 10. Number of Operators per Machine — One. Work- Holding' Devices — Universal 10-in. three-ja^v chuck; steady- rest. Tool-Holding Devices — Toolholder, boring bar, Pig. 56. Cutting Tools — Cutter for boring bar. Cut Data — 150 r.p.m. Coolant — None. Average Life of Tool Between Grindings — 30 pieces. Gages — Maximum and minimum length of thread, Fig. 57. Production — 160 per 8 hr. OPERATION 10. ROUGH BASE-COVER GROOVE Transformation — Pig. 64. Machine Used — Bardons & Oliver turret lathe. Pig. 58. Number of Operators per Machine — One. Work-Holding Devices — Set collet pads, 3 in. in diameter. Tool-Holding Devices — Holder for cutter. Cutting Tools — Circular roughing cutter. Pig. 65. Cut Data- — 115 r.p.m., 50 ft. cutting surface speed. Coolant — None. Average Life of Tool Between Grindings — 60 pieces. Gages — Diameter of groove. Fig. 66. Production — 240 per 8 hr. FIG. 60. BAND-ASSEMBLING GROUP PIG. 61. SPECIAL BAND-TURNING MACHINE FIG. 62. TURNESTG BANDS IN A LATHE FIG. 63. RESIZING THREADS AND COUNTBRBORE [35] Stamp: name of she//, name of/io/ckr' and mac/iine. place ofmanufacfure ana cfate (year) . --- 4' A II h - -SS!!. - „ MA Ctl. STEEL , rinish/taO/ ' 4025x0.75 Std. Stee/Sefscreivsr/atlrw FIG. 68 Inside To o I tllGtt-SPCCD STEEL FIG. 69 Outside Joo\ , HIGH-SPEED STEEL FIG. 70 OPERATION -pCtZlSl^Mm. V ""~fe \\-O.I5S'Max. f.Kff,-- >i\) ,-J \-0.IS5Min. 0.04-'4y-\i'J& „ MaiQ5<--Min. SAW STEEL rinisl7/tO.Ol''Harc/en FIG. 71 From this machine the cases go to an automatic, Fig. 7, where the point and the hourrelet are roughed and finished with similar tools carried in tool blocks on oppo- site ends of the same cross-slide. In finish-turning the body, it is held in a lathe just the reverse of that in the rough-turning, as shown in Fig. 8. The point rests in a centering plug in the spindle, and the base is held in a special revolving center. The base-notching fixture is shown in Fig. 9. The shell is held in a collar into which it is locked by means of a setscrew. The outer end is supported by two rollers. As the cutter runs, the operator works the feed lever with one hand and indexes the shell with the other. These notches are cut so that the fuse can be locked in place after it is screwed home. For the purpose of boring the interior the shell is chucked base out in a universal three- jawed chuck, with the outer end in a steadyrest, as shown in Fig. 10. A strip of tin is wrapped around the shell where the chuck jaws grip, in order to give them a better hold and not mar Faur0.i!5'U5 Bolts and Nuts ^ usfoB" § 05>\ f O'l'VlM^'Soi' COLD-DRAWN STEEL Finish fmi'Jm OSIS'Huts V- — 75"-- -^CAST ' ' IRON„ ' r 'f'ToH ^'^'' asiififsmd fiv-e , t-CAST STCCL 1, .fr~ '.A-SOiforZgSPro/ectileA-SlforSPrgectile ^ /A'59'r 5d' » A-4.6!''47 • "^ A-6.14 • 6" f FIG. 74 SECTION A-a-C Punch Bofr .TT.X-'^Up^jrX^l ^ ^0^^^' 8 ^jjjoj it\ 1 , •'J-— -^ ^ COLD-DRAW STEEL g, « JL l__^'-^^J^ /t-^-1 , t*- FinishftaOl" •^ '•-I' -'-t-^-'— -^^ 9 Four QW'af Huts \>W5'mOI'!<- FinishfiO.002' ^ i\iO6k00l'tf Harden TapforSix0.?5'0i75 0.(5' 'J^ Cskliead Steel Screws. ZT S hlSTSU a; ''■aiSiti)' -H 2.Z5"h Base aiTio? 7-00, 0375Dnlk Bushing ■••■■■.,.li" ■ 0.575:\ ,^ Bperiment IZCoits OS' STEEL MUSIC WIRE (^0.01)' Spring ^^^r-S) -2_o.75 BRASS Finish/mi Q2fv> i;i'--4S >*i MACHINE STEEL FinisllftO.Of V 0.6Z5"StdTli d. ^ .^^"""P ( -0.875' m '-L azi-- ' >il.5'AppmV 0.b' Finish J i 0.002" Harden Punch ca75"-_ . -m'simd ^^^ aiq'w S.0, 8.75 COLD-DRAW STEEL FirishiOOf mis '0.115 ^ . am' TOOL STEEL SUThd «^co>."- -^%1'pf^^l- Top.Std:\.^^'-a875 d/o' COLD.- DRAWN STEEL Handle FI6. 73 WLU.-UHAWNSIttL. Distance Pipfp iuuloiccl nnishjtaoi" TmOSIEtif/iuts '^'Stance nece Finish ft 0.00f Harden Pivot Stud Cam OPERATION 12 [36] the work. The horing bar is of the ordinary type with a single-point cutter. The inside of the shell is trued np for about 3 in. from the outer end, and the length of thread shoulder is machined back from the inside to the required distance. The base-cover groove is first roughed out with a cir- cular cutter, Fig. 58, the shell being held in a collet -6.55- -0.002 tao/iaooe' -r^S- HIOH-SPCED STEEL (Finish f± 0.01, Harc/en) FI6.80 -4.85'^.-.. - -\m7"4) % '0.05"±0.005" 3 fllGH-SPEED STEEL ( Finish fi 001 , Harden) FIG.81 OPERATION 13a chuck. From this machine the shell goes to the one shown in Fig. 59, where the groove is dovetailed and finished to correct dimensions. The work on the copper rotating bands is the same on both the common and the shrapnel shells. The outfit used in assembling the bands to the shell case is shown in Fig. 60. The bands are placed in the furnace at the left by means of a long rod, about a dozen or more being handled at a time. The bands are heated to a low red heat; then one is seized with a pair of tongs and placed in a locating fixture in the arbor press. A shell is then set in and pressed down until the band is on a line with the groove. It is lightly pressed in and passed to the hydraulic band- ing press, where the band is forced securely into the groove. OPERATION 11. FINISH BASE-COVER GROOVE Transformation — Pig. 67. Machine Used — Flather 16-in. lathe, Fig. 59. Number of Operators per Machine — One. Work-Holding Devices — Universal lathe chuck, 9 in.; steady- rest. Tool-Holding Devices — Tool holder. Fig. 68; tool post. Cutting tools — Inside tool, Fig. 69; outside tool. Fig. 70. Cut Data — 150 r.p.m. Gages — Diarneter of groove. Fig. 66; depth and viridth of groove, Fig. 71. Production — 160 per 8 hr. OPERATION 12. ASSEMBLE BAND Transformation — Fig. 72. Machine Used — Banding press, furnace arbor press, Pig.' 60. Number of Operators per Opera- tion — Two. Pressure Required — 1300 lb. Special Fixtures — ■ Fixture to locate band in groove, Fig. 73; set of banding dies, Fig. 74; tongs, Pig. 75; bar for bands. Gages — None. Produc- tion — 150 per hr. Note — First operator puts about 40 bands on a bar and inserts in furnace; "when the bands are at red heat, the operator takes one out with tongs and drops into arbor-press fixture, then drops in shell butt first, slightly com- presses band and passes shell to man at banding machine, who finishes the operation. OPERATION 13. TURN BAND ON LATHE Transformation — Fig. 76. Machine Used — Reed 18-in. lathe, Fig. 62. Number of Operators per Machine — One. "Work- Holding Devices — Universal 9-in. three-jaw chuck. Tool- Holding Devices — Two tool posts. Cutting Tools — Standard band-turning tool; standard band-facing tool; 10-in. mill file. Number of Cuts — Two, forming and facing. Cut Data — 330 r.p.m., 320 ft. surface speed. Average Life of Tool Between Grindings — About % day. Special Fixtures — Revolving cen- ter; form. Fig. 77; form holder. Fig. 77; form follower. Fig. 77. Gages — Band profile. Pig. 78; maximum diameter of band ring. Pig. 79; minimum diameter of band ring. Fig. 79. Production — 400 per 8 hr. Note — Band is profile turned, faced, and then smoothed "with file. OPERATION 13-A. TURN BAND ON SPECIAL MACHINE Transformation — Fig. 76. Machine Used — Fig. 61. Number of Machines per Operator — One. Cutting Tools — Roughing tool. Fig. 81; finishing tool, Fig. SO; end scraper for hand use on rest. Number of Cuts — Two. Cut Data — Spindle runs 145 r.p.m.; 120 ft. per min. surface speed. Special Fixtures — Out- side swing bracket is a stop; front swing bracket is hand- scraper support. Gages — Same as operation 13. Production — 750 per 8 hr. r -4.mr4)^^°"-' -3'- 0.25 FI6.76 5_^ "PP^-—^0.il2'gTap5fd \(0.4S'Deep OmZfiZ^Y'- J TWL STEEL OMWR. (Harden) Fi nish/tOOOS" -Z34"- ^-ForOS'Bolts Q :tL© ■Si* ■ISP ..r,. H5'^---l°->^--l"—^nOLSTEEL, One A '■005' (Fori Inch Conn.5hrapnel) One /K' 0.04 (For 2.95 Inch Shrapnel) Form "r^ 9i >I>.SI5g aSvt" H S Form Follower MKHII1ESTEELFinishJ±0.005" nK'(i}X0.75'5tyFill5terhead Steel Screws Nut W5: 07^- -~.-4687i4iej^gQ05'' ^ ,,,„ I T^ to rr- @ ^ ForaW(]ffFiiisterheadJ S8$® — ;'e) otn- . t Standard Screw ' . *ICW/Vf STEELfinishf-^OOl ^ "'^ O.X'(^'Xt5'5tandardmiterhec,dSteel5crew Holder Fie. 77 '> KKHINE STEEL FinishJtaOOS' 05"Nuts Tie Bolt OPERATION 13 <---fl5 [---^- -o.se- ■>\ Max.Height ofProfile L-QSS'Drill # Min Height of Profile EngraveLines ,0005' Wide ; O.OOS'Peep si <—-0.S"- fOsiU Auqk' ■-0S6- d -1.5"- snw STEEL, (Harder^) Finish J+0.01" FIG. 78 ajaoez'^ 0.5" FIG.79 [37] .,_rt__-^.Z^;^j_ . . „//'■'. ■ ///^ F1G.82,0RI4 FIG.89, ORIS a/S"Sfd.Steel HexJIead Boll- a7S"long and Nut Upper Ring Punch OPERATION 14. RESIZE THREADS AND COUNTERBORE Transformation — Fig. 82. Machine Used — Warner & Swasey turret lathe. Fig. 63. Number of Operators per Machine — One. Worlc-Holding Devices — Pot chuck; steady- rest. Cutting Tools — Boring tool; counterbore; tap. Cut Data . — 80 r.p.m. Coolant — Lubricated with lard oil put on with small brush. Gages — Thread gage and counterbore. Produc- tion — 280 per 8 hr. Note — The shells are now inspected all over and divided into three weight classes: 12 lb. 1 oz. to 12 lb. 4 oz., 12 lb. 4 oz. to 12 lb. 8 oz., and 12 lb. 8 oz. to 12 lb. 12 oz;; these weights are then averaged in the loading process. OPERATION 15. SANDBLAST Transformation — Pig. 89. Number of Operators — One. Description of Operation — The operator lays a row of shells on the special bench, Pig. 83, with open ends out, pulls the hinged cover nearly down and thrusts the end of sandblast nozzle into hole in shell, sandblasting the interior to remove scale. Apparatus and Equipment Used — Paxson-Warren sand- blast equipment, using No. 5% chilled-steel shot, made by Globe Steel Co., Mansfield, Ohio; 80 lb. air pressure, with %-in. diameter nozzle outlet. Gages — None. Production — 3000 per 8 hr. FIG. 83, SANDBLASTING APPARATUS FIG. 84. PRESS FITTED FOR HYDRAULIC TESTING [38]' OPERATION 16. HTDRAULIC TEST Description of Operation — Case is placed in a vise, and a plug is screwed into the end to make it water-tight; the case IS then placed in a special fixture, Pigs. 84 and 90, in a 1500- ton heading press; the pressure applied is 350 tons, or 20,000 lb., per sq.in. Apparatus and Equipment Used — 1500-ton head- ing press; pressure pump; testing fixture, Fig. 90; triplex chain drop; common vise. Gages — None. OPERATION 1. PAINTING INTERIOR BY HAND Transformation — Fig. 91. Number of Operators — Two. Description of Operation — Operator pours case full of Cebal- ine anti-acid paint up to threads, then pours it out and sets case in raolc, base down, to drain a minute or so; second oper- ator takes a drained case" from rack and wipes end and threads with waste, and places it in truck box to dry; paint dries rapidly in about 1 hr. Apparatus and Equipment Used — Cans of paint, pans, draining rack, waste. Fig. 92. Produc- tion — 1200 per 8 hr. OPERATION 1-A. PAINTING INTERIOR WITH A SPRAT Transformation — Pig. 91. Number of Operators — One. Description of Operation — Using the spraying apparatus. Pig. 85, the operator thrusts the nozzle inside a shell, presses the valve lever and sprays the inside to the threads; he then shuts the valve and withdraws nozzle. Apparatus and Equipment Used — Eureka spray and Cebaline anti-acid paint. Production — 10 per min. OPERATION 2. WEIGHING Number of Operators — One. Description of Operation — Operator places case on scale platform, weighs it and chalks weight on side, Pig. 93, then places piece in tote box, ready for elevating truck. Apparatus and Equipment Used — Small platform scale. Production — 1600 per day. OPERATION 3-A. FILLING WITH TRINITROTOLUOL Transformation — Pig. 94. Number of Operators — Three in gang for filling and compressing. Description of Operation — A complete fuse and base cover are kept on platform of scale; first operator weighs out enough trinitrotoluol in a tin con- tainer to bring total weight of case, fuse and base cover to 15 lb.; he then pours the trinitrotoluol into case on holding PIG. 85- INTERIOR PAINT-SPRAYING OUTFIT PIG. 86. PILLING WITH TRINITROTOLUOL FfG. 87. COMPRESSING THE TRINITROTOLUOL FIG. 88. HOLDING FIXTURE AND RAMMER [39] block and rams down powder with brass rammer and heavy rawhide hammer; load is then compressed in hydraulic press; in case of a light-weight shell, more powder is added and again compressed, in some cases several compressions being necessary to get enough powder in to bring weight high enough. Apparatus and Equipment Used — Small platform scale, rawhide hammers, brass rammer, holding blocks. Fig. 86. Production — 320 per day. OPERATION 3-B. COMPRESSING THE TRINITROTOLUOL Transformation — Fig. 95. Machine Used — Riehle 40,000-lb. hydraulic press. Number of Operators in Gang — Three. Punches and Punch Holders — Bronze ramming punch, Fig. 96. OPERATION 4. REAMING FOR FUSE CASE Transformations — Pigs. 103 and 104. Machine Used — Small lathe. Fig. 97. Number of Machines per Operator — One. Cut- ting Tools — Reamer, Fig. 105. Gages — Stop collar on reamer. Production — 1200 per 8 hr. OPERATION 5. CLEANING THREADS AND COUNTERBORB Number of Operators — One. Description of Operation — Operator places case on revolving fixture. Fig. 98; cleans threads and counterbore with hook tool and scraper; then wipes with waste soaked in benzol and finally wipes with dry waste. Apparatus and Equipment Used — Fixture, Fig. 107.. Production — 350 per 8-hr. day. FIG. 97. REAMING FOR FUSE CASE FIG. 98. CLEANING THE THREADS FIG. 99. PAINTING THE OUTSIDE FIG. 100. PUTTING IN FUSE AND BASE COVER FIG. 101. PRESSING ON BASE COVER WITH TRACER PIG. 102. PLANISHING THE BANDS Description of Operation — Second operator takes filled case and puts in hydraulic press; third operator then operates valve levers from outside of "bombproof," as soon as second operator is outside, and watches operation of press ram from a mirror placed as shown in Fig. 87; about 30 sec. is required for ram stroke each way; the punch is forced in 4% in. from end of case, which is 4% in. -|- %-in. allowance for end of detonator fuse. Pressure Required — Pressure varies according to amount of trinitrotoluol needed to bring weight of case to 15 lb. ± 2% oz.; on cases weighing 12 lb. 2 oz., about 24,000 lb. pressure is required; from 12 lb. 4 oz. to 12 lb. 6 oz., 14,000 lb.; 12 lb. 14 oz., 8000 lb.; as a rule, 12-lb. 2-oz. cases are considered too light, as the pressure required to force in enough trinitrotoluol makes the work too dangerous. Special Fixtures — Case-holding fixture, Fig. 88. Production — 320 per day. Note — The bombproofs in which the presses are placed are of concrete about 7 ft. wide, 9 ft. long, 10 ft. high, with walls 1 ft. thick. OPERATION 6. PAINTING OUTSIDE Transformation — Pig. 108. Number of Operators — One. Description of Operation — Operator chucks case in small lathe. Fig. 99, fitted with split centering chuck, pushing butt end in as far as the rotating band will allow; he then starts lathe, which runs 240 r.p.m., and applies paint with wide brushes. Apparatus and Equipment Used — Black, red and gray paint; three brushes to suit. Production — 350 per day. OPERATION 7-A. PUTTING 'IN FUSE (WITHOUT NIGHT TRACER) Transformation — Pig. 109. Number of Operators — One. Description of Operation — Operator puts case in vise and sees that reamed cavity is clean and deep enough; if not, he puts m a reamer and pounds and rotates it until of the desired ^'/''L ".,**^^ threads are tight, he retaps them; the threads of the detonating fuse are greased with cosmoline, and it is [40] Fie. 103 Hclefor fl/87gK/g/' No4 Morse - f r+ 1 Tape rPin ; 'h ' Taper as75^. „ , raws' , qfeX — Ji 1 "" ir_ J STEEL(Haraer\0.65 \^0.5i\<-- V 4.6"- ^v- 1 J'Hm-SPEED SWELfHarden) I Finishj:±0.00^,nnish Cutting Edges Jg j \ Fie. 121 "^ ^ i§; h k- o" i J -H D/am.-^ 5" 16 <- i ^ ! i FIC I -H 0.5" i<- I k — - /.^'^ >l FI6. 