' SP-fS^???*?

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SECURITY CLASSIFICATION OF THIS PAGE (When Dmtm Entered)

REPORT DOCUMENTATION PAGE

I. REPORT NUMBER
*m Volume 1
f>jP-Xue rwi ruttirti» ■ ■ ■ ■■ —i
* ^PRODUCTION BASELINE *—
MK82 BOMB BODY ASSEMBLY, \/c|vj|rW
ENGINEERING ASSESSMENT OFJ>LANT EQUIPMENT
PACKAGE (££g) MODERNIZATION PROGRAM
»I «II »<— I' ■ w

Kaiser Engineers
in Association with Stetter Associates, Inc.

9. PERFORMING ORGANIZATION NAME AND AOORESS

Kaiser Engineers
300 Lakeside Drive, P. 0. Box 23210
Oakland, CA 94623
11. CONTROLLING OFFICE NAME AND ADDRESS
Department of the Army
Project Manager, Munitions Production Base
Modernization & Expansion, Dover, NJ 07801
U- MONITORING AGENCY NAME ft ADDRESSff/ different

1ft. DISTRIBUTION STATEMENT (ot thie Report)

Approved for public release; distribution unlimited

17. DISTRIBUTION STATEMENT (ot the ebetrect entered In Block 20, II different horn Report)

i O
O It. SUPPLEMENTARY NOTES

The production baseline was designed as a standard for evaluating existing

MK82 bomb production facilities.

tft. KEY WORDS (Continue en re we* me old* II neceeemry end Identity by block number)

Plant Equipment Package Model Line

PEP Bomb
PEP Modernization MK82
Metal Parts Production Line
Ü7 ABBTHACT (Cemtmve em T— emm It imwmy ami identity by Meek numbot)
\k production baseline is a theoretical production line based on technical
data package configurations and specifications. This report describes
alternative methods and provides a recommended method for the production
of metal part components and the assembly of the MK82 bomb body. t.

0/
_z?y 6-i ~ Mi
DO t'JSn W3 EOf TtOM OT t MOV ft* IB ETE Unclassified
SECURITY CLASBIFICATIOM OF TXtB PAGE Dote Entered)
A.^ ^tSS^jJi***^^^:-*^ -^,- ■-,.-:■■ : .. „.i^toaa^l mtm I •- ■''^■-'--«-.■"■«■fa-*^.w.s
 ^g*»s^p^^ r.rir- -*-;■■■ . ,

**■»

KAISER
ENGINEERS

PRODUCTION BASELINE
MK82 B0K3 BODY ASSEMBLY

REPORT NO. 78-13-R-1

Volume 1

ENGINEERING ASSESSMENT OF
PLANT EQUIPMENT PACKAGE (PEP) MODERNIZATION PROGRAM

Prepared for Project Manager

Munitions Production Base Modernization and Expansion

Administered by U.S. Army Armament Research and Development Command

Contract No. DAAK10-78-C-0020

July 1978

KAISER ENGINEERS
In Association with Stetter Associates, Inc.

C r\ \y o
C o \j

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 ^^^g*^^ ~- ■• ,,-.-.•. . •

KAISER
ENGINEERS

TABLE OF CONTENTS

i i
Section Page

I. Introduction 1-1

II. Process Description Summary II-1

III. Analysis of Operations III-1

A. Casing, Bomb, MK82 Mod 1 (1380548) III-1

B. Ring, Adapter, Bomb Body (1252606) 111-17
C. Plug, Base, Bomb Body (4902487) 111-22
D. Insert, Suspension Lug (1212112) 111-27
\ E. Insert, Forward (1380230) 111-31
F. Retainer, Fuze Liner (4902493) 111-35
G. Fuze Liner, Aft (4902490) 111-37
H. Canister - Item 1, Part of (4902490) 111-38
I. Collar - Item 2, Part of (4902490) 111-39
J. Sleeve, Fuze Liner (4902492) 111-40
K. Fuze Liner, Aft (4902490) 111-41
L. Fuze Liner Assembly (4902494), Aft 111-43
H. Fuze Liner, Forward (1239593) 111-44
N. Canister - Item 1, Part of (1239593) 111-45
0. Collar - Item 2, Part of (1239593) 111-46
P. Sleeve, Fuze Liner (4902492) 111-47
Q. Fuze Liner, Fwd (1239593) 111-48
R. Fuze Liner Assembly (4902495), Fwd 111-50
S. Body Assembly, Bomb, General Purpose
(1380545) 111-51

IV. Recommended Production Baseline for the MK82

Hod 1, 500-lb Bomb Body Assembly IV-1

A. Casing, Bomb, MK82 Mod 1 (1380548) IV-4

B. Ring, Adapter, Bomb Body (1252606) IV-9
C. Plug, Base, Bomb Body (4902487) IV-11
D. Insert Suspension Lug (1212112) IV-13
E. Insert, Forward (1380230) IV-15

■ nr imW
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 *mmmwmmww*-*^Mm!mm&wm*wm^ «a'ggR'&w^MaPiH^it'^ ■ .

KAISER
ENGINEERS

LIST OF TABLES

Tafrleg £a*£

II-1 Process Description Summary for Body

Assembly (1380547) H-3

II-2 Process Description Summary for Adapter Ring

(1252606) II-9

II-3 Process Description Summary for Base Plug

(4902487) H-11

II-4 Process Description Summary for Insert,

Suspension Lug (1212112) 11-13

II-5 Process Description Summary for Forward

Insert (1380230) 11-14

IV-1 Recommended Sequence of Manufacture

Tube Method for Casing (1380548) IV-17

IV-2 Recommended Sequence of Manufacture

Hot Cup Method for Adapter Ring (1252606) IV-20

IV-3 Recommended Sequence of Manufacture

Bar Stock Method for Base Plug (4902487) IV-21

IV-4 Recommended Sequence of Manufacture

Hot Cup Method for .nsert, Suspension
Lug (1212112) IV-22

IV-5 Recommended Sequence of Manufacture

Hot Cup Method for Insert, Forward
(1380230) IV-23

IV-6 Estimated Equipment Cost Summary for

Recommended Production Baseline IV-24

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KAISER
ENGINEERS

I.TST OF FIGURES

Follows
Iigy££Ä Page

III-1 Casing, Bomb, General Purpose

500 Pound MK82 Mod 1, Empty, Part
No. 1380547 III-1

III-2 Flow Chart, MK82 Bomb Body Sub-Assembly

(1380547) III-1

III-3 Flow Chart, MK82 Bomb, Ring Adapter

(1252606); Base Plug (4902487); Insert,
Suspension Lug (1212112); Insert, Forward
(1380230) 111-17

III-4 Body Assembly, Bomb, General Purpose,

500 Pound, MK82 Mod 1, Eapty, Part No.
1380545 111-51

III-5 Flow Chart, MK82 Bomb Body Assembly

(1380545) 111-51

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KAISER
ENGINEERS

I. INTRODUCTION

The production baseline described herein is a theoretical munitions

production line developed from technical data package configuration and
specifications applicable to th-3 manufacture of the MK82 bomb body
assembly. This baseline reflects the best elements of current methods
of manufacture utilized by existing producers, and it is limited to
proven state-_f •the-art production technology.

The production baseline includes industrial production equipment and

critical support equipment only. Discussion of all other contributory
factors is restricted to general comments.

When possible, examples of recommended equipment are included in the

general discussions of each operation. An example cited should be
considered neither as the only choice nor as an indication of any
exclusion. The type of tooling used in the operations is included only
when it affects equipment choice. Without specific costs and design
data, any detailed discussion of tooling is of doubtful value.

The MK82 production baseline is designed to produce the following metal

parts and assemblies:

1265394 Charging-tube fitting

1252606 Bomb-body adapter
1380547 Bomb casing
1212112 Single lug
1380230 Double lug
1239593 Forward fuze-liner assembly
4902493 Fuze-liner retainer
4902490 Aft fuze-liner assembly
4902487 Base plug

The remaining parts of the MK82 bomb body assembly are purchased from
vendors specializing in the process required to produce the part. For
example, part No. 251634, a fuze insert shipping plug made from plastic
material, would be produced by a vendor with plastic molding
capabilities.

1-1

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KAISER
ENGINEERS

II. PROCESS DESCRIPTION SUMMARY

Following this page are process description summaries that show the
sequence of operations required to manufacture the components of the
MK82 bomb body assembly. Equipment used to perform each operation,
including any applicable alternate equipment, is also listed. Only
industrial plant equipment (IPE) is specifically identified. Other
plant equipment (OPE) is discussed only where necessary to identify the
process requirements.

The operation numbers are four-digit characters indicating the numerical

sequence of operations. Across from the operation number is a
description of the operation, with the equipment listed below.

Under the operation sequence, a path shown by X's indicates steps of

I manufacture. If an alternate method of manufacture is available, it is
shown as an alternate on the flow charts, Figure III-2 and Figure III-3-

For a detailed description of each operation, see section III, Analysis

of Operations.

Gross capacities, production capabilities of the equipment designated

for the operation, are shown in pieces per hour. These figures are not
factored for downtime or delays. As an example, a press capable of
cycling in 10 seconds (i.e., 6 cycles per minute) will have a gross
capacity of 360 pieces per hour.

The drawing/specification of the MK82 bomb casing shows a hot-forge

option -o the seamless and seam-welded tubing. The MK82 production
baseline report addresses both the forging and tubing processes,
although the forging process appears not to be economical. The forging
process demands presses (hammers) of both nigh tonnage and extra stroke
length. The presses neither are readily available nor can they be
specially manufactured within a reasonable lead time.

II-1

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— '
 mrrrmm wprnm* wmm K.m ~:.^™™r^T>m?*

KAISER
ENGINEERS

The following process description summaries are provided:

Table ILUfi

II-1 Casing (1380548)

II-2 Adapter Ring (1252606)
II-3 Base Plug (4902487)
II-4 Insert, Suspension Lug (1212112)
II-5 Forward Insert (1380230)

l- \

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ENGINEERS

III. ANALYSIS 02 OPERATIONS

A. CASING. BQMBr MK82 MOD 1 (H80S48)

This section provides an analysis of operations for the production

of the casing for the 500-pound MK82 Mod 1 bomb. Details of the
body assembly are shown in Figure III-1. The flow chart depicting
the sequence of operations is shown in Figure III--2.

Material - Carbon steel, seamless extruded tube/seam welded plate

- Carbon steel, forging quality

1. Operation 1110 - Handle Billets/Tubes

Equipment - Standard cranes, hoists, and transfer equipment

The handling of steel billets/tubes is not a step in the

production process, but the materials handling problem must be
anticipated in any line designed for high-tonnage consumption of
steel billets/tubes. The operations that must be considered are
discussed below.

a. Receiving Bulk Sfcaofc

This operation includes moving rolling stock and trailers
and stacking material in the storage areas. Overhead
cranes, forklifts, and jib cranes are used to unload the
stock. The stacking is arranged to assure material
traceability.

