SYSTEM AND METHOD FOR HIGH-VOLUME PRODUCTION OF ARTILLERY SHELL CASINGS USING GIGA-CASTING

Abstract

A system and method for high-volume production of artillery shell casings using giga-casting are provided. The system includes a giga-casting press with first and second die components that form a die cavity for multiple shell casings, an injection channel connected to the cavity, and a piston to inject molten metal under high pressure. The method involves moving a movable platen toward a fixed platen to close the die components, applying a clamping force to keep them closed, delivering molten metal to the injection channel, and advancing the piston to inject the metal into the cavity under high pressure. The process includes cooling to solidify the shell casings, reducing the clamping force, opening the die components, and ejecting the shell casings.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This utility patent application claims priority to and the benefit of U.S. Provisional Patent Application 63/747,245, filed Jan. 20, 2025, the entire contents of each of which are incorporated herein by reference.

FIELD OF THE DISCLOSURE

The present disclosure relates to systems and methods for making artillery shell casings.

BACKGROUND

This section provides background information related to the present disclosure which is not necessarily prior art.

Currently, forging is the industry standard manufacturing technique for producing artillery shell casings. This process involves shaping high-strength materials, such as ultra high strength steel or advanced alloys, through compressive forces. The process begins with the heating of raw material billets to temperatures sufficient to make them malleable. These heated billets are then placed into precision-engineered dies and subjected to immense pressure using hydraulic or mechanical presses. This deformation refines the grain structure of the material, enhancing its strength, toughness, and resistance to fatigue. Forged casings then go through post-processing procedures, such as machining to finalize the casing.

While forging serves its purpose, modern combat has shown an increasing need for ranged artillery munitions. Accordingly, there is need for improvements to approaches to making artillery shells to accelerate production.

SUMMARY OF THE DISCLOSURE

According to an aspect of the disclosure, a system for producing artillery shell casings includes a giga-casting press that has first and second die components that together define a die cavity shaped to form a plurality of artillery shell casings. An injection channel is fluidly connected to the die cavity. A piston is configured to inject molten metal through the injection channel into the die cavity under high pressure to produce the plurality of artillery shell casings.

According to another aspect of the disclosure, a method for producing artillery shell casings includes moving a movable platen of a giga-casting press toward a fixed platen to close first and second die components and define a die cavity shaped to form a plurality of artillery shell casings. The method also includes applying, with the giga-casting press, a clamping force that maintains the first and second die components in the closed condition. The method also includes delivering molten metal to an injection channel fluidly connected to the die cavity. While maintaining the clamping force, the method includes advancing a piston in the injection channel to inject the molten metal into the die cavity under high pressure to form the plurality of artillery shell casings. The method also includes cooling the molten metal in the die cavity to solidify the plurality of artillery shell casings. The method also includes reducing the clamping force and moving the movable platen away from the fixed platen to open the first and second die components. The method also includes ejecting the plurality of artillery shell casings from at least one of the first and second die components.

Among other benefits, the use of giga-casting technology for artillery shell casings provides improved material and weight optimization, permits the use of lightweight materials, reduces a weight of components without comprising strength, improves manufacturing efficiency by consolidating multiple components into a single casting, reduces the number of manufacturing steps, and provides enhanced structural performance.

BRIEF DESCRIPTION OF THE DRAWINGS

Other advantages of the present disclosure will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

FIG. 1 is a schematic diagram of an example giga-casting machine, according to an aspect of the disclosure; and

FIG. 2 is a flow diagram of a method for giga-casting artillery shell casings.

DESCRIPTION OF THE ENABLING EMBODIMENT

Example embodiments will now be described more fully with reference to the accompanying drawings. In general, the subject embodiments are directed to systems and methods for producing artillery shell casings 25, however the example embodiments are only provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth, such as examples of specific components, devices, and method operations, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms, and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

More particularly, referring to the figures, wherein like numerals indicate corresponding parts throughout the several views, embodiments of systems and methods for producing artillery shell casings 25 are shown.