125 FIG. 128 -4" ■■Z79S" j>|- -asos"- ->|| rx^ OPERATION J FIG. 129 ■--0125' OPERATION 1. CUT PROM TUBING (COPPER) Transformation — Fig. 115. Machine Used — 15,000-lt). ad- justable-stroke crank press. Number of Operators per Machine — One. Special Fixtures — Shearing- attachment, Fig. 116. Gages — Maximum and minimum width, Fig. 117. Pro- duction — 3000 in 8-hr. day. OPERATION 2. ANNEAL, Number of Operators — Three. Description of Operation — Bands are placed 1000 at a time in a large pan; four of these pans are put into furnace and heated for % hr. to about 1200 deg. F. ; they are then placed on trucks and run out into the air to cool. Apparatus and Equipment Used — Annealing pans, truck, furnace. Production — 40,000 per S-hr. day. OPERATION 1. DRILLING, COUNTERBORING, TAPPING Transformation — Fig. 120. Machine Used — Brown & Sharpe automatic. Number of Machines per Operator — Three. Cutting Tools — %-in. twist drill (drills in i| in. for counter- bore); Ji-in. twist drill; combination reamer and counterbore. Fig. 121; tap. Pig. 122; circle chamfering tool, 3 in. in diameter; circle cutoff tool, 3 in. in diameter by 0.10 in. thick. Cut Data — 1200 r.p.m. for all but tapping; 530 r.p.m. for tapping. Coolant — Zurn cutting oil. Gages — Depth of drilled hole, Fig. 123; maximum and minimum reamed diameter plugs, Fig. 124; depth of counterbore feeler, Pig. 125; maximum and minimum diameter counterbore. Fig. 126; diameter of thread. Pig. 127; depth of thread, Fig. 128; maximum and minimum length. Fig. 129. Production — 800 per 8-hr. day. Note — Made from hard- rolled brass rod, %-in. diameter ±0.005; tools are used in order given. OPERATION 3. PICKLE Number of Operators — Two. Description of Operation — Bands are put in baskets and pickled in 1 part vitriol and 6 parts water until scale is removed and pieces are brightened. Production — 8000 per 8 hr. OPERATION 4. "WASH Number of Operators — Two. Description of Operation — Washed well in cold water to remove pickle solution. Appa- ratus and Equipment Used — Basket and tank. Production — - 8000 per day. Note — Pickling and washing tanks are side by side, and a basket of pickled bands is simply hoisted out of one tank Into the other and, after washing, suspended a short time to drain. OPERATION 5. PLANISHING Transformation — Fig. 118. Machine Used — 15,000 lb. adjust- able-stroke crank press. Fig. 102. Number of Operators per Machine — One. Special Fixtures — Fig. 119. Gages — Maximum and minimum. Fig. 117. Production — 3000 per 8 hr. Turning of the bands is done on either a special ma- chine or a lathe, as shown in Figs. 61 and 63. On the lathe two tools are nsed in the same slide. One roughs off and edges the band, and the other finishes it, being guided by means of a profile block and follower at the back. A final dressing is given with a mill file. On the special machine, the band is roughed off with one tool and then finished with a form tool. A tool rest is then dropped in place and the band smoothed up with an end scraper. Following this the threads and counter- bore are carefully sized, as shown in Fig. 63. This oper- ation, however, is not always necessary and is only done when needed. [43] IKHHJ-tHHW-U-'^tHl-iJ-tKHHj-lHl-tC i. ■I 0375"k K FI6.I30 ffd/ust/ng /IScrews -isos"-- ■■■ ■€ ^ ^ -Hik- FIS.I33 Fie.l3l OPERATION 2 (< 3? >i h-r- '5 Threads per Incfi, Left Hand, US. Standard FIG. 132 OPERATION 2. FACING END AND THREADING Transformation — Fig. 130. Machine Used — Turret lathe, Fig. 131. Number of Operators per Machine — One. "Work- Holding Devices — Collet chuck. Cutting Tools — Facing tool; die to cut 0.625 ( + 0.000, — 0.004) diameter, 18 left-hand U. S. Standard thread. Cut Data — Speed, 850 r.p.m. Coolant — Lard oil. Gages — Maximum and minimum thread gage. Fig. 132; length gage. Fig. 133. Production — 1200 per 8-hr. day. OPERATION 1. PUNCHING INNER DISK Transformation — Fig. 134. Machine Used — Small punch press. Number of Operators per Machine — One. Punches and Punch Holders — Fig. 135. Dies and Die Holders — Fig. 136. Lubricant — Mineral oil. Production — 'About 75,000 per 8 hr. Note — Press flywheel runs 70 r.p.m. OPERATION 2. PUNCHING OUTER DISK Transformation — Fig. 137. Machine Used — Small punch press. Number of Operators per Machine — One. Punches and Punch Holders — Fig. 138. Dies and Die Holders — Pig. 139. Lubricant — Mineral oil. Production — About 75.000 per 8 hr. Note — Press flywheel runs 70 r.p.m. OPERATION 3. TURNING IGNITION TUBES Transformation — Fig. 140. Machine Used — Brown & Sharpe automatic. Number of Machines per Operator — Three. Cut- ting Tools — Drill; countersink; formed tool; cutoff tool. Cut Data — Spindle runs 2400 r.p.m. Coolant — Zurn Cutting oiL Gages — Combination, Fig. 141. Production — 3500 per 8 Ur. Note — Made from ^-in. diameter brass rod. OPERATION 4. Transformation — Fig. MILLING IGNITION TUBES 142. Machine Used — Hand miller. Number of Operators per Machine — One. Work-Holding De- vices — Miller vise and formed jaws. Fig. 143. Cutting Tools — Milling cutter, 1% in. in diameter, 20 teeth. Cut Data — Cutter runs 600 r.p.m. Production — 4000 per day. OPERATION 5. ASSEMBLING IGNITION TUBE TO OUTER DISK Transformation — Fig. 144. Number of Operators — One. Apparatus and Equipment Used — Bench riveter. Pig, 145. Production — 1600 per 8 hr. TOOL STUi \ FinishftOWS' ~ -^ Harden 5+0 o L, .3;'. J MACMmeSTCEL PnishfiaOOZ" 0.l5"xO.}75'3t'd.Niaterhead Steel Screws Stripper FIG. 136 OPERATION 1 , aeBkrStcl. ShelSe/screws QSS'HZ5"SmSfeelSelscrms CASrmoNtaOf Die Holder [44] The next in order is a thorough inspection of the en- tire case by a group of regular inspectors who also divide ihe shells according to weight, after which the inside back ■of the threads is sandblasted, as shown in Fig. 83. The shells are laid in a row on a wooden grating, open ends cut, and the operator thrusts the sandblast nozzle into each in turn. This, thoroughly cleans out the part of the cavity that has not been machined. The hydraulic testing is. done in the apparatus shown in Pig. 84 and in detail in Fig. 90. The test is an ex- ternal one, a plug being screwed into the base to make it water-tight ; then the shell is hoisted into the testing cyl- inder by means of a chain block hooked to a screw-eye in the base plug. The testing cylinder slides on ways, so as to be moved from loading to testing positions under the press ram. The moving of this testing cylinder is accomplished by the operation of a small hydraulic cylin- der at the back of the press, the connecting-rod of which is coupled to the cylinder, as can be seen in Fig. 84. Af- ter the cylinder, full of water and with the shell inside, is in place under the press ram, the ram is lowered and pressure applied until it is equal to 350 tons, or about 20,000 lb. per sq.in. on the surface of the shell. This test shows whether there are any flaws, weak spots or blow-holes leading into the interior. The first operation directly connected with the loading of the explosive charge is painting of the interior with acid-proof paint, the various loading operations being in the following order : 1. Painting interior by hana 1-A. Painting- interior with a spray 2. Weighing 3-A. Pilling with trinitrotoluol 3-B. Compressing the trinitrotoluol 4. Reaming for fuse case 5. Cleaning threads and counterbore 6. Painting outside 7-A. Putting in fuse (without night tracer) 7-B. Pressing on base cover (with night tracer) 7-C. Screwing in night tracer Painting of the interior may be done in either one of two ways : By hand, using the outfit shown in Fig. 93, or with a spray, using the apparatus shown in Fig. 85. The hand method is slower, but may be used where a spray i.s not available or when it is out of order. The operator fills the cavity to the threads with paint and pours it out. SHEETBfiASS aoe5i"fhick ■ \^-0.l49" III III! Ilil liiji; iP 'Hli<' " I 0) Y°-^i5"-\ Q CiS'TapStd. V>0.69"'\' to 1. -^O © O FIG. 140 -*| aSl' \'-Rsam\ *1 ■^1 r- TOOL'STEEL MACHINE STEEL Finish ftO.Ol" 0.25'i'l.25"Std.Headles5Steel Setscrews 025'^a5"5ld.Headless Steel Sehcnws ^-ae5f±ao[e'-^-o.352°±aoo?'^^ Finishf+aOOtlHarden „ ■•i'Y^/ieam ' a/87 f^) Ream \'0.5/"<\ -A W-0.17" Outer Disk Die FIG. 139 MACHINE STEEL Finish f ±0.01", CaseHarden Fie. 141 FI0.I43 I-. - -. 0.5l"Diomr FIG.I44 [45] OPERATION 1. LOADING ILLUMINATING POWDER Transformation — Fig. 146. Number of Operators — Three, Description of Operation — Tracers are filled and mixture com- pressed in a bombproof with the same type of Riehle press used for trinitrotoluol loading; tubes are first filled with illuminant powder and placed 10 at a time in the fixture showa in Fig. 147 and given 40,000 lb. total pressure, equal CO 4000 each; this is repeated three times. Apparatus and Equipment Used — Riehle hydraulic press; holding fixture and OPERATION 5. TRIMMING END Transformation — Fig. 153. Machine Used — Small turret lathe. Number of Operators per Machine — One. Work-Hold- ing Devices — Collet chuck. Cutting Tools — Pig. 154. Cut Data — Spindle runs 350 r.p.m. Production — 2000 per day. Note — Tracer is chucked and end of tube faced oft until about 0.002 in. from outer disk; inside of mouth and disk is then coated heavily with nonacid paint, except opening in ignition tube: complete night tracer is shown in Fig. 155, ' 7/////^< ruV'L'-UA.-u"v>?i, V/A ■,.--. ^ . ■7 - ■ : . - " ■: ^^r"- ^^.'T^.'- s^'riii^-^^^^':'?^. iti^^S^"^*^ OZ k-C^'-H ■K"--'-i;'-^l"--:i'^C"^i'':j^v%':^^'VV'-^^'^ ±0Z5\ musT not bz more than 0.5 Inch- FIG. 146 \^ ■>j(7fl<-fl75"->j U -3.37S- SiampName of Fuse, Part, Operation, Place of Manufacture and Date f Year) \ TOOLSTeafHardenjFinistiftOOl" '°>* ... FirJish Cutting Eddesfa 4grlgnWngFbwder:'^'°'^' pig ,49 Finish Cutting Edgesjg w/y <^^ i^ ' W m^ 'i J- 'i J* m P i/v\aA. J- M T/ iffl ^ Z4-gr Fie. 150 0201'Cbare/ aoiB'' FIG. 153 0635 Dian -^ 3"Deep^ \^—-a5'iO.OOl"—A -'Oi>LSTEEL(Harden) FinishftOMS" Pressure 'Punch f FIG. 146 a 147 OPERATION I jt FI6.l48ai49 OPERATION 2 'mis FIG. 150 OPERATION 3 T Fie.l5l8cl5E OPERATION 4 FIG.IS5,l64a:l55 OPERATION 5 FIG. 154 4-gr Igniting Mix ture. X--B3' 167 gr Illuminating Powder ' gr Black Poy^der- pressing punches for 10 tubes; small-handled powder meas- ures or dippers. Production — 1000 per 8-hr. day. OPERATION 2. COUNTERBORING Transformation — Fig. 148. Machine Used — Small turret lathe. Number of Operators per Machine — One. Work-Hold- ing Devices — Collet chuck. Cutting Tools — Counterbore, Fig. 149. Cut Data — Spindle runs 350 r.p.m. Production — 2000 per 8-hr. day. OPERATION 3. LOADING IGNITION MIXTURE Transformation — Fig. 150. Number of Operators — Three. Description of Operation — 4 gr. igniting mixture is poured into drilled and counterbored hole and shaken down; 24 gr. black powder is then poured on top of this and a brass inner disk placed on top of the powder; each tube is given 4000 lb. pressure, using the same fixture as for illuminant; in loading, two holders are used with one set of punches in the press, and they are employed alternately, as the illuminating and igniting powder are loaded in turn. Apparatus and Equipment Used— r- Same as for operation 1. Production — 1000 per 8-hr. day. OPERATION 4. LOADING RETARDING MIXTURE Transformation — Fig. 151. Description of Operation — On top of the inner disk is poured 12 gr. delay mixture; the outer disk is put on, the holes in the two disks being placed on opposite sides; two tubes are compressed at once at 14,000 lb. total pressure, or 7000 each, using the holders and punches shown in Fig. 152. Apparatus and Equipment Used — Riehle hydraulic press in bombproof. Production — 1800 per 8-hr. dav then passes the shell to another, who .wipes the threads with waste. The spray method is far quicker and does not smear the threads so much, as the operator turns on the spray, after the nozzle is inside the shell and turns it off before removal. The weighing of the case is for the guidance of the fillers, the weight being chalked on each shell, as shown in Fig. 93. The fillers work in gangs of three, one fill- ing, one carrying and refilling, and one operating the press. These operators shift positions or help on the different opei-ations, as occasion demands in order to balance the work. The high explosive, or trinitrotoluol, is a yellowish- white powder not dangerous in the ordinary sense, until compressed; but when compressed and fired by means of a detonator, it is one of the most powerful explosives known. [46] Compressing the trinitrotoluol is done with a hydraulic press placed in a concrete bombproof room, the oper- ator watching the actual work by means of a mirror, as shown in Fig. 87. A shell in the holding fixture with the punch or rammer ready to descend is shown in Fig. 88. The rammer presses the explosive solidly into the shell and leaves a cavity for the insertion of the detonator. This cavity afterward has to be reamed out to size, which is done as shown in Fig. 97. The reamer is held in a chuck and passes over two jaws of a steadyrest, which not only steadies the reamer, but acts as a stop' for the depth of the cut. Fig. 105 shows a stop collar on the reamer, but in the actual shop practice this is no longer used. The operator places a shell on the guiding block and presses it forward onto the revolving reamer until the end of the shell contacts with the steadyrest Jaws. After being reamed out, the threads and counterbore have to be cleaned. This is done by placing the shell on the fixture shown in Fig. 98 and using the hook tool there shown to clean the threads as the operator rotates the shell by hand. The counterbore is scraped out with a scraper made from an old file. Following these operations the shell is painted from point to band, while held as shown in Fig. 99, the operator applying the paint with wide brushes. The detonator fuse is next screwed in, with the shell held in a bench vise. Fig. 100. A detonator is shown at A. If the threads are a little tight, a tap B is run in. If the hole is not quite deep enough or has not clearance enough, it is made larger by pounding and rotating the reamer C in the hole. With everything clear, the fuse is screwed home vnth the spanner J) and locked to the notches in the shell with a punch and hammer. In case no night tracer is to be used on the shell, lead plugs are pounded into the spanner holes, and a sheet-metal cover E is put over the end with the edges in the cover groove. A calking lead ring F is then pounded into the groove as indicated in Fig. 109. Where a night tracer is used, the fuse is put in in the same way, the lead slugs are pounded in, the special cover put on and a lead ring put in place. This ring, however, is not pounded in as previously described, but is pressed in as shown in Fig. 101, the process being graphically shown in Figs. 112-A and 112-B. Screwing in of the night tracer consists in placing the tracer in a vise and screwing the shell onto it by hand. Making the Band Operations on making the copper band are as follows : 1. Cut from tubing 2. Anneal 3. Pickle 4. Wash 5. Planish - The list of operations is almost self-explanatory; the details, however, are given under the proper headings. The last operation, planishing, is really a sizing for width, as the band is pressed between two flat dies, as shown in Fig. 102. Making Night Teacek 1. Drilling-, counterboringr, tapping 2. Facing end and threading Night tracers are made from brass rod in automatic screw machines; the order of procedure is as given above and is the usual standard screw-machine practice in every way. Facing and threading of the closed end is done in a hand screw machine. Making Night-Teacee Disks 1. Punching inner disk 2. Punching outer disk 3. Turning ignition tubes 4. Milling ignition tubes 5. Assembling ignition tube to outer disk The making of the disks is a punch-press Job, as shown by the punches and dies. Figs. 135, 136, 138 and 139. The ignition tubes are made on automatic screw machines from brass rod and are milled off at a sharp angle on the outer end in a hand miller. The assembling of the ig- nition tube to the outer disk is done by hand, and then the tube is riveted fast in the disk in the bench riveter, Fig. 145. Loading Night Thacee 1. Loading illuminating powder 2. Counterboring 3. Loading ignition mixture 4. Loading retarding mixture 5. Trimming end The loading of the night tracer with the illuminating powder is done in a hydraulic press, using the holders and punches shown in Fig. 147. Several fillings and press- ings are needed to complete the work. After the illumi- nating powder has been pressed in, it is machined out at the open end of the tracer in a small turret lathe, using the combination drill and counterbore. Fig. 149. The object of drilling into the illuminating powder is to give the ignition mixture a better chance 9f surely doing its work. The ignition mixture is next put in and the inner disk pressed in. On top of this a slow-burning powder is placed, and then the outer disk is pressed in. Finally, the end of the tracer is faced off -(vith the tool shown in Fig. 154. The tracer is now ready to be screwed into the base of -the shell. It may be noted that the thread on the base of the tracer is left-hand, so that there is no tendency to unscrew as the shell is fired from the gun. [471 Three-Inch United/S^tes Navy^Projectiles By Lieut. A. G.Dibrell * r ?