Production equipment

High-power munitions production technology

Stiletto Uniqueness

Manufacturing excellence:

Vertically integrated manufacturing: Case / Primer / Bullet / Core

Computer controlled manufacturing including pressures driving, world class

production results in terms of tolerances and homogeneity – Swiss tech:

NOBAG, PFIFFNER

Manufacturing process of casing allows significant cost saving:

Stiletto = 20mm square strips from large rolls (1m) vs. other ammunition

manufacturers = 131mm rolls (expensive) processed in a series of 12

round stamps leading to up to 40% waste

Re tooling: ~2hrs vs ~2 days and over

Ecologically clean: no soap or acids used as is currently the case

Stiletto technology uniquely and dramatically

reduces manufacturing costs whilst simultaneously improving quality

and accuracy

Stiletto Uniqueness Description of Production Process :

PHASE I Starting from the material warehouse, brass sheets are transferred to the workshop in coils and used for production of bullet casing and bullet jackets. Material specifications including hardness and structure are confirmed by the Supplier’s certification. Certification is supplied to the design and engineering departments for statistical accounting of materials supplied, which may be further used for optimization of the technological processes. At the same time, pig lead for the production of cores and steel wire for the production of armour piercing cores (armour piercing core - alloy material) is supplied to the same workshop. Control of these materials is also performed as above. Semi-finished bullet casings are produced on a five-positional press and semi-finished bullet jackets are also produced on a five-positional press, with a capacity of 240 items per minute. The press technology allows for successive passage of each semi-finished product one by one. The machinery has five pairs of blocks containing punch pins with emulsion lubricant. As a result, semi-finished products of the same type and size are created (tight tolerances). Simultaneously, out of pig lead, wire is drawn by means of a submerged stove re-melting process and extruded through a hydraulic press. Ready wire is coiled and goes through an ageing operation by

way of a water bath.

Stiletto Uniqueness Control of chemical composition and structural integrity of the produced lead wire is performed by plant employees using proven equipment and processes.

Armour-piercing cores are produced by specialized equipment. Control of geometry and sorting by weight of armour-piercing cores is performed by plant employees using specialist and automated equipment.

Further: Semi-finished (blank) bullet casing and bullet jackets go to the annealing line where in an automated regime, washing, annealing, cooling and lubricating operations are performed;

Lead wire goes to a five-positional press where using a lubricating emulsion lead jackets or cores are produced. This press is identical to the above described, therefore the lead jackets or cores are the same size and type within tight tolerance. Tool is guaranteed for 20,000,000 cycles. Control and sorting of lead products is performed using specialist equipment.

NOTE: production waste from the lead jacket or lead core are recycled to the stove for re -

melting and used in further production of lead wire.

Stiletto Uniqueness Finished bullet cases (blanks) go into two streams for secondary and tertiary drawing and trimming (cutting). Each blank goes through the operation of final drawing, controlling the bullet casing wall

width, preliminary trimming, formation of the capsule pocket, marking, squeezing and final trimming. Ready bullet casings (cases) go through the operation of grinding, geometrical control, sorting and then go to the cartridge assembly workshop.

NOTE: waste from case and jacket production is sorted by grade and is sent to the supplier for recycling.

Next bullet assembly is performed in the workshop. Initially, at first assembly the «NODULE» (lead jacket and core) is assembled. Then, at the second assembly the «NODULE» is installed in a bullet jacket. After several technological operations a formed bullet is produced. The ready bullet goes through the final operation of «GRINDING», after which the bullet goes to the assembly workshop for cartridge assembly. Geometry controlled bullet sorting and formation into batches are performed automatically on the specialized equipment.

NOTE: final control of cases produced, bullet jackets and finished bullets is performed by firing for determining fire accuracy at a distance of 300 meters from a ballistics barrel at the plant’s testing laboratory.

Stiletto Uniqueness PHASE II Prior to cartridge assembly, the testing laboratory performs a series of operations on the cartridge charge. In the process of these activities the main specifications of the cartridge are determined – initial speed of bullet trip, bullet ballistic coefficient and maximum pressures. Upon primer fitting, the cartridge is tested for its performance. An assembly of a pilot batch of cartridges for plant testing is carried out. Based on the results of plant testing, a decision is made to manufacture final cartridge batches. Finally the capsule is pressed into the case. After this, powder is put into the capsuled case and the bullet is fixed. Further, finished cartridges are transferred to the sealing line, where they are sealed with further drying. All activities aforementioned are repeated when a new batch of raw materials, powder and primers enter the plant. In the cartridge assembly and packaging workshop, cartridges are packaged in batches.

