Systems and methods for forming centerfire ammunition cases

Abstract

Methods for forming an ammunition cartridge casing from metal tubing stock are disclosed. The processes can include a sequence of deformation operations such as diameter reduction, axial compression, and drawing to shape the tubing into a finished case. Disclosed operations form a thickened head section, a web with a flash hole, and a primer pocket without cutting or drilling. Disclosed methods include elongating the powder chamber, forming a rim and extraction groove through axial compression, and shaping the neck and shoulder using precision tooling. Select operations may be combined or staged to manage material flow and strain distribution.

Description

SYSTEMS AND METHODS FOR FORMING CENTERFIRE AMMUNITION CASESCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of United States Provisional Application Serial No. 63 / 669,339, filed on July 10, 2024, and entitled SYSTEMS AND METHODS FOR FORMING BOXER-PRIMED CENTERFIRE AMMUNITION CASES, the entirety of which is incorporated herein by reference for all purposes.BACKGROUND

[0002] Ammunition cartridges typically include a case that serves as a container or holder for the primer, propellant, and projectile. Cases for firearm cartridges are conventionally made in numerous steps and on successive machines. Traditionally, cases are formed from sheet metal coils from which coins are cut that are then cupped and then drawn in multiple stages, with intervening annealing steps performed between drawing operations. In one example, after the drawing and annealing, a trim step may be performed to take off extra material at the top of the case. Subsequently, the partially formed case is rammed against one or more tools to create the primer pocket and headstamp. An extraction groove is then typically cut into the case, after which the case is processed through one or more tapering press stations. Another trimming process is then performed on the tapered case, after which a flash hole is punched into the head of the case. Finally, under some conventional case forming methods (particularly for rifle rounds), the mouth and neck of the case are then annealed.

[0003] The subject matter described herein is not limited to embodiments that operate only in environments such as those described above. Rather, this background is only provided to illustrate one example technology area where some embodiments described herein may be practiced.SUMMARY

[0004] A method for forming an ammunition cartridge case may include a plurality of acts or operations to alter the geometry’ of a metal tube. The plurality of operations can include compression and expansion / drawing steps that move the material of the metal tube to various locations, forming an ammunition cartridge case.

[0005] In one or more embodiments, a method for forming a web of an ammunition cartridge case can include obtaining a metal tubing material that defines a through hole. The method may further include forming a thickened portion of the metal tubing material by axially compressing a first portion of the metal tubing material. The method may also- Page 1 - Docket No. 23692.2ainclude forming a web that defines a flash hole by axially compressing the thickened portion of the metal tubing material.

[0006] In one or more embodiments, a method for forming an ammunition cartridge case can include obtaining a metal tubing material that defines a through hole and performing a plurality of operations on the metal tubing material to form the ammunition cartridge case. The plurality of operations may include reducing a diameter of a first portion of the metal tubing material and axially compressing the first portion to thicken the first portion and form a head section. The plurality of operations may also include drawing a second portion of the metal tubing material to elongate the second portion of the metal tubing material.

[0007] In one or more embodiments, a method for forming an ammunition cartridge case from a metal tubing material that defines a through hole can include reducing a diameter of a first portion of the metal tubing material. The method may also include axially compressing the first portion to thicken the first portion and form a head section. The head section can include a primer pocket and web, and the web can define a flash hole. The method may further include drawing a second portion of the metal tubing material to elongate the second portion of the metal tubing material to form a powder chamber. The method may also include axially compressing the metal tubing material to form an extraction groove and a rim and also reducing a diameter of the section portion of the metal tubing material to form a neck. The method may further include urging a tool through an inner diameter of the metal tubing material to smooth the neck. In some implementations, the flash hole is not formed through drilling, cutting, or punching.

[0008] Additional features and advantages will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice. The features and advantages may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features will become more fully apparent from the following description and appended claims, or may be learned by the practice of the examples as set forth hereinafter.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Reference will be made to embodiments of the disclosure, examples of which may be illustrated in the accompanying figures. These figures are intended to be illustrative, not limiting. These figures are given in the context of a so-called ‘‘rimless” rifle case. Although the disclosure is generally described in the context of these embodiments, it should be understood that it is not intended to limit the scope of the- Page 2 - Docket No. 23692.2adisclosure to these particular embodiments. Items in the figures are not necessarily drawn to scale.

[0010] Figure 1 illustrates a diagram of an example ammunition cartridge casing.

[0011] Figure 2 illustrates an example flow diagram depicting acts associated with forming an ammunition cartridge casing, in accordance with implementations of the disclosed subject matter.

[0012] Figure 3A illustrates example tooling for performing a diameter reduction operation pursuant to forming an ammunition cartridge casing, in accordance with implementations of the disclosed subject matter.

[0013] Figure 3B illustrates example completion of a diameter reduction operation pursuant to forming an ammunition cartridge casing, in accordance with implementations of the disclosed subject matter.

[0014] Figure 4 illustrates a close-up view of an ammunition cartridge bead and contact area, in accordance with the implementations of the disclosed subject matter.