Receiving inspection is completed before «* lot becomes

available for processing. If the material's supplier
certification is acceptable, a verification of quantity,
either by weight or by length, is accomplished without extra
handling.

b. HpYttBont Qf Blllcta/Tub« from Bulk Steam fca

Flrat EEQfllfll Station. 8-1/2-Inch RCS. S.'ttO lb
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ENGINEERS

This operation includes:

W •
o Separating stock into single billets/lengths. Special
handling equipment such as magnets, hooks, grapples,
slings, and hoists are needed.

o Continuously processing individual billets/lengths

through weighing devices, metallurgical scanning, and
physical measuring devices. This activity is required
to develop the correct mult/length weight to be
generated at the billet/tube separation operation. A
computerized system to scan weight and length is the
preferred control system. Although the system does not
increase the yield per billet/tube, it assures the
cutting of mults to the required weight/length.

o Moving billet/length through separation operation. This

activity involves controlling the alignment and
progression of the billet/length and handling the
rejects. Included are any additional functions, such as
multiple-racking saw-trim requirements and a possible
laydown or holding requirement.

An example of the proper equipment to use is a Shepard-Niles

25-ton bridge crane.

2. Operation 1120 - Separate Lengths. Tube

Equipment alternatives:
- Saw, carbide tipped, 24 inch, 25 hp (sawing)
- Saw, band, 16 inch, 15 hp (sawing)
- Flame cutting equipment
- Cutoff machine, rotary, 60 hp

a. Circular Saw

Carbide-tipped circular saws produce precision lengths.

An example of the proper equipment to use is a Heller

Gebrueder SSH 630, circular saw, 25 hp.

III-2

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KAISER
ENGINEERS

b. Band Saw
The band saw, although less accurate, is less expensive than
a circular saw. The band sawing process is slow, compared
with the forging rate; therefore, materials handling
provisions must be developed for multiple machines.

An example of the proper equipment to use is a Do-All

Automatic C70, band saw, 15 hp.

c. Flaae Cutting

Flame cutting equipment can be used with an automated

rotating device and materials handling equipment.

An example of the proper equipment to use is an H&M Pipe

Cutting 4 Beveling #2, with a machine torch adapted for
synthetic fuel.

d. Rotary Cutting

*n The tube is cut off to the required length, while chamfers

are generated on the outside diameter. This method
eliminates end deburring.

An example of the proper equipment to use is a Stamet Co.

S024450, lathe, automatic, 95-r/min spindle, 60 hp.

3. Operation mo - Separat? Mult?« Fgrginfi

Equipment alternatives:
- Press, 2,200 ton (cold shearing)
- Saw, carbide tipped, 2M inch, 30 ^P (sawing)
- Saw, band, 16 inch, 25 hp (sawing)
- Press, 1,000 ton, and torch (nick and break)
- Flame cutting equipment

The weighing of ea n mult is an integral part of this operation.

•
I KAISER
m \ ENGINEERS

a. Cold Shear

The 2,200-ton shear press requires automatic feed, clamp,

and eject attachments. The press may be in the production
line to minimize materials handling and traceability pro-
blems, but the press can be off-line if facilities dictate.

An example of the proper equipment to use is a Buffalo

I ! Billet Shear, 2,200 ton.

b. Circular Saw
Carbide-tipped circular saws produce precision mult.

Abrasive cutting, even done wet, is not approved.

Experience has shown that trapped abrasive causes excessive
tool wear during forging.
i*
An example of the proper equipment to use is a Heller
Gebrueder SSH 630, circular saw, 25 hp.

c. Band Saw
The band saw, although less accurate, is less expensive than
a circular saw. The band-sawing process is slow, compared
with the forging rate; therefore, materials handling
provisions must be developed for multiple machines.

An example of the proper equipment to use is a Do-All

Automatic C70, band saw, 15 hp.

d. Nick and Break

This process is based on the concentration of a stress

called the nick in the cold billet, followed by a cold-
breaking operation.

An example of the proper equipment to use is a Production

Machinery Division U.S. Industry Press, Mechanical,
Vertical, Straight Sided KS11000-42, 1,000 ton and Arcair
62-001, Electrode 1/U - 3/4.

III-U

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KAISER
ENGINEERS

e. Flame Cutting

Flame cutting is not recommended, because it is slow and

wasteful of material. It may also affect the metallurgy of
the mult.

4. Operation 1140 - Heat Mult. Forging

Equipment alternatives:
- Heater, induction, 2200 F, 5000 kW, 180 Hz
- Rotary-hearth furnace,gas, 2200 F
- Continuous-tunnel furnace, gas, 2200 F, 8-1/2-inch RCS

This step is required for the hot-cup, hot-draw process. Time

at temperature should be long enough to assure uniform heating,
but excessive soak time should be avoided, because of the high
degree of scaling that occurs in gas furnaces with natural
atmosphere.

Examples of the proper equipment to use are:

a. Tocco induction heating in-line system with multicoil

stations for sequential heating, 2200 F.

I . Flinn and Dreffein Inc., rotary hearth, gas fired, 2200 F.

c. Lindburg Bros. Co., T-slot oven, open flame, gas fired, 2200
F.

5. Operation 1150 - Descale Mult. Forging

Equipment - Cabinet, water-jet automatic feed

The removal of scale from hot mults prior to forging is

accomplished by water jets. Water pressures of 1,200 to 2,200
lbf/in2 and flow rates of 1/2 to 2 gal/s normally are used,
•ower feeding of the hot mults is done by chain conveyor or
pusher.

This equipment is normally custom-made to incorporate handling

as well as descaling equipment.

III-5

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KAISEF*
ENGINEERS

An example of the proper equipment to use is a Pangborn Div. of

Carborundum Co. ES421, descaling machine, 7-1/2 hp.

6. Operation 1160 - Cabbage. Forging

Equipment - Press, hydraulic, 1,500 ton, 48-inch stroke

In the cabbage step, the heated square mult is shaped into a

round die. Once the mult is sized, the pierce operation
accomplishes the first major movement of metal, with or without
reheating.

An example of the proper equipment to use is a Verson Allsteel

Press 1500HDI-76T, 1,500 ton, 48-inch stroke.

7. Operation 1170 - Pierce. Forging

Equipment - Press, hydraulic, 1,250 ton, 60-inch stroke

The pierce step is a hot-working proces^ that uses a backward

extrusion technique to form the sized mult into an intermediate
hollow length. The uniformity of metal flow determines the
effectiveness of the succeeding forging operations in attaining
overall dimensional accuracy and a high level of quality.

An example of the proper equipment to use is a Verson Allsteel

Press 1250 HD1-84T, 60-inch stroke.

8. Operation 1180 - First Draw. Forging

Equipment - Press, hydraulic, 600 ton, 144-inch stroke

The casing is hot-drawn, and the wall thickne^. is reduced as

the casing is extended through rings and over a mandrel.

An example of the proper equipment to use is a Bliss Co. press,

horizontal, special, 600 ton, 144-inch stroke.

9. Operation 119Q - Draw and PUrce Baa?, ForKln*

Equipment - Press, hydraulic, 600 ton, 144-inch stroke

III-6

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KAISER
ENGINEERS

The bomb casing is open at both ends. It is now hot-drawn to

length, and during the same stroke, the end is pierced.

An example of the proper equipment to use is a Bliss Co. press,

horizontal, special, 600 ton, 144-inch stroke

10. Operation 12QQ - Cool

Equipment - Tunnel, cooling

High carbon steels have mechanical properties sensitive to the

rate at which the steel is cooled from forging temperatures. To
produce the best metallurgical structure for subsequent
machining operations, the cooling must be slow. Slower cooling
introduces fewer thermal stresses and less warpage.

An example of the proper equipment to use is a Selas Corp.

tunnel, four stage, special.

11. Operation 1210 - Descale Inside Surface. Forging

Equipment - Cabinet, abrasive cleaning, 75 hp

The descaling by abrasive cleaning is necessary Drior to sub-

sequent machining and forming operations.

An example of the proper equipment to use is a Wheelabrator-

Frye, 42D393» blast-cleaning machine.

12. Operation 1220 - Swale, Qytsr Surface, For ft Ins

Equipment - Cabinet, shot blast, automatic feed, 75 hp

The removal of scale from the forging is accomplished by

propelling steel shot at high velocity against the surface while
the forging is being conveyed on skewed and tapered rolls. This
exposes all of the surface to the scaling media.

An example of the proper equipment to use is a Wheelabrator-

Frye, 42D393, blast-cleaning machine.

III-7

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KAISER
ENGINEERS

13. Operation 1210 - Trim & Turn Nose and Base Ends. Forging

Equipment - Way-type machine, single station, double ended

horizontal, boring, 50 hp

This operation prepares the forging for the nosing operations.

An example of the proper equipment to use is a machine made by

Heald Machine Co., 442A, 80-inch-long table, 50 hp.

iu. Operation 12HQ - Pre-form NQge End

Equipment - Press, hydraulic, 500 ton, 36-inch stroke

Preforming the nose is a combination of reducing the diameter of

the nose end and upsetting the tube end to increase the wall
thickness.

An example of the proper equipment to use is a Verson Allsteel

Press 500HDI-48T, 500 ton, 36-inch stroke.

15. Operation 1250 - Pre-form Nose and Base End. Tube

Equipment - Press, hydraulic, 600 ton, 48-inch stroke

The preforming of the nose and the forming of the base may be
combined when using tubing.

An example of the proper equipment to use is a Verson Allsteel

Press 600HDI-66T, 600 ton, 48-inch stroke.

16. Operation 1260 - Heat Nose End

Equipment - Heater, induction, 1400 F, 500 kW, 180 Hz

The nose end of the casing requires heating prior to the nosing
operation. A convenient heating method is induction heating
ranging from 1200 F to 1400 F.

An example of the proper equipment to use is a Westinghouse

Electric induction coil.

III-8

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ENGINEERS

17. Operation 1270 - Form Nose

Equipment - Press, hydraulic, 500 ton, 36-inch stroke

Forming the nose is a combination of reducing the diameter of

the nose and upsetting the end to increase the wall thickness to
meet the required length for the fuze liner wall.

An example of the proper equipment to use is a Verson Allsteel

Press 500HDI-48T.

18. Operation 1280 - Heat Base End. Forging

Equipment - Heater, induction, 1400 F, 500 kW, 180 Hz

To form the base end of the casing from a forging requires prior
heating. This operation may not be required for casing made
from tubing.

An example of the proper equipment to use is a General Electric

Co. induction coil.

19. Operation 1290 - Form Base End

Equipment - Press, hydraulic, 500 ton, 36-inch stroke

The diameter of the base end is reduced when it is formed. The

wall is to be thickened only slightly. In the case of the
forged casing, the ring adapter No. 1252606 is formed in this
operation.

An example of the proper equipment to use is a Verse Allsteel

i Press 500HDI-48T.

20. Operation HOP - Rough-Machine Nose End

Equipment - Lathe, automatic, chucking, 12-inch swing,

72-inch centers, 30 hp

The nose end of the casing is rough-bored, counter-bored, and

faced.

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KAISER
ENGINEERS

An example of the proper equipment to use is a Lodge & Shipley

Co., Profiturn 50, automatic lathe, 12-inch swing, 72-inch
centers.

