L .

- . ..... ._._ _ _ _ __.....

.o R-C0-76-037

ELECTROCHEMICAL MACHINING OF
CARTRIDGE CHAMIER AND
RIFLING CONTOURS FOR SMALL ARMS

CHARLES MAIORANO
Anocut Engineering Covpany "

and

RAYMOND A. KIRSCHBAUM
Rock Island Arsenal

S~SEPTENBER 1976

['-"N CUT ENGINEERING COMPANYro

__-__-.ROCK ISLAND ARSENAL

197
DISTRIlBUTION STATEMENT
Approved for public release, distribution unlimited.

DDC
"c iT WUL*i L"Lb,- "O NI 'ilb
l'E ~ NOV 10 17
w E.f ~Lf3U UaLLL.u
RESEARCH DIRECTORATE
GENERAL THOMAS J. RODMAN LAIORATORYB
ROCK ISLAND ARSENAL
ROCK ISLAND, ILLINOIS 61201 ),
'p
;I,

DISPOSITION INSTRUCTIONS:

Destroy this report when It is no longer needed, Do not return It

to the originator,

DI'ICLAIMER:

] The findings of this report are not to be construed as an official

Department of the Army position unless so designated by other authorized
documents.

A..... .. . .
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BEFORE COMPLEINJ')G FORM

1.REPORT NUMBER 3.0NOVT

ACCESSION N PIENT'S CATALOG NUMBER

fl LECTROCHEHICAL MACHINING OF CARTRIDGE ;HAMBE Thc .. .. +w

ANDi RIFLINC
*',|
CONTOURS FORSMALLVARJS
" -"..
s " Iecnical -v
teLJ
I.I"MRFOM~iNG OMG. REPORT NUMBER

AUT ORsCONTRACT 00 GRANT HUMBEM;)"

Charle/alorano ON Raymond A./Kirschbaum 7,P'-C-1 76

iDMFI- V
IS. PERFORMING ORGANIZATION NAME AND ADDRESS 10. PROGRAM ELEMENT, PROJECT, TASK
SAnocut Engineering Company AREA & WORK UNIT NUMBERS

2375 Estes Avenue AMS Code6.6770

Elk Grove Village, Illincis 60007 .
11.ICDR,
CONTROLLING OFFICE NAME AND ADDRESS
Rock Island Arsenal (/// Setlr B
IGEN Thomas J. Rodman Laboratory, SARRI-LR ;.... ,,AGw
-
IRock Island, I11inios 61201 42
14. MONITORING AGENCY NAME A ADDRESS(Il dill I Controliund Office) IS. SECURITY CLASS. (of thle report)

d ]SISa.
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IS. DISTRIBUTION STATEMENT (of hli. Report)

Approved for public release, distribution unlimited.

17. toBok20 Idteetto

17OISTRISU )ION STATEMENT (of the ebtrect entere B.c

it,! 0 fdifrn r Repor

IS SUPPLEMENTARY NOTES

IS. KEY WORDS (Continue on reveree side If neceoeer,, a Identify by block number)
1. Machining 4. Rifling
2. Electrochemical 5. Cartridge chambers

3. Gun Barrels
"20. ABSTRACT (Continue an revere eide If neceeey and identlf by block number)

The feasibility of electrochemically machining rifling and cartridge chamber

contours in gun barrels was determined. Electrochemical machining (ECH) tests
were conducted using single-electrode, continuous-feed, straight-plunge cut-
ting. Multiple-groove, straight rifling was formed successfully In 7.62mm and
20mm, Cr-Ho-V steel (MIL-S-46047) gun barrel sections.

Cartridge chambers were machined in 20mm sections of AISI 1018 cold rolled'
(cont.) ove
DD D, AN
O ,UNCLASS
1473 EDITION OF INOVSS IS
1OSOLETE IFl ED
SECURITY CLASSIFICATION OF THIS PAGE (When eta Entle .
5

- -4
 UNCLASS I FIED
t)
SECURITY CLASSIFICATION OF THIS PAGE(laha DMO Ette

20. (coot.)
"steel and Cr-Mo-V steel. Although ECH tests were successful with the mild steel
(1018), shape and surface-finish tolerances were not concurrently achieved in
the low alloy steel (Cr-Mo-V). Test results did Indicate that ECH of cartridge
chambers In the low alloy steel could be possible with additional experimenta-
tion.