[0015] Figure 5A illustrates example tooling for performing a primer pocket and flash hole formation operation pursuant to forming an ammunition cartridge casing, in accordance with implementations of the disclosed subject matter.

[0016] Figure 5B illustrates example partial completion of a primer pocket and flash hole formation operation pursuant to forming an ammunition cartridge casing, in accordance with implementations of the disclosed subject matter.

[0017] Figure 5C illustrates example tooling for compressing the ammunition cartridge to form the web, a primer pocket, and partial flash hole pursuant to forming an ammunition cartridge casing, in accordance with implementations of the disclosed subject matter.

[0018] Figure 5D illustrates an example of a formed web, partial primer pocket, and flash hole pursuant to forming an ammunition cartridge casing, in accordance with implementations of the disclosed subject matter.

[0019] Figure 6A illustrates example tooling for performing a powder chamber elongation operation pursuant to forming an ammunition cartridge casing, in accordance with implementations of the disclosed subject matter.

[0020] Figure 6B illustrates example completion of a powder chamber elongation operation pursuant to forming an ammunition cartridge casing, in accordance with implementations of the disclosed subject matter.

[0021] Figure 7A illustrates example tooling for performing a rim and extraction- Page 3 - Docket No. 23692.2agroove formation operation pursuant to forming an ammunition cartridge casing, in accordance with implementations of the disclosed subject matter.

[0022] Figure 7B illustrates example completion of a rim and extraction groove formation operation pursuant to forming an ammunition cartridge casing, in accordance w ith implementations of the disclosed subject matter.

[0023] Figure 8A illustrates a close-up view of example tooling for performing a rim and extraction groove formation operation pursuant to forming an ammunition cartridge casing, in accordance with implementations of the disclosed subject matter.

[0024] Figure 8B illustrates a close-up view of example completion of a rim and extraction groove formation operation pursuant to forming an ammunition cartridge casing, in accordance with implementations of the disclosed subject matter.

[0025] Figure 9A illustrates example tooling for performing a neck formation operation pursuant to forming an ammunition cartridge casing, in accordance with implementations of the disclosed subject matter.

[0026] Figure 9B illustrates example tooling for smoothing a formed neck pursuant to forming an ammunition cartndge casing, in accordance with implementations of the disclosed subject matter.

[0027] Figure 9C illustrates example completion of a neck formation operation pursuant to forming an ammunition cartridge casing, in accordance with implementations of the disclosed subject matter.

[0028] Figure 10A illustrates example tooling for performing a partial thickening operation pursuant to forming an ammunition cartridge casing, in accordance with implementations of the disclosed subject matter.

[0029] Figure 10B illustrates example additional tooling for a diameter reduction operation pursuant to forming an ammunition cartridge casing, in accordance with implementations of the disclosed subject matter.

[0030] Figure 10C illustrates example completion of a w eb formation operation pursuant to forming an ammunition cartridge casing, in accordance with implementations of the disclosed subject matter.

[0031] Figure 11A illustrates example tooling for performing a full thickening operation pursuant to forming an ammunition cartridge casing, in accordance with implementations of the disclosed subject matter.

[0032] Figure 11B illustrates example completion of a diameter reduction and web formation operation pursuant to forming an ammunition cartridge casing, in accordance- Page 4 - Docket No. 23692.2awith implementations of the disclosed subject matter.

[0033] Figure 12A illustrates example tooling for performing a preformed web formation operation pursuant to forming an ammunition cartridge casing, in accordance with implementations of the disclosed subject matter.

[0034] Figure 12B illustrates example completion of a diameter reduction and web formation operation pursuant to forming an ammunition cartridge casing, in accordance with implementations of the disclosed subject matter.

[0035] Figure 13A illustrates an example head section of an ammunition cartridge casing having a reduced diameter, in accordance with implementations of the disclosed subject matter.

[0036] Figure 13B illustrates an example head section of an ammunition cartridge casing having a partially reduced diameter, in accordance with implementations of the disclosed subject matter.

[0037] Figure 13C illustrates an example head section of an ammunition cartridge casing having a non-reduced diameter, in accordance with implementations of the disclosed subject matter.DETAILED DESCRIPTION

[0038] The disclosed subject matter relates to systems and methods for forming ammunition cases. The disclosed systems and methods can be applied to at least boxer- primed centerfire ammunition cases and variations thereof. One will appreciate, in view of the present disclosure, that at least some principles described herein can be applied to the manufacture of other types of ammunition cases.

[0039] As noted above, conventional firearm cartridge case manufacturing methods can include numerous operations performed on a sheet metal coil material using successive machines, such as a sequence of cupping, iterative drawing and annealing, pinching, ramming to form a primer pocket, ramming to flatten the head and apply a headstamp, extraction groove cutting, head annealing and tapering, trimming, flash hole punching, and final annealing. Such traditional firearm cartridge case manufacturing methods are associated with various challenges and drawbacks. For instance, traditional methods that utilize sheet metal coils typically produce a high scrap ratio, are prone to dimensional variability7, use multiple chemical washes, and / or utilize considerable equipment, facilities, and skilled labor. Furthermore, annealing procedures performed pursuant to conventional firearm cartridge case manufacturing methods can also increase manufacturing costs, including equipment, maintenance, energy, and labor costs.- Page 5 - Docket No. 23692.2a

[0040] At least some disclosed embodiments are directed to methods and associated tooling and components for forming cartridge case blanks from metal tube stock. Disclosed techniques utilize a series of tools and dies to perform deformation operations on the metal tube stock to shape it into an ammunition cartridge case.