21. Operation niQ - Machine Base End. Tube

Equipment - Lathe, automatic, chucking, 12-inch swing, 72-inch

centers, 30 hp

The base end is cut off, a bore is made for the ring adapter,
and the outside and inside end are chamfered for welding.

An example of the proper equipment to use is a Lodge & Shipley

Co., Profiturn 50, automatic lathe, 12-inch swing, 72-inch
centers, 30 hp.

22. Operation H20 - Machine Nose and Base End. Tube (Alternate)

Equipment - Way-type machine, single station, double ended,

horizontal, boring, 50 hp

Operations 1300 and 1310 are combined on one double end machine,
where the nose and base ends are machined simultaneously.

An example of the proper equipment to use is a machine made by

Heald Machine Co., 442A, 80-inch-long table, 50 hp.

23. Operation mo - Rough Machine Base - Adapter Ring. Forging

Equipment - Lathe, automatic chucking, 12-inch swing, 72-inch

centers, 30 hp

This operation is used for the adapter ring as forged with the
casing. The base is bored, faced, and cut for a relief groove,
and the adapter section is turned.

An example of the proper equipment to use is a Lodge & Shipley

Co., Profiturn 50, automatic lathe, 12-inch swing, 72-inch
stroke, 30 hp.

111-10
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ENGINEERS

24. Operation IMfl - Flame Cut Lag and Charging Ma Adapter iial&a
Equipment alternatives:
- Two automatic machine torches
- Two 500-600 A power supplies
- Special cradling and fixturing machine base

The bomb body is conveyed into the special flame-cutting

machine. The body is aligned and positioned. The two torches
can be guided either mechanically by templates or by a
numerically controlled device to follow the required cutting
pattern.

An example of the proper equipment to use is a Linde Division,

Union Carbide Co., CM-56 with CVM5 cutting torches.

25. Operation I35fl - Weld Lug and Charging Adapters

Equipment alternatives:
- Two automatic machine torches, gas shielded with
flux-cored wire
- Two 500-600 A 100 percent duty-cycle power supply
- Special cradling and fixturing machine base

The bomb-body sub-assembly is conveyed into the special welding

machine, where the lug and the adapter are installed facing up.
The body is aligned and positioned. The two torches can be
guided either mechanically by templates or by a numerically
controlled device to follow the required weld pattern.

An example of the proper equipment to use is a Linde Division of

Union Carbide Co., VI600 welding power supply, SWM-23 wire
feeder, ST-5 water-cooled machine torch.

26. Operation H60 - Wald Ring. Adapter. Tubing

Equipment - Automatic machine torch with arc-length sensor,

gas shielded with flux-cored welding wire
- 500 - 600 A 10ü percent duty-cycle power supply
- Special cradling and fixturing machine base

111-11

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The bomb-body sub-assembly is conveyed into the special welding

machine. The bomb body is affixed in place. The arc is then
started, while the bomb body rotates 360 degrees for a one pass
weld.

An example of the proper equipment to use is a Linde Division of

Union Carbide Co. VI-600 welding power supply, SWM-23 wire
feeder, ST-5 water-cooled machine torch.

27. Operation 1T70 - Heat Treat and Temper

Equipment alternatives:
- Heater, induction, 1550 F to 1650 F, 3000 kW,
180 Hz or
- Furnace, gas, 1550 F to 1650 F; hardening and
- Furnace, gas, 750 F to 950 F; tempering

The strength of the case is achieved by heating and quenching.

Furnace or induction heating is used to heat at 1550 F to 1650
F. Quenching should be by immersion in an agitated bath. The
case is tempered at 950 F in an atmosphere-controlled draw
furnace.

An example of the proper equipment to use is a special heat-

treat and temper r stem made by Flinn & Dreffein Engineering
Co., special.

28. Operation H80 - Blast Clean ID and QD

Equipment - Roto-blast unit

All scale is blast-cleaned from inside and outside surfaces.

An example of the proper equipment to use is a Wheelabrator &

Frye Co., 42D393, blast-cleaning machine.

29. Operation nqo - Check Hardnaaa

Equipment - Hardness tester, brinnel, automatic

The hardness required by specifications is checked.

111-12

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 jLUiiiuuiUU IP'J». mwMW mäiimjxiM,,,^\i., mgmmamgKgggfi/iffgfgggg^t^gmitKU

KAISER
ENGINEERS

An example of the proper equipment to use is a Rockwell Corp.,

5JR, hardness tester.

30. Operation 1400 - Bore. Face. Thread Nose End

Equipment - Lathe, turret, automatic 12-inch swing, 72 inch

centers, 30 hp

This is a standard machining operation.

An example of the proper equipment to use is a Warner-Swasey,

automatic lathe, 12-inch swing, 72-inch centers, 30 hp.

31. Operation 1410 - Bore. Face. Thread. Machine Base End

Equipment - Lathe, turret, automatic 12-inch swing, 72-inch

centers, 30 hp

This is a standard machining operation.

An example of the proper equipment to use is a Lodge & Shipley

Profiturn 50, automatic lathe, 12-inch swing, 72-inch centers,
30 hp.

32. QpsraUon Ugfl - Step. Drill aad Tap Lifting Balaa and
Charslag Halfl

Equipment - Drill press, tapping multistation,

2-1/4-inch capacity

This is a standard machining operation.

An example of the proper equipment to use is a Barnes

multispindl« drill press, special.

33. Operation lAifl - Prill and Coimttraink 16 HQI« Bare End

Equipment - Drill press, multisplndle, 3/9 capacity

This is a standard machining operation.

111-13

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 pBljgyfcy^M.iMiwi'.mjfr l,^,J,;J^yw?^^^w^g^ljf^^^'; \
...

KAISER
ENGINEERS

An example of the proper equipment to use is a Barnes

multispindle, horizontal drill press, special.

34. Operation 1440 - Drill Countersink & Tap Nose Look Hole

Equipment - Drill press, tapping, 3/3 capacity

This is a standard machining operation.

An example of the proper equipment to use is a Zagar, Inc.,

Special.

35. Operation 1450 - Drill 16 Holes. Base End and Drill and
Tap BflM End

Equipment - Drill press, multispindle, 2 units, horizontal

This operation finish-machines the casing in one setup.

Operations 33 and 34, on the other hand, require two setups.

An example of the proper equipment to use is a Barnes

multispindle, horizontal drill press, 15 hp.

36. Operation 1455 - Machine Complete

Equipment - Special transfer-and-shuttle type with turning,

boring, drilling and threading heads, and
attachments

This alternate operation reduces the handling and extensive

setups (outlined in the preceding steps, starting with Operation
1400 to Operation 1450) which relate to conventional equipment
and processes.

An example of the proper equipment to use is a specially

designed and built transfer-and-shuttle turnirj machine.

37. Operation 1460 - Teat Lifting Lug Adapter

:
Equipment - Special test machine
■: ü

111-14

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 IHiiiji^iPi'Uuviyj -T^y^-jgBssffwfl^ . ■

KAISER
ENGINEERS

The required push-and-pull test shown in the drawing is

conducted.

An example of the proper equipment to use is special test

equipment manufactured to dictated parameters.

38. Operation 1470 - Pressure-Test Bomb Body

Equipment - Special test equipment

The required pressure test shown in the drawing is conducted.

An example of the proper equipment to use is special test

equipment manufactured to dictated parameters.

39. Operation 1480 - Stamp Identification

Equipment - Machine, stamping, rotary, 5 hp

The stamping is performed on a horizontal rotating fixture. At

this time, the nomenclature, date of manufacture, lot number,
and contractor's identification are imprinted.

An example of the proper equipment to use is a James H. Matthews

Co. Marking Machine N2201.

40. Operation 1A3Q - Phosphats IrsaL

Equipment - Chemical line (multistage spray/dip system)

Foreign particles are removed, an<l the surface is prepared for

subsequent painting.

An example of the proper equipment to use is a five-stage

phosphatizer made by Litton Unit Handling Systems.
1 4 41. Operation 1500 - Paint Exterior

Equipment - Paint spraying machine, automatic,

electrostatic

111-15

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PPPI^^WWHMWWWiyM^^f^i^

KAISER
ENGINEERS

Except for the threads, both the inaide and outatde surfaces are
painted.

An example of the proper equipment to use is be a speoial unit

made by Binks Manufacturing Co.

111-16

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KAISER
ENGINEERS

B. RING. ADAPTER. BOMB BODY (1252606)

This section contains a detailed analysis of operations for the

production of the adapter ring. The flow chart depicting the
sequence of operations is shown in figure III-3.

Material - Carbon steel with yield strength MO,000 lbf/in2 and

tensile strength 70,000 lbf/in2, forging quality

1. Operation 211Q - Handle Billet

Equipment - Standard cranes, hoists, and forklift trucks

The handling of steel billets is not a step in the production

process, but the materials handling problem must be anticipated
in any line designed for high-tonnage consumption of steel
billets. How these operations must be considered, is discussed
below.

a. Receiving Billets
This operation includes moving rolling stock and trailers
and stacking material in the storage areas. Overhead
cranes, forklifts, and jib cranes are used to unload the
stock. The stacking is arranged to assure material
traceability.

Receiving inspection must be completed before a lot becomes

available for processing. If the material's supplier
certification is acceptable, a Verification of quantity,
either by weight or by length, can be accomplished without
extra handling.

o. Hovfiflsnt of BUUts Frog Storage, to Firat Process SUUin

5-inch RCS. K7QQ-lb-£ach Billet

This operation includes the movement of stock to the

sawing or shearing operation of the billet preceding the
first processing step.

111-17
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 KAISER
ENGINEERS

Examples of the proper types of equipment to use are a

Shepard-Niles 25-ton bridge crane and a Clark 2-ton forklift
truck.

2. Operation 2120 - Separate Mults

Equipment alternatives:
- Shearing machine, 1,000 ton (cold shearing)
- Saw, carbide tipped, 24 inch, 30 hp (sawing)
- Saw, band, 16 inch, 25 hp (sawing)

a. gold Shear

The 1,000 ton shearing machine requires automatic feed,

clamp, and eject attachments. The press may be in the pro-
duction line to minimize materials handling and traceability
problems or be off-line if facilities dictate.

An example of the proper equipment to use is a Buffalo Forge

Co., shearing machine, 5-5/8-inch bar, model 13.

b. Circular Saw

Carbide tipped circular saws produce precision mult.

Abrasive cutting, even done wet, is not approved.

Experience has shown that trapped abrasive causes excessive
tool wtar during forging.

An example of the proper equipment to use is a Heller

Gebrueder cut-off machine, circular saw blade, manual, model
No. SSH630.

c Band Saw
Although a band saw is less accurate, it is less expensive
than a circular saw. The band-sawing process is slow,
compared with the forging rate; therefore, materials
handling provisions must be developed for multiple machines.

An example of the proper equipment to use is a Do-All cut-

off machine, automatic feed, horizontal, model No. P16M.

111-18

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KAISER
ENGINEERS

3. Operation 2130 - Heat Mult

Equipment alternatives:
- Heater, induction, 2200 F, 400 kW, 180 Hz
- Rotary-hearth furnace, 2200 F
- Continuous tunnel furnace, 2200 F

Induction heating is the preferable method since the heating is

normally fast enough to prevent scaling of the mult. If furnace
heating is used, the furnaces should have dual fuel burners.