The subject system and method employ a giga-casting (also known as mega-casting) process for efficiently producing a large number of shell casings 25 at once. Giga-casting may be implemented as a large-scale form of high-pressure die casting in which a die cavity is filled by injecting molten metal under high pressure while a press maintains a clamping force that resists separation of die components during injection and at least a portion of solidification. By utilizing large casting machines capable of exerting thousands of tons of clamping force (e.g., at least 6100 tons), giga-casting enables creation of single, monolithic castings and/or multi-cavity castings that replace conventional assemblies composed of multiple smaller components.

Traditional manufacturing methods for large components like artillery shell casings 25 often involve welding, riveting, or bolting multiple parts together. While effective, these processes introduce additional weight, potential points of failure, and increased production time. Giga-casting addresses these challenges by consolidating parts into a single, seamless component. This not only reduces weight but also enhances structural integrity and simplifies the manufacturing process.

More particularly, as shown in FIG. 1, the subject system utilizes a giga-casting press 10 that is rated at 6100 tons or greater. Other press configurations may be used, such as a 9000-ton press. The giga-casting press 10 includes a fixed platen 12 and a movable platen 14. The movable platen 14 is slidable relative to the fixed platen 12 along a pair of tracks 16, although any number of tracks 16 may be used. A first die component 18 is fixed to the fixed platen 12, and a second die component 20 is fixed to the movable platen 14, allowing it to move with the movable platen 14. Together, the first and second die components 18, 20 define a die cavity 22, which is shaped to form the resulting shell casing(s) 25. In the shown embodiment, the first and second die components 18, 20 are shaped to provide four shell casing segments 23A, 23B, 23C, 23D to ultimately produce four artillery shell casings 25. The die cavity 22 can have other numbers of casing segments 23A, 23B, 23C, 23D to produce any number of shell casings 25 per casting operation. The first and second die components 18, 20 may be engineered to accommodate intricate geometries and maintain tight tolerances under high injection pressures while the press applies and maintains a clamping force.

An injection channel 24 is fluidly connected to the die cavity 22. The injection channel 24 has an inlet 26 for receiving molten metal 28, such as aluminum, advanced aluminum alloys, magnesium alloys, titanium alloys, or other lightweight metal materials suitable for forming artillery shell casings 25. A piston 30 is positioned at one end of the injection channel 24 and is slidable within the injection channel 24 to inject the molten metal 28 into the die cavity 22 at high pressure. One or more ejector pins 32 (also referred to herein as injector pins) may extend through at least one of the platens 12, 14 and through at least one of the die components 18, 20. The ejector pins 32 are slidable toward the die cavity 22 to release and/or eject the resulting shell casings 25 from at least one of the die components 18, 20 after opening of the die components 18, 20.

According to a method 100 of using the giga-casting system 10 shown in FIG. 2, the method includes 102 moving the movable platen 14 toward the fixed platen 12 to define the die cavity 22. The method further includes 104 applying, with the giga-casting press 10, a clamping force that maintains the first and second die components 18, 20 in the closed condition. In some embodiments, 104 applying the clamping force includes applying at least 6100 tons of clamping force. The method further includes 106 delivering molten metal 28 to the injection channel 24 via the inlet 26. While maintaining the clamping force, the method includes 108 advancing the piston 30 in the injection channel 24 to inject the molten metal 28 into the die cavity 22 under high pressure to form the plurality of artillery shell casings 25, and 110 maintaining the clamping force at least during injection and optionally during a packing/hold interval. The method further includes 112 cooling the molten metal 28 in the die cavity 22 to solidify the plurality of artillery shell casings 25. After sufficient solidification, the method includes 114 reducing the clamping force and moving the movable platen 14 away from the fixed platen 12 to open the first and second die components 18, 20. The method further includes 116 ejecting the plurality of artillery shell casings 25 from at least one of the first and second die components 18, 20, such as by advancing the ejector pins 32 to release the plurality of artillery shell casings 25 from the die component(s). In some embodiments, after ejection, the method further includes 118 quenching the plurality of artillery shell casings 25 in a liquid to provide rapid cooling. The method may further include 120 separating the plurality of artillery shell casings 25 from one another and/or from a sprue and runner structure, and 122 smoothing edges of the plurality of artillery shell casings 25 to predetermined specifications. The method may further include 124 loading and finalizing the shell casings 25 such that they are in final form and meet performance and safety standards.