Based on program test results and state-of-the-art, when compared to the effi-
ciencies of other forming processes such as rotary forging and broaching, it is
recommended that no Immediate efforts be made to apply ECH In the production of
small arms gun barrels. However, future developments in ECH should be monitored
for application of small arms rifling and chambering, especially for gain twist
rifled gun barrels. (Malorano, C. and Kirschbaum R. A.)

ISAittIOUIItCEU -

...
..........
... ...............
.........................

* ii _____ UNCLASSIFIED
SECURITY CLASSI'ICAT ON OF THIS PAGE(Whlen Date Enteretd)
 FOREWORD

This repnrt was prepared by Charles Maioiano uf Anocut Engineering

Company, Elk Grove Village, Illinois 60007, in compliance with Contract
DAAFOI-70-C-1076 and by Raymond A. Kirschbaum of the Research Directorate,
GEN Thomas J. Rodman Laboratory, Rock Island Arsenal, Rock Island, Illinois
61201.

The work was authorized as part of the Manufacturing Methods and Tech-
nology
and was Program of the U.S. Army Materiel Development and Readiness Command,
administered by the U.S. Army Industrial Base
Engineering Activity.

i iii
 CONTENTS

Page
DD FORM 1473 . .

FOREWORD . . . . . . . . . . . .. . . . . . . . . . . . . . . . . ..

TABLE OF CONTENTS ...................... .......................... iv

TABULAR DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . v

1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . I

2. PROCEDURE .................. .............................. I

S2.1 General ....................... .......................... 1

i 2.2 Methods and Techniques .............. ................... 2

2.3 Tests ....................... ........................... 4

3. RESULTS AND DISCUSSION ................. ..................... 7

p 3.1 20mm Rifling .................... ........................ 7

3.2 7.62mm Rifling .................. ....................... 10

3.3 20mm Cartridge Chamber . .................. 10

4. CONCLUSIONS AND RECOMMENDATIONS .......... ................ 11

4.1 Contlusions ................... ....................... 11

4.2 Recommendations ................. ..................... 11

APPENDIX A - Photographs of Tooling ........ ................. ... 12

APPENDIX B Results of 20mm Rifling Tests ......... ............. 25

APPENDIX C Results of 7.62mm Rifling Tests .... ............ ... 35

APPENDIX D - Results of 20mm Chambering Tests. ............ 38

: DISTRIBUTION.................................. ......... 41

iv

...
 TABULAR DATA

TABLE PAGE

S. Workpiece Blank (20mm) Inspection Readings 3

Rr

2.

4.
20mm Rifling Tests Machining Conditions

20ram Chamber Tests Machining Conditions

I
(Material: MI L-S-46047) 8

5. 20mm Chamber Tests Machining Conditions

(Material: 1018 Cold Rolled Steel) 9

v-
 I. I NTRODUCT ION

Small caliber gun barrels are generally rifled by broaching, and

chambered by step drilling, contour reaming, and polishing. The opera-
tions are slow and expensive, particularly for- the machining of proto-
type barrels of new, difficult-to-machine alloys. Consequently, this
program was conducted to determine the adaptability of electrochemical
machining to replace or augment these operations. The feasibility of
eliminating the multistep conventional machining operations through the
use of single-step electrochemical processing has been of particular
interest, even for machining conventional materials, for possible re-
duction of machining time and for elimination of costly tool wear.
During feasibility testing, the sharpness of contours and the quality
of finishes obtainable by various combinations of electrochemical
machining parameters were of particular concern. The parameters tested
in various combinations were Those of electrolyte strength, pressure,
temperature, voltag(, amperage, electrode feed rate, and starting gap.
Work materials used in the testing were Cr-Mo-V steel (MIL-S-46047) and
1018 cold-rolled steel.

2. PROCEDURE

2.1 General

The testing was conducted in three parts:

a. The rifling in a 20mm gun barrel was electrochemically

machined in accordance with section D-D, Rock Island Arsenal Drawing
77980, sheet I.

b. The rifling in a 7.62mm gun barrel was electrochemically

machined In accordance with section B-B, Rock Island Arsenal Drawing
11701204, sheet I.

c. The cartridge chamber in a 20mm gun barrel was electro-

chemically machined in accordance with U. S. Army Weapons Command Print
7790801, sheet 2, section E-E.

Straight (rather than spiral), short length (maximum length of

8 inches) rifling grooves were machined. This method was used for more
simple and economical testing since some means of accurately rotating
the gun barrel section or tool would have been required for spiral grooves.
Although such a rotating mechanism could have been constructed, this
action would have been unnecessary and costly for feasibility tests. Also,
the straight-plunge machining of the grooves minimized any difficulties,
e.g., vibrations and dimensional Inaccuracies, which, if introduced by a
rotating mechanism, could have "masked" other problems encountered.