Examples of the proper equipment to use are:

a. Tocco induction-heating in-line system with multicoil

stations for sequential heating, 2200 F.

b. Flinn and Dreffein Inc., rotary hearth, gas-fired, 2200 F.

c. Lindburg Bros. Co. T-slot oven, open flame, gas-fired, 2200

F.

**■ Operation 2140 - Descale

Equipment - Squirrel-cage tumbler

The raults are placed in a squirrel-cage tumbler to remove the

scale formed from exposure to the atmosphere. This operation
normally is not necessary, if induction heating is used.

Typically, the squirrel-cage tumbler is custom designed and made

for the part being tumbled.

5. fl&eraUon 215Q - Pancate, prQ-fgrm. furiQh, and RestriKe

Equipment - Press, mechanical, 2,000 ton, 10-inch stroke

The pirt is forged in a three-stage die with one part in each

stage at a time.

An example of the proper equipment to use is a National

Machinery Co. Maxipress 2000, mechanical.

111-19

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 KAIL'ER
ENCIN.'^RS

6. Operation 2160 - Descale

Equipment - Blast-clean and finishing machine, horizontal

During this operation, forging scale is removed by tumble

blasting.

An example of the proper equipment to use is a Pangborn

Corporation blast-cleaning machine, endless-belt barrel type,
model 15GN3.

7. Operation 2170 - Ring Roll

Equipment - Ring rolling-machine, 10-inch diameter x 3-inch

capacity

This operation enlarges and rough-rolls the adapter ring outer

and inner contour to expedite machining and conserve material.
This operation can be eliminated, if the ring adapter was forged
to rough size at Operation No. 2150.

An example of the proper equipment to use is a Wagner-Dortmund,

KFRWT-630, four-mandrel, ring rolling mill.

8. Operation 2175 - Rough and Finish Machine

Equipment - Lathe, six-spindle, automatic chucking,

10-inch capacity

The forging is rough-and-finish machined without being ring

rolled.

An example of the proper equipment to use is a National Acme Co.

RPA6 automatic chucker, 30 hp.

9. Operation 218C - Machine Ends and Outside

Equipment - Lathe, six-spindle, automatic chucking,

10-inch capacity

The inside surface is forged to size. Machining is required on

the ends and the outside contour.

4 111-20

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»- —-
KAISER
ENGINEERS

An example of the proper equipment to use is a National Acme Co.

automatic chucker, 30 hp, model RPA6.

10. Operation 2190 - Clean

Equipment - Vapor degreaser

This is a standard cleaning process to prepare for welding.

This equipment is classified as "other production equipment."

An example of the proper equipment to use is a Baron-Blakeslee,

model 1019.

111-21

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 KAISER
ENGINEERS

C. PLUG. BASE. BOMB BODY (4Q02487)

This section contains a detailed analysis of operations for the

production of the base plug. The flow chart depicting the sequence
of operations is shown in figure III-3.

Material - Carbon steel with yield strength 40,000 lbf/in2 and

tensile strength 70,000 lbf/in2, forging quality
I !
- Carbon steel with yield strength 40,000 lbf/in2 and
tensile strength 70,000 lbf/in2 bar stock

1. Operation 3110 - Handle Bar/Billet

Equipment - Standard cranes, hoists, and forklift trucks

The handling of steel bar/billet is not a step in the production

process, but the materials handling problem must be anticipated
in any line designed for high-tonnage consumption of steel
bar/billets. The operations to be considered are discussed
below.

a. Receiving Bulk Stock

This operation includes moving rolling stock and trailers

m and stacking material in the storage areas. Overhead
cranes, forklifts, and jib cranes wil] be used to unload the
stock. The stacking is arranged to assure material
traceability.

Receiving inspection must be completed before a lot becomes

available for processing. If the material's supplier
certification is acceptable, a verification of the quantity,
either by weight or by length, can be accomplished without
extra handling.

b. Movement of Bar/Billets From Storage to First

Process Sta ion. 4-inch. 1.100-lb-Bach Billet and
6-1/2-irwh, 2.2QQ-lfr-Sach par

This operation includes the movement of stock to the sawing

or shearing operation to produce forgings for the first
machining operation.

111-22

laa *tfb
 KAISER
ENGINEERS

An example of the proper equipment to use is a Shepard-Niles 25-

ton bridge crane and a Clark 2-ton forklift truck.

2. Operation 3120 - Separate Milts

Equipment alternatives:
- Shearing machine, 1,000 ton (cold shearing)
- Saw, carbide tipped, 24 inch, 30 hp (sawing)
- Saw, band, 16 inch, 25 hp (sawing)

a. gold Shear

The 1,000-ton shearing machine requires automatic feed,

clamp, and eject attachments. The press can either be in
the production line to minimize materials handling and
traceability problems or be off-line if facilities dictate.

An example of the proper equipment to use is a Buffalo Forge

Co., shearing machine, bar, model 13.

b. Circular Saw

Carbide-tipped circular saws are used to produce precision

mult.

Abrasive cutting, even done wet, is not approved.

Experience has shown that trapped abrasive causes excessive
tool wear during forging.

An example of the proper equipment to use is a Heller

Gebrueder cut-off machine, circular-saw blade, manual, model
No. SSH630.

c. Band Saw

The band saw is less accurate but, less expensive than a

circular saw. The band-sawing process is slow, compared
with the forging rate; therefore, materials handling
provisions must be developed for multiple machines.

An example of the proper equipment to use is a Do-All cut-

off machine, automatic feed, horizontal, model No. P16M.

111-23

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 ■

KAISER
ENGINEERS

3. Operation H3fl - Heat Mult

Equipment alternatives:
- Heater, induction, 2200 F, 150 kW, 180 Hz
- Rotary hearth furnace, 2200 F
- Continuous tunnel furnace, 2200 F, 3|000

Induction heating is the preferable method, since the heating

normally is fast enough to prevent scaling of the mult. If
furnace heating is used, the furnaces should have dual-fuel
burners.

Examples of the proper equipment to use are:

a. Tocco induction heating in-line system with multicoil

stations for sequential heating, 2200 F.

b. Flinn and Dreffein Inc., rotary hearth, gas-fired 2200 F.

c. Lindburg Bros. Co. T-slot oven, open flame, gas-fired, 2200

F.

4. Operation 31*tQ - Descale, Mult

Equipment - Squirrel-cage tumbler

The mults are placed in a squirrel-cage tumbler to remove the

scale generated by exposure to the atmosphere. This operation
normally is not necessary, if induction heating is used.

Typically, the squirrel-cage tumbler is custom designed and made

for the part being tumbled.

5. Operation ^150 - Pancake. Pre-form. Punch, and Restrlke

Equipment - Press, mechanical, 2,000 ton, 12-inch stroke

The part is forged in a three-stage die, with one part in each

stage at a time.

An example of the proper equipment to use is a National

Machinery Co. Maxipress 2000,

111-24

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,—. ■
--*
 KAISER
ENGINEERS

6. Operation 3160 - Descale

Equipment - Blast clean and finish machine, horizontal

The forging scale is removed by tumble blasting.

An example of the proper equipment to use is a Pangborn

Corporation endless belt barrel type, model 15GN3 blast-cleaning
machine.

7. Operation 3175 - Machine Inside and Outside Diameters.

Bar Stock

Equipment - Lathe, four-spindle, automatic bar, 7-3/4-inch

capacity

Machining is required on the inside and outside diameter.

An example of the proper equipment to use is the National Acme

Co. RB-4.

8. Operation 3180 - Thread Outside Diameter and Face,

Bar Stock/Forging

Equipment - Lathe, chucking, horizontal, six spindle,

automatic, 8-inch capacity

Machine complete except for drilled and tapped holes in face.

An example of the proper equipment to use is the National Acme

Co. 30 hp, model RA6, automatic chucking lathe.

9. Operation 31Q0 - Drill and Tap Six Holes

Equipment - Drill press, 2 spindle, 3/4 cap.

Six holes are drilled and tapped with the index fixture and
multiple-drill head.

An example of the proper equipment to use is a Leland Gifford

Co., drilling machine, manual, model 2LMS-26.

111-25

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 KAISER
ENGINEERS

10. Operation 32QQ - Mark

Equipment - Marking machine, reciprocating die, semiautomatic

■ i
feed, mechanical power

The required part number is marked.

An example of the proper equipment to use is

a Noble and Westbrook marking machine, model 245.

11. Operation 1210- Clean

Equipment - Vapor degreaser

This is a standard cleaning process.

ff This equipment is classified as "other production equipment.11

An example of the proper equipment to use is

a Baron-Blakeslee, model 1019.

111-26
V

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 KAISER
ENGINEERS

D. INSERT. SUSPENSION LUG (1212112)

This ection contains an analysis of operations required for the

productidi of the suspension-lug insert. The flow chart depicting
the sequent cf operations is shown in figure II1-3.

Material - Carbon steel with yield strength 40,000 lbf/in2 and tensile
strength 70,000 lbf/in2, forging quality

1. Operation 4110 - Handle Bar/Forgings

Equipment - Standard cranes, hoists, and forklift truck?

Although the handling of steel bar/forgings is not a step in the

production process, the materials handling problem must be
anticipated in any line designed for high-tonnage consumption of
steel bar/forgings. The operations to be considered are
discussed below.

a. Receiving Bar Stock/Forgings

This operation includes moving rolling stock and trailers,

and stacking material in the storage areas. The unloading
activity will utilize overhead cranes, forklifts, and jib
cranes. The stacking is arranged to assure material
traceabilily.

Receiving inspection must be completed before a lot becomes

available for processing. If a material's supplier
certification is acceptable, a verification of quantity,
either by weight or by length, can be accomplished without
extra handling.

b. Movement of Bar/Forgings from Storage to First

Process Station

This operation includes the movement of raw material to the

sawing or shearing operation for forgings to the first
machining operation.

111-27

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—H--- ---
 ■■ ■■ ■ '■■' - '■ ... .■'.■-.-:■

KAISER
ENGINEERS

Y
4*
Examples of the proper equipment to use are the Shepard-Niles
25-ton bridge crane and a Clark 2-ton forklift truck.

2. Operation H12Q - Separate Mult?

Equipment alternatives:
- Press, shear, 350 ton (cold shearing)
- Saw, carbide tipped, 24 inch, 30 hp (sawing)
- Saw, band, 16 inch, 25 hp (sawing)

a. Cold Shear
The 350-ton shear press requires automatic feed, clamp, and
eject attachments. The press can either be in the
production line to minimize materials handling and
traceability problems or be off-line if facilities dictate.

An example of the proper equipment to use is a Buffalo Forge

Co., shearing machine, 5-inch bar, model 12.

b. Circular Saw

Carbide-tipped circular saws produce precision mult.

Abrasive cutting, even done wet, is not approved.

Experience has shown that trapped abrasive causes excessive
tool wear during forging.