< SYNOPSIS — Shells of the size described here are required in large nurnbers for use in guns placed on destroyers or on boats of the type hnown as submarine chafers. These shells differ considerably from the S-in. ones used in field guns or coast artillery, which have been previr- ously described. The various machine operations are given with considerable detail. The manufacture of munitions in navy yards, an ex- perimental enterprise, inaugurated last year, has proved signally successful at Puget Sound. As a general propo- sition in peace times, the Government unquestionably is wise in giving such contracts to private individuals, there- by releasing its own plants for the more important repair work on ships. But the Government should nevertheless be able to perform any class of work necessary for the proper supply of the fleet in all its essentials and have definite information at , 7«/' hand for the use pf individ- uals, should an emergency arise. In the machining of projectiles there is a great amount of preparatory work necessary — special-tool man- ufacture, gage manufacture and the equipping of ma- chines — before the projec- tiles can be properly and economically machined. Ev- idence of this has been ob- tained in every munition plant visited. Hundreds of rejected shells were seen, most of which were made during the early stages of the shops' contracts. This was owing to the fact that the manufacturers had only drawings and specifications to guide them in the selection of necessary machines and equipment. The Government - should furnish the American manufacturers with con- FIG. 1. •United States Navy, Submarine Division. Crete actual working examples of all the minute details necessary for the proper and efficient manufacture of munitions. Owing to the great number of 3-in. shells that will probably be required to supply the submarine chasers and patrol boats now building, a description of the method adopted at Puget Sound is here given. The machines used are common to all shops, and it is hoped that this description will enable private individuals to equip their plants and be ready to start the work of machining as soon as forgings are rer ceived. Fig. 1 gives the di- mensions of the 3-in. forg- ings furnished the navy yard by the American Car and Foundry Company. A radial drill is equipped for the first operation for the 3-in. shells. The chuck shown in Fig. 2 is a universal three-jaw lathe chuck. In the base of the chuck is a center point. The female center shown in the nib on the point of the rough forgings fits over, this male point. The jaws of the chuck are then set up to hold the forging, while the small hole in the base is drilled out to If in. in diameter. The center in the nib is con- centric with the cavity of the forging, and the method of chucking and drilling the fuse hole in the base of the shell brings this hole also concentric with the cavity." The DETAILS OF UNITED STATES NAVY THREE-INCH COMMON PROJECTILE [48] Jaws of the chuck grip the shell about SJ in. from the base. The surface of the forgings is somewhat distorted by the dies in closing in the base, and the chuck must grip below Ihis part of the forging. The swinging arm carrying a hardened bushing is closed to engage a perma- nent stop and fastened in place by a wing nut, as shown. FIG. 5. TURNING BASE AND BAND SCORE A Jf-iii. twist drill running at 280 r.p.m. and with a feed of 0.008 in. is used to enlarge the hole. This permits the gage rods, shown at A and C, Fig. 3, in operation 2 to enter, and also removes rough stock for chasing the threads for the fuse. The lubricant is soap-water com- pound, which has proved very satisfactory for this work. OPERATJON Z 5IZ£5 ON BAND 5WREAIi£ mr nNI5HE0 BAND XO/fe COMPUTtD ON OPE/fATtOli 8 PIG. 3. ARRANGEMENT FOR OPERATION 2 Two machines are equipped for performing the second operation, as this operation requires the greatest amount of time to complete. A 16 x 20 x 1^-in. Warner & Swasey belt-driven turret lathe and an 18x24x3-in. Jones & Lamson belt-driven turret lathe are used. Fig. FIG. 4. TURNING BASE AND BAND SCORE 3 shows the Warner & Swasey lathe fitted for performing the operations. The forging is held in a collet chuck of six segments, separated by small springs, and each segment is knurled to give a better grip. The forging is first tested for eccentricity by means of the indicator A. The finger travels back and forth on the walls of the cavity and moves the pointer along the grad- uations shown. If the movement of the point- er exceeds the limits of the graduations, the forging will not clean up and is marked and set aside. The base of the shell is next faced off by the tool B on the turret head at- tached to the crossfeed to suit the gage G on the lathe turret. This establishes the dimen- sion 7.42 in. from the nose of the cavity to the face of the base. About 3 in. of the base is next turned to a diameter of 2.995 in. by the tool B, finished by the tool E to 2.980 in. and the band score cut to a diameter of 2.850 in. and 0.630 in. wide by the tool ¥. The tool G rounds the base to the fillet shown on the drawing. The stop B. is set for the tools I), F and G. This machine is shown in Fig. 4 ; the view of the shell A on the lathe turret and B, Fig. 11,, show the machining done. The turret head at- tached to the cross-slide is an ordinary square tur- ret head holding tools at the corners. The lubri- cant used in this opera- tion is a compound of soap and water. The cut- ting tools are all of tung- sten tool steel. The Jones & Lamson turret lathe, Fig. 5, works continu- ously on operation 2, the tool layout being shomi in Pig. 6. All selective gear is removed from the spindle drive, and a single back-gear shaft is in- stalled. The forging is gripped in a draw-in collet chuck, operated by hand lever, the female center hole in the nib &f the f org- ino- fitting over a male center point at the rear of the chuck. The depth of the chuck allows about 3^ in. of the forging at the base clear for machining. The diameter at the base is rough turned by the tool A at 45 ft. per min. speed, 0.01-in. feed and ^^-in. cut. (Where fins have been left by the closing-in die at the base, the depth of cut is more than ^^ in.) The turret is indexed one position, a straight gage rod is inserted in the base hole. FIG. 2. DRILLING CENTERS [49] and the forging is faced off at the base by the tool B the correct length, which in this case is 7.042 in. from the srctreme point of the cavity in the shell. center supported through the turret hole, suitably ar- ranged for quick disengagement when the work is un- chucked. The roughing cut is taken over the body forward of the band score to the bourrelet, as shown in Fig. 8 and at C, Fig. 11. Two tools are used in the special carriage mentioned above to shorten the distance of tool travel. A speed of 55 ft. per min., -^J^-in. feed and (\ Gages — Maximum and mini- mum ring gage diameter of band; profile and position of band. OPERATION 11. WASH IN HOT SODA Equipment Used — Pair of tongs. OPERATION 12. PAINT INSIDE ■^oogl-oslaof M' Head filler: yF£W Matrix miNANOmE WHITE COMMEKIAL NAPTHALENE (Not Crystallized). Stopper ,6Uhl COTTON J in?5"K Case STEEL Y'lSffrhckUS W5l' ■W5R. , 5 Notches %fb"''"^'!^'f\-\IJZX% 'Q|5 / Q2S^i l< IS Xi-m'r^-if^-- m- Slightly moisten these Joints with Cosmolene Sty. Thread <^STEEL.Enish^W5^--^^S% ^ ^ 5| Washer ,^ STEELmS^ •■■© ^-a :^ Lock Rn |'|"& X-MPerhck US STEELfinish/tOm" Section of Band Diaphragm 5TEEL,iW5" Retainer BRASS T. — ^ Inner Tuloe COPPERmi" Form of Scores -i^^'i^ -''fSiY'-mos ^ gg^ Band COPPER [56] ui J ■"* ^ iTLcL/ir, Washer JTZZZ^i?!!^-" DiapViragm smmo5° [57] Opekatioxs ox the Head After the head has heen rough-machined, it is assem- bled to the case, as the iifth operation on the case. The Lead and bourrelet are then Jinisli-turned. OPERATION 1. MACHINE FROM BAR Tools and Fixtures — Set of chuck pads and bushings; feed shell pads and bushings ; stop ; twist drill ; drill holder ; set rough grooving tools; set rough combination grooving tools; holder; set finish grooving tools; combination counterbore and reamer; collapsible tap and chasers; double-end flat forming tool; cutting-ofE tool and suitable holders. Gages — Length and diameter of thread; length from front to thread; inside diameter of crimping wall; maximum and minimum thread plug; depth of groove; length over all. OPERATION 2. COUNTERSINKING Tools — Chuck; beveling tool. Gages — Diameter and profile of fuse-seat bevel; minimum diameter of fuse seat and fuse- seat thread. OPERATION 3. THREAD AND CRIMP IN STEEL WASHER Tools — Chuck ; crimping tool ; circular thread cutter ; leader and follower. Gages — Maximum and minimum thread ring. Pre5S Mefatof Fuse info Notch for Loci Inxee Tube operation 1. machine . Tools — Stop; 60-deg. countersinks; belling tool; chamfering tool; cutoff tool. Gages — Combination length and diameter of bell. Central Tube operation 1. machine Tools — Reamers for inner-tube seat; 90-deg. countersinks; cutoff tool; chamfered tool. Gages — Length; combination depth and diameter; inner-tube seat. Washee operation 1. punch Tools — Punch and die. DiAPHEAGM OPERATION 1. DRILL AND COUNTERBORE Tools — Special chuck; twist drill; counterbore; counter- sink and holders. Gages — Maximum and minimum plug; diameter of counterbore; depth gage for counterbore; maxi- mum and minimum ring; outside diameter. ■SJZS-- I Slighfly moisten fliese Joints with Cosmolene , I Y-—2.08"-^—- V - --- -7I.55- Assembly X''~'^ IdPerlnchMS. 02^ \^a8-A 5fU Thread >\^a/ff' UPerlnckUS^ 5fd. Thread \ Q2J ^^■■45" 6a se Cover emss i0.005" Fuse Hole Plug DIE CAST WHITE METAL NON comsivE F1G.9 Matrix STEEL Fuse Hole Plug 5TEEL0R BRONZE OPERATION 4. MILL. NOTCHES IN HEAD Special Fixtures — Milling cutter and arbor. OPERATION 5. GROOVE FOR WATERPROOF COVER T„.„T?°'^~^°''®'^t chuck; special lathe tool. Gages— Water- proof-cover scratch gage; position of waterproof-cover groove OPERATION 6. PAINT INSIDE HEAD OPERATION 7. PUT IN RETAINER AND FILL HEAD OPERATION 8. CUT OUT SURPLUS RESIN Tools — Special chuck and right-hand side-facing tool. OPERATION 9. COAT THREADS WITH COSMOLINB OPERATION 10. REASSEMBLE HEAD TO CASE Tools — Special wrench. OPERATION 10-A. INSERT INNER TUBE Tools — Punch. OPERATION 11. PIN HEAD TO CASE Tools — Drill chuck; twist drill; fixture for holding case. operation 12. final inspection Locking Pins (Bae Stock) operation 1. machine Tools — Stop; cutoff tool; form tool. Gages — ^Length. Eetaixee OPERATION 1. MACHINE Tools — Stop; cutoff; chamfer tool. Gages- -Length. OPERATION 2. HEAT-TREATMENT, 1600 DEG. F. OPERATION 2-A. PLACE IN COTTONSEED-OIL BATH OPERATION 2-B. RUMBLE IN HOT SALT TO REMOVE SCALE OPERATION 2-C. HOT SALTPETER BATH, 900 DEG F OPERATION 3. REMOVE SCALE FROM COUNTERBORE OPERATION 4. GRIND BASE OPERATION 5. PAINT BASE OPERATION 6. ASSEMBLE TUBE Special Fixtures — Centering fixture! Gages — Length. Loading OPERATION 1. INSERT DIAPHRAGM IN TUBE OPERATION 2. FILL CASE OPERATION 3. COMPRESS BALLS rr^^i OPERATION 4. CUT OUT SURPLUS RESIN -Depth ''^^''^'^ chuck; steady-rest; resin cutter. Gages The 4.7-In. Common Sheapnel (60 Lb.) A dimensioned forging of the 4.7-in. common shrapnel is shown in Fig. 4, and a dimensioned case is given in 5. The complete projectile is illustrated in Fig. 6. Fig [58] The operations, tools and gages are of practically the same type as for the 3.8-in. size. The 6-In. Common- Sheapnel (120 Lb.) In Fig. 7 is a dimensioned forging of the 6-in. common shrapnel.' A dimensioned case is shown in Fig. 8, and the complete projectile is illustrated in Fig. 9. The oper- ations, tools and gages are of the same type as for the preceding sizes. The 3.8-Iisr. Common Steel Shell, Model 1905 Fig. 10 shows a dimensioned forging of the 3.8-in. common steel shell, and a dimensioned case is presented form for point; follower. Gages — Combination snap maximum and minimum rough diameter of bourrelet; projectile profile; profile of point. OPERATION 4. MILL. THREADS IN BASE Tools — Thread milling cutter; arbor; spring chuck. Gages . — Maximum thread plug; minimum thread plug and eccentric- ity of counterbore. OPERATION 5. MACHINE BASE-COVER GROOVES Tools — Toolholder (fixed spindle); four roughing tools; toolholder; fixture on cross-slide with finishing tools; finishing toolholder and two tools. Gages — Inside diameter working gage; diameter depth and width. OPERATION 6. HEAT-TREATMENT (A) Heat in furnace; (B) cottonseed-oil bath; (C) heat in lead furnace. OPERATION 7. FINISH-GRIND BOURRBLBT Tools — Electric grinder; special chuck; steady-rest. Gages — Maximum and minimum ring diameter of bourrelet. OPERATION 8. ASSEMBLE BANDS Tools — Banding dies; tongs; gas furnace. t<- ■M./3±aJi' — - f7/}/s/i outside f. Rough insick except r/kre marked f Cocrt inside with non-acid paint except Ythere marl| ,^J.,Coatwitha,smte„ebefi,r. assemUm )<-wo">\ Y-aB" \,.-tnhreads per Inch, Lefi Hand, US Standard-.^ 3 notches equally spaced. Force fuse metal into notches « H-)<.ff ^ Weight Q791b Steel "■ ass lb. Bronze fas"AUo.i" i<-l.45''-4 Die castflfhite Metal) non-corrosive, iOOf ■Fuse-Hole Plug "nG.li STEEL OR BRONZE Fuse-Hole Plug in Fig. 11. The operations are practically the same as for the 4.7-in. shell. The 4.7-In. Common Steel Shell, Model of 1905 From Fig. 12 may be obtained the dimensions of the forging for the 4.7-in. common steel shell, while Fig. 13 shows a dimensioned case. OPERATION 1. ROUGH- TURN BODY Tools — Universal chuck; revolving center; right-hand lathe turning tool. OPERATION 2. MACHINE INTERIOR AND EXTERIOR OP ^ BASE AND FINISH-TURN BODY Tools — Chuck pads; combination counterbore and reamer; recessing tool; circular form tool; knurling tool; right-hand lathe turning tool and holders. Gages — Depth of cavity and warp; base plug flange seat; maximum and minimum ring diameter rear of band; combination snap diameter band seat; position of band seat and crimping grooves; combination snap diameter of body; position of grooves; length of base to bourrelet. OPERATION 3. FINISH-TURN POINT AND ROUGH-TURN BOURRELET Tools— Special chuck; steady-rest; left-hand lathe turning tool; former rear of cross-slide; extension bracket and roller; OPERATION 9. TURN BANDS Tools — Special chuck; steady-rest; right-hand side-facing tools; band-turning tool; special stop; form and follower rear of cross-slide. Gages — Maximum and minimum ring diameter of band; position and profile of band. OPERATION 10. HYDRAULIC TEST Equipment Used — 1500-ton heading press with pressure pump; testing fixture; triplex chain drop. Base Plugs operation 1. machine from bar Tools — Stock stop; two twist drills; two drill holders; com- bination floating counterbore and reamer; forming tool; facing tool; cutting-off tool; chuck pads; feeding finger pads and toolholders. Gages — Maximum and minimum plug diameter of small hole; depth and diameter of counterbore; maximum and minimum diameter of flange; maximum and minimum snap diameter of thread; overall length of base; plug and w^idth of flange; length of thread. OPERATION 2. MILLING INTERNAL THREAD Tools — Combination milling arbor and cutter; spring chuck. Gages — Maximum and minimum thread plug. OPERATION 3. CUTTING EXTERNAL. THREAD ON TURRET LATHE Tools — Threading attachment; chuck; screw for chuck; circular thread cutter; chamfering tool. Gages — Maximum and minimum thread ring. [59] u ff/s" 1 mW-''is---4 015 K " I I s& ? Base Plug pompsmafinish fuse Hole Plug WROUeHTIRON Ftnishfmi" FIG. 1 5 ■ Fuse Hole Plug DIECAST WHITE 0ETAL Non-corro5ive-QOl" [60] OPERATION 3. CUTTmo EXTERNAL THREAD ON ^HE 6-In. CoMMON StEEL ShELL Tools— Thread milling cutter; arbor for cutter; spring aj- ■ i i!j.i./>- j.it,ii- chuck. Gages— Maximum and minimum thread. • f e, ^ dimensioned case 01 the 6-in. common steei snell IS OPERATION 4. NOTCH BASE shown in Piff. 14. The operations on this shell are prac- Tools — Fixture; milling- c-utter; arbor. +,-„„n j.1, j; j-i, a iv ■ ■ OPERATION 5. MILLING WRENCH SLOTS ^^^^^^^^ ^'^^ ®^™S ^^ ^^^ ^^^ ^-^-l"^- ^^^S" [61] raon .. erchantmen SYNOPSIS — The necessity that has forced us to either arm our merchantmen or give tip our rights to sail the seas makes necessary the manufacture of shells for the guns to le used on merchantmen. The sinking of the numerous vessels without warning of any kind emphasizes the necessity for arms and ammunition with which to protect our commerce and the lives of American seamen. This article gives in detail the methods used by the navy yard at Puget Sound for making 6-in. common naval shells. Owing to the great demand made upon this country, many shops are now thoroughly familiar with the process of manufacturing British, French and Eussian shells. The United States Navy pro- jectiles differ radically from the army shells of foreign countries and require a de- parture from the methods of manufacture of foreign shells. As the time for shops to get started on this work may he short in case of war, it is be- lieved that a description of a successful method of ma- chining the navy projectiles will make it possible for con- tractors to equip their ma- chines by the time forgings can be obtained. Further- more, the ideas here set forth may enable mechanics in the United States to improve on this method, thereby decreas- ing the cost and increasing the output. There are three essentials in the machining of projectiles : (1) They must be of a certain weight within a very small tolerance, because a standard weight, or charge, Submarfne Division. PIG. 1. ROUGH-FORGING AND FINISHED UNITED STATES NAVY 6-IN. COMMON PROJECTILE 'Unitea States Navy, of powder is used and undue variation in the weight of the projectiles affects the range; (2) the center of gravity must be maintained or the projectile will "tumble" in flight; (3) the projectile must be concentric or it will give an erratic flight, causing wide dispersion. These bal- listic qualities a shell must have; but just how to ob- tain them and keep within all the small tolerances allowed in the dimensions is the me- chanical problem to be solved. Prom experience gained' at the Puget Sound navy yard, and in other shops visited, it may be stated as a general rule that the ordinary tliree- and four- jawed lathe chucks cannot be successfully em- ployed in the manufacture of shells. Draw-in, or pot chucks, collet chucks and expanding mandrels must be used. To save the cost of handling, as many operations as possible .should be performed at one chucking; and where engine lathes are employed turret heads should be fitted to the crossfeed. [62] Kg. 1 gives the dimensions of the rough forging fvir- nished the navy yard, but not the dimensions of the fin- ished projectile. It was assumed that the steel billets would be punched forging is pierced too much out of center or flat on the radius, it is marked and no machine work is wasted on it. The machine consists of a cast-steel stand with two forming in the dies at one stroke. In that case allow- a n c e must be made for the punch running out of true ill a great many forg- ings. Fig. 2 shows the centering and gaging niaehine. This m a c h i n e serves two pur- poses : I'irst, cen- tering the outside of the forging true witli the cav- FlCiS. 2 TO 4. CENTERING GAGE AND THE METHOD )OF DRH^DING THE CENTER Pig-. 2 — View of centering and gaging rig, operation 1. Pjg. 3 — Six-inch pkojectile forging in centering and gaging rig. Pig. i — Drilling center in 6-in. forging, operation 1 ity, for rough-turning the outside, and second, determin- ing whether or not there is sufficient stock in the forg- ing for finishing. If insufficient stock is found, or the columns between which the forging is placed for center- ing and gaging. On top of the column is a swinging arm secured by a handle nut, containing the centering bush- ing. The stop on the back allows the spindle to tilt about 65 deg. for slipping the rough forging over the spindle a Detail of Bushing FIG. 5. EXPANDING MANDREL, FOR HAMILTON LATHE. OPERATION 2 RADIUS-TURNING ATTACHMENT FOR HAMILTON LATHE, OPERATION 2 The weight of the shell on the cone forces the three rollers out against the base of the forging, firmly holding the forging true with the cavity. The forging is thrown back into the frame and the top plate closed. The forg- ing is removed by the forked handle shown. [63] A later development was fitted to offset the forgings when too much out of center for the machine. This con- sists of handwheels on threaded stems operating the base of the spindle and giving an offset of Each forg- revolved on PIG. 7. ROUGH-TURNING 6-IN. FORGING, OPERATION 2 the centering spindle while the movable indicator pins are held against the forging. Should the stock pins, Pigs. 2 and 3, show insufficient stock for finishing, the lines on the indicator pins pass beyond the es- tablished marks. If the forging is good, it is center-punched through the bushing, as shown in Pig. 3, and the bench mark is established on the base of the forging. The forging is then removed and the center drilled in a radial drill press. Pig. 4. The bush- ing in the swing lever has recently ' been enlarged, and the base of the casting is bolted to the press table so that the drilling is done without re- moving the forging from the center- ing machine. This operation has been found necessary, as the points of many forgings dropped in cooling. Poi operation 2, an old 32-in. by 8-ft. Hamilton engine lathe was fitted with an expanding mandrel and a radius- turning attachment. The outside hav- ing been centered with the cavity, the forging may be held on a mandrel for rough-turning. The mandrel was design- ed to grip the inside of the forging firmly, so that it would be rough-turned the entire length concentric with the cav- ity. The mandrel is made of cast steel and fits over the lathe spindle. The forging is gripped by three dog wedges of tool steel, shown at A in Pig. 5, which are held in place by pins and springs, shown at B and C. These dog wedges are forced out by the medium-steel taper spindle shown. The rod screwed into the taper spindle runs through the hollow spindle of the lathe and is operated by a handwheel. The grip is over a length of 3 in., and the shell is further supported by the tailstock in the center drilled in operation 1. In order to obtain a heavy cut and prevent chatter- ing of the tool a positive radius-turning attachment was made for the roughing machine, in accordance with Pigs. 6 and 7. The frame consists of two arms of cast iron secured to the back of the lathe bed, shown at A. The radius arm B is of medium steel on a radius of 45.5 in. and is secured to the tool carriage by a composition G- bolt. In order to remove the metal on the roughing cut as quickly as possible, two tools were fitted ; one to take the straight cut and the other to begin at the bour- relet and take the radius. Marks established on the lathe face- PIG. 9. GISHOLT LATHE FITTED FOR PERFORMING OPERATION 3 plate and a carriage indicator is used for setting each forging correctly. A shell is accurately gaged from this machine once each day to determine whether the tools are properly set and that the forgings- are leav- ing the machine in accordance with instructions. The forging is chucked on an expanding mandrel and accurately set with the tram in the bench mark and the established mark on the mandrel nut. The center line of the radius-turning bar is set 7.03 in. from the bench mark established in operation 1 ; at this point the indicator on the lathe carriage coincides with the established gage on the lathe. With the carriage set in this position, the FIG. 8. DETAILS OP BORING BARS AND BORING HEADS FOR GISHOLT LATHE, OPERATION 3 FIG. 10. CUTTING AIR VENTS IN SINUSOIDAL RIBS, OPERATION i [64] radms-turning cool is accurately set with gages. The tool for turning the straight body is set 10.5 in. behind the radius-turning tool. The base of the forging is then faced off to the bench mark. The forgings are 6| in. in diameter in the rough, and to turn to e-Jjjin. requires a cut of /^ in. on a side. This gives ^ in. to finish. No cutting compound is used in this operation. The cutting tools are made of J x l^-in. tungsten tool steel. A speed of 47 ft. per min. with a feed of V23 in. is used, and it is necessary to sharpen tools about every sixth shell. This operation is also shown in Pig. 7, which is a view taken from the back of the lathe to show the radius attachment. The outside having been rough-machined concentric with the cavity, the forging can now be chucked in a universal pot-chuck for boring the cav- ity. Gisholt turret lathes were the most available for the boring, opera- tion 3, a universal chuck, bolted to the faceplate flange be- ing used. This is a draw-in chuck with a 30-in. wheel, the collet being made in six segments carefully machined. The segments are separated by small springs, which release the forging when the nut is backed off the taper. Fig. 8 shows the special boring bars and cutting heads for the Gisholt turret lathe. The straight head A car- ries the cutting tools for boring, these being made of |-in. square tungsten tool steel. Two heads were made for each bar, so that the cutting tools could be changed amount of metal that the machine will pull. The finish- ing head is shown at C and the finish cutters at D. These cutters leave a clean, smooth surface. The point of the shell is finished by the cutter E. The Cutting Compound In order to obtain cutting compound on the point of the cutting tool f-in. holes (not shown in the drawing) were drilled through the bars, the discharge opening be- PIG. 11. DETAILS OF PLATE FIG. 13. SIX-INCH PROJECTILE FORGING IN BANDING PRESS, OPERATION 5 and a reserve head remain always available. The rough- boring bar removes /^ in. of metal, finishing a hole to 3|^ in. and leaving ^ in. to be removed by the ;finish- ing tool. The forgings are received with an inside diam- eter of 3f in. and must be finished to an inside diam- eter of 4 inches. The roughing.'radius head is shown at B. The cutters are made of ^ x |-in. and ^ x 1-in. tungsten tool steel and the lengths of cutters vary as shown in the illustration. These cutters are designed to remove the maximum PIG. 12. DETAILS OP MANDREL AND EJECTOR FOR BANDING PRESS, OPERATION 5 ing in the heads. A plug was fitted to each bar and the flexible hose connection made by means of a bayonet joint. This is shown in Fig. 9. The cutting compound is a mixture of 2 lb. of borax dissolved in 10 gal. of boiling water, to which is added 2 gal. of boiling lard oil. The tools require changing about once a day or about every tenth forging. Each bar is fitted with an independent stop and these are tested and adjusted once daily. A boring speed of 30 ft. per min. with a feed of Vio in. per revolution is used. In addition to the boring operations a turret head is fitted on the tool car- riage of these lathes to carry tools for cutting the copper band groove, undercutting, cutting the sinusoidal rib and round- ing the base. The band score is first rough-cut to a diameter of 5.8 in.; then the sinusoidal cam is thrown in and the groove finished to 5.7 in. at the bottom. The undercutting is done next and finally the base of the shell is rounded. This requires four tools on the turret head of the tool carriage, these oper- ations being completed during the boring. The sinusoidal rib-cutting cam arrangement is shown in Fig. 9. The cast-iron camplate A is bolted to the face- plate of the lathe, and the cast-iron plate B is fast- ened to the lathe carriage. The medium-steel arm C con- PIG. 14. MARKING BASE,' OPERATION 6 [65] neets the two pieces, the cam motion being positive, by means of casehardened rollers on each side of the cam- plate. Operation 4 consists in cutting air vents in the sinusoi- dal ribs. Pig. 10. The copper band is slipped over the in about 0.015 in. in banding. To prevent this a special mandrel was designed, Figs. 11, 12 and 13. A large hexagonal ^-in. plate A, Fig. 11, was fitted inside of the rams of the press. Through this plate a hole was cut 7 in. in diameter. Underneath this plate are fitted two 12 Threads FIGS. 15 TO 17, GAGES AND METHOD OP WEIGHING FOR OPERATION 7 Fig, 15 — Measure weight and gage, operation 7. Fig. 16 — Details of gage lor operation 7. Pig. 17 — Depth gage usea in operation 7 and gages for base and base plug base and struck a blow vnth a wooden mallet to seat it in the groove, operation 5. Experiments conducted after the arrival of the banding press indicated that the base of the forging was crushed 1 5 |iWllllll((lllll llll|iS iiM -4-3- \'-zi--^ [^^^j 7) KIG, 18, EXPANDING MANDREL, PITTED TO LB BLOND ENGINE LATHES -FOR FINISH-TURNING, OPERATION 8 hinged plates B with lugs sliding in slots cut in the upper plate A. The diameter of the plate B is 5f in. A spring slips over the lugs to hold the plate in place while the shell is being put in and taken out of the press. The spring and the lugs are better shown in Fig. 13. In Fig, 12, A is an expanding mandrel of medium steel which slips into the base of the forging and is forced out against the inner walls by the taper spindle B. PIG, 19. GAGE FOR DETERMINING ECCENTRICITY OP WALLS, OPERATION 8 is a screw bushing which screws into the telescopic sleeve D. The guide for the mandrel is operated by a hand lever. This guide works in the inner sleeve E of the telescope. The action is as follows : The plates B are closed and locked by the spring. The forging is set on its base on this plate and the mandrel handle lifted, forcing the mandrel into the cavity. The plates B [66] are thrown out and the forging levered to the banding position, which is determined by a stop. The band is given four squeezes of the press, the forging being slightly PIG. 20. FINISH-TURNING, SHOWING RADIUS ATTACHMENT, OPERATION 8 rotated after each squeeze. A gage jDressure of 2500 lb. is applied, which gives a total pressure of 100 tons on the copper band. The hand lever is again lifted, the plates B thrown under the base of the forging, and the mandrel withdrawn. The device for marking the base, oper- ation 6, consists of a cast-iron base to which are secured the two uprights, Fig. 14. The dieplate containing the letter die slides up and down on the uprights. The dieplate is secured to the base of the shell by means of a set- screw. The counterweights lift the die and plate after marking. On the base of the marker is mounted a conical chuck for taking the nose of the forg- ing, which is protected from burrs by thin copper sheets. On top of the up- rights is a yoke supporting the air- hoist cylinder, which lifts the weight after the blow has been delivered. The weight, when released by opening the air-exhaust valves, drops by gravity. The letters shown in the pocket at the right are for marking the lot and serial numbers by hand. The forging is taken from the band- ing press and set nose down in the chuck shown. The letter die in the dieplate is placed over the base of the shell and the weight of 550 lb. dropped from a height of 2 feet. The forging is next weighed and gaged in accordance with Pig. 15. The length is taken by the gage shovni in Pig. 16 and the depth of cavity by the gage shown in Fig. 17. The diameter is taken with micrometers and all the dimensions are marked on the forging as indicated in Fig. 15. The forging, therefore, goes to the finishing lathes, operation 8, with the necessary information for an accurate finish. The man in charge of the job checks the gaging, operation 7, before the finish-cuts are taken. Fitting 24-in. LeBlond lathes for finishing the forgings, operation 8, was one of the most difficult and costly equip- ments made. Eeferring to Pig. 18, the mandrel block was first made of cast steel ; but the castings would either take a set or be so porous that they would spring. The block, as fitted at present, is made of forged steel. This block screws over the hollow spindle of the lathe. Through the hollow spindle from the back of the lathe runs a forged steel rod that screws into the expanding mandrel A, which is made of forged steel casehardened. The jaws B are of tempered tool steel and are 7 in.. long, thus giving a grip practically the entire length of the cylinder cavity. PIG. 21. FINISHING, OPERATION 8 PIG. 22. WEIGHING AND GAGING, OPERATION 8 The diameter of the jaws. is slightly less, than 4 in., enough to enter the forging, and is accurately ground to size. A handwheel