Examples of shell casings 25 and related components that the subject system and method may be used to make include, but are not limited to, 155 mm shells, 105 mm shells, mortars, tank shells, missile housings, and replaceable barrels used to fire such shells.

The adoption of giga-casting technology to make artillery shell casings 25 is driven by several factors including material and weight optimization, manufacturing efficiency, enhanced structural performance, design flexibility, and sustainability. Giga-casting allows for the use of lightweight materials such as aluminum or advanced aluminum alloys, which can reduce weight without compromising required strength when properly engineered and qualified. By consolidating multiple parts into a single casting, giga-casting may reduce the number of manufacturing steps, assembly time, and associated costs. Utilizing the subject system and method, a rate of 45 castings per hour can be achieved in some implementations, and with the die configured to produce four shell casings 25 per casting operation this can yield 4,320 shell casings 25 per day. Monolithic or consolidated castings can exhibit improved structural integrity by reducing or eliminating joints such as weld seams or bolted interfaces. Advanced die design and simulation may be employed to enable complex geometries with reduced post-processing. Additionally, the system may include one or more sensors and a control system configured to monitor process parameters and detect and correct defects in real time during casting of the plurality of shell casings 25, including by adjusting one or more of injection parameters, melt temperature, die temperature, cooling parameters, or cycle timing to maintain quality and precision.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in that particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or later, or intervening element or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

Although the terms first, second, third, etc. may be used herein to described various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in any embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims

1. A system for producing artillery shell casings, comprising:

a giga-casting press including first and second die components that together define a die cavity shaped to form a plurality of artillery shell casings;

an injection channel fluidly connected to the die cavity; and

a piston configured to inject molten metal through the injection channel into the die cavity under high pressure to produce the plurality of artillery shell casings.

2. The system of claim 1, wherein the giga-casting press is configured to exert a clamping force of at least 6100 tons of force.

3. The system of claim 1, wherein the molten metal is of an aluminum material.

4. The system of claim 1, further comprising a cooling system configured to cool the molten metal in the die cavity to solidify the artillery shell casings.

5. The system of claim 1, further comprising an AI-driven quality control system configured to detect and correct defects in real time during casting of the artillery shell casings.

6. The die assembly of claim 1, wherein the die cavity is configured to produce four artillery shell casings per casting operation.

7. The die assembly of claim 6, configured to cooperate with injector pins to release the artillery shell casings from the die components.

8. A method for producing artillery shell casings, comprising:

moving a movable platen of a giga-casting press toward a fixed platen to close first and second die components and define a die cavity shaped to form a plurality of artillery shell casings;

applying, with the giga-casting press, a clamping force that maintains the first and second die components in the closed condition;

delivering molten metal to an injection channel fluidly connected to the die cavity;

while maintaining the clamping force, advancing a piston in the injection channel to inject the molten metal into the die cavity under high pressure to form the plurality of artillery shell casings;

cooling the molten metal in the die cavity to solidify the plurality of artillery shell casings;

reducing the clamping force and moving the movable platen away from the fixed platen to open the first and second die components; and

ejecting the plurality of artillery shell casings from at least one of the first and second die components.

9. The method of claim 8, further comprising, after ejecting the plurality of artillery shell casings, quenching the plurality of artillery shell casings in a liquid to provide rapid cooling.

10. The method of claim 8, further comprising smoothing edges of the plurality of artillery shell casings to predetermined specifications.

11. The method of claim 8, wherein applying the clamping force comprises applying at least 6100 tons of clamping force.

12. The method of claim 8, wherein the molten metal comprises aluminum.

13. The method of claim 8, further comprising detecting and correcting defects in real time during casting of the plurality of artillery shell casings.

14. The method of claim 8, wherein the die cavity is shaped to form four artillery shell casings during a casting operation.

15. The method of claim 8, wherein ejecting the plurality of artillery shell casings comprises releasing the plurality of artillery shell casings from the first and second die components with ejector pins.