An example of the proper equipment to use is a Heller

Gebrueder cut-off machine, circular-saw blade, manual, model
No. SSH630.

c Dand Saw
The band saw, although less accurate, is less expensive than
a circular saw. The band-sawing process is slow, compared
with the forging rate; therefore, materials handling
provisions must be developed for multiple machines.
I! An example of the proper equipment to use is a Do-All cut-
off machine, automatic feed, horizontal, model No. C70.

*. 111-28
»*

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 KAISER
ENGINEERS

3. Oppugn *mo - Heat MuU

Equipment alternatives:
- Heater, induction, 2200 F, 250 kW, 180 Hz
- Rotary hearth furnace, 2200 F
- '■ ->ntinuous tunnel furnace, 2200 F

Induction heating is the preferable method, since the heating is

normally fast enough to r f
ent scaling of the mult. If furnace
heating is used, the furnaces should have dual-fuel burners.

Examples of the proper equipment to use are:

a. Tocco induction heating in-line system with multicoil

stations for sequential capacity, 2200 F

b. Flinn and Dreffein Inc. rotary hearth, gas-fired, 2200 F

c. Lindburg Bros. Co. T-Slot Oven, open flame, gas-fired, 2200

F.

4. Operation *mQ - pggcale

Equipment - Squirrel-cage tumbler

The heated mults are placed in a squirrel-cage tumbler to remove

scale. This operation normally is not necessary, if induction
heating is used.

Typically, the squirrel-cage tumbler is custom-designed and made

for the part being tumbled.

5. Qara&laa USA - Pro-Torn and RaatriKg

Equipment - Press, mechanical, vertical, straight sided,
single crank, 500 ton, 6-inch stroke

The part is forged in a three-stage die, vi*.h one part in each

stage at a time.

II1-29

- ■— - --■— m i . . _,^-,. ,-,.-^.... :..- - -. ^... . ..,„__._.•,_„ ..^ ,_^..„_ .,.,_ ...
Si_i___ ...
 KAISER
ENGINEERS

%/ An example of the proper equipment to use is

a National Machinery Co. Maxipress 2000 mechanical press,
model No. 500.

6. Operation U16Q - Descale

Equipment - Blast-clean and finish machine, horizontal

endless-belt barrel type

The forging scale is removed by tumble blasting.

An example of the proper equipment to use is a Pangborn

Corporation 15GN3 Blast Cleaning Machine.

7. Operation 4170 - Clean

Equipment - Vapor degreaser

This is a standard cleaning process to prepare for welding.

This equipment is classified as "eth*r production equipment.H

■» •

E
111-30

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 KAISER
ENGINEERS

E. INSERT, FORWARD UMm.)

This section contains an analysis of operations required for the
production of the forward insert. The flow chart depicting the
sequence of operations is shown in Figure III-3.

1. Operation 511Q - Handig Bar/Forging.»

Equipment - Standard cranes, hoists, and forklift trucks

The handling of steel bar/forgings is not a step in the pro-

duction process, but the materials handling problem must be
anticipated in any line of this type, that is designed for high
tonnage consumption of steel bar/forgings. These operations
must be considered, as discussed below.

a. Receiving; Bar Stook/Forfilnga

This operation includes moving rolling stock and trailers
and stacking of material in the storage areas. The
unloading activity utilizes overhead cranes, forklifts, and
jib cranes. The stacking is arranged to assure material
traceability.

Receiving inspection is completed before a lot becomes

available for processing. If a materials supplier
certification is acceptable, a verification of quantity,
either by weight or by length, can be accomplished without
extra handling.

b. Hoveaent of Bar/Forgings from Storage to First

Procfisa Station
This operation includes the movement of raw material to the
sawing or shearing operation for forglngs to the first
machining operation.

Examples of th* proper equipment to use are a Shepard-Niles 15-

ton bridge crane and a Clark 2-ton forklift truck.

III-31

4
KAISER
ENGINEERS

2. Operation 512Q - Separate Mults

Equipment alternatives:
- Press, shear, 500 ton (cold shearing)
- Saw, carbide tipped, 24 inch, 30 hp (sawing)
- Saw, band, 16 inch, 25 hp (sawing)

a. Coiq Shear

The 350-ton shear press requires automatic feed, clamp, and

eject attachments. The press may either be in the
production line to minimize materials handling and
traceability problems or be off-line if facilities dictate.

An example of the proper equipment to use is a Buffalo Forge

Co., Shearing Machine, 5-inch bar, model 12.

b. Circular saw

Carbide tipped circular saws produce precision mult.

Abrasive cutting, even done wet, is not approved.

Experience has shown that trapped abrasive causes excessive
tool wear during forging.

An example of the proper equipment to use is a Heller

Gebrueder cut-off machine, circular-saw blade, manual, model
No. SSH630.

c. Band Saw

The band saw, although less accurate, is less expensive than

a circular saw. The band sawing process is slow, compared
with the forging rate; therefore, materials handling
provisions must be developed for multiple machines.

An example of the proper equipment to use is a Do-All cut-

off machine, automatic feed, horizontal, model No. C70.

111-32

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1
KAISER
ENGINEERS

3. Operation sno - Heat Mult

Equipment alternatives:
- Heater, induction, 2200 F, 250 kW, 180 Hz
- Rotary-hearth furnace, 2200 F
- Continuous-tunnel furnace, 2200 F

Induction heating is the preferable method, since the heating is

normally fast enough to prevent scaling of the mult. If furnace
heating is used, the furnaces should have dual-fuel burners.

Example of the proper equipment to use are:

a. Tocco induction heating in-line system with multicoil

stations for sequential heating, 2200 F

b. Flinn and Dreffein Inc. Rotary Hearth, gas-fired, 2200 F

c. Lindberg Bros. T-Slot Oven, open flame, gas-fired, 2200 F

4. Operation 51HQ - Deggale

Equipment - Squirrel cage tumbler

Heated mults are placed in a squirrel-cage tumbler to remove

scale. This operation normally is not necessary, if induction
heating is used.

Typically, the squirrel-cage tumbler is custom designed and made

for the part being tumbled.

5. Operation 5150 - Pre-form and Restrike

Equipment - Press, mechanical, vertical, straight sided,

single crank, 500 ton, 6-inch stroke

The part is forged in a three-stage die with one part in each

stage at a time.

An example of the proper equipment to use is a National

Machinery Co. Mechanical Press, model No. 500.

HI-33

'— ■■.....■.-..«■- - --~ ■ . ..--* -iliiMITllMJyJI

ENGINEERS

6. Operation 5160 - Descale

Equipment - Blast-dean and finish machine, horizontal,

endless-belt barrel type

The forging scale is removed by tumble blasting.

An example of the proper equipment to use is a Pangborn

Corporation 15GN3.

7. Operation 5170 - Clean

Equipment - Vapor degreaser

This is a standard cleaning process to prepare for welding.

This equipment is classified as "ocher production equipment."

III-3U

--"- *■•-..; ,iirtfji;«nina

KAISER
ENGINEERS

F. RETAINER. FUZE LINER (UQQ24Q3)

The following section contains a detailed analysis of operations for

the production of the fuze-Hner piece parts and assembly.

Material - Carbon-Steel Tube, 5-inch OD x 3-lA-inch ID, MIL-T-

16343

1. Operation 6110 - Handle Tube

Equipment - Standard cranes, hoists, and forklift trucks

The handling of steel bar is not a step in the production pro-

cess, but the material handling problem must be anticipated in
any line designed for high-tonnage consumption of steel bar.
The operations to be considered are discussed below.

a. ReggiYinR Tubs Stock

This operation includes moving rolling stock and trailer and

stacking material in the storage areas. The unloading
activity will utilizes overhead cranes, forklifts and jib
cranes. The stacking is arranged to assure material
traceability.

Receiving inspection is completed before a lot becomes

available for processing. If the material's supplier
certification is acceptable, a verification of the quantity,
either by weight or by length, can be accomplished without
extra handling.

b. Movement of Tube from Storage to First "rocess Station

This operation includes the movement of stock to the first

machining operation.

Examples of the proper equipment to use are a Shepard-Niles

25-ton bridge crane and a Clark 2-ton forklift truck.

111-35
 KAISER
ENGINEERS

2. Operation 6120 - Machine Complete and Cut Off

Equipment - Lathe, bar, horizontal, four spindle, automatic

5-inch dia bar

The machining is complete except for drilled holes in the face.

An example of the proper equipment to use is a National Acme Co.

automatic bar lathe, four spindle, model RBH, 5-1/8-inch dia
bar.

3. Operation 6130 - Drill Two Holes

Equipment - Drill press, two spindle

The index fixture is used to drill two holes.

An example of the proper equipment to use is a Leland Gifford

Drilling Machine, model 2LMS-26.

4. Operation 6140 - Clean

Equipment - Vapor degreaser

This is a standard cleaning process.

The equipment is classified as "other production equipment."

111-36

HMUu "HI, ^»■ttit- ■•■■»-,

J
ttflÜ -■•!■■ ,
 KAISER
ENGINEERS

G. FUZE LINER. AFT (4902490)

1. Operation 7110 - Receive Raw Material

Equipment - Forklift and hoist

This standard operation, which is used in all processes,

requires standard material handling equipment.

2. Operation 7120 - Handle Coil Strip. Bar & Tube

Equipment - Standard cranes, hoists, and transfer equipment

Handling of material is not a step in the production process but

materials handling must be anticipated in a line designed for
high utilization of coil strip and bar. Handling of the
material is accomplished by standard equipment such as overhead
hoists, conveyors, hooks, slings, and lift trucks. No example
of specific equipment or manufacturer is required, because the
equipment used is standard to the metal-working industry.

111-37

, - - --- -^— • ,w—-.-.f..^-.,..^. ..•..,

•>—*■ «■ , ^ ~ -^ .... - ... ^ -..->
 KAISER
ENGINEERS

H. CANISTER - ITEM 1. PART OF (4902490)

Material - Steel, (CRDQ) QQ-S-698 (.072 thick)

1. Operation 7130 - Blank and Form

Equipment - Press, straight sided, m* jhanical, 230 ton,

15-inch stroke, coil-stock reel, straightener,
lubricator, and scrap chopper

The stock is pulled from the reel through the straightener and
lubricator into a five-station die. The die stations include
blanking, three draws and a punch at the last draw station, and
trim to length. The unused strip is chopped to facilitate scrap
removal from the press area.

An example of the proper equipment to use is a Bliss 5S,

mechanical, vertical, straight sided, double-action press.

2. Operation 7140 - Decrease

Equipment - Degreaser, conveyorized

Parts are received from the previous operation, loaded onto

racks with the large open end down, and conveyed through the
degreaser unit to remove all contaminants.

An example of the proper equipment to use is a Baron-Blakeslee

Degreaser, 1019, type TH-LL-V.

111-38

I - n«. r----rtm«f ii tiitriirniarytil irifr —.» HiH.liHH

 KAISER
ENGINES R^i

I. COLLAR - ITEM 2. PART OF (4902490)

Material - Steel tubing, type 1, MIL-T-16343

1. Operation 911Q - Turn Complete

Equipment - Lathe, horizontal, six-spindle automatic,
4-inch diameter bar, 30 hp

Parts are produced from lengths of tubing by a standard

machining operation. All parts are complete except for the
inside diameter which must be .12 inches smaller in each part.
This material is removed after welding in Operation 4010. The
machine production rate is based on double-tooling the machine,
thus two finished parts are produced with each cycle of the
machine.

