The Stockpile from March 2024

Extrusion lines for shotgun shells

Biorientation technology increases some performances of the thermoplastic material. It’s applied for the extrusion of HDPE pipes to produce thin wall pipes but with a very high resistance. AMUT has developed this technology in the production of small pipes for shotgun shells.

Because of their higher properties, the thermoplastic pipes have fully replaced the traditional cardboard pipes previously used for shotgun shells. The extrusion line ensures the best quality parameters with very low tolerances while obtaining an in-line cut-to-size pipe that means no need to handle the pipe again for the successive cut steps.

This is possible because of the mechanical biorientation technology, based on the use of a stretch-mandrel. This technology ensures the easy operation of the extrusion line, the use of different materials, the achievement of high outputs, and the possibility of the cut-to-size directly in-line. The technology of mechanical biorientation ensures very high tensile strength values (more than 22kg/mm2) and because of this property it’s possible to produce small pipes for shotgun shells that can be recharged up to 15x.

Another advantage offered by the line is the possibility to produce bioriented pipes of small diameter (11mm) necessary for the smallest gauges (gauge 36 - .410), otherwise produced by means of rigid, expensive injection technologies. The extrusion line is easy to operate and flexible – change of product can be made in one hour.

AMUT SpA https://www.amut.it

Automated gun barrel production cell

The R-4-2-2 fully automated gun barrel production cell provides continuous and synchronous production. The cell gundrills four barrels at once, while two gundrilled barrels are precision reamed and two others receive the final step of button rifling, simultaneously.

Robots and conveyors can be machine mounted or used to combine multiple machines or operations.

The R-4-2-2 production cell uses a smart conveyor to simultaneously load four-barrel blanks into a UNI four-spindle gundrilling machine. Drawing from a bulk feeder, this automated loading is the starting point for many hours of unattended operation. The four gundrilled parts are moved out of the machine by the conveyor, and a 6-axis robot loads two gundrilled parts into the UNR reaming machine.

After precision reaming, the robot transports the two gundrilled and reamed barrels to a blow-off station and then loads them into the R-series rifling machine. Gundrilling, reaming, and rifling operations are happening simultaneously for maximized productivity. The robot then delivers finished, rifled parts to a multi-level discharge magazine.

UNISIG https://unisig.com

Fully automated spin forming machine

The fully automated spin forming machine has been engineered to redefine the production of critical hardware for space exploration missions and next-generation defense applications demanding the highest standards for reliability and performance.

The machine is equipped with an advanced heat management system featuring robotic heating and infrared cameras, delivering precision, consistency, and efficiency for improved quality control compared to traditional metal spinning with manual torch methods. Furthermore, the machine offers a wide range of forming capabilities for complex geometries and a variety of materials including high-strength alloys and exotic metals for applications including missile nose cones, liquid fuel tanks, pressurant tank hemispheres, as well as components for maritime and land combat systems.

Karman Space & Defense https://karman-sd.com

Superabrasive finishing systems

Bore finishing systems have been successfully used in the precision honing of the barrel prior to rifling. Single-pass technology improves the roundness and straightness of the barrel and enhances the cosmetics. In some cases, the accuracy of bores in precision trigger assemblies has improved. Single-pass bore finishing technology delivers superior-fitting bores when compared to bores finished through conventional honing.

Conventional honing uses a reciprocating tool with relatively fast-wearing bonded stones that must expand and contract during each cycle. Single-pass technology spreads the work over a series of progressively finer, preset diamond tools requiring a single pass from each tool. It’s this preset capability of the tooling, combined with the extremely slow wear of the diamond coating, that allows the single-pass process to achieve superior bore size capability.

Engis offers a standard machine platform for firearm component finishing applications which can be customized to meet unique production and part quality requirements. Engis can also design automation and/or robotic parts handling systems, brushing stations, and in-line post- and pre-gaging systems which can further reduce labor and inspection costs.

Engis Corp. https://www.engis.com

Benefits:

• Improved bore quality
• Tool cuts on full periphery
• Improved Statistical Process Control
• <2μm of distortion on 20" barrels
• Long tool life results in lower overall cost per piece
• High production rates

AI cobot

The TM AI cobot integrates visual processing directly into the robot arm so it can execute tasks such as pick-and-place, autonomous mobile robot (AMR) operations, palletizing, welding, and product manufacturing with rapidity and precision.

The S Series, particularly the TM25S model, boasts the highest payload capacity in its class at 25kg. With a reach exceeding 190cm, the TM25S provides adaptability, catering to diverse industrial needs.

A defining feature of the S Series is the integration of a built-in vision system coupled with cutting-edge artificial intelligence (AI) technology, ensuring the cobot operates with accuracy and efficiency. It seamlessly fits into existing workflows, enhancing productivity in operations.

TM Robot can be equipped with various lenses and 36 external cameras, optimizing its Automated Optical Inspection system with AI-driven solutions. With its integrated smart vision, the TM AI cobot refines pick-and-place applications and eliminates the need for third-party cameras.

Techman Robot Inc. https://www.tm-robot.com

DevSecOps software platform

Sigma Software Studio is a development, security, and operations (DevSecOps) platform designed for transformation and software modernization across the Department of the Navy. The platform has been accredited with Authority to Operate (ATO) by the U.S. Navy and U.S. Marine Corps.

Sigma Software Studio enables rapid and secure stand-up of software factories with reduced cost and complexity compared to traditional methods. By providing a proven, secure DevSecOps platform that unifies and streamlines software development processes, Sigma Software Studio accelerates the deployment of software applications and can significantly lower costs compared to traditional approaches.