II
 The workplece blank., listed in Table I, were provided by Rock
Island Arsenal.

Fixtures, cathodes, cathode guides and electrolyte Inlet mani-

folds wtre fabricated for rifling and chambering tests. Photographs of
this tooling are presented in Appendix A. The fixtures were built to
hold the gun barrel sections for test machining in standard (8 - I in.
maximum stroke) 10,000 amp Anocut underdrive machines. The guides were
designed to ensure that the cathode entered the workplece at the correct
location and the proper angle, remained straight and held to a minimum
of vibration.
tThe electrolyte entered the top of the workplece, proceeded
through the combination manifold and guide (moving downward around the
outside of the cathode; and emerged from the bottom of the workpiece.
This flow direction was selected to produce the best possible surface
finish or the sides of the cut. Fresh and uncharged electrolyte flowed
down between The previously-cut hole and the sides of the cathode when
this flow direction was used. Charged electrolyte from the cutting zone
exited through the unfinished predrilled hole in the bottom of the part.
The Anocut machine used for this testing was equipped with a large elec-
trolyte pump capable of producing 200 psi of electrolyte pressure at a
flow rate of 200 gpm. The electrolyte system of the machine contained
a by-pass valve so that varying amounts of electrolyte could be directed
around the tooling and returned directly to the electrolyte tank. With
this high-pressure pump and electrolyte system, tuol electrolyte pressures
up to a maximum of 200 psi were easily attainable. The relatively small
clectroiyte outlet hole beneath the workpiece served to restrict the flow
through the cutting area and to produce back pressure when higher inlet
pressures were used.

2.2 Methods and Techniques

E!ectrolytes carry a charge when :eaving the cutting zone and

this charge can cause some etching as it passes over the workplece sur-
face. Although metal removed by such etching can seldom be measured, the
etching does cause deterioration in the machined surface. Consequently,
in all the machining tests, electrolyte flow was directed from the top
through the bottom of the predrilled workpieces to produce better surface
finishes. Fresh, uncharged electrolyte flowed downward between the
already-cut hole and the side of the cathode; when charged from the
cutting zone, it emerged from the unfinished, predrilled hole in the
bottom of tho part. Also, when any holes are electrochemically machined
where the length-to-diameter ratio is large (above 15:1), an accurate
guide is essential for the cathode. So, the cathode guides used in
the rifling tests facilitated hole location, angle, concentricity and
surface finish.

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 The direction o~f electrolyte flow was particularly important
for precision during test machining of the cartridge chambers. Generally,
clean electrolyte was supplied to the finishing end of the electrode for
final generation of the part size and finish.3
Electrolyte pressures are measured at the point where the
electrolyte enters the tooling or machining area. Meusuring pressures
at this location is expedient although it is not the area In which the
electrolyte Is cutting. Positive control of pressure Is desired In
the machining gap between the workpiece and 4 he cathode or tool. There-I
fore, the pressure in the electrolyte Inlet manifold should not be assumed
to be equal to the pressure In the machining gap. Pressures In these
two places are seldom the same and are not linearly related.

P2.3 Tests

I,
2.3.1 20Wi RIflI ng Tests
The 6 In. long blank used for this testing had a pre-
drilled hole through Its entire length. A V-block fixture was used to
locate and clamp the part. Preliminary experimentation was conduicted
at electrolyte Inlet pressures of 150 and 175 psi. The bulk of the test-
Ing was conducted at 210 psi. Machining coinditions In each complete
experiment were gonerally the same, except the cathode feed rates were
Increased from 0.050 to 0.210 in. per min. The performance of this
operation was not satisfactory at the 0.210 In. per min. feed rate so
the cathode feed rate was reduced to 0.180 in. per min.; this appeared
to be optimum with a 210 psi electrolyte pressure. Machining conditions
used during the testing are listed In Tabl6 2.

2.3.2 7 .62 mm
Rifling Tests
A V-block fixture was used to locate and clamp the
part. Again, tests were conducted at electrolyte Inlet pressures of
150, 175 and 200 psi. The tooling appeared to perform best at 175 psi,
and all compleite test runs were conducted at this pressure. Th.- cathode
feed rate was varied from 0.180 to 0.275 in. per min. The voltage was
varied from 12 to 11 volts and the amperage was varied~ from 12.5 to 10.5
Table 3.