An example of the proper equipment to use is a Cone-Blanchard

Machine Co., automatic screw machine, model SZ, six-spindle.

2. Operation 8120 - Deburr

Equipment - Finishing machine, vibratory type, circular bowl,

20-cubic-ft capacity with automatic washer and
unloader

All burrs and sharp edges are removed by the abrasive media and
the vibratory motion.

An example of the proper equipment to use is a Sweco Inc., model

FM20, finishing machine.

3. Operation 8HO - Decrease

Equipment - Degreaser, conveyoriied

Parts are loaded into racks and conveyed through the degreaser
unit to remove all contaminants.

A typical example of the proper types of equipment to use would

a Baron-Blaksslee Degreaser, type TH-LL-V, model 1019.

III-39

mtmm -^ ^"^■■*^ ■ — -----

 KAISER

J. SLEEVE, FUZE LINER (1902492)

Material - Steel, AISI 1025, 1024, or 1022

1. Operation 3110 - Machine Complete

Equipment - Lathe, bar, horizontal, six-spindle automatic,

1-5/8-inch dia bar, 30 hp

Standard machining practices are used to produce a finished part

with each cycle of the machine.

An example of the proper equipment to use is a Cone-Blanchard

Machine Co. automatic screw machine SW, 30 hp.

2. Operation 912Q - Bflgcaaafl

Equipment - Degreaser, conveyorized

Parts are loaded on racks and conveyed through the cleaning

cycle to remove contaminants.

An example of the proper equipment to use is a Baron-Blakeslee,

type TH-LL-V, model 1019.

III-M0

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 KAISER

K. FUZE LINER. AFT (4QQ24QQ)

1. Operation 10110 - Friction Weld (Inertia Weld!

Collar to Canister
Equipment - Friction welding machine, special with automatic
load and unload

Parts are automatically loaded in the machine and joined by the

friction weld process which consists of one part rotated at a
controlled r/min while the other part, restrained from turning,
is forced against the rotating part. The heat generated by the
rotation and the force or forging action created a weld without
filler materials, fluxes, or shielding gases, Only a narrow heat
zone is required.

An example of the proper equipment to use is a Manufacturing

Technology Inc., 180-B Inertia Welding Machine.

2. Operation 1Q12Q - Machine Weld Flaah

Equipment - Lathe, automatic chucking, 3-inch dia bar, 10 hp

This is a standard machining operation which includes back-

boring the flash on the inside diameter of the collar and
plunge-cutting the external flash from the part.

An example of the proper equipment to use is a Warner & Swasey

OAC, 441ö Automatic Turret Lathe, 3-inch bar, 10 hp.

3. Operation 1&130 - Degreaae

Equipment - Degreaser, conveyorized

Parts with flange down are loaded on racks and conveyed through
the degreaser unit to remove all contaminants.

An example of the proper equipment to use is a Baron-Blakeslee,

type TH-LL-V, model 1019.

111-41

,.—MMtr i i - - -nil- *r- - mm^mutmrn i 1 i ^igjug^gg

KAISER
ENGINEERS

4. Operation 1Q14Q - Magnetic Particle Inspection

Equipment - Magnetic particle inspection, magnaflux

To determine imperfections, parts are inspected by standard

procedure.

An example of the proper equipment to use is a Magnaflux

Corporation model H720 with a No. SB1U16 de-magnetizer.

111-42
 KAISER
ENG NEER5

L. FUZE LINER ASSEMBLY (UQQ2UQÜ). AFT

1. Operation 11110 - Friction-Weld (Inertia Weld) Sleeve to

Canister Sub-Aasemblv

Equipment - Friction welding machine, special with automatic

load and unload

Parts are automatically loaded in the machine and joined by the

friction-weld process. One part is rotated at a controlled
r/min and the other part, restrained from turning, is forced
against the rotating part. The heat generated by the rotation
and the force or forging action creates a weld without filler
materials, fluxes, or shielding gases. There is also a narrow
heat zone.

An example of the proper equipment to use is a Manufacturing

Technology Inc. model 90-B Inertia Welder.

2. Operation 11120 - Zins Plate

Equipment - Zinc plating machine, automatic, return type,
continuous 12

Parts are racked and processed automatically through the plating

machine. Loading and unloading is manual.

An example of the proper equipment to use is a Udylite Co.,

Division of OXY Finishing Corp., Custom Zinc Plating Machine.

III-M3

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KAISER
ENGINEERS

M. FUZE LINER. FORWARD (123QW)

1. Operation 12110 - Receive Raw Material

Equipment - Forklift and hoist

This standard operation used in all processes requires standard

material handling equipment.

2. Operation 12120 - Handle Coil Strip. Bar and Tube

Equipment - Standard cranes, hoists and transfer equipment

Although it is not a step in the production process, materials

handling must be anticipated in a line designed for high
utilizatin of coil strip and bar. The handling is accomplished
by standard equipment, such as overhead hoists, conveyors,
hooks, slings, and lift trucks.

No specific equipment or manufacturer is required, because the

equipment used is standard to the metal-working industry.

III-4M

m-fian ^^ ■miwwM
KAISER
ENGINEERS

N. CANISTER - ITEM 1. PART OF (12^959^)

Material - Steel (CRDQ) QQ-S-698 (072 THK)

1. Operation 1&13Q - Blank and Form

Equipment - Press, straight sided, mechanical, 230 ton,
15-inch stroke, coil-stock reel, straight-
ener, lubricator, and scrap chopper

The stock is pulled from the reel, through the straightener and
the lubricator into a five-station die. The die stations
include blanking, three draws (with a punch at the last draw
station), and trim to length. The unused strip is chopped to
facilitate scrap removal from the press area.

An example of the proper equipment to use is be a Bliss 5S,

mechanical, vertical, straight sided, double action press.

2. Operation 121HQ - Decrease

Equipment - Degreaser, conveyorized

Parts received from the previous operation, are loaded with the
large open end down onto racks and conveyed through the
degreaser unit to remove all contaminants.

An example of the proper equipment to use is a Baron-Blakeslee

Degreaser, 1019, type TH-LL-V.

III-M5

mmmm ------ — -—-■-—-

 KAISER
ENGINEERS

0. COLLAR - ITEM 2, PART OF (1239591)

Material - Steel tubing, type 1 MIL-T-16343

1. Operation 1311Q - Turn Qowplste

Equipment - Lathe, horizontal, six-spindle automatic,

4-inch dia bar, 30 hp

Parts are produced from lengths of tubing by standard machining

operations. All parts are complete except for the inside
diamete*, which must be .12 inches smaller on each part. This
material is removed after welding in Operation 4010. The
machine production rate is based on double-tooling the machine,
thus two finished parts are produced with each cycle of the
machine.

An example of the proper equipment to use is a Con^-Blanchard

Machine Co., automatic screw machine, model SZ, six spindle.

2. operation 13120 - Defrurr

Equipment - Finishing machine, vibratory type, circular bowl,
20-cubic ft capacity with automatic washer and
unloader

All burrs and sharp edges are removed by the abrasive media and
the vibratory motion.

An example of the proper equipment to use is a Sweco Inc., model

FM20, finishing machine.

3. Operation 13130 - Decrease

Equipment - Degreaser, conveyorized

Parts are loaded into racks and conveyed through the degreaser
unit to remove all contaminants.

An example of the proper equipment to use is a Baron-Blakeslee

Degreaser, type TH-LL-V, model 1019.

111-46

'
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KAISER
ENGINEERS

P. SLEEVE. FUZE LINER (4902492)

Material - Steel, AI5 1025, 1024, or 1022

1. Operation 14110 - Machine Complete

Equipment - Lathe, bar, horizontal, six-spindle automatic,

1-5/8-inch dia bar, 30 hp

Standard machining practices are used to produce a finished part

with each cycle of the machine.

An example of the proper equipment to use is a Cone-Blanchard

Machine Co. automatic screw machine, SW, 30 hp.

2. Operation 1H120 = Decease

Equipment - Degreaser, conveyorized

Parts are loaded on racks and conveyed through the cleaning

cycle for removal of contaminants.

A typical piece of equipment to use is a Baron-Blakeslee, type

TH-LL-V, model 1019.

111-47
 KAISER
ENGINEERS

Q FUZE LINER r FWD (12WM3)

1. Operation 15110 - Friction Weld (Inertia Weld)

Collar fcfl Canister
Equipment - Friction-welding machine - custom built
automatic load and unload

Parts are automatically loaded in the machine and joined by the

friction-weld process. One part is rotated part rotated at a
controlled r/min and the other part, restrained from turning, is
forced against the rotating part. The heat generated by the
rotation and the force or forging action create a weld without
filler materials, fluxes, or shielding gases. Only a narrow
heat zone is required.

An example of the proper equipment to use is a Manufacturing

Technology Inc., 180-B Inertial Welding Machine.

2. Operation 15120 - Machine Weld Flash

Equipment - Lathe, automatic chucking, 3-inch dia bar, 10 hp

This is a standard machining operation which includes back

boring the flash on the inside diameter of the collar and then
plunge-cutting the external flash from the part.

An example of the proper equipment to use is a Warner & Swasey

OAC, 4410 automatic turret lathe, 3-Inch bar, 10 hp.

3. Operation 15HQ - Degreaae

Equipment - Degreaser, conveyorized, liquid-vapor-liquid type

Parts are loaded with flange down on racks and conveyed through
the degreaser unit to remove all contaminants.

An example of the proper equipment to use is a Baron-Blakeslee,

type TH-LL-V, model 1019.

111-48

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 KAISER
ENGINEERS
I

4. Operation 1514Q - HarogUQ-ParUole

I i
Equipment - Magnetic particle inspection, magnaflux
I:
I il
Parts are inspected by standard procedure to determine
imperfections.

An example of the proper equipment to use is a Magnaflux

Corporation machine, model H720 with a No. SB1416 de-magnetizer.

III-49

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K/XISBR
ENGINEERS

R. FUZE LINER ASSEMBLY (4902495). FWD

1. Operation 16110 = mcUon WQld (Ineru^-lteid)

Sleeve to Canister Sub-assemblv

Equipment - Friction welding machine, custom built with

automatic load and unload

Parts are automatically loaded in the machine and joined by the

friction-weld process. One part is rotated at a controlled
r/min and the other part, restrained from turning, is forced
against the rotating part. The heat generated by the rotation
and the force or forging action creates a weld without filler
materials, fluxes, or shielding gases. Only a narrow heat zone
is required.

An example of the proper equipment to use is a Manufacturing

Technology Inc. model 90-B inertia welder.

2. Operation 16120 - Zinc Plate

Equipment - Zinc plating machine, automatic, return type,

continuous 12

Parts are racked and automatically processed through the plating

machine. Loading and unloading is manual.

An example of the proper equipment to use is a Udylite Co.,

Division of OXY Finishing Corp., Custom Zinc Plating Machine.