Stiletto Uniqueness PHASE III Finished and accepted cartridges go to the primary packaging line where they are aligned, laid and packaged in paper packing. On the secondary packaging line, cartridges in paper packing are put into metal or plastic cases. The cases are sealed, marked and boxed. The boxes are marked and tagged. Finally, the confirmed number of finished products goes for final

acceptance and testing, thereafter they are stored at the warehouse for shipping.

Stiletto Uniqueness Technological Scheme of Case Production

NOTE: the case production line may operate using coiled rods or rolled sheets.

Equipment for cap

production and annealing

Equipment for primary

drawing and trimming

Equipment for

secondary annealing

Equipment for secondary drawing

and squeezing (crimping)

Equipment for case trimming

and annealing

Cap production Primary drawing Secondary drawing and

squeezing (crimping)

Case trimming

Stiletto Uniqueness

Stiletto Uniqueness Technological Scheme of Bullet and Cartridge Production

Equipment for core

production

Equipment for jacket

production

Equipment for jacket-core

nodule assembly

Equipment for bullet assembly, crimping and

grinding

Core production Jacket production Assembly of jacket-core

nodule

Bullet assembly, crimping and grinding

Stiletto Uniqueness

Stiletto Uniqueness Bullet Jacket Production

2

Basics: Press products

NOBAG – Presses are used

for the production

of thin wall cylindrical parts

First of all for

ammunition cases:

Basics: Field of application

of NOBAG machines

From Sheet

Coil

to Ammunition

cases

1st Step: Cup shaping

1) Disc punching

2) Cup drawing

3) Cup annealing

with NOBAG –

machines!

2nd Step: draw to length

4) 1st draw

5) 2nd draw

6) Cut to length

7) Recrystallisation annealing

with NOBAG machines!

18

3rd Step: case shaping

8) Heading

7) Indenting

10) Datum spamp

9) Ignition hole punching

11) Tapering

14) Score turning

13) Cut to length

12) Taper annealing

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NOBAG

Single stage machines

for small calibre

Cupping

press

NP 10-60 II V

Draw press

WON 5 II N

Draw press

WON 5 II F

Cutt – off

machine

BSA II JH

Heading press

WON 6 II H

Necking press

WON 7 II V

Application: Caliber 9mm / 5.56mm / 7.62mm or similar

Neck

annealing

machine

HGM - JH

20

Cupping press, NP

The cupping press is designed to produce cups from blanks or flat material.

The press is laid out as a vertical eccentric press with two different strokes for punching and drawing operation.

The main ram for punching operation is carried on long pre loaded linear guide rails. The ram for drawing operations is mounted on the main ram carriage and guided in cylindrical roller cages, fitted slightly pre loaded.

The die holders are fitted on the housing and easy accessible, which guarantees rapid tool change over. Auxiliary equipment

- Decoiler - Conveying system for strips - Scrap chopper for rest strip

Technical data Number of stroke min-1 180 Productivity pcs/min n x 180 Weight to 12

Draw press, WON 5 II N

This draw press is designed for the first draw of ammunition cases.

The press is a horizontal eccentric press. The ram is supported on long V- needle guide bearing. This play-free bearing guarantees even drawn components. The punch- holders are fitted on the press ram and can be centralized by adjusting screws. The die holders are fitted on the housing and are designed for rapid tool change. The central lubrication system serves the bearings and guides with oil. Automatic feeding system The cups are fed into the two feeding hoppers, from where they are guided by means of the turntable, channel and feed in front of the machine tool station of the press.

Examples of work

Ironing and stripping

Technical data Capacity of main ram kN 200 Stroke mm 200 Tool stations 2 Number of strokes min-1 120 Weight to 4,5

22

Draw press, WON 5 II F

This draw press is designed for the second draw and third draw of ammunition cases. The press is a horizontal eccentric press. The ram is supported on long V- needle guide bearing. This play-free bearing guarantees even drawn components. The punch- holders are fitted on the ram and can be centralized by the adjusting screws. The die holders are fitted on the housing and are designed for rapid tool change. The central lubrication system serves the bearings and guides with oil. Automatic feeding system The tubes are fed into the two feeding hoppers, from where they are guided by means of the turntable, channel and feed in front of the machine tool station of the press.