at the end of the lathe fits the'mandrel nut. By turning this wheel the mandrel A is drawn back, the taper forcing the jaws B hard out against the cavity of the shell and giving a good grip. The mandrel is tested daily for trueness; a few forgings are tested daily for eccentricity by means of the gage. Fig. 19. The maximum eccentricity obtained was 0.015 in. ; the aver- age is about 0.005 in. This small eccentricity is due to the spring in the turret head when an exceptionally hard forging is being machined. The cutting tool being at the corner of the turret does not give the required stiffness when working on hard forgings. These lathes were not large enough to fit a positive- acting radius-turning arm similar to the one fitted to the Hamilton lathe for the rough-turning, so the profiling attachment shown in Fig. 20 was designed. The cast- iron radius form A is bolted to the taper attachment at the back of the lathe. A cast-steel guide bracket is bolted to the tool carriage. Other brackets are bolted to [67] the bedplate at the back of the lathe and support the bar B, which acts as a trolley for the rollers of the guide bracket. The cast-steel roller bracket C inside the guide bracket is bolted to the crossfeed screw. A f-in. wire cable is attached to the roller bracket, is led over the pulley D and made fast to a 200-lb. weight at the back of the lathe. The base- plug forgings shown in the photo- graph were added to increase the weight. The design works perfectly on ordinary forgings, but some of the forgings are so hard that the pull is insufficient to hold the tool to a full cutting depth. This tendency of the tool to leave the shell has been over- come by using a second plate and roller below the one sho^vn, with the curve away from the lathe. When the roller tends to leave the radius form the second form takes the pressure. A spring was tried out, and it worked well when the tension was maintained, but some operators were careless and the form was substituted for the spring. The turret head fitted to the tool carriage of these lathes is an ordinary square turret head made of cast steel and is secured in the desired posi- tions by means of the lock screw. The wide copper cutting tool and gang tools for cutting the grooves in the copper band are se- cured near the middle of the side, while the steel cut- ting tools are secured at the comers. Eeferring to Pig. 21, the sequence of operations and tools used is as fol- lows: Cut groove in rear of copper band, tool marked G; shape copper band, tool B; cut grooves in copper band, tool C; remove burrs and finish copper band to size, tool B; turn bourrelet and radius, tools D and E; Counterboring Jool, Gages and Guides. :Stops-^ ' sign to those fitted to the Gisholt turret lathes. The chuck head screws on the lathe spindle instead of bolting to the faceplate, as with the Gisholts. The other features PIG. 23. THREADING THE BASE IN A LE BLOND LATHE, OPERATION 9 of the design are similar in all respects to those described for the Gisholt machines. On account of the weight of this chuck and the great overhang (17 in.), the steady- rest shown in Pig. 23, is used. The turret head for hold- ing the tools is sipailar to the one used in operation 8. In this design, however, all the tools are held at the corn- ers and the head is bolted to the crossfeed for working in the cavity of the shell. Fig. 24 shows how the shell is held and how the turret head is fitted with cutting tools and stops, also the se- quence of operations in threading. A chasing tool with six chasing threads has been substituted recently for the single-point thread-cutting tool B, and tool C has been fitted with a lip that cuts the counterbore for the base plug, so that the counterboring tool on the tailstock is more of a forming tool. These changes were made to in- crease the production. The tool A is shown in the shell ; FIG. 24. TOOLS USED IN THREADING THE BASE OF 6-IN. PROJECTILES, OPERATION 9 remove weight shell, weigh and gage as per Fig. 22, correct by turning cylinder of shell between copper band and bourrelet, tools A and F; turn point of shell, tool Gj reweigh and mark weight on shell. Turning tools D, E, A, F and G are of | x l|-in. Midvale tool steel ; 5 is of carbon steel 2 J x 1 in. ; the gang tools C are of tungsten special. The cutting compound pre- viously described is used in these machines. The speed of each machine is 80 r.p.m. and the feed V40 inch. The 18-in. by 8-ft. LeBlond lathes were fitted with collet chucks for cutting the threads in the base of the forging, operation 9. These chucks are similar in de- < Inside 1 i [ I !; \"\ \'}' <''' '1 1 ;,,=!i-i'lfi:il!:yil'',:fb!^,,,; 6^r^- — --S; © FIG. 25. TANKS AND NOZZLES FOR WASHING 3- AND 6-IN. PROJECTILES, OPERATION 10 [68] the head revolves clockwise. The sizing tap B and the master rectifying tap are inserted in the tailstoek. The sizing counterboring tool is shown at F. The projectile is next thoroughly washed in a boiling solution of soda and lye water to remove all oil and grease, operation 10. Fig. 25 shows the tanks fitted for both 6- and 3-in. projectiles. The pump shown on the column in Fig. 26 forces the boiling mixture FIG. 26. VIEW OP WASHING TANKS AND DRAIN BOARD, OPERATION 10 spraying nozzle shown for washing the cavity. This illus- tration also shows a forging in the tongs just lifted from the washing tank by means of the air cylinder. This air cylinder travels on an overhead trolley. The shell is next suspended in the second tank, which contains clear, boiling water for rinsing. The lacquering, operation 11, as originally designed was to be done on a tipple. A thread guard bushing was screwed in the base, the lacquer poured in hot, the shell revolved and the lacquer poured out. The guard did not prevent the lacquer running into the threads. Also the time required for screwing the bushing in and out was as much as was required when using a brush and painting by hand. No time is lost, because another shell is being washed while the lacquering is being done. The base plugs are next installed, operation 12, the projectile is dropped into the swinging chuck shown in Fig. 37 and the base plug screwed in by means of a special cone on each end is so centered that when revolved by hand, these cones will alternately engage the driving disk. A spring stop is provided for holding the arm in place while the shell is being painted. While one shell is being painted, the shell that has already been painted is removed from the idle disk by the tongs, Fig. 29, and a fresh shell put on. From here the shell goes out to the shipping station, where it is given its final inspection and stamped before being racked. The only special equip- ment made for machining the base plugs was a mandrel for finish-turn- ing the outside of the plugs ; this man- drel was fitted to the engine lathe. Operation 14 consists in rough-turning the face and body of the base plug. The forging is held by the flange in a four-jawed chuck of a 2-in. Jones & Lamson turret lathe. The inside face of the base plug is first turned to about Iff in. from the inner face of the flange. Kext the thread space is turned the entire length, leaving the diameter of the forgings about 4^ in.; 100 forgings are finished in this operation and the machine is then changed for operation 15. The forging is chucked on the thread space and the flange and the fuse hole finished. A small drill press is used for drilling the holes in the base plug for the spanner wrench, operation 15. The forging is bolted to the table and two J-in. holes drilled, stops for depth being used. The base plugs are threaded, operation 16, in a Le Blond engine lathe, a' special mandrel being employed. PIG 27 TRUNNION STANDARD CHUCK POR INSTALLING BASE PLUGS, 6-IN. PROJECTILES, OPERATION 12 wrench which fits the two holes. Fig. 28 shows the layout of these tables and the sequence of operations. After the plug is installed, the forging is weighed on the scales shown and the final weight is stamped on the base by hand. The number of the plug is also stamped by hand to agree with the number of the projectile. This illus- tration also shows the painting rig, operation 13, at the left. Briefly, it consists of a constant-speed motor which runs at 1200 r.p.m. and is geared down to drive a conical disk at 88 r.p.m. A swinging arm carrying a east-iron PIG. 29. DETAILS OP TONGS USED IN HANDLING FRESHLY PAINTED 6-IN. PROJECTILES, OPERATION 10 The flange is turned to 4.748 in. in diameter and faced to a thickness of 0.35 in. The thread relief and the threads are then cut 7 thread, left hand, TJ. S. S. form, each plug being tested with a ring gage. The plugs are fitted in projectiles in operation 8. The cost of equipping all the machines was less than $5000, including labor and indirect and material charges. All the special equip- ment was installed and the machines ready to start work when the first shipment of forgings was received. The manufacture of projectiles at the Puget Sound navy yard is secondary to the regular routine repair work on ships and only a few machines were utilized. The out- put of eleven machines is 18 projectiles per 8-hour day and the average cost for direct labor $1.75 per shell. In view of the large amount of detailed information already published in these columns on the making of pro- [69] i ]eetiles of various sizus, it has not been considered nooes- sary to go into the minute details of each and e\erv operation. The operations descrilied and the equipment sliown will, Irowever, a'ive sufficieiu information to enable anyone to proceed with the work with very little delay and with comparatively sli,u-ht modifications of his present equipment. With these methods as a basis and the in- formation as to cost as a eaiide m malving estimates, there should tie no delay in a'ettiiiu' contracts started, sliordd a large supply of shells be- come necessary, as now seems likely to lie the case. By carefully studying the needed modifications of standard machines, it will lie found that these changes can ]ii'obably he made befon foraings can be obtained PIG. 28. WASHING, LACQUERING, INSTALLING BASE PLUGS AND PAINTING [70] CopyilgUt. 1817, McCraw-mil.PubUslung Co. The Ordnance Department reqiiirements for brass cart- ridge eases of all types used by mobile artillery are given in the following specifications : 1. All cartridg-e cases will be constructed in accordance n-ith drawings provided or approved by the Chief of Ordnance, and no deviation therefrom will be allowed without his authority. 'i. The necessary 'Working- gages, templets, etc., will be furnished by the contractor except such as the Ordnance Department may furnish for inspection purposes exclusively. The working- gages furnished by the contractor will conform to the inspection gages. 3. The manufacture of the articles contracted for -and of all material therefor .shall be open to inspection by the officers and employees of the Ordnance Department assigned to duty for that purpose and shall in all its details and in all its stages receive the approval of the inspector or such of his assistants as he may designate. 4 A lot of cartridge cases of calibers up co and including 3.8 in. will consist of 20,000 cases. A lot oi cartridge cases ot 4.7 in. or greater diameter will consist of 10,000 cases. 5. Before beginning the manufacture of cartridge cases in quantity, the contractor will be required to demonstrate to the satisfaction of the inspector, in the case of at least one caliber, by the actual firing test prescribed below and by microscopic examination that he has established such methods of manufacture as will produce cartridge cases that will be satisfactory in service and of a crystalline structure in all parts satisfactory to the inspector. 6. This ballistic test will consist of firing three cases, five rounds each, at a pressure 12 per cent, above the maximum powder pressure allowed by the powder specifications in the particular gun or howitzer for which the cartridge cases are intended. The cases will be resized after each round; and after five rounds have been fired and the cases have been resized four times, none of them shall show longitudinal or transverse cracks, bulges or other defects that will prevent complete obturation or in any other way affect their service- ability for further use. 7. If during the firing any case swells to such an extent that it cannot be extracted by the service extractor of the cannon, it shall be considered unfit for further use. In addition to the preliminary ballistic test prescribed in the preceding paragraphs, not less than five cases will be sectionalized and microscopically examined to determine whether the various mechanical operations and subsequent heat-treatments have been such as to leave the crystalline structure of the material in proper condition for storage. These sectionalized cases will also be examined to see whether the walls or heads of the cases show any folds either external or internal 8. As the object of the preliminary test is to determine whether the manufacturer has so regulated the mechanical and heat-treating operations as to produce satisfactory cases, and as it is not a question of accepting or rejecting a lot as the result of this test, any further preliminary tests that he may desire -will be made at his expense. 9. An analysis will not be required of the materials used in making the brass, but the finished brass will be analyzed and must in all cases show a total copper and zinc content not below 99.88 per cent, with a lead content not above 0.12 per cent, and an iron content not above 0.02 per cent, with negative results as to tin, antimony, bismuth and cadmium. Any spelter and copper that will give the above results may be used by the contractor at his own risk subject to the chemical, ballistic and microscopic tests herein prescribed. The chemical analysis of the brass used in cartridge cases 3.8 in. in diameter and under will have a copper content of 68 per cent, plus or minus 1 per cent, and a, zinc content of 32 per cent, plus or minus 1 per cent. The brass used in cart- ridge cases of 4.7-in. diameter and larger must show a copper content of 70 per cent, plus or minus 1 per cent, and a zinc content of 30 per cent, plus or minus 1 per cent. 10. Eight cartridge cases will be selected from each lot for microscopic examination and a chemical examination and for ballistic test. Five of these cases will be sectionalized, polished, etched and examined microscopically to determine the crystalline condition of the material. Chemical samples for analysis will also be selected from these five cases. The remaining three cases will be subjected to the same ballistic test as prescribed for the preliminary test in paragraph b above. 11. Should any or all of the cases selected fail on the ballistic test, the contractor is entitled to a retest at his own expense. In this event five cases will be selected by the inspector, and the ballistic test as prescribed above will be repeated. If the retest is satisfactory as to all the cases, the lot will be accepted; and if not satisfactory, it will be finally rejected and no further retest allowed. 12. The contractor must have at his works or convenient thereto the necessary apparatus for making the chemical analysis prescribed and must in addition have a satisfactory, modern, metallurgical microscope and the necessary equip- ment to enable microscopic examination of the metal in the cartridge cases to be made, 13. The manufacturer must have installed the necessary suitable pyrometers to enable the inspector to check at any tiine the temperature of the annealing operations, 14. The upper portion of the case after the last drawing operation will be annealed at a temperature of from 400 to 450 deg. C, In the annealings between drawings the tempera- ture will in no case exceed 650 deg. C. [71] Stamp LotNumberof Ammunition OOS'Deep') -H055K- Buff inside of Case before Soldering. Solder with soft Solder Stamp Name and Model of6un, Place and Year of Manufacture 0.02'Peep OM ''Fill with Red Painllo indicate that Projectile \ is fitted with a Tracer After assembling, paint Groove as follows ■ Red for H.E.Shrapnel. Yellow for Com. Shrapnel, Black for H.E. Shell Composition of Solders- Soft Solder'3 Parts Lead, iParts Tin, I Part Bismuth Hard Solder- 50% Lead, 50% tin. T^rSeat for 110 Brain Percussion Primer Rough Bore to 0.375 'Diam. Mandrel to 0.44"[)iam. Finish Bore Taper 0.4698 "at large End Taper 0.00 fin Diam. per Inch of Length Split and solder with so-ff Solder, Crimp Cartridge Case at four Places in each of two drooves in Projectile. Crimps 45° apart aiRJRIDSE BRnss Cartridge ±0005' Case LapSeam,solder with hard Solder -m'<-±aoo5 Use for Ammunition without Tracers ^^WeightofCartridg&Case'£.illb. XI Wight of Charge- I.K5 lb. OS^-\Solder with hard Solder , Use for.Ammunition with Tracers sum BRASS, OOl'ThickiO.005" Diaphragm FI6.I Caeteidge Case foe 3-In. Field Gun, Models of 1902, 1904 AND 1905 OPERATION 1. CUPPING Transformation — Fig-. 