scope:

This expanded revision of AMCP 706-249 covers aspects relating to production of munitions that the design engineer must consider early in the development stage of the life cycle. Each munition type cited represents different disciplines with regard to design, materials, manufacturing methodology, and end use. The descriptions of acceptable manufacturing processes for manufacturing the current generation of projectiles and cartridge cases arc based on stale of the art and recognize current trends aimed at reducing production costs and meeting higher standards of product reliability.

Even as early as the concept exploration phase, emphasis is placed on the need to create realistic munitions designs. Thus an inordinate amount of time and project funds will not be wasted in pursuing an approach that is impractical from a production point of view. The full-scale development phase, during which requirements for materials, dimensions, and physical properties are established, has the greatest influence on the production cost of the item. For this reason, this handbook addresses the impact of overly restrictive dimensional and mechanical properties on the manufacturing process.

Examples of various munitions are given because they represent not only a basic process or a specific material but also because they exemplify the reasons a particular sequence of operations was selected. Also explanations are provided as to why an alternate procedure may have been considered and then eliminated.

Materials and manufacturing methods not covered in the previous edition of this handbook are included for production of artillery projectiles. A summary of this new information is in the paragraphs that follow.

The manufacture of kinetic energy (KE) armor-defeating munitions represents a major departure from the forming and machining procedures used in manufacture of artillery munitions, and therefore it is treated in this handbook. The use of heavy metal alloys as penetrators and the more severe firing environment of KE munitions mandate the need for a coordinated approach among design, development, and manufacturing controls.

The use of nonferrous materials, such as heavy metals, copper and aluminum alloys, and plastics, has increased in recent years. The processing of these materials into munitions components is also discussed. These components may interface with other metallic components, and knowledge of the various constraints and advantages in their use should be beneficial to the munitions designer.

Mortar ammunition metal parts production is included because it combines much of the deep cavity projectile manufacturing process and also includes nonferrous metal components.

Training ammunition production has become increasingly more important because of its potential to reduce costs and increase safety. Here the use of alternate, lower cost materials and methods of manufacture arc possible because terminal effectiveness is not a prerequisite. If no negative training results are experienced with the use of this type of ammunition, the trainer can shoot more rounds at a lower cost than if he used service rounds.

Overall, new and more sophisticated inspection methods have been introduced to keep pace with the use of new materials and the requirement for greater reliability and maintainability of modern munitions. Quality assurance measures have always been an integral part of munitions production and play an important role in product qualifications. New studies in nondestructive testing developments have reduced the number of firing tests required in acceptance and stockpile surveillance and have increased the assurance of failure-free materiel.