Technical data Capacity of main ram kN 50 Stroke mm 220 Tool stations - 2 Number of strokes min-1 120 Weight to 3,6

2. Zug 3. Zug

Cut- off machine, BSA II H

The cut- off machine is used to cut off the components after the final draw.

The housing is constructed from robust steel tubes. The crankshaft of the

feeding ram drive and the camshaft of the feeding slides are driven by an

AC- motor.

The two rotating chucks are each driven by a belt from an AC- motor. The feeding ram is supported by linear guiding. The motions of the cutters are

controlled by the camshaft. The cut –off parts slide out of the machine

through a chute into a box.

The penetration depth of the feeder punch is individually adjustable.

The punch- and cuttholders are designed for easy tool change.

Advantages of the machine - Absolutely rectangular, burr free cut

- Quick tool change with quick change attachment

- Easy caliber change

- It is possible to pre-set the knives with a gauge

- The components are not cut on the punch

Automatic feeding system

The components are fed into the two feeding hoppers. They are then fed

through the feeding slide to the tool station in the cut- off machine.

Tool room Technical data

Tool stations 2

Number of cuts min-1 2 x 120

Weight to 1

Case body annealing

machine, RGM

The case body annealing machine is designed for recrystallisation annealing of ammunition cases for calibre 7.62mm or similar. The drive of feeding mechanisms and transport are driven by the main motor located under the turntable. The components rotate while they pass through the inductors, to guarantee even annealing. A downstream cooling system by water-air-heat exchanger is cooling down the cases and pins to room temperature.

High process safety is assured by the surveillance of acceptable mechanical, electrical and thermal limits. The machine stops immediately in case of any exposed machine elements and gives visual error indication.

Technische Daten

Annealing performance pcs/min 240

Heating performance kW 18

Heating system - induktiv

Heading press, WON 6 II H

The heading press is designed for indenting and heading of ammunition cases.

The press is a horizontal eccentric press. Both rams are guided by V- needle bearings. This play- free bearing type guarantees even drawn components.

The immersion depth of the punches can be individually adjusted. The punch- holders can be centralized by adjusting screws.

Automatic feeding system

The tubes are fed into the two feeding hoppers, from where they are guided by means of the turntable,

channel and feed in front of the machine tool station of the press.

Examples

of work

Tool room

Technical data Capacity of main ram kN 300 Stroke mm 160 Tool stations - 2 Number of strokes min-1 120 Weight to 4,2

Neck annealing machine,

HGM - JH

The neck annealing machine is designed for annealing tapered or non-tapered small-calibre ammunition cases.

The housing is constructed of a robust steel frame, covered with steel plates.

The components rotates while they pass through the inductors to guarantee even annealing. The optimum annealing temperature can be controlled from the temperature gauge.

High process safety is assured by the surveillance of acceptable mechanical, electrical and thermal limits. The machine stops immediately in case of any exposed machine elements and gives visual error indication. Standard equipment consists of: - Middle frequency generator - Complete drive unit - Electrical equipment - Two automatic feeding hoppers with feeding pipes - One turntable - Safety devices

Necking press, WON 7 II V

Necking and

calibration

The necking press is designed for the necking of ammunition cases in

more than one stage.

The press is a vertical eccentric press. Both rams are guided by play-free

bearings. This guarantees an even necking operation.

The punch- holders are fixed onto the main ram. A fine adjustment in

length can be made on each of the punches individually. The die- holders

are fixed onto the press housing.

The central lubrication system serves the guides and bearings with oil.

Advantages of the machine - 2 x 6 tool stations , i.e. the machine is multipurpose

- Operation sequences are variable

- Tools are individually adjustable

- Easy to change to other calibres

Auxiliary equipment - Punching unit for punching fire holes

- Fire hole control

- Greasing unit to grease the shell case

Necking,calibration

and punched fire hole

Technical data

Capacity of main ram kN 70

Stroke mm 140

Tool stations - 2 x 6

Number of strokes min-1 120

Weight to 5,3

Gauging machine, HDM - JH

Rough control- and

measuring stations

The gauging machine is designed to measure ammunition cases.