2-B. Machine Used — Waterbury- Parrel 450-ton hydraulic press, Fig. 3. Number of Operators per Machine — Two. Punches and Punch Holders — Punch and die, Fig. 9. Pressure Required — 40 tons. Lubricant — Drawing- and tapering compound, 2 lb. New Era No. 4 to 1 gal. water. Production — 4200 in 8 hr. Note — Brass disk: Maximum diam- eter, 5.805 in.; minimum, 5.800 in.; maximum thickness, 0.313 in.; minimum, 0.308 in.; weight, 2.544 lb.; Fig. 2-A. OPERATION 2. WASH AND ANNEAL, Number of Operators — Three. Description of Operation — ■ Wash in plain hot water; heat in furnace to 1300 deg. P. for 1 hr. Apparatus and Equipment Used — Tank of hot water, annealing furnace, truck and tray. Fig. 4. Production — 5200 in 8 hr. OPERATION 3. PICKLE AND WASH Number of Operators- — Two. Description of Operation — Dipped in a solution of 6 parts water to 1 of vitriol, then washed in plain hot water. Apparatus and Equipment Used — Dipping baskets and tanks. Pig. 5. Production — 4300 per 8 hr. The various operations on the different sizes of cases are practically alike, the main difference heing a few more draws on the gun cases than on those for the howitzers. The punches, dies and gages are all of the same general form, only the dimensions heing suited to the several sizes of cases. For this reason detailed descriptions of the operations on all the cartridge cases are unnecessary, since one set of detailed operations will serve as a general guide for all the others. A detailed drawing of a 3-in. field-gun cartridge case for models of 1902, 1904 and 1905 is given in Fig. 1. It shows not only the case itself, but also the position of the primer and diaphragm, together with details of the two types of diaphragms for use with and without night FIG. 2. STEPS IN THE EVOLUTION OF A 3-IN, CARTRIDGE CASE [72] tracers. The various steps in the evolution of this case are as follov^s: 10 11 12 13 14 15 16 17 18 19 20 Cupping Wash and anneal Pickle and wash First draw Wash and anneal Pickle and wash Second draw Wash and anneal Pickle and wash Third draw Wash and anneal Piclile and wash Fourth draw Trim Wash and anneal Pickle and wash Fifth draw Trim Wash for heading Heading 21 Punch primer hole 21-A Drill primer hole and rough head 22 Broach 22-A Burr out 28 Point anneal 24 Taper 25 Finish head 26 Stamp 27 Finish trim 28 Inspect The principal operations are Illustrated in Fig. 2. The iirst step after the blanking of the disk is the cupping, shown in Fig. 3. The operator dips the disk into the bucket of dravi^ing compound, places it in the die and trips the press, forcing the cup down through the die into a receptacle beneath. The details of the punch and die for this cupping operation may be seen in Fig. 9. Fig. 3 — Cupping-. PIGS. 3 TO 8. VARIOUS OPERATIONS ON FIELD-GUN CARTRIDGE CASES Pig. 4 Annealing. Fig. 5 — Pickling and washing. Fig. 6 — Drawing. Fig. 7 — First trimming. Fig. 8 — Second trimming [73] Sperlar-^ 9,5ll"(9i"- U.S.Sfd.\Fit1o1aper (a'Orill Third Draw Die TOOL STEEL Fin!shfyi0.005 (Harden) OPERATION 4. FIRST DRAW Transformation — Fig. 2-C. Mac.hine Used — Waterbury- Farrel raclt press. Number of Operators per Machine — Two. Punches and Punch Holders — Punch and die, Fig. 10. Pressure Required — 22 tons. Lubricant — New Bra No. 4, 2 lb. to 1 gal. water. Production — 4300 per 8 hr. OPERATION 5. WASH AND ANNEAL, Number of Operators — Three. Description of Operation — Same as befor-e. Production — 5600 per 8 hr. OPERATION 6. PICKLE AND WASH Number of Operators — Two. Description of Operation — Same as before. Production — 3500 per 8 hr. fiitoTaper Sage ,, ,,• imhrebdiperMh-_^!!l^ OPERATION 7. SECOND DRAW Transformation — Pig. 2-D. Number of Operators per Machine — Two. Punches and Punch Holders — Punch and die. Fig. 11. Pressure Required — 9 tons. Production — 3700 per 8 hr. OPERATION 8. WASH AND ANNEAL Number of Operators — Three. Production — 6000 per 8 hr. OPERATION 9. PICKLE AND WASH Number of Operators — Two. Production — 3300 per 8 hr. OPERATION 10. THIRD DRAW ■ Transformation — Fig. 2-E. Machine Used — Waterbury- Farrel rack press. Number of Operators per Machine — Two. -WOLSTEEL,(Marden)Finishfgid.0O5' Fourtli Draw Die FIG. 13 OPERATION 13 HISH SPEED STEEL,(Hcirclen) Fini5hJ.±0.0l" Fie. 14 OPERATION 14 [74] TOOL STEEL, (Harden) Finish fgtO.OOS' Fifth Draw Die Fie. 15 OPERATION 17 Punches and Punch Holders — Punch and die. Pig-. 12. Pressure Required — 7 tons. Production — 3400. per 8 hr. OPERATION 11. WASH AND ANNEAL, Description of Operation— Heat to 1300 deg. F. for 50 rain. Production — 3400 per 8 hr. OPERATION 12. PICKLE AND WASH Production — 2400 per 8 hr. OPERATION 13. FOURTH DRAW Transformation— Fig. 2-P. Machine Used— Rack press, E'^- S.- x?'"™^^'" o* Operators per Machine— Two. Punches and Punch Holders— Punch and die, Fig. 13. Pressure Required— 7 tons. Production — 2400 per 8 hr. OPERATION 14. TRIM Machine Used — Pratt & Whitney, Fig. 7. Number of Oper- ators per Machine — One. Cutting Tools — Cutoff tool, Fig. 14. Production — 1200 per S hr. Note — Trim off 20 per cent. OPERATION 15. WASH AND ANNEAL TT Number of Operators — Three. Description of Operation — Heat to 1300 deg. P. for 50 min. Production — 3600 per 8 hr. OPERATION 16. PICKLE AND WASH Production — 1700 per 8 hr. OPERATION 17. FIFTH DRAW Transformation — Fig. 2-G. Machine Used — Hydraulic or rack press. Number of Operators per Machine — Two. Punches and Punch Holders — Punch and die. Fig. 15. Pressure Re- quired — 3 tons. Production — 1900 per 8 hr. OPERATION 18. TRIM Transformation — Fig. 2-H. Machine Used — Lathe, Fig. 8. Number of Operators per Machine — One. Work-Holding Dpvices — Three-jaw universal lathe chuck. Cutting Tools — Cutoff tool, Fig. 14. Cut Data — 420 r.p.m. Production — 1350 per 8 hr. OPERATION 19. WASH FOR HEADING Description of Operation — Wash in solution of 25 lb. 6-B washing compound to 75 gal. water. Production — 3500 per 8 hr. OPERATION 20. HEADING Transformation — Fig. 2-1, minus primer hole. Machine Used — 1000-ton hydraulic press, Fig. 16. Number of Operators per PIGS. 16 TO 21. VARIOUS PRESS AND MACHINING OPERATIONS -Pig. 16, -Heading the small-siz'e cases. Pig. 17— Heading large cases. Pig. 18— Punching primer hole. Pig. 19— Drilling and roughing head. Pig. 20— Sizing primer hole. Pig. 21 — Burring primer liole [75] Machine — One. Punches and Punch Holders — Punch, Fig. 22. Dies and Die Holders — Die, Fig. 23. Pressure Required — 600 tons. Gages — Snap gage, diameter of head. Pig. 45, operation 25; thickness of head, micrometer gage. Fig. 24. Production — 800 per 8 hr. OPERATION 21. PUNCH PRIMER HOLE Transformation — Pig. 2-1. Machine Used — Small press, Fig. 18. Number of Operators per Machine — One. Punch and Die — Pig. 25. Production — 2800 per 8 hr. OPERATION 21-A. DRILL PRIMER HOLE AND ROUGH HEAD Machine Used — Potter & Johnston turret lathe. Fig. 19. Cutting Tools — Tool for turning under head, Fig. 26; drill, reamer. Cut Data — 270 r.p.m. Production — 800 per 8 hr. Note — This is only done when punch press is not available. OPERATION 22. BROACH Machine Used — Fig. 20. Number of Operators per Machine — One. Tool Used — Sizing drift or broach, Fig. 27. Special Fixtures — Fig. 28. Production — 2800 per 8 hr. OPERATION 22-A. BURR OUT Machine Used — Pig. 21. Number of Operators per Machine ■ — One. Cutting Tools — Burring tool. Fig. 29. Cut Data — Tool runs 750 r.p.m. Special Fixtures — Fig. 30. OPERATION 23. POINT ANNEAL Number of Operators — One. l~>escription of Operation — A •case is placed as shown in the machine. Pig. 31, the gas jets being so regulated as to heat the case a low red on the open end with the heat gradually lessening toward the head; the holding spindle revolves about L"'J r.p.m., and a case will heat in about 1 min. Production — 1200 per 8 hr. The cups are next washed in plain hot water to remove the soapy drawing solution and are then annealed. This is done by placing the cups in trays, as shown in Pig. 4, and pushing the loaded trays into a furnace. Here they are heated to about 1300 deg. F. for an hour; then the tray is pulled out onto the truck and run out into the open air. The tray shown is filled with fourth-draw cases, but the method of procedure is the same in the' other annealing operations. After annealing, the cups are pickled to remove the scale and are then washed in hot water. The pickling the left. After washing, the work is ready for the first draw, the punches and dies for which are illustrated in Fig. 10. The washing, annealing, pickling and washing follow each drawing operation with but slight variations and TT U ^//---J TOOL 5na,(Harden)Fmlsh/gi0005 Punch -Z9B'- mLSTCcUHarden) Finish fa 1 0.005' Fie. 25 ^. •'^ OPERATION El ,„ ^'^ ^m\ I -235"- ... >, OJS" 1^1 ■>i [STC£L,Finishf ±0.005' I I Fie. 26 OPERATION 2IA need not be further described. Details of the punches and dies for the second draw are given in Fig. 11. Figs. 12 and 13 show those for the third arid fourth draw. The latter is also illustrated in Fig. 6. Here a tank for the Head Rn _,.-„,^,-.- TOOLSTEELiHardenj 'o3^;S^k' .i9§sh^ois"{ ^'"''J^kzS^ jS;..-jrfej'i •'' o.e7s"Dia. u.5.sm thu^ JH g^lf..--''TOOL STEEL. (Harden), Finishfg ±0.005" COLD DRAWHSTEEL FinishflOOl" Punch FIG. 22 r25\ ■075 0.05/f, Stamp Name of Cartridge Case Operation, Placeof^. Manufacture and . ' Date(Year).. FIG. 23 -./754I ,•■ Ring „ IHACHINE5TEEL(Stinnlton'Die)Fi'ni5tlf±0.0f 2?:o.ooo;^o.po2f V ^ ^ MM-'^'^" I tf ;-" ¥Dri>'e\ TOOL STEEL (HardenJFinishfgWOOS' Die t3".r -4I-- --^SIS'A 05 Drill ItlACHINE STEEL.Finish/'-O.OI COLD l^RAWM STEEL, Finishfi Rod Base ft, Fbr0.099tsunt< Rod 0IB7W*aO0O'aO02''^.^^ i H^admScrew 03^^0.1"* 'iCI'-t4. k... , J .,?*H^S V t -' 4425'- J +0O0Z" mi\YQZ'■ V-Q75"-aooo'. *aooi a562\ 1^ TOOLSTEEL(Harden) 3 FmshfyiQOOS" Scale 075 iSrS: MACHINESTEELFiniih, Guide-Left .,q.ips'std.m. U 9S'-—A cASTimr/,faor" Scale Holder _ 'mde iriloSO Fara099 titini Equalfbrts ttead Std Screw I^ACHINE5TEEL,Finisl7/ia0l'^^u„^^^„„^.,,,,^y,^y Guide-Right 0.75 f 0.000 -Q002,ritd, Thrd ®\%\ . Q575!\ \^025'/?eom , „ ^>-e.pS-'->H-2.25-t>i S ~,„,-"^^^-^^^„. I<--'"i1 V, MACHINE STEEL.FinisllfiO.Ol" T ■ (J^S/ OOOO-OO O^ Drive.i_ ai25R; [^^"S Clomp Serw? TOOLSTEEL(liarden)Finisti/±00l" Point .%m I |J_i ftf^ -22.5' ij I rt^,<-^- -262--- ->^ ovd u' COLD DRAWN STEEL /^f'd ' Finish pool' LOcIt -*^ f* Post tilACHINBSTEEL, Finistl/tOOl" n>:t Base FIS.24 OPERATION 20 tMCHINESTEEL. FinishitQOI Post Head .ail'StdlTM tif mCHINE STEEL, FinishpQOl* Screw ts done as shown in Fig. 5. The parts to be pickled are placed in a large basket, as shown at the right, and im- mersed in the solution. When the scale has all been cut, the basket is raised and run along to the hot-water tank at drawing solution is shown just at the left of the press. The operator dips his work into this tank before he places it in the die. After the fourth draw the case is trimmed as shown in Fig. 7, about 20 per cent, of it being removed. [76] The fifth-draw punches and dies are illustrated in Kg. 15, and the trimming operation, which immediately follows, is shown in Fig. 8. After the case is trimmed, it is washed in a special solution ; then it is headed in a hydraulic press, as shown in Fig. 16. Two dies are used in this press, so that the work is practically continuous. A case is placed in one die, as at A, while the heading punch B is descending on the one at C. The die at C is then pulled back and the one at A pushed into its place, and so on. Details of the die are given in Fig. 23. A press. Fig. 17, is fitted differently for heading and is used principally on the larger sizes. The case is held in punching operation, and the drift is shown in Fig. 27. Burring of the primer hole is done from the inside on a small lathe fitted as shown in Fig. 21. The burring tool, detailed in Fig. 29, is carried on the end of a long rod chucked as shown. The case is placed on an adjusta- ble carrier that slides along the lathe bed. The adjust- ment of the V's allows the fixture to be used for all sizes of eases. Details are given in Fig, 30. Point annealing of the cases is done in special ma- chines, Figs. 31 and 32. The case to be annealed is placed on the revolving table, and the gas jets play on it in such a way as to heat the mouth end to a good red heat. This TOOl STCU FimshfiaOD5'(Harden) -^ — l^= i_ §- aoof 0.43' ■'\0.43' i\^ •as FIG.27 Ram *-3.687-'^ A ■ Wass" Plug for 2.9S"Mfn.Gun Case -j/'l-j.2fWi ''ojs^aa' Plug for 3°Mtn.Howitzer Case ■ N 1 U— 4.25'— A PIugfor47 Gun&How.Cases (25' 3S \-—f£5'- "^aser ^CVj .^^ggy^.|Flug for 5 Field Gun Cose k-JfJ"-- \,....^25'-'A FIG.28 Plug for 3.8'How. Case ' " A,' 4.15"-^ U 7?....... aiS'l'Std.Filisterheaiiaeel Screws aZ'M. Brass Washer Q37S''*\X^ ^75"^rive-M-'r* j i- ■ uJ^ -0-005' ^ ?!ii Shaft ' am". .. i a4S4', a375"Std Wrought Iron Pipe h'M5"anda25' Distance Piece Plug for 6''How.Case aisA^^Rt VaTm TOOisriiL ■—^RnishftaorCHarden) End Mill (a25l<(B75"StJ.5te(!l Sefsam) [<— //'!-»| TOOLSTUL f/nisfi/taofmorden) pilot ][ V- ,.24'!.- W-/.3r5-'-^ Holder ia/87''fi')x0.87S''See/flh-Drive FIG. 29 aT!" m'- ^ri -—5° E^ (273-.' I'^^' q^ iflffi" "r- Assembled Views Pf .aZS'TapSM. rJ r a. Fbr(X25''Fth'3krhead5td.Scr^w oi25r- >l mmmcsrm m'Q^MR/js/erheaJ Steel Screws Tie Plate '^^TOOL STEEL ED=|(25' Finishf±DDl'(Hankn) a37S^-'1a5sr---i-q % ■U3/J- Guide Plate mSTapSld.Oi'de^ A^n^^ Jovv Support MACHINE STEEL Steel Screws Roller FI6.30 NOTE: FIG.27,Z8 OPERATION 22. FIQ.29,30 OPERATION 22a. the die at A. The die is held in a carrier B, which slides on the rails C and is run in or out by means of a small hydraulic cylinder and piston at the back. Primer holes are punched in the small press. Fig. 18. The die is carried in a post hinged at the bottom so that the work and the die may be swung in or out under the punch. Details of the punch and die are given in Fig. 25. Ordinarily, all primer holes in this type of case are punched; but where no press is available, the hole is drilled and the head roughed off in a turret lathe, as shown in Fig. 19. An ordinary twist drill and a turn- ing tool. Fig. 26, are used. Following either the punch- ing or drilling of the primer hole, a broach or drift is forced through as shown in Fig. 20, to size the hole ac- curately. The fixture used is made like that for the heating gradually lessens toward the head of the case, so that the case is left hard on the head end, but increasingly soft toward the mouth, so that as the case is forced into the tapering die, as shown in Fig. 33, the head end does not buckle under the pressure and the case is tapered toward the open end. The tapering die is illustrated in Fig. 37. The heads are finished in a seifti-automatic. Fig. 34. In this machine the head is faced, chamfered, the paint groove cut and the primer hole reamed and counterbored. The tools used are given in detail in Figs. 38, 39, 40, 41, 42 and 43. The gages are given in Figs. 24, 44 and 45. Following the finishing of the head, it is stamped in a hydraulic press. Fig. 35, details of the fixture being given in Fig. 46. The final trimming to exact length is done [77] in a specially fitted turret lathe, Fig. 36'. The head is held in a turret chuck A and pressed to the revolving- tool B on the spindle. This chuck and tool are shown in detail in Kgs. 47 and 48 respectively. Inspection fol- lows, some of the gages for this purpose being shown in Figs. 50, 51 and 52. OPERATION 24. TAPERING Machine Used — Punch press, Pig-. 