2.3.3 2 0mm Cartridge Chamber Tests

Exierimejnts were conducted in machining a cartridge
chamber cavity in ea(.oi of five Cr-Mo-V steel gun barrel sections. Un-
e pected difficulty was encountered with the occurrence of striations
(grooves and channels) In the surface of the cavities, and more difficuity
arose with size tolerance than was expected. After these five workpleces
had Oeen machined, .considerablymore testing appeared to be necessary to
reach conclusive results. Therefore, Anocut prepared additional cold-
rolled steel blanks for continuation of the testing, and Rock Island
Arsenal prepared 3dditional blanks of Cr-Mo-V steel. A total of sixteen

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V pleted with the ten additional Cr-Mo-V steel blanks provided by Rock Island
Arsenal to bring the total of cartridge chambering tests to thirty-one.

Various cathode feed rates and various electrolyte

pressures were tried during the first series of tests on the Cr-Mo-V
steel workpieces. Back pressure was used throughout these tests and
was established by use of an electrolyte flow restrictor at the electro-
lyte exit from the tooling. Restrictors of 3/8 and 1/4 in, diameter
bores were alternatively tried In the initial testing and the 3/8 in.
restrictor was used in most of the succeeding tests. The cathodes used
were altered for the difference in electrochemical machinability of the
Cr-Mo-V and cold-rolled steel workpleces. Cross sections were examined to
determine part tolerances. Machining conditions used during the testing
are presented in Tables 4 and 5.

3. RESULTS AND DISCUSSION

3.1 20mm Rifling

Electrochemically machining the rifling in 20mm gun barrels

is feasible. The 6 in. long samples produced were within tolerances
for geometric sizes and had a very smooth surface finish.

Further effort is required to produce tooling and machinery

for handling the full-length barrels and to develop a turning mechanism
to provide the rifling spiral. The tooling for full-length barrels
should embouy the principles developed in this test tooling. Also,
machining parameters should coincide with those developed in this test
work, e.g.,

Electrolyte: 3.25 lbs. of NaNO 3 per U.S. gal. of water

Electrolyte temperature: 95*F
Machining voltage: 13 volts

Machining current: 150 amps.

Cathode feed rate: 0.180 in. per min.

Electrolyte pressure: 210 psi

The inspection results of the test machining are given in

Appendix B.

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In this test machining, considerable difficulty was encountered

in maintaining location. The predrilled holes in the gun barrel sections
were not exactly concentric with the outside diameters of the sections.
Also, the end faces of the sections were not exactly square (perpendicu-
lar) with the bore. This meant that the line of motion of the cathode,
as the cathode moved through the workpiece, was not always paral'el to
the axes and surfaces of the predrilled holes in the rigidly clamped
workpieces. This condition caused the cathodes to cut off center in
some tests, in one test, this caused one cathode to break off in the
upper manifold-guide. However, electrochemical machining or rifling in
a 7.62mm barrel is feasible. The 6 in. long samples produced in these
tests had very smooth surface finishes and the rifling forms were within
tolerances.

Tooling and machinery for handling full-length barrels and a

turning mechanism for the rifling spiral are required. The tooling for
full-length barrels should embody the principles developed in this test
tooling. Also, machining parameters should coincide with those developed
in this tes+ work, e.g.,

Electrolyte: 3.5 lbs. of NaNO 3 per U.S. gal. of water

Electrolyte temperature: 90*F

Machining voltage: II volts

Machining current: 10.5 amps.

Cathode feed rate: 0.275 in. per min.

Electrolyte pressure: 175 psi

The inspection results of this testing are given in Appendix C.

3.3 20mm Cartridge Chamber

Resu;ts of test machining the 2 0mm cartridge chamber were less

promising than the results of the rifling tests. Problems were encountered
in an attempt to concurrently achieve both size and finish tolerances.
Tne striations occurring in the machined cavity surface, particularly in
the test blanks of Cr-Mo-V steel (MIL-S-46047) material, were the most dif-
ficult problem. Although both size and finish tolerances were achieved
in electrochemical machining of the cartridge chamber cavity in a cold-
rolled steel test blank, the combination of both size and surface-finish

10

L~
 tolerances was not achieved in the MIL-S-46047 blanks. The striations
appeared to be related to the alloy. Although the exact causes are not
known, striations are affected by electrolyte pressure, electrolyte compo-
sition, electrolyte flow in the machining gap (which is related to the sur-
face finish on the electrode), and by the composition and heat treatment of
a given alloy.