Measuring station for

- Case length (A)

- Primer hole depth (B)

- Primer hole diameter (C)

- Shoulder length (D)

- Base diameter (E)

- Groove diameter (I) - Edge strength (G)

- Open end diameter (H)

Advantages of the machine - Each case is full measured and all measures are stored

- The measured cases are ejected at the end of the machine

according to contingent faults

- Sorting out of the cases is programmable

- Easy to change to other calibres

- Programmable measuring system

Technical data

Number of stations 23 Rough control 5

Dimension control 6

Ejection control 5

Interstage stations 8

Collecting boxes 4

Single stage machines

for medium calibre

(12.7 – 40mm)

Cold flow press

WON 3U - 315

Draw press

WON 2U - 50

WON 2U - 160

Cold flow press

WON 3U - 315

WON 3U - 400

Necking press

WON 4U - 30

WON 4U - 65

Calibre 12,7 – 30mm: WON 3U-315 / WON 2U – 50 / WON 3U – 315 / WON 4U - 30

Calibre 30 – 40mm: WON 2U – 160 / WON 3U – 400 / WON 4U - 65

Draw press,

WON 2U – 50 / WON 2U - 160

This draw press is designed for the drawing of cases from

12,7 – 40mm made of steel or brass.

The press is equipped with a semi- automatic feeding system. Auxiliary equipment - Double tool station up to calibre 20mm (2 shell cases per stroke) - Automatic feeding system

Technical data WON 2U - 50 Capacity of main ram kN 500 Stroke mm 500 Number of stroke min-1 30 – 50 Weight to 11 Technical data WON 2U - 160 Capacity of main ram kN 1’600 Stroke mm 600 Number of stroke min-1 25 Weight to 18

Tool room

Cold flow press,

WON 3U – 315 / WON 3U - 400

The press is designed for heading and indenting steel or brass

ammunition cases from 12.7 – 40mm. Any other forward or

backward extrusion operations can be produced on this machine.

The press is equipped with a semi- automatic feeding system.

Advantages of the machine

- Easy change to other components

- Herringbone gear (noise reducing)

Auxiliary equipment - Automatic feeding and ejecting systems

-Double tool station up to calibre 20mm

(2 shell cases produced per stroke)

Examples of

products

Technical data WON 3U – 315 Capacity of main ram kN 3’150

Stroke mm 320

Number of stroke min-1 30 – 52

Weight to 20

Technical data WON 3U - 400

Capacity of main ram kN 4’000

Stroke mm 250

Number of stroke min-1 25

Weight to 25

Necking press,

WON 4U – 30 / WON 4U - 65

The necking press is designed for the necking of ammunition cases from 21,7 – 40 mm in steel or brass, in more than one stage. The press is equipped with a semi- automatic feeding system. Advantages of the machine - Constant working speed - Easy change to other components - Herringbone gear (reduction of noise)

Auxiliary equipment - Automatic feeding system - Double tool station up to calibre 20mm

(2 shell cases produced per stroke)

Technical data WON 4U - 30 Capacity of main ram kN 300 Stroke mm 496 Number of stroke min-1 50 Weight to 12

Technical data WON 4U - 65 Capacity of main ram kN 650 Stroke mm 600 Number of stroke min-1 25 Weight to 27

Presses: Combined

machines for Small calibre

Cupping press

NP

Combined draw

and trim machine

KZP

Neck- annealing

machine

HGM

Combined heading

and tapering machine

KBEP

Case body

annealing machine

RGM

Application: Calibers 9mm / 5,56mm / 7,62mm or similar

Cupping press, NP

The cupping press is designed to produce cups for rounds from blanks or flat material.

The press is a vertical eccentric press with two different strokes for punching and drawing operation.

The main ram for punching operation is carried on long pre-loaded linear guide rails. The ram for drawing operation is mounted on the main ram and carried in cylindrical roller cages, fitted slightly pre loaded.

The die holders are fitted on the housing which guarantees rapid tool change over.

Auxiliary equipment

- Decoiler - Conveying system for strips - Scrap chopper for rest strip

Technical data Number of strokes min-1 120 - 180 Punch force kN 100 – 1’000 Draw stroke mm 60 – 120 Productivity pcs/min n x 120 / 180 Weight to 12

35

Combined draw and

trim press, KZP

The configuration is designed to draw and trim of ammunition cases.

The press is a vertical eccentric design and is equipped with an AC- servomotor, automatic feeding system, electrical control including operating panel.