33. Number of Operators per Machine — One. Dies and Die Holders — Die, Fig. 37. Pres- sure Required — 12 tons. Production — 1800 per 8 hr. OPERATION 25. FINISH HEAD Transformation — Pig. 25. Machine Used — Potter & John- ston automatic. Fig. 34. Number of Machines per Operator — Two. Cutting- Tools — Circular form tool. Fig. 38; facing tool. Pig. 39; chamfering tool. Fig. 40; grooving tool, Fig. 41; reamer. Fig. 42; counterbore, Fig. 43. Cut Data — 250 r.p.ra. Gages — Primer-hole gage. Fig. 44; diameter under head. Fig. 45; primer-hole counterbore, Fig. 44; thickness of head. Figs. 24 and 44; diameter of head. Fig. 45. Production — 500 per 8 hr. OPERATION 26. STAMP Transformation — Fig. 2-K. Machine Used — 30-ton hydrau- lic press. Fig. 35. Number of Operators per Machine — One. Stamp — See Fig. 1. Pressure Required — 13 tons. Special Fix- tures — Fig. 46. Production — 2500 per 8 hr. OPERATION 27. FINISH TRIM Machine Used — Turret lathe. Fig. 36. Number of Operators; per Machine — One. Work-Holding Devices — Special chuck. Fig. 47. Tool-Holding Devices — Fixture (tool holder). Fig. 48. Cutting Tools — Inside chamfering. Fig. 48; outside chamfer- ing. Pig. 48; facing. Fig. 48. Cut Data — 950 r.p.m. Gages^ Length, Pig. 49. Production — 1800 per 8 hr. OPERATION 28. INSPECTION Apparatus and Equipment Used — Fig. 50. • Gages — Mouth plug gage, Pig. 51; primer-hole gage. Fig. 44; primer-hole counterbore. Pig. 44; thickness of head, Pig. 44; diameter of head. Fig. 45; diameter under head, Fig. 45; length gage, Fig. 52; cylinder gage. Fig. 50. PIGS. 31 TO 36. ANNEALING, PRESSING AND MACHINING WORK Fig. 31 — Point-annealing machine open. Fig. 32 — Same machine closed. Fig. 33 — Tapering the case. Fig. 34 — Machining the head. Fig. 35 — Stamping the head. Fig. 36 — Finish trimming [78] stamp- name of cartridge case, operation arxtc/k, p/ace of manufacture and TOP SECTION-'' "^-MIDDLE SECTION Tapering Die •BOTTOM SECTION TOOL ST£EL f/nish/(ftaOOS''ftarden FI&.37,0P.24 Stam-name ofcase^ dimension%'place or manufacture and A'/.980ta-Z9SMt.QjnCartCas^ high SPefD stffl A-2mror3T^e/d6unM.m2:o^ ^ m/sh/tOO/''/taMn A-l3S7"forS°mHoiirMod.l907'//d47'Ho>i'. FIG. 3S A'Z.00Z"f(r4J"Gun Mod 1906 Cart Case A-mJ fbr6"/1o»Mod /90e. 08 Cart Case L _il J ->pj<- JJ fe^* TOOL STCCL Finishjl^i-aoi'tiorden FIG. 40 K JL ■to" 2^. TOOL STEEL rmisfi/taoC'ttarden FIG.4I ml ysey^y^^^ FIG. 39 025"> OJST^i")- \lief W% ■Grind *:^ Ci/tiyttmSS. ■S aA I V* It. Ji fr/nd V^ t CMS7-A(i)^-t.t25"—A^^—-z''- A Cutteribreroovingx zf,i9"i^l^\ ^^ >l ^ ^SS^ (^reJ ^ Section B-B Counterbore TOOL STEEL (Finish, Harden) Reci me r TOOL STEEL (finisiJ, Harden) FIG. 42 S OPERATION £5 ft ft -| ^ Finishjtaof te|4 'ttarden l<-.-/^"..->t Counterbore Stop TOOL STEEL ,, finish Q25x0.25"fieadlessStd.SetScre>r FIG 43 *£^Z^^ 71 .'/ 'jt.nnnn" FmishftaOl' , „ . Hga^i^gT'w^ ■ ^ Bottom Rjst (MACHmesrca) zisy 4.T'hmk' \\^ fiASfeelScrsws^ n-OMO" '-'^ °fa005 Punch Holder '•• /-a5°--punihHoUerBracker''^<' -0.00" Assembled Views l.05"-A-\-- "■taOl" FlnishftWI" ■omz- '-„^iL.aoo' MACHINE SnCL 0./5.}K,„ Finish/iaOl" " TopR>5t(3'W/7,*«J „.,„0.000" P-^f^m" Y-'-o.ooe".-- .■05"Rod. ^ Firi!shji±aor^.^,ji-mm , i MACHINE Smi O )'• "i-^^J"^'^ Top Post , ^^'l^^''^^'^'^'"^ ©jypj '^gs-i^i ii- 0.75"Rd'd. ^I^Si^'l MACHINE STEEL '^'^^^""^ Post Base ^ , ,,j-^jT, J ic"-fO:000" 6perln.U.SSld.Thread~, I-7 -0.005 '• IT) FinishJtaoF' mCnWESIEEL e :> >, ill 11.3'' ■'^■Z%5"k --m"- -J vS- Post a"FieldGun) 0.5' §l.«^'^-.,.. H£/'i»----«7y is FMshftaOl Bottom Post 1.5" MACHINESTEEL ~ V///////////Z27\ Finishf±O.Ol"\ .y".--. J Filling Piece (4.7"Cun) nx'-aOO"^.,.,, , Ub tf^d/ii ^-3.4 ■»' Top Post W7S6%«; Finish f±m (machine STEiL) Z-4.56"^'a575%r47%mt2er Top Post (4:7 Gun) C'6J6"D^0.e5"„6" ., T^r0.dB2"DrMiei5mims^, I .. w Hi ^?„.w.^w" „ I (5£%nf.,2.95"Mtn.6un,4f6un,3"Mtn.t1ow^ -^rt^^^^I^-n:.?! f^'i^'2^75"fi>r3" Field Guns \ Note far (ryfW57m~^ ffili fi.-M5"R-2.8i5"for3"Mtn.tloK,3.8'Hom,6"How.Vp°l^ ^ 'mm^'^^'^f k-3.5"^'i.25"for4rHo«. j^"?* .IOT;*-> -^^"^ ■^MACHINESTEEL ' k=t5"^'tS5"for4J"Gun8:235"Htn.Gm } Holder •mi"m% p,-„i,,,j±aoi" Top Post (l.95'Mountain6un) FIG.46 OPERATION 26 ., . I'l Head Gage FORGED STEEL leS (ttarden SGriml) FOR I/O GRAIN PRIMER Primer Hole Counterbore ^PSSI^o'^^^F^Nf'! F0PGE^f^ELtlo5 ''^■fo'. fir7ist7,tt.&G FIG.44,0P.25 ' II ^^^^^-^/r^If ^ -^ ""m" u........^/"- >( FOR ZO GRAIN PRIMER Primer Hole Counterbore Primer Hole Gqae Gage FORGED STEEL NS J FORGED STEEL N? 3 ■ finish tl.&G. finisti,tl.&G. [79] I i <: 'Had. -J.U.(2?5" CaDDRAWHSTm. ..2M)0ff..A Finish f±aor(CaseHardm> '>■"' A'!35%r3'Fieki0una3'MfnMoi,. Bushing t^'iSff'fa-eM'Mtn.Oun &7"- -> 0.5f-/J5-^ Finishfiaoi' i-ojooci I \ HI6HSP£aST£EL ^IT'' Finish/} (Honien) Facing Tool ■J i _/fi~-ir: +0000'' HIOHSPtlOSTEB. ■ ^.1 u,,^^,. Finish/gCHarden) ^flT ±0.01" Ou-fside ChamfcringTooI LJj' \jfi Finish fg (Harden) j^ +0000"„ |\ \ I -0.001^ \ \--^ ' -J4O ^ HIGH SF^ED STEEL Inside Chamfering Tool OJlflg'^l'StdMexaganalHeadSteelSaeies Collar FIG.48 aOSS'priH Na40TD.a5.W.O. K ■/ Maximum ^ 31 aOS'lf.] U Minimum— -^\ „,_ U-- A — J^-'^' EORGED STEEL (Harden and Grind) Leng+h Gage 0.098 Drill NoMT.D.&S.m. ai'ii. s Q -///>7, ^ I ---c ~l fOKGED STEEL ( Harden and Grind ) Lengfh Gage 0.098' Drill No.40 ID. &S.W.G. \jj Max.--—'i 0.098"Drill No.40 T.D.&SMG. o;£f' F)G.49 V A J FORGED STEEL (Harden and Grind) Lengih Gage Q ..M!n. — ^\ -"t-^^ ..C J fl/'/f."l u U FORGED STEEL (Harden andOrirtd) Leng-fh Gage M> A' iO.OZ'M GOe^^--'-" Max. -y Case Mar(ien Gaging Surfaces A' Heac/ Diameter B=UrKterHe(K/Diam. C'Rim under Head Diam. MACHINE Sr££L FIG. 45, OP. 25 operation 27 The Diaphhagm and the Tube foe Tracers The diaphragm is made of sheet brass ;. the operations are: Operation 1 2 Blank and form Pierce for tracer tube The punches and dies used for the first operation are shown in Fig. 54, but the second is a simple piercing operation. The tube is set into the diaphragm when a night tracer is used. It is also made of sheet brass and is evolved in the following order: Operation 1 Blank and first draw 2 Anneal 3 Pickle and wash 'se harden FI6.50 02^ fV>l ^-0.15' ""Caseharden [80] Fie.51 4 Second draw b Anneal « Pickle and wash 7 Third draw 8 Anneal « Pickle and wash 10 Fourth draw il Anneal 12 Pickle and wash 13 Fifth draw 14 Trim lb Start flange iti Assemble 17 Solder The blanking and first drawing die may be seen in Pig. 56. The second- and third-draw dies are sliown in Pig. 57 and those for the fourth and fifth draw in Pig. 58. The trimming and flanging fixtures are illustrated in Fig. 59. OPERATION 7. THIRD DRAW Transformation — Fig. 57. Punch and Die — Fig. 57. duction — 4000 per 8 hr. Pro- OPERATION 8. ANNEAL, Production — 10,000 per 8 hr. OPERATION 10. FOURTH DRAW Transformation — Fig. 58. Punch and Die — Fig. 58. Pro- duction — 4000 per 8 hr. OPERATION 11. ANNEAL Production — 10,000 per 8 hr. OPERATION 12. PICKLE AND WASH Production — 10,000 per 8 hr. OPERATION 13. FIFTH DRAW Transformation — Fig. 58. Punch and Die — Pig. 68. Pro- duction — 4000 per 8 hr. or 3iiZ Graduate and stamp with Maximum Lengths and Names of Cartridge -,, Cases. 6raduationO.Ol"mde bv D.Ol "Deep] 0.i25"Steel Pin driven ;n-'->ll<-fefea;" J. ri--^8H j'ciig IZThreadsper "^Tr, ilnch U.S.Std. "fe (^ 443f[-A -45- "~% i4*"/-25'-">| * -^OIB" -■46.437'(46fs)'- F0R6ED STEEL N^Z, Finish Graduated Length Bar aSji^K § ,ra08l"m6TP.&SW.6age OSf- OUST IRON Foot Plate -^ -^f- S-i-^W^ ^tt ZOJhreadsper i ji B -id/ J? W' Inch.USSU if" ^Ig -> ; «■ F0R6ED STEEL N^Z Finish Thumb Screw a08IN^46 K-U5'- >i T.D&5M.6a^--\ ' , ' OIEB'R.--' ■^. '034^{^ m'-^ \'<--^^f-'>| ttjol steel U ^7^/'.— -J (HJ^RDENJ Flnishf+O.OOS" j^.^ Blanking Punch Nok'Deiermine exacfsize O.OB" fff blank by iryinq ibrming punch iirsf-y i\.t< •^.p:gpc' TOOLSTEELfHARDEN) r._izn_,Tr Assembled O.0l"5hed-Brass "Zj For 0375)^0.875 SFH Filisierheaa^ SteelScrews- ariR: (FIRSTDmw) Night Tracers \< 3.97" -—■A F16. 55 OP. E TOOL STEEL Aca/L"-0-0OO".~A ^■^^^+0.001 Collar MMHINE STEEL (HABDEH) FiniahftaOl' Finish f ±0.01" I -^ 0.T75" (HARDEN) \^'537S"-'^ FinishftO.OI ^5.rtZf'^..,j7';0.ooo ^ e.7s" ->] ,.'Tap5iy. 0.5R. ^ Assembled View ForO.Z5"LMPIn fimS-A cast IRON ^»' Vi jff,/^| >| amyeep (harden) ^'S^JkKzT) 'i_ ,. I V. 'I 0.6''-"V^.2''-'A Die Holder M/tCWNESTEiL Finishf^aOl SAW STEEL : ''&^d ■sSfcx^l -^Thread a/STiRONiaoi' mif(i)rapStd FinishftaOOS p^^^^ ^^ij^^ Die Holder Collar wr^^^^c^.. ''"'•S^ Night-tracer Tube.Sldand 313^ Draw, „ . , ^^. O Vb-t r-T^i-i , ^ nrhUS^^ , . P""'^^^^^ °"d Dies O ^l^Daof/? WEm^^^^^ ^ .lnch.US.5fd. 2,S7|^J/ OPERATION . 4 a 7 «•/? Vj ^^ H""^'^- t '^ q£ J l6Thnad5'^tO'^' j. ;fff" f 1 rM^:?^-»' *W rooLSTEEL,iHarfen)Pnishj:mf '^^K«w^>fl^4/^ iDraH 6ne.Mn'.5'->^Braw TO0Lsr£EL,(Harden) Fini.'ihfiOJOl' O'la ^ini'< ,i< 5"-->i '■'-ms' coLP-PsmH sr£a.FimshfiaOI TmsrE£L,(Harden)Fmish/UOr Clamping Screw Punch Holder asT WON 1 0.01' Die Holder h-t perhchM-SSfd StdThreads '^ lOThreads §A I per/nch, " ^ rm STEEL, (HardenjF/nishf-aOl ^°"°'' ^ mcH.5TClL.Finishjtmi' -ntim'' y^ Jg-.'^'^^^'^M'nact Punch-guide Holder ® ■^^-'-------=--^^i^^-f-ftThre<,d ,C=^^ =.^-4SSf -->^ • -JZf -^ MerTrimmm ™«,cSi'/u "'/)£•• "L^nnil' SHEET BmSS.O.I)nhick ^mLSrCEL,(HardenjFmish/±SOI TracerTube.BLh Draw Punch, 4t6 Draw ^Lr'' :C ^.•M5" ^*;.F2r/f. TMSTCEL,(Haa/enJFinishj:il!.OI' Punch, 5tt Draw roOLSTEEL.(Harden)Finish/±O.OI' OneA-0.87'B-l , 4tb Draw "^AfterTrimming SHEET BIIIIS5.Q0l'Tflicl< Tracer Tube.Stb Draw OneA-Oie" B-085';Stt'Draw Punch Guide OPERATION 10 6:13 Fie. 58 4th and 5th Draw Trimming Operation Flange Operation ASSEMBLED VIEWS ' * /izi-oooo" r -^"^^(^lif- - - - ">1 ^IIP"* Onek-aS4' B-O.S', 4*-^ Draw OneA-069' B-m'St-f-Draw TOOL STmL,(Harden)Finishf± BOl' Trimming Bushing a43iUf oeis-] r(ij Flange Bushing,5tSDraw S„ug m'Orill-' men. STEEL, FmishftO.OI' Holder 5ts Draw One f<'0S4'^4tiDmw One /K^m; 5tt Draw , mcH.STECL, Finish/ ±0.01 Spacer lOThreadspet , o,r» lnchUS.Std'^r'-""''-^ - -' MRCH.STCEL, FinishfiOOr Holder, 4*-" Draw FIG. 59 Fixture for Trimming and Flanging "~^ OPERATION 14415 20 Sixth-draw trim; trim off 20 per cent. 21 Wash and anneal 22 Pickle and wash 23 Seventh draw; punch and die. Fig. 78; pressure re- quired, 10 tons 24 Seventh-draw trim 25 Wash and anneal 26 Pickle and wash 27 Eighth draw; punch and die. Fig. 79; pressure re- quired, 7 tons 28 Eighth-draw trim 29 Wash for heading 30 Heading; punch and die. Fig. SO; pressure required, 850 tons SI Rough-turn heads and drill primer hole 32 Broach primer hole 33 Burr out minimum diameter, 9.375 in.; maximum thickness, 0.438 in.; minimum thickness, 0.428 in.; weight, 9.25 lb. ^ SUCCEEDING OPERATIONS Operation 2 Wash and anneal 3 Pickle and wash 4 First draw; punch and die. Fig, 85; pressure re- quired, 45 tons 6 Wash and anneal 6 Pickle and wash 7 Second draw; punch and die. Fig, 86; pressure, 40 tons 5 Wash and anneal 9 Pickle and wash 10 Third draw; punch and die, Pig. 87: ■?"essure. 30 tons 11 Wash and annea! [83] 12 Pickle and wash 13 Fourth draw; punch and die, Pig. 88; pressure, 30 tons 14 Wash and anneal 15 Pickle and wash 16 Fifth draw; punch and die, Pig. 89; pressure, 20 tons 17 Wash and artneal 18 Pickle and wash 19 Sixth draw; punch and die, Pig. 90; pressure re- quired, 10 tons 20 Sixth-draw trim; trim off 20 per cent. 21 Wash and anneal 22 Pickle and wash 23 Seventh draw; punch and die. Pig. 91; pressure re- quired, 8 tons 24 Seventh-draw trim 25 Wash and anneal 26 Pickle and wash 27 Eighth draw; punch and die. Pig. 92; pressure, 5 tons 28 Eighth-draw trim 29 Wash for heading 30 Heading; punch and die, Pig. 93; pressure, 1050 tons 31 Rough-turn head and drill primer hole 32 Broach 33 Burr out 34 First point anneal 35 First taper; die. Pig. 94; pressure, 50 tons 36 Second point anneal 37 Second taper; die, Pig. 95; pressure, 50 tons 38 Pinal trim 39 Finish-turn head 40 Stamp 41 Pinal anneal 42 Inspect Solder wl1h 50 fSoidsr-'^ A Assembled Views ^Long- Solid braided \ white Cotton CordH'5^ - Oipin hot '-H'araffine .,,., 7 long- Stamp LotM'of nmmunilion dOS'Deep Section A-A 4Crimps, a S , , SThreadsper .pffi> lnch,US.Std.\ ^i^^P^^E. y^-^-os' ;«s".-:;;a TWLSTCEL,(Harden)Fini5hygtaW5' Third Draw Puncli Third Draw Die .. ^I^move , ll^J^S^^arp ■ •^Comers K'Seat for 110 6rF^cuS5ion . Primer Rough Bored. Oi]o\ liani.MandreledtoHW "^^.^ Ham. finish Borelaper «^ ■amS'atlargeEnd. V Taper OOOZ'in Diam.per 5 Inch uf Length i Stamp tiame and i^odei of HoMzer, Place and Year of Manufacture. _ Letters and Figures 0.OZ' - T.2 ^^ -Finish jfapprot US' back frmSioulder Lgc'+u(,j» amicBi BIIII55 Cartridge Case |<- em' OS HI lOOL 5rC£L,(Harden)Finish/fftm5' Fourth Draw Punch FIG. 65 Fourth Draw Die I--4S37M'- -"fy, -S- ^' iS37(Sf--- {oiLSKLL (Harden) Finish fgmm' Second Draw Punch FIG. 63 OPERATION 7 Z--" Vm^'S'"^ '■•TopSectm lOOLSIltL.ihardenjFinish^ttOOS' Tapering Die FIG. 68 OPERATION 24 Second Draw Die k- 64S"---->t Body6agefor47-m Howitzer Case Stamp Name of Cartridge Case, 6tige,Dlmensions qaqed. Place of Manufacture and Date(}iar) FI0.69 OPERATION Z8 [84] M3 Max. *, WSMix. Chamber \; «Vi >* | ij mo?iaK-- -^55^:5^^^?J?5^W5^^^%%^M ^^^IvfHJ :iy' ^r <7iZC '■^l^ &&l^ 00!-t H/g •'^yHi^htofCase&JSIbs Case 1 Vi i k Is' ■■/^ij?;^^/^- _..l!5^o^J"wi' Charge 5 lbs _2_ S)& - " ::^^:-;j^.. ■ 4-M--55'!- u •2U5-Q05''- StampLatNa of Ammunition; ,, \.^ w VO.S'^QOOS" Buff insids of Case before Sokiering. ^L t\^ S^n rfy*^ — *s. Solder with Soft S(^der after Assembling ■^>m ^^Um-/ N D,sfa„cem. Soft Solder Composition .- _ 5PartsTin.5 Parts Lead! Fhrt Bismuth Note--- This Cartn'i^e Case bused in 15 F&h Car^ridae Gise BRASS Guos,Modelof 1902, Bethlehem Design ^ Dipp'nragm and Guns Model of I^.Driggs-5^kjryDesign 1 FIG.70 ^ . \^^^Sa-rInch'USSty.. i8P^ -:-:7:d ^"^ x^. Do not harden this end ^ Stamp Name of Car tndgeCas^ § '^"^^^W^!SP^f"^ '^ be turned afi^^ other end Operation.PlaceofManufacturf\ j~| has been hardened and ground. and Dateffear). 'y-— -^ TmLSmL(Harden)riniihfffi(W5" ^\^ - - ^-324"- ■ ■ -^^^ Punch FIG.76,0P16 jWimafHir^enjflmih/ytOOOS' «^%-^ ,4'- .^->l/ ^^^f7i SFerlnclt-UJSftfg^, V7-->-' ■,:^-- 15—/-^, Thread ^^-jj -■^^OlS'.iCIOi^lt. --;r—lZ.5l ->—>J ^ ^-TZPTpiTS — '' Oo not harden thsentJ' Siamp NameofCartndgeCase. is -r ^.r'f Tobe turned aHer other end Operation.PlaceofMani/facture "^^ k has been hardened and ^roi/nd artd DatefYear). TWLSTEEl/h/ardenJFimih/ff'OX'S" ^ TWL3n[L(Hankn)Fini!hfy^Q005' a i^^/r 1^"* .» |-^^?f%-// ' FIG,7ZOP19 Die' Stamp Name of CartridgeCase^ ^ *tj;; Operation,Place of «i ^ T^b^j^ Donot harden fhisend Manufaciure and S J Sic turned after other end Dat^Year). ->-.„ A^j Afew hardened aftd ground. TOOLSTE£L(Hardsn)llm!hfgiOOOS" S U ^ if. Punch FIG.71,0P1 JVf^^ .■its'' ^005' \s. ^^^e':-/ia^i 1% ^ Fit to IdperGa^e A^SPerlnch-USStH.Thread |< L.-ii^"- -iX'Stamp Name of Cartridge Case, '^''~^a^=,s»^ n tQOOO Cbnofhardenthisend. ''F^'f"-'^;''f*^"<^'^rT'''l<-"-'m!^^^^^^^ Tbbefornedafterotherend V"l Date (Year). ;t^4 ' JT ■= V -n fe f has been hardened and ground. _ ^ ^ V^^'^^ i ' l'/?t7f.^,v a -i,^ ^ -5i5-- Stamp Mame ofGirfridgeCase,.—^^j. Operation, Place of Manufacture ^ [hnot harden thisend. '' h be turned alter other end has been bardrned and gmund. and IhtefYear). W0L5TaL(Harden)Fini5hfyiQ005 TQOLSTEEL(Harden)Pin,shfgt(m" ^Y-m' Punclvi K-iXB-U-// FIG.78,OP23 ,^ Die ,^f , U .-^(.....viKi"-— "^l-U.^friM/S ^j. " /J,«,/A,^,»iitr«K/-- / itdlhread. „ 41 Do not harden thsend. To be turned afier other end ,.,-wP\g StdJhread. „ :^-l^ 5/(7rt7^ Name of Cartridge Case.r'i^ i T0OLSTECL(Harden)Finishfyi0O05" Punch W^VssiP^mvSs' ■-1^5'-'— >* ,' Thread. Do rwt harden tftis e^ Stamp Name of Cartridge Case, 'L L To be turned after otherend Operation.Place of Manufacture''^ \ has been hardened and and DafefYearJ. ^^ '^ ground. . J Punch j£^_„i^,pooi':.(iiiP' r»i JT«2 (HardenjFinishfyiQOOS" FI6.73,0P7 Die ••>i p-a?" "1: ^ ■95" ./..IS".. —55"— ■>\ ^ Uo not harden thsend. ■ ^,-,,r ,"■■«'",.. ,„.„..^... ■^^ lO^S'^OOCf-L Tobeturnedafterotherend Operatm.Fhce of Manufacture ip,^l"!K^%, has been handentd and gmund. <'nJ Dafe(rear). jfTTf^^^iS-^' TOOL ST£[L (tfarden)Fnish/a!COOS ' Punch s (<-::-.-:<.'•: -."-'^'■t^^.. ,*«; ^/7 hardened andgmund. "'^'"'"HJ^'t "' "•""imure -^ , ^ " ""■ ' " '' „ n,0L5T5a(Hanien)fin,sh%.'Cm' ■''^^'WW^, |r|G.79 TOOLST,,LMFn,sl,/^-'m ' Punch rr-..;^,>,-^ -;^^/'^;,;^, -/-f-?/^ ■-:^ F-5=S^ °^^^ • - ■ ■ ■ ■ ■ ■ ■ ■ ■ |?'-\ '^' / YS.75- - ■■^395 , imL STEEL(Harden)Finislifg^OOS' FI6.8I.0P35 Stamp Home ofCartridgeCdse 4''Sectior, Vwss" / \-SHrInch- ^~.—f~' ■'!.^...^...55'.'/...JUSStdThr>ad S \<-IO.F3'*pmV.003'},zr,i^ I irr'l ' / J . * ' Obif „.Tr". -.