111-50
KAISER
ENGINEERS

S. BODY ASSEMBLY, BOMB. GENERAL PURPOSE 113805*15.)

This section contains an analysis of operations required for the

body assembly shown in Figure III-4. The flow chart depicting the
assembly of the bomb is shown in Figure III-5.

1. Operation 17110 - Complete

Equipment - Special tube expander air activated

- Special air activated asser' y holding fixture
- 100 candle power light source

The bomb body is secured in the special air activated assembly

holding fixture. This procedure is necessary to hold the body in a
fixed position to allow ease of assembly of charging tubes, fuze
liners, plugs, and rings. The fixture should be so designed as to
allow vertical, horizontal, and rotary movement of the body for the
various assembly operations. The operator can manipulate the body
without leaving the assembly station. Tools, and parts to be
assembled, should be located for easy access in the assembly work
station. The expansion tools should be located to allow for their
efficient use. The use of balance suspension equipment is
recommended.

The assembly station must have a light source capable of providing

100 candle power of light inside the bomb body cavity without
impairing the vision of the operator looking into the interior of
the body.

The light is required to adequately view the holes in the charge

inserts for ease of installation of the charge tubes, and to inspect
the interior of the cavity for possible damage to the bituminous
protective coating.

The bomb body will be processed into the assembly station by

conveyor and moved out to the next operation the same way.

Detailed assembly steps are performed as follows:

111-51
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KAISER
frNCSlNEt:ff 5

a. Install Forward and Aft Charging Tubes

The forward charge tube is manually inserted into the boss

on the forward insert. (Care is taken to assure the forward
most boss is used, and the rear one is to receive the aft
charging tube.) The tube is aligned in the proper position
to mate with the forward and aft fuze wells, which are
installed in the next operation. The position of the tubes
in relation to the bosses is critical. Care must be taken
to assure that the tubes are fully inserted into the bosses.
The tubes must bottom-out against the flanges at the bottom
of the holes.

The joint must be pressure tight after expansion. A seal

compound is suggested if needed to assure proper sealing of
the joints.

Should the compound be used, it must be applied just prior

to the insertion of the tubes into the bosses.

b. Form Joints of Forward and Aft Charging Tubes

To form an air-tight joint an air-activated expansion tool

is used to expand the steel tubing into the coupling.

The inside diameter of the tube must remain open throughout

the entire length of the tube.

Both ends of the forward charging tube are expanded in this

operation. The depth of insertion of the expansion tool
into the charge tube varies at each end. The operator must
take care to insert the tool to the proper depth before
expanding the joints. Improper use of the special expansion
tool could cause permanent damage to all parts (bomb body,
charging tube, and fuze well assembly).

c. Aaaaafrlfl Forward EUM Liaac In Baab Bate

The fuze liner is threaded and must be carefully screwed
into place. The threads are coated with an antiseize com-
pound before the fuze liner is inserted into the bomb body.

111-52
 J
KAISER
ENGINEERS

Care must also be taken to assure the proper alignment of

the forward charge tube with the coupling that is at the
rear of the fuze liner. The two parts must slip together as
the fuze well is . crewed into position. The flange on the
fuze well is later coated with a bituminous coating
compound, MIL-C-450.

The thin coating ensures proper sealing of the two parts and
prevents leakage and exposure of the explosives used in the
bomb.

The fuze liner should be torqued to 200 ft-lb.

The depth of penetration of the charging tube into the fuze

liner flange must be inspected. Care is required to make
the tubes conform to the drawing specifications.

d. install Aft Eaafl Liner

Slip the aft fuze well flange onto the aft charging tube.
The position of the aft fuze well is critical, and the rela-
tionship of the base plug must be properly maintained prior
to expanding the joints of the charge tube.

Care must also be taken to assure the proper alignment of

the aft charge tube and the coupling at the rear of the fuze
liner. The two parts must slip together as the fuze well is
screwed into position.

The flange on the fuze well is to be coated with a thin

layer of a bituminous coating compound MIL-C-450 to ensure
the proper sealing of the two parts and to prevent leakage
and exposure of the explosives used in the bomb.

The depth of penetration of the charging tube into the fuze

liner flange must be inspected.

111-53

rr- Tf-'fil-i -j. „- -- iii'V-, i■ i T.1 in ■ I-. i-i ■um,..j.-M

 KAISER
ENGINEERS

e. Form Joints of Forward and Aft Charging Tube

An air activated expansion tool is used to expand the steel

tubing into the coupling to form an air tight joint to
withstand the mechanical force associated with the applica-
tion.

The inside diameter of the tube must remain open throughout

the length of the tube.

f. Inspect CavitY
The entire interior surface of the body cavity, the charging
tubes, and the fuze wells is inspected for any damage to the
coating compound.

Special attention should be given to the fuze well

coupling/charge tube joints and the charge tube insert and
tubes.

Any exposed surface is coated with the bituminous coating

compound MIL-C-450.

In addition, any other foreign material trapped in the

cavity is removed.

g. install Bm Plug
The threads of the base plug are coated with an antiseize
compound according to MIL-A-907.

The base plug is screwed into the bomb body ring adapter.
Care is required to properly align the aft fuze well with
the base plug.

The base plug is then torqued to 200 ft-lb.

The seat of the fuze well that mates with the base plug is
applied with a thin coating of bituminous compound MIL-C-
450.

111-54

- - -iiiiiiMiiiiMari
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KAISER
ENGINEERS

i. Install Aft Fuze-Liner Retainer

The aft fuze-well retainer is screwed Into place by

attaching It to the aft fuze-well assembly.

Prior to assembly, the threads are coated with antiseize

compound required by MIL-A-907.

The retainer is torqued to 200 ft-lb/min.

The screw is not installed in this procedure. The set screw

is shipped separately with each finished bomb body assembly.
It is clearly identified and packaged.

j. Move Completed Assembly to Next Operation

The completed bomb assembly is released from the assembly

fixture and taken away on a conveyor. The assembly station
is now clear for the next unit.

111-55

.^.. ■ :--. - ■■- ... -■ .... _

KAISER
ENGINEERS

IV. RECOMMENDED PRODUCTION BASELINE FOR THE MK82 MOD 1.

5QQ-LB BOMB BQttX ASSEMBLE

The recommended production baseline for the MK82 bomb body assembly is
summarized in Tables IV-1, 2, 3, 4, and 5 by operation number. The
recommended process and equipment are based on the findings of the PEP
modernization study. The rationale and assumptions used in preparing
the baseline are discussed below.

The lack of an assigned production rate required the arbitrary

establishment of a gross capacity production rate as a basis for
quantifying the equipment requirements. Capacity can be altered by
adding and deleting equipment for each operation.

The technical data package indicates the casing may be formed by the hot
forging process or by using seamless or welded-seam tubing. The MK82
production baseline analysis addresses both the forging and tubing
processes. The forging process does not appear to be economical in that
the forging process will require presses of high tonnage with
exceptionally long strokes. Presses of this type are not available in
existing equipment inventories, nor are they of the design and size that
can be manufactured within a reasonable leadtime. Therefore, the
baseline processes and equipment are planned and designed to use steel
tubing to produce the bomb casing.

The initial evaluation of the manufacturing requirements considered all

feasible methods for producing the MK82 piece parts. In some instances,
this evaluation led to the identification and evaluation of the
alternate production equipment/methods discussed earlier in this report.

Operations for which alternate methods were discussed are listed below
along with the rationale for selecting the process shown in the
recommended baseline.

IV-1

■..-■—
■ >!■> _^_^_
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 -

KAISER

Table IV-1, Bomb Casing, Operation 1120 - (Separate Lengths of

Tube). The four methods investigated for this operation were
band sawing, circle sawing, flame cutting, and rotary cutting.
Rotary cutting is the most efficient means of performing this
operation. This method, which produces a clean, accurate
parting of the tube section at a gross rate of 200 pieces/h is
much faster than the other methods and does not result in any
material loss to saw or torch kerf. Moreover, the roll cutters
generate a chamfer on the outside diameter of the tube ends and
thereby eliminate the need for deburring.

Table IV-2, Adapter Ring, Operation No. 2120 - (Separate

Mults). Three methods were considered for this operation.
They included cold shearing and types of metal sawing (circle
and band). Cold shearing is the most productive and accurate
method. Moveover, this method generates appreciable material
savings by eliminating saw kerf.

Table IV-2, Adapter Ring, Operation 2130 - (Heat Mult). The

induction heater was chosen over the rotary hearth or through-
feed furnace processes. Although the productivity of the
induction heater is less than the continuous furnces, there is
a termendous energy savings due to the localized heat control
and startup/shutdown response. This method also minimizes soak
time and consequently produces less surface scale and related
material loss.

Table IV . Insert Suspension Lug, Operation No. *»120 -

(Separate Mults). Three methods were considered for this
operation. They included cold shearing and two types of metal
sawing (circle and band). Cold shearing is the most procuctive
and accurate method. Moreover, this method generates
appreciable material savings by eliminating saw kerf.

IV-2
KAISER
ENGINEERS

Table IV-5, Forward Insert, Operation No. 5130 - (Heat Mult).

Induction heating was selected over the rotary hearth and
tunnel furnaces. This choice was based on energy savings
resulting from the startup/shutdown response time, localized
heat zone control, material savings from reduced surface
scaling, and elimination of subsequent descaling operations.

IV-3
KAISER
ENGINEERS

RECOMMENDED MANUFACTURING PROCESS: ANALYSIS OF OPERATIONS

A. CASING, BOMBr MK82 MOD 1 (H80548)

The recommended sequence of manufacture is summarized in Table IV-1.

The operation numbers are the same as those shown in Section III.

1. Operation 1110 - Handle Tubes

Equipment - Standard cranes, hoists, and transfer equipment

An example of the proper equipment to use is a Shepard-Niles 25

ton bridge crane.

2. Operation 1120 - Separat? Lenins, Tv/oe

Equipment - Cutoff machine, rotary, 60 hp

d. Rotary Cutting

The tube is cut to the required length while chamfers are

generated on the outside diameter. This method eliminates
end deburring.

An example of the proper equipment to use is a Stamet Co.

model S024450, lathe, automatic, 95 r/min spindle, 60 hp.

3. Operation 1250 - Pre-form Nose and Base End. Tube

Equipment - Press, hydraulic, 600 ton, 48-inch stroke

An example of the proper equipment to use is a Verson Allsteel

Press model 600HDI-66T, 600 ton, 48-inch stroke.

IV-4
KAISER —
ENGINEERS

4. Operation 126Q - Heat Nose End

Equipment - Heater, induction , 1400 F, 500 kW, 180 Hz

An example of the proper equipment to use is a Westinghouse

Electric induction heater.

5. Operation 1270 - Form Nose

Equipment - Press, hydraulic, 500 ton, 36-inch stroke

An example of the proper equipment to use is a Verson Allsteel

Press model 500 HDI-48T.

6. Operation H1Q - Machine Base End. Tube

Equipment - Lathe, automatic, chucking 12-inch swing, 72-inch

centers, 30 hp

An example of the proper equipment to use is a Warner-Swasey

automatic lathe, 12-inch swing, 72-inch centers, 30 hp.