Sigma Defense Systems LLC https://sigmadefense.com

Hole cutting machine

Achieve significant time savings and cutting accuracy when cutting pipe and vessel heads with the HGG SPC 1500-3000 PT/VC cutting machine, designed to automate layout, marking, cutting, beveling, and grinding profiles from 3"to 118". By importing the customer’s specifications into HGG’s ProCAM software, the entire tape measure-paper drawing-chalk markup pre-cut practice is eliminated as is the time required to complete those tasks. Customers have realized up to 90% reduction in time due to the machine’s FitPerfect technology. Featuring a longitudinal and transversal axis designed to create a perfect circle in one plane, holes can be cut without rotation of the vessel. The height axis adjusts the cutting torch to the fluctuating level of the material surface while the AutoFocus robot performs beveling along the cutting path, safeguarding the true dimensions of the hole and resulting in a perfect and smooth weld preparation along the fit line of the nozzle hole connection. This is especially beneficial to shops handling thick-walled profiles, where weld volume reduction is key.

The SPC 1500-3000 PT/VC machine provides clean operation using plasma or oxyfuel to perform programmed cuts and is capable of ink, punch, and plasma marking depending on the application. Difficult-to-cut holes – such as hillside holes, saddle set-in holes, and hole set-in for pressure connections – are cut quickly and easily with the weld prep performed by the Autofocus Robot incorporated into the machine.

By automating the vessel cutting process, production time is reduced, which can reduce on-site labor costs by as much as 30%.

HGG Profiling Equipment https://hgg-group.com

Measurement tool

The ColliMeter measurement system is for precise setup and qualification of collimators.

Optikos manufactured, aligned, and installed refractive and reflective collimators using this technology in the OpTest testing product line. It was reserved for internal use, but in response to numerous customer requests, Optikos offers this instrumentation for sale under the ColliMeter family. From the visible to long-wave infrared, and from small to large aperture systems, customers can precisely set the collimation of a source object or determine the apparent distance of a projected object.

The instrument comes in two configurations; the ColliMeter 350 for larger collimators with a horizontal beam and the instrument brought to the collimating system, and the benchtop ColliMeter 50 in which smaller target projectors are mounted vertically on the instrument. Both systems use Optikos ColliMetric software application.

Optikos https://www.optikos.com

Manual BSF tooling

The manually actuated BSF is for back spot facing applications where coolant flow is too weak to actuate the blade and air supply is unavailable or inconsistent. The blade can be retracted by manual collar and swing out because of the activation speed. The BSF manual was developed for instances where traditional actuation methods were ineffective, including when coolant isn't available through the spindle, when through-spindle-air is unavailable or not programmable, when less than 280psi pressure is available, or when filtration is poor. It’s ideal for counterbores up to 2.3x through-hole diameter. Standard sizes available are 6.5mm to 20.5mm (0.256" to 0.807") with specials available from 6mm (0.236") to 40mm (1.575"). Safer and more reliable than bayonet style tooling, the BSF manual is suited for large boring mills and open-air machines.

The tooling works without an anti-rotation device, change of spindle direction, or machine adaptations, allowing components to be spot faced in the same direction as the bore is drilled. This saves time and cost of turning the workpiece, while allowing the spot-facing of difficult-to-reach areas like casting flanges and bolt head faces. The tool works vertically and horizontally, with replaceable carbide-coated blades for extended tool life. They’re ideal for gear housings, yokes, engine casings, compressors, aerospace components, and other parts in a wide range of materials.

Existing BSF tools can be modified by exchanging the shank to allow manual activation, as the housings, controls, and blades are identical to the standard BSF range.

Heule Precision Tools https://www.heuletool.com

X-ray CT systems

Three new models of the VOXLS range of X-ray CT (computed tomography) systems for non-destructive inspection have been launched. The 30 Series is for users looking for an automation-ready system with the versatility to meet a wide range of industrial applications.

The VOXLS 30 C 225, 30 C 320, and 30 C 450 models have maximum source energies of 225kV, 320kV, and 450kV respectively for examining parts of various densities and sizes. They also have a more compact footprint than Nikon’s 40 Series while maintaining advanced features traditionally exclusive to larger, more expensive solutions.

At the core of this series is a metrology-grade, granite-based manipulator coupled with rigid steel towers, which provide a thermally stable and solid construction. High-precision motors, ball screw drives, and encoders ensure precise positioning and accurate movement of all axes, including the synchronous vertical motion of the X-ray sources and detectors.

The systems feature motorized bi-parting radiation doors that open and close in less than five seconds, behind which the cabinet interior can accommodate items up to 1,000mm in diameter by 1,370mm tall. The 30 Series’ 225kV model offers an industry-leading scan volume within its size class, while all models offer impressive maximum scanning volumes of more than 600mm diameter by more than one meter high. The systems are powered by Nikon’s proprietary X-ray source technology, including their unique 225kV Rotating.Target 2.0 and 450kV reflection target.

The 30 Series cabinets use a manipulator-interlocked, glass outer door to give the operator visibility into the enclosure when the inner radiation safety doors are open. This design enables confident positioning of the scan object, minimizing the risk of collision with the X-ray source and detector while providing a physical safety barrier between the operator and the moving manipulator. Multiple internal high-resolution video cameras provide a view with the inner radiation safety doors shut and X-rays on.

Nikon https://industry.nikon.com