In summary, although size and surface tolerances were not ob-

tained with MIL-S-46047 material, these tests indicated that cartridge
chambers could probably be electrochemically machined with additional ex-
perimentation. Testing of various combinations of electrolytes, electrodes,
and work material heat-treatments or preshaping wotld be required.
The inspection results of this testing are given in Appendix D.

4. CONCLUSIONS AND RECOMMENDATIONS

14.1 Conclusions
14.1.1 Rifling. Multiple groove, straight rifling of 7.62 and 20mm
contours can be electrochemically machined in gun steel (MIL-S-46047); and
no significant technical problem is foreseen in development of special equip-
ment to electrochemically machine spiral rifling in such gun bores. Machin-
ing rates in the tests conducted indicate that ECM would be faster when com-
pared to conventional broaching of rifling. However, for bores of smaller
diameter, contemporary limits of ECM have to be considered. For example, in
conventional direct shaping by continuous flow of a salt-base electrolyte
and travel of the tool or workpiece, the minimum radius obtained at the inter-
sections of machined surfaces is approximately 0.002 in. and the maximum
ratio of length-to-bore diameter of a rifled barrel is approximately 70 to 1.
Smaller radii and larger ratios are possible but special equipment, electro-
lytes and techniques would have to be developed.

4.1.2 Chambering. Although ECM tests were successful with the mild
steel (1018), shape and surface-finish tolerances were not concurrently
achieved in the low-alloy steel (Cr-Mo-V) by direct-plunge cutting with a
center hole flow-through cathode of the 20mm cartridge contour. Test results
did indicate that successful machining would be accomplished with further
development work. However, as is the case for rifling, the minimum radius
obtainable is approximately 0.002 in. and additional development would be
required to approach the tolerances required in small-bore cartridge chambers.

4.2 Recommendations
Based on program test results and state-of-the-art, when compared to
the efficiencies of other forming processes such as rotary forging and broach-
ing, it is recommended that no i-nmediate efforts be made to apply ECM in the
production of small arms gun barrels. However, future developments in ECM
should be monitored for application of small arms rifling and chambering,
especially for gain twist rifled gun barrels. it is also recommended that
ECM be considered as a preparatory process, prior tc. chamber reaming and/or
rifling, to achieve stress-free surfaces for improved machinabi lity and
formability in close-tolerance shaping.

ill! .. . S11 .. ....

 APPENDIX A

Photographs

Figure Page

I ECM Tooling, Rifling and Chamber 13

2 20mr RiflIng Tools 14

3 30 mm RRi f I i ng Tool Arrangement 15

4 Workplece Holder for 20mm Rifling 16

5 7.62mm Rifling Tools 17

6 7.62mm Rifling Tool Arrangement 18

7 7.62mm Rifling Cathode Tip and Guides 19

8 Workplece Holder for 7.62mm Rifling 20

9 20mm Cartridge Chamber Tooling 21

10 20mm Cartridge Chamber Tool Arrangement 22

II 20mm Cartridge Chamber Cathode - Workpiece 23

12 20mm Cartridge Chamber Workplece Holder 24

12

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 FIGURE 4. WORKPIECE HOLDER FOR 20MM RIFLING

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FIGURE 5. 7.62*1 RIFLING TOOLS

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42
 APPENDIX B

Inspection Results of 20mm Rifling Tests

Page
Figure

I Concentricity of Land's and Grooves, Part 5 26

Corcentricity of Lands and Grooves, Part 6 .27

2

3 Cathode Inspection 28

4 Land and Groove Diameters, Part B 29

r 5 Land and Groove Diameters, Part C 30

6 Groove Depths, Part 5 31

S32
7 Groove Depths, Part 6 32

8 Land and Groove Diameters Through Part 5 33

9 Land and Groove Diameters Through Part 6 34

25

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 APPENDIX C

Inspection Results of 7. 6 2
mm Rifling Tests

Figure Page

I Groove Diameters, Part 7 36

2 Land Diameters, Part 7 37

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 APPENDIX D

Inspection Results of 20.mmnChambering Tests '

Figure page1
120nm Breech, Cold Rolled Steel 39

2 2Onlm Breech, Cr-Mo-V Steel (MIL-S-46047) 40

38I
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FIGURE I. 20"1 BREECH, COLD ROLLED STEEL

39......;..
 R. X_ 0* f9 - 'V' e&

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FIGURE 2. 20MM4 BREECH, Cr-No-V STEEL (MIL-S-46047)

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