Die blocks are designed for quick tool changeover

The electrical control consists of one separate control cabinet and two identical swivable panels, which are located on both sides of the press.

Anti vibration shoes are fitted under the machine.

A special foundation is not necessary.

Technical data: Tool stations n 2x3 Capacity of main ram kN 400 Number of strokes min-1 80 – 120 Weight to 12

Tool room Row 1 Turntable in operating position

Operations: Cup feeding Initial draw Final draw Trim to length Eject drawn and trimmed tubes Eject excess material (trim) Checks: Components loaded Attendance Position control Initial draw Final draw Eject drawn and trimmed tubes Eject excess material Cooling system

Tool room Row 2 Turntable in tool change position

Tool room Row 2 Trimming

Combined draw and

trim press, KZP

USP‘s: - Cascade production: the case isn‘t pushed back through the dies

- „Milking machine“-principle, minimizes drive performance, weight and vibrations

- Very easy accessible, pleasant working height

- Easy and quick exchange of single part holders (plastic holder fingers)

Cascade processing

Working room, accessible from two sides

Part holder

Combined draw and

trim press, KZP

Combined heading and

tapering press, KBEP

The press is designed for heading, tapering and piercing ammunition cases.

The press has vertical toggle levers and is equipped with an AC- servomotor, automatic feeding, electrical control including operating panels.

The punch holders for indenting, heading and tapering are adjustable.

The blocks are designed for quick tool changeover and guarantee an easy access to the tool area.

The electrical control consists of one separate control cabinet and two identical swivable panels, which are located on both sides of the press.

Anti vibration shoes are fitted under the machine, therefore a special foundation is not necessary.

Technical data: Work stations n 2 x 20 Capacity of main ram kN 650 Number of strokes min-1 80 - 120 Weight to 16

Combined heading

and tapering press, KBEP

2

Case feeding Indenting punch Shell flip Die chuck

Operations: Case feeding Indenting Heading Date stamp Fire hole piercing Tapering Mouth calibration Checks: Components loading attendance Position control* Heading process finalised Fire hole pierced Necking process finalised Neck existing Case unloaded *The components will be position controlled loaded into the clips of the turntable

Adjustable punch chuck Heading punch Turntable with case holding finger clip Die chuck

Fire hole piercing Date stamp Stripper 4 taper stations

3

Combined heading and

tapering press, KBEP

USP‘s: - Very good accessibility from all 4 sides, pleasant working height, 2 mobile control panels

- Easy, quick tool exchange

- 1 mechanical drive train

- Press forces by Toggle levers, therefore better process behaviour at heading and indenting

- all further movements optimized by control by eccentric shafts and cam wheels

- Part transportation by two rotary tables instead of a single transport bar, therefore less vibrations

- Complete press has half the weight of comparable competitor's product, less strong fundament required

Combined heading

and tapering press, KBEP

Measuring

machines

SC Combined

machines

Comb. Draw

press KZP

Comb. Heading/

Indenting/Taper KBEP

Special purp.

machines Home Engineering

MC Single

machine

SC Single

machines Basics

Annealing

machines Forming

Special

presses

NOBAG’s presses:

Engineering & special presses

Tools

Production and running-in

Processes

- State calculations

- Tool calculations

- Machine development

- Cleaning and annealing

processes

- Chaining

- Running-in

Complete Cupping press tool block

Dimensioning, tests and running-in at

customer’s site

(example with a 3rd party machine)

Special press, Lead core

press KP 5-60 II H

The lead core press is suitable for forming projectile cores made of lead wire.

The press is a horizontal eccentric press consisting of ejector carriage, automatic feeder with wire feed unit and tool holder.

Tool room

Specifications Press force kN 50 Number of strokes min-1 120 Productivity pcs/min 240 Weight to 1,8

Stiletto Uniqueness Production uniqueness:

Full production cycle

Modern high-performance equipment leading international quality standards

Ecologically clean production

Technology and auxiliary equipment allows for autonomous provision of

accessories and tools for the manufacture of all ammunition components

Production uses raw materials in coiled brass rods and rolled sheets for

minimizing waste

Ability to produce ammunition of any caliber from 5.56 mm to 30 mm.

Use of customer-tailored Swiss and German equipment

Stiletto Systems Ltd.

www.stiletto.uk.com

[email protected]

- Power to Perform -