^OjU UiJ t<. \ I- - --/■- Ponot harden thisend' Stamp Name of Cartridge Case Tobeturnedafterotherend OperatiOn.Place of Manufacture -^ i ^479'^Q002'^^-^^ ^ has iieen hardened and ground, and l^ate(Year). ^ ^ -10.17 "' *^ „ V0OLSrEEL(Harden)Finishj:g^0O0S" ' jooLSTECL(Harden)FinishfyiQ005 Punch Dis FIG.75,OP13 ^|l 3"^ Section \ Tapering Die Operation.Di€Numb^,Pla(x of ._/:-_- -..^^ -^_ _ - r^ - - "^- - - - - - ^gnufactvre, andDatf(^). __2i -- -/^- ■ ""i-t-..-^ T00LSTEEL(Harden)Fini5hfyt0CI0S" Taperina Die FI6.82,0P37 [85] Punch FI5.S9, OP. !6 Tapering Die (z»'0PeilATIOH} FI&.95.0P.37 [86] The operation lists, dimensions, dies and other infor- mation on the other cartridge cases up to 6 in. in both the gun and howitzer types are' as follows : Cartridge Case for 3.8-In. Howitzer, Model 1908 operation 1. cupping Details of Cartridge Case — Pig. 107. Punch and Die — Fig. 108. Pressure Required — 50 tons. Dimensions of Disk — Maximum diameter, 6.005 in.; minimum diameter. 6 in.; max- imum thickness, 0.431 in,; minimum thickness, 0.421 in.; weight, 3.739 lb. SUCCEEDING OPERATIONS Operation 2 Wash and anneal 3 Pickle and wash 4 First draw; punch and die. Fig. 109; pressure re- quired, 30 tons R Wash and anneal fi Pickle and wash ♦' Second draw; punch and die. Pig. 110; pressure, tons 20 s Wash and anneal 9 Pickle and wash 10 Third draw; punch and die, Fig. Ill; pressure, tons la n Wash and anneal IS Pickle and wash 13 Fourth draw; punch and die. Fig. 112; pressure, tons 13 14 Wash and anneal IS Pickle and wash 16 Fifth draw; punch and die. Fig. 113; pressure, tons 10 17 Fifth-draw trim 1R Wash for heading 19 Heading; die. Fig. 114; pressure, 1000 tons Rough-turn head and drill primer hole 20 ai Broach 22 Burr out 23 Point anneal 24 Taper; die. Fig. 115; pressure, 20 tons HampbtthofAmnunitmW'brrit 0/05rap=4!MitUSSlcl ■'\ri{10S?C!Ol" tOlW tarn' JfiUfrHmdSmmiifxil/yspaca/ nuCHiNeilltL \U-rM}/fj0->\ ., , !,Cop,Plate U -I025-*000i"' TO0L5TE€L(Harden)Fm,5hfy^000S ' FlG.108 Cupping , ,, f Solder wifhhar J '• Solder 5oM BroK^ ^WkfeCoHanCordHoSi Uipint Assembly Charge Ba^ fastened toCose wthTwine ^of'^/yw/i ~^pas5edthivij^ Screw E^es and Ends fastened together Gi-UW£^ I Twine tobe6la^edJuteorGh2&if^x,tobreal«^4pproxWLh K" 456 - ^ 4 I Di^dinhoflhraffineThefbrafinefortheTwineoftheMMeCharge — - \<"r-45$S'-OO02''-- -^\ .fli?i;"p V^fobeccforedwiihRosanilme'-:^ ;— 1^- " ■% ^ > Cupping ^^.^^^jf^m'....'..^ 4^'...u,.^Mn5.5 ■^"^■^ , „ ' FIG.I08andl09 Y- ---m^ix/- Y- 49f^-----A ll<-.-:-473"'to/-— -> Wl' V- 824'°^' - -,H T00L5TEEL(Harden)rmishfy-Q00S Trd.n riw.ill -m'— -:■—■}* JOOLSTECL TO0UT[EL(Hard,^)finahfy:i FIG.I09 ^ fsj XStampNomeofCartnd^e i y-^ 'KsOperahonflaceofMoiiui 3"'Draw ■■44''--— >l K -aujii jmiTm.Fnish/^-WOS' 1 X~ FitfoTaperOa^. 2' SHrlKkUSJfdTkraid ^J^^%»^'J ..^x' I ^ ^f ^^qp-z of V'-—45 11 I SS 4'"-Draw '^^ • ' — ^ — "^ — yrmi \i^-r-4l!9-'m/''-A./>iP("P U itJt;:^ ■^■-y-—A/"\< t< —...-824''-- -;-J j(m.STEa(Hi:rJen)fin5hfy-000! FIG no L ] TVOL 5TCeL(Hankn)Fnshfyfmy Heading FVjnch Fie.114 [87] 25 Finish-turn heads 26 Drill for scre^v-eyes 'J,'i Tap for screw-eyes 28 Stamp 29 Final trim 30 Inspect Caeteidge C-iSE FOE -i.T-Ix. Gun, Model 1906 OPERATION 1. CUPPING Details of Cartridge Case — Fig. 116. Punch and Die — Fig. 117. Pressure — 65 tons. Dimensions of Disk — Maximum diameter, 8.630 in.; minimum diameter, 8.625 in.; maximum thickness, 0.505 in.; minimum thickness, 0.495 in.; -weight, S,.9S7 lb. SUCCEEDING OPERATIONS Operation 2 3 4 9 10 11 12 13 14 15 16 17 18 Wash and anneal Pickle and wash First draw; punch and die, Fig. 118; pressure, 60 tons Wash and anneal Pickle and "wash Second draw; punch and die. Fig. 119: pressure, 45 tons Wash and anneal Pickle and wash Third draw; punch and die. Fig. 120; pressure, 40 tons Wash and anneal Pickle and wash Fourth draw; punch and die. Fig. 121; pressure, 30 tons Wash and anneal Pickle and wash Fifth draw; punch and die. Fig. 122; pressure, 25 tons Wash and anneal Pickle and wash 19 Sixth draw; punch and die, Fig. 123; pressure, 20 tons 20 Sixth-draw trim; remove 20 per cent. 21 Wash and anneal 22 Pickle and wash 23 Seventh draw; punch and die, Pig. 124; pressure, 16 tons 24 Seventh-draw trim 25 Wash for heading- 26 Heading; die. Fig. 125; pressure, 1400 tons 27 Rough-turn head and drill primer hole 28 Broach 29 Burr out 30 Point anneal 31 Taper; die. Fig. 126; pressure, 45 tons 32 Finish-turn head 33 Stamp; pressure, 15 tons 34 Final trim 35 Inspect Caeteidge Case foe 4.7-Ix. Howitzee, Models of 1907, 1908 AND 1913 operation 1. CUPPING Details of Cartridge Case — Fig. 127. Punch and Die — Pig. 128. Pressure — 90 tons. Dimensions of Disk — Maximum diam- eter, 7.105 in.; minimum diameter, 7.100 in.; maximum thick- ness, 0.465 in.; minimum thickness, 0.455 in.; weight, 6 lb- 9 oz. Operation 2 3 SUCCEEDING OPERATIONS Wash and anneal Pickle and wash First draw; punch and die, Fig. 129; pressure, 50 tons Wash and anneal Pickle and wash Second draw; punch and die, Fig. 130; pressure, 46 tons .^ Harikn 7^ppro>! I p.... -....^/JJ?-.- .V...J ''■* TWLSTCa^dmjFlmifymiS" -rooLSTEEL.FashfyftmS" FIG.IEO 3"'Draw ■'.S J\Hor/en9%K FI6.II6 Wi"l^p,filkdwifhl?fdBid Seaf for 110 Groins l^rcussmf^imer IndKaksthatlOZdihe Rough BorKi(157S"DiciinMandreledfoG44\ Shrapnd are fiHed witba Finish Bore^ers 0696 large Em:^ l<..._ ShellTracer "kper OWE in Dmrn per hchm Length, i ._// gXA^g?'-''^&J- j i^-'--.-^-g"- ■t rvV -i-gy?w/--- XoiFf'g It. - QrlridgeCase tohecrimped aifourBmisinea^h ofthelmGrwi -I iMmE5rEEii-\^ ^ /gupF.tate--f§Ti| . .., ■■in5'i<-}is'^}!5'M-S7S---My--.f U-SS"-^ ./Q.!- >J ^- -M"- -;-^ TOOLSTCCLfmishfyWmS -FIG.iai 4*- Draw " ' Y !(^'- ■-.ast I, „2'-J------'^--^ T00aTm(Hanliri)Fmishfyt(IX5' ^ olFourfimfsineafihoftheTmGnioves „ ^^044" . [< 565"- — ^ , [■i -> — § ' TOOUTICL,! Cupping 1^, H'^^'*-^^-;-'^^--'^ ^ K!r--^-~-^'--y gfe ? li-.jj''...,^ !}•- ,t / lOOLSTCELtHmlmjrnlhfy^OL 4? S , „ K- lis' ■; -; '^- ,-,-„, 5**'Drav» ^^^^^^ „„„„a* — ^-Stainpnsmol TmLiTEELfmishfytaOeS FIS.IZZ , ^ ■*ni^-]is"< ir- stJM ^,.....J5'?-_i4<_../»....>^ JVOUTEELjym Ura'H "m\vW «--««-•»<- -7'— WOLlTEa.Unahfy-'OOOS" F1G.II8 l'*Drow . „„« J!(7;"UH'I1„, 6 Draw K —m'vm"- I &sS|ifS: . -rST !<•■••■■- ^/^'- '™ ^ ■l/p'-S"' ~ mL5rEtL(thrAn)F;,ahfymS' FIG.I23 "ffil «?....M,«i,« P?"i I r "' Ts'Oriir~% E"<'Drc FIG.II9 (&-/ri7swm.^if'^ m'^ il-f I- .^../^.«:-.-:'-^..:^, 7JX7i SrEE^ (Harden) Fmishf^ ■ TjfR. * 12"- H/V- ZS" -'■—■A TOOL STEEL. Fmh/^-O.OOS" T^Draw Stamptbmol- -.- FIG. 124 A Oix,0penilm.Flx">f ■ -77i''--:>iom'k U--^*- .-.-,// Lsse.Uperaiion.ncKe of tr-lTS'^mi ■>) UanuhclmandOalAt^i TOI'^ . „™„. Heading. I''"8 ^i^^Si^ nG.I25B lOOLSTEELiHardtnjFinl^/gWOS" Topenng FIS.I [88] S Wash and anneal 9 Pickle and wash 10 Third draw; punch and die, Fig. 131; pressure, 30 tons 11 Wash and anneal 12 Pickle and wash 13 Fourth draw; punch and die. Fig. 132; pressure, tons 14 Wash and anneal 15 Pickle and wash 16 Fifth draw; punch and die. Fig. 133; pressure, tons 17 Fifth-draw trim 20 15 18 Wash for heading 19 Heading; die. Fig. 134; pressure, 1350 tons 20 Rough-turn head and drill primer hole 21 Broach 22 Burr out 23 Point anneal 24 Taper; die, Fig. 135; pressure, 30 tons 25 Finish-turn head 26 Drill for screw-eyes 27 Tap for screw-eyes 28 Stamp; pressure, 15 tons 29 Final trim 30 Inspect ---- MS"--- /d^i- /l/,Ct2S'lras'Sfee/nnsSWf 16.5" Heading- , /„^/'^f',i TOOL STEEL, nnish/gtaOOSIhnTen 'S/m" nG.134,0P.2O Shrink onOie \i...^^../a/7"---.m..... 'i^.? Draw, ,» .' TOOL srca, nmsh/gtOMS Hanlen riG.13l.0RII U..7"-->l Tapering TOOL STECL/inish/gtmS Harden nG.I35.0P25 TOOL ST£EL,Finish/gtamsmrtlef ' "^ '"""' FIG.I32,0RI4 nG.I33,0P.t7 [89] :f»=^-S, Skimp Lot NO .' ofAmmunrtion ai'Tap SiampNameand Model of 6un, 30°- J\^ Place and Yearof Manufacture, letters and Figures OOZ'Oeep 45 Threads per ,^ lnch,US.Std BI!»S5,iOt Screw Eye Cartridge Case fl/i. Charge 19" Total 4llb. (MjRme. BHAss S Cartridge Case X° Rough bored D.'SJS'Diam. Mandreledfo 0-44'Oiam. Finish Bore Taper 0.4698 at large End. Taper Q002 'in Diam. per Inch in Length \\Solderwith I Jsoff Solder SoHenrith soff Solder Tear off offer Assembling f in Cartridge Case ^_s: Total Length W6'm' ^ Composition of soff Solder 3 Parts Lead, iParts Tin, FIG. 136 > Part Bismuth SHS£7 BWsa.QOS'Thick Diaphragm )ragm to press Stamp Home I3nd Model b-.^mp Lot m of W/4S° of Howitzer and Place and .^ ,-, .j.. nn'?>'a \ 7 » ■ -■- - - . .^„^_Ammunition 00c Seep >~\wwS+SOI WTTT Year of Manufacture. Leiters ^nd figures QOl 'Deep II ../fV Assembled Views X=Seaf for 110 gr Percussion f^imer RoughSoredQ32''Diam. , ^^ Mandreiedto044''0iam. ^ \ S§ Finish BoreTaper 0.4698 at «^ V, large End. Taper0002"in Diapi. "g ^ per Inch of Length ~~" FIQ.I49 MumsrcEL .1?!- ^JFUshja Filisterhead. r<. _ ,,»_. >J\fmish MOf'-'-Jm Bnll M'Ammf Harden Sfd.Screw\Y^. ... „. .... '' . ...J^CupPfeite !§'*«' .■I»J( ^ , „ -A/i-y- - -■--,-97i'±i).im-'- nnish;f approximately..-' ..-■"' U .» -9Si ti Z'lxidr fnm Shoulder W-Wi CSRmiiec BDHss'^l Cartridge Case w.9ApprID^?:5/f. j^ K-iS" •>«--/()' -H ^+.„ k- 10.94"- ^\ .... . > g 5- Draw ■■»-"^ "-^ m-Drll! - ™-l55 11 fOfP\,M-'''""""'^'"'^ h --ii'Ui t<--iJ«->«-5'..M '*^ , ^A'hpprm^ Harden 1IJ Hhff^;'' f< "■'■■13.94'- "*' l?f Draw FI6.I5I AnS^375"-'^-S.5--*'--^6--^ISi<-^ '<-SS'-^ /3'- >■ ^' I /- ■-«+«»■■- *i 77'- •>! I •^ -m'-i75'-m25% T<--S.5'-»<-S'^ • 'iS'Approx.l' Harden ,^«^^K. /^-J' FI6.I52 ■■xy-30' r-k --7S-- -eftmi'—->i. ■ to f L.,.. ™., ^ ^-^/75V-3,75'>I<- 15'--^^ -Z5---^/5l«----463'''''^W^-L„ iBee-s"-^ Draw ■/W"' jj Ring ^ mcH.5Tea,Finislijmi' FIS.I59 Shrink'on Die Tapering i^-tamp Name of Cartridge Case, Operation, Place of Manufacture and Date (Year) on each Punch •and Die Fit all Shanks to Taper Gage. All Threads 5 per Inch, U.5. Std. Pound off shtrf Corner on all Dies. [90] Cartridge Case for 6-In. Howitzer, Models of 1906 AND 1908 OPERATION 1. CUPPING Details of Cartridge Case — Fig. 149. Puncli and Die — Fig. 150. Pressure — 75 tons. Dimensions of Dislc — Maximum diameter, 9.680 in.; minimum diameter, 9.675 in.; maximum thiclcness, 0.405 in.; minimum tliicltness, 0.395 in.; weiglit, 9.0524 lb. SUCCEEDING OPERATIONS Operation 2 Wash and anneal 3 Piclile and wash 4 First draw; punch and die. Fig. 151; pressure, 50 tons 5 "Wash and anneal 6 Piclile and wash 7 Second draw; punch and die. Fig. 152; pressure, 45 tons 8 Wash and anneal 9 Pickle and wash 10 Third draw; punch and die. Fig. 153; pressure, 35 tons 11 Wash and anneal 12 Pickle and wash 13 Fourth draw; punch and die. Pig. 154; pressure, 30 tons 14 Wash and anneal 15 Pickle and wash 16 Fifth draw; punch and die. Fig. 155; pressure, 25 tons 17 Fifth-draw trim; trim 50 per cent. IS Wash and anneal 19 Pickle and wash 20 Sixth draw; punch and die, Fig. 156; pressure, 25 tons 21 Sixth-draw trim 22 Wash and anneal 23 Pickle and wash 24 Seventh draw; punch and die. Fig. 157; pressure, 15 tons 25 Seventh-draw trim 26 Wash for heading 27 Heading; die. Fig. 158; pressure, 1800 tons PIGS. 160 TO 165. PREPARING FOR THE LOADING OP THE PROPELLING CHARGE Pig. 160 — Polishing the mouth. Fig. 161 — Inserting primer. Fig. 162 — Spot drilling, for tracer mark. Fig. 163- lot number. Pig. 164 — Weighing and putting in the powder. Fig. 165 — Inserting the diaphragm -Stamping [91] "S Rough-turn head and drill primer hole 2s) Broach 30 Burr out 31 Point anneal 32 Taper; die. Fig. 159, pressure, 43 tons 33 Finish-turn head 34 Drill for screw-eyes 35 Tap for scre'w-eyes 36 Stamp; pressure. 13 tons 37 Final trim 38 Inspect Loading the Propellixg Charge and Assembling TO Projectile Like the various drawing and other operations on the cartridge eases, the loading of the propelling charge fol- lows pretty closely along the same general lines, so that only one size will be followed through. In this particular case the powder is put loose into the case, but in others, especially in the howitzer types, the powder is placed in one or more bags. In the howitzer these bags are tied in by means of cords run through screw-eyes placed inside of the head. In a large number of cases the assembling is done in the field or just previous to actual use. This, however, has nothing directly to do with the manufac- turing or machining processes, so will not be expanded upon here. The example chosen to illustrate the loading process is the case and projectile for the 3-in. field gun, models of 1903, 1904 and 1905, and the operations are: 1. Polish mouth 2. Insert primer 3. Pill color groove 3i. Spot for tracer paint mark Fig. PIGS. 166 TO 171. VARIOUS ASSEMBLING, SOLDERING AND TESTING OPERATIONS 166 — Soldering in the diaphragm. Fig. 167 — Pressing in the projectile. Fig. 168 — Creasing machine. Fig. 169- Soldering on the can lid. Pig. 170 — Testing for leaks. Fie. 171 — Packed in boxes [92] 4. 5. 6. 7. 10. 11. 12. 13. Stamp lot number Put in propelling charge Insert diaphragm Solder in diaphragm Fill crimping grooves Press in projectile Crimp and drop in can Solder on can top Test and solder small hole Varnish and box The mouth of the case is polished to provide a clean bright surface for the soldering in of the retaining dia- phragm. The case is chucked as shown in Pig. 160. As it turns, the operator holds emery cloth so as to polish out the mouth back for several inches. Waste on the end of a stick is also used to wipe the surface clean. Primers are inserted by means of a small hand press, as shown in Pig. 161. They are carried to the bench on board trays holding 300 primers. All cartridge cases intended for use with projectiles hav- ing night tracers must be spotted with a blunt-end drill and the spot filled with red paint, as a distinguishing mark. The spotting of the head is done as shown in Pig. 163. The case is held in a guiding fixture and fed for- ward onto the drill by means of the tailstock spindle. A stop bolted to the top of the front lathe bearing is used to gage the depth of the spot. The lot number is stamped in a hand press, as shown in Pig. 163. The order of some of these minor opera- tions is occasionally varied according to changing shop conditions, but this is not important. In loading the pro- pelling charge into this case, the required amount of pow- der is weighed out and poured into it, the outfit used be- ing shown in Pig.164. The next operation after pouring in Ihe powder is the pressing in of the diaphragm, which is done with the handled gaging plug illustrated in Pig. 165. In getting ready to solder in the diaphragm the operator first polishes the inside edges of the diaphragm slightly with emery cloth and then proceeds to solder the edges to the case, using ordinary soldering coppers heated in a bench furnace as shown in Fig. 166. Pollovring the work on the diaphragm, the projectile is pressed in, as shown in Pig. 167, and then the case is crimped into the grooves at the base of the projectile, using the machine shown in Pig. 168. Continuous creases all around are not produced, but indentations like those at A are made. After crimping, the assembly is thrust into the gaging chamber B and then dropped into a tin can. The can cover is next put on and soldered in place in the bench fixture. Fig. 169. The can is tested for leaks with the device illustrated in Pig. 170; and after varnish has been applied wherever the can has not been coated, it is ready for packing in boxes, shown in Pig. 171. Of this size, four cans are packed in each box. The boxes are then covered and nailed ready for shipment. Loading 3-In. Cartridge Case and Assembling TO Projectile for Field Gun operation 1. POLISH MOUTH Machine Used — Lathe, Pig. 160. Number of Operators per Machine — One. Work-Holding Devices — Chuck; work runs at 475 ft. surface speed. Production — 800 per day. Note — No. 2 emery cloth is used, and vcorkman presses it inside of mouth to polish for soldering in diaphragm. OPERATION 2. INSERT PRIMER Machine Used — Small hand press. Pig. 161. Number of Operators per Machine — One. Production — 1850 per day. OPERATION 3. PILL COLOR GROOVE Number of Operators — One. ' Description of Operation — Operator sets case on end and applies paint to the circular groove in the head. Apparatus and Equipment Used — Small round brush and can of paint. Production — 2000 per day. Note — Colors: Red for high explosives, yellow for shrapnel and black for shell. OPERATION 3J. SPOT FOR TRACER PAINT MARK Machine Used — Lathe, Pig. 162. Cutting Tools — Blunt-point ^"o'i-^^"" ^'^^^''- '^"' Data — Spindle runs 600 r.p.m. Production 7-