7. Operation H20 - Machine Nose and Base End. Tube

Equipment - Way-type machine, single station, double ended,

horizontal, boring, 50 hp

An example of the proper equipment to use is a machine made by

Heald Machine Co., model 442A, 80-inch-long table, 50 hp.

8. Operation H40 - Flame Cut Lug and Charging Tube Adapter Holes

Equipment - Two automatic machine torches

- Two 500 to 600-A power supplies
- Special cradling and fixturing machine base

An example of the proper equipment to use is

a Linde Division of Union Carbide Co., model CM-56 with CW-45
cutting torch.

IV-5
KAISER
ENCilNBERS

9. Operation 1V>Q - Weld Lug and Charging Adapters

Equipment - Two automatic machine torches, gas shielded with

flux cored wire
- Two 500 to 600-A 100-percent duty-cycle power supply
- Special cradling and fixturing machine base

An example of the proper equipment to use is a Linde Division

of Union Carbide Co. model VI-600 welding power supply, SWM-23
wire feeder, ST-5 water-cooled machine torch.

10. Operation H60 - Weld Ring Adapter

Equipment - Automatic machine torch, arc-length sensor,

gas shielded, flux-cored welding wire
- 500 to 600-A 100-percent duty-cycle power supply
- special cradling and fixturing machine base

An example of the proper equipment to use is a Linde Division

of Union Carbide Co. model VI-600 welding power supply, SWM-23
wire feeder, ST-5 water-cooled machine torch.

11. Operation 137Q - Heat Treat and Temper

Equipment - Furnace, gas, 1550 F to 1650 F

An example of the proper equipment to use is a Flinn & Dreffein

Engineering Co. heat-treat and temper system, special model

12. Operation I3SQ - Blaat-elean ID and 0B

Equipment - Roto-blast unit

An example of the proper equipment to use is a Wueelabrator &

Frye Co., model M2D393, blast-cleaning machine.

13. Operation H9Q - Cheek Hardness

Equipment - Hardness tester, brinnel, automatic

An example of the proper equipment to use is a Rockwell Corp.,

model 5JR, hardness tester

IV-6
 KAISER
ENGINEERS

14. Operation 1400 - Bore. Face, and Thread Nose End

Equipment - Lathe, turret, automatic 12-inch swing, 72-inch

centers, 30 hp

An example of the proper equipment to use is a Warner-Swasey,

automatic lathe, 12-inch swing, 72-inch centers, 30 hp.

15. Operation 1410 - Bore. Face. Thread., and Machine Base End
1 t!
Equipment - Lathe, turret, automatic 12-inch swing, 72-inch
centers, 30 hp

An example of the proper equipment to use is a Warner-Swasey,

automatic lathe, 12-inch swing, 72-inch centers, 30 hp.

16. Operation 1420 - Step Drill and Tap Lifting Holes and
flagging Hals
Equipment - Drill press, tapping multistation, 2-1/4 inch
capacity

An example of the proper equipment to use is a Barnes

multispindle drill press, special.

17. Operation 1450 - Drill 16 Holes. Base End and Drill, and
Tap Noae End
Equipment - Drill press, multispindle, two units, horizontal

An example of the proper equipment to use is a Barnes

multispindle horizontal drill press, 15 hp.

18. Operation lifiQ - Iaafc Lining Lag Adapter

Equipment - Special test machine

An example of the proper equipment to use is a special test

equipment manufactured to dictated parameters.

IV-7
 KAISER
ENGINEERS

19. Operation 1470 - Pressure-test Bomb Bodv

Equipment - Special test equipment

An example of the proper equipment to use is a special test

equipment manufactured to dictated parameters.

20. Operation 1480 - Stamp Identification

Equipment - Stamping machine, rotary, 5 hp

An example of the proper equipment to use is a James H.

Matthews Co., Marking Machine N2201.

21. Operation 14Q0 - Phosphate Treat

Equipment - Chemical line, multistage spray-dip system

An example of the proper equipment to use is a Litton five

stage phosphatizer.

22. Operation 15QQ - Paint Exterior

w x
\ Equipment - Paint spraying machine, automatic,
I electrostatic

An example of the proper equipment to use is a Binks

Manufacturing Co. special unit.

I IV-8
KAISER
ENGINEERS

B. RING. ADAPTER. BOMB BODY (1252606)

Material - Carbon steel with yield strength 40,000 lbf/in2 and

tensile strength 70,000 lbf/in2, forging quality

1. Operation 2110 - Handle Billet

Equipment - Standard cranes, hoists, and forklift trucks

An example of the proper equipment to use is a Shepard-Niles

25-ton bridge crane and a Clark 2-ton forklift truck.

2. Operation 2120 - Separate Mults

Equipment - Press, shear, 1,000 ton

An example of the proper equipment to use is a Buffalo Forge

Co., shearing machine, 5-5/8 inch bar, model 13.

3. Operation 2HQ - Heat Mult

Equipment - Heater, induction, 400 kW, 180 Hz, 2200 F

An example of the proper type of equipment to use is a Tocco

induction heating in-line system with multicoil stations for
sequential heating, 2200 F.

4. Operation 21 SO - Forge Complete

Equipment - Press, mechanical, 2.000 ton, 10-inch stroke

An example of the proper type of equipment to use is a National

Machinery Co., Maxipress 2000, mechanical.

5. Operation 2160 - Descale

Equipment - Blast-clean and finishing machine

An example of the proper type of equipment to use is a Pangborn

Corporation blast-cleaning machine, endless-belt barrel type,
model 1bGN3-

IV-9
KAISER
ENGINEERS

Operation 21 An - Rough and Finish Machine

Equipment - Lathe, six-spindle, automatic chucking, 10-inch

capacity

An example of the proper equipment to use is a National Acme

Co., model RPA6 automatic chucker, 30 hp.

Operation ?1Q0 - Clean

Equipment - Vapor degreaser

An example of the proper equipment to use is a Baron Blakeslee,

model 1019.

IV-10
KAISER
ENGINEERS

C. PLUGr BASE. BOMB BODY (4QQ2487)

Material - Carbon steel with yield strength 40,000 lbf/in2 and

tensile strength 70,000 lbf/in2, bar stock

1. Operation lUfl - Handle Bar Steak

Equipment - Standard cranes, hoists, and forklift trucks

Examples of the proper equipment to use is a Shepard-Niles 25-

ton bridge crane and a Clark 2-ton forklift truck.

2. Operation 3175 - Machine Inside and Outside Dlametera

Equipment - Lathe, automatic chucker, four-spindle

An example of the proper equipment to ute is a National Acme

model RA-4 four-spindle automatic, bar-type, horizontal turning
machine.

3. Operation 3180 - Thread Outside Diameter and Face

Equipment - Lathe, automatic chucker, six-spindle

An example of the proper equipment to use is a National Acme

Co. automatic chucker, 30 hp, model RPA6.

4. Operation 31qo - Drill and Tap Six Holes

Equipment - Drill press, 2-spindle, 3/4-inch capacity

An example of the proper equipment to use is a Leland Gifford

Co., drilling machine, manual, model 2LMS-26.

5. Operation 3200 - Stamp Identification

Equipment - Marking machine, reciprocating die, semiautomatic

feed, mechanical power

An example of the proper equipment to use is a Noble and

Westbrook marking machine, model 245.

iV-11
KAISER
ENGINEERS

6. Operation 321CLs Clean

Equipment - Vapor degreaser

An example of the proper equipment to use is a Baron Blakeslee,

model 1019.

IV-12
KAISER
ENGINEERS

D. INSERT. SUSPENSION LUG (1212112)

Material - Carbon steel with yield strength 40,000 lbf/in2 and

tensile strength 70,000 lbf/in2» for«in8 quality

1. Operation 4110 - Handle Bar

Equipment - Standard cranes, hoists, and forklift trucks

Examples of the proper equipment to use is a Shepard-Niles 25-

ton bridge crane and a Clark 2-ton forklift truck.

2. Operation 4120 - Separate Mults

Equipment - Shear press, 350 ton

An example of the proper equipment to use is a Buffalo Forge

Co., shearing machine, 5-inch bar, model 12.

3. Operation 4HO - Heat Mult

Equipment - Heater, induoMon, 2200 F, 50 kW, 180 Hz

An example of the proper equipment to use is a Tocco induction

heating in-line system with multicoil stations for sequential
capacity, 2200 F.

4. Operation 4150 - Pre-form and Reatrlk«

Equipment - Press, mechanical, vertical, straight-sided, single

crank, 500 ton, 6-inch stroke

An example of the proper equipment to use is a National

Machinery Co., Maxipress 2000 mechanical press, model No. 500.

5. Operation 4160 - Descale

Equipment - Blast-clean and finish machine

An example of the proper equipment to use is a Pangborn

Corporation codel 15GN3 blast-cleaning machine

IV-13
 KAISER
ENGINEERS

6. Operation H17Q - Clean

Equipment - Vapor degreaser

This equipment is classified as other production equipment.

IV-14
••
KAISER
ENGINEERS

E. INSERT. FORWARD (H80230)

Material - Carbon steel with yield strength 40,000 lbf/in2 and

tensile strength 70,000 lbf/in2 forging quality

1. Operation 5110 - Handle Bar Stock

Equipment - Standard cranes, hoists, and forklift trucks

Examples of the proper equipment to use is a Shepard-Nilea 15-

ton bridge crane and a Clark 2-ton forklift truck.

2. Operation 512Q - Separate Multa

Equipment - Press, shear, 350 ton

An example of the proper equipment to use is a Buffalo Forge

Co., shearing machine, 5-inch bar, model 12.

3. Operation 513Q - Heat Mult

Equipment - Heater, induction, 2200 F, 250 kW, 180 Hz

An example of the proper equipment to use ia a Tocco induction

heating in-line system with multicoil stations for sequential
heating, 2200 F.

4. Operation 5150 - Pre-form and Restrike

Equipment - Press, mechanical, vertical, straight-sided,

single crank, 500 ton, 6-inch stroke

An example of the proper equipment to use is a National

Machinery Co., mechanical press, model No. 500.

5. Operation 5160 - Deacal«

Equipment - Blast-clean and finish machine

An example of the proper equipment to use is a Pangborn

Corporation model 15GN3.

IV-15
 wpp^jpwp^

KAISER
ENGINEERS

6. Operation 5170 - Clean

Equipment - Vapor degreaser

This equipment is classified as "other production equipment."

IV-16

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KAISER
ENGINEERS

TABLE IV-6
RECOMMENDED PRODUCTION BASELINE FOR
MK82 MOD 1, 500-LB BOMB BODY ASSEMBLY
ESTIMATED EQUIPMENT COST SUMMARY

Qty
Reference of
Table Component Part No. 1E£ Estimated Cost.*

IV-1 Casing 1380548 24 3,750,000

IV-2 Adapter Ring 1252606 6 1,545,000

IV-3 Base Plug 4902487 5 706,000

IV-4 Insert, Suspension Lug 1212112 5 826,000

IV-5 Insert, Forward 1380230 5 916,000

TOTAL 7,743,000

IV-24