[0041] In one example case manufacturing process, a fraction of metal tube stock material sufficient to form the head of the case can be initially reduced in diameter and then compressed. This creates a thickened curved area (e.g., the bead) in the region of the extractor groove, which can act to prevent folds in the material that may otherwise occur in subsequent steps. The angle of the bead exterior can approximate that of the angled section of the extraction groove. The material is then compressed further to thicken what will become the head of the case. The profiles of the tools used for this compression embody the general dimensions of the primer pocket, web, and flash hole, causing the formation of the primer pocket, web, and flash hole as the compression occurs. A manufacturer can draw or urge the material through a die to extend the length of the body and to reduce the wall thickness to the desired thickness. The rim of the extraction groove can then be formed by a deformation step as the material can be compressed axially into a segmented die (alternatively, the rim may be formed by a rolling or machining operation). The striking of the headstamp may be included in this operation or may be a separate step. The neck and body taper can then be formed by forcing the material into a die with a target body, neck, and shoulder shape, either in a single step or through a plurality of steps. An additional neck smoothing step can include the removal of a tool from the formed neck.

[0042] The disclosed case manufacturing techniques can facilitate various advantages relative to conventional methods. For instance, the disclosed techniques can reduce the number of process steps or operations needed to form the desired case shape, as the starting material (i.e., metal tubing stock) can be selected to generally correspond to the desired case diameter and length. With the dimensions of the starting material already corresponding to the desired case diameter and length, the case body and neck can be formed with a low amount of total strain compared to traditional methods. Furthermore, in some implementations of the disclosed techniques, only 1-2 drawing operations are performed to draw the initial material to its final length, in contrast with conventional techniques where numerous iterative drawing and annealing processes are performed. Unlike traditional methods, the general shape of the starting material in the disclosed techniques does not approximate the size and shape of the head of the cartridge case. Thus, a large amount of strain can be accumulated in the head area of the cartridge case, which- Page 6 - Docket No. 23692.2acan advantageously result in high strength at the head area. The disclosed techniques can advantageously reduce or eliminate the need for annealing or other heat treatment steps.

[0043] In at least some implementations, aside from cutting the metal tubing stock material to an initial size, the disclosed case forming techniques can avoid trimming, piercing, and / or machining operations, instead relying on deformation, compression, and drawing operations. The flash hole, the extractor groove, and the rim of cartridge cases can thus be formed without scrap generation, without the generation of new surfaces or pieces, or with limited scrap generation steps (e.g., no more than two scrap generation steps). For example, the flash hole can be formed without any drilling, cutting, or punching. In this regard, the disclosed case manufacturing methods can be regarded as "topology preserving’" (i.e., the topology of the initial metal tubing stock material is preserved). The disclosed techniques can thus achieve cartridge case manufacturing in a manner that reduces the needed equipment, machinery', facilities, and skilled labor (relative to conventional methods).

[0044] Furthermore, the disclosed techniques can cause incidental or deliberate rounding of the flash hole edges or formation of specific profiles for the flash hole wall and edges. These may improve the transfer or behavior of gases during the primer bum and may improve the ignition of the powder when the ammunition is fired.

[0045] Figure 1 illustrates a diagram of an example ammunition cartridge casing 100. As shown in Figure 1, the casing 100 includes a head 101 that can be configured to hold the primer and can be generally the thickest part of the casing. The primer pocket 106 is a space in the head 101 of the cartridge casing 100 that can retain a primer and seal the head of the cartridge (also referred to as a “head section’’ herein). The head 101 also includes a rim 107 and an extraction groove 108. which provide surfaces for an extractor to hook onto, enabling the removal of the cartridge casing 100 from a firearm chamber.

[0046] The casing 100 also includes a flash hole 102 that allows the transfer of flame from the primer to the powder charge (residing in the powder chamber 104). The casing 100 can include a web 103 that forms a junction between the case body 109 and the case head 101. The casing 100 defines a powder chamber 104 that can be configured to hold the powder charge. The casing 100 can include a shoulder 105 or shoulder region extending from the body 109 with a narrowing or tapered diameter. The casing 100 furthermore can include a neck 110 extending from the shoulder 105, which defines a mouth 111 or opening at an end of the casing 100. The neck 110 can facilitate holding of a proj ectile that is inserted into the mouth 1 11.- Page 7 - Docket No. 23692.2a

[0047] Figure 2 illustrates an example flow diagram 200 depicting acts associated with forming an ammunition cartridge casing. Although the acts represented in flow diagram200 are discussed and / or illustrated in a certain order, no particular ordering is required unless specifically stated or required because an act is dependent on another act being completed prior to the act being performed. One will appreciate that certain embodiments of the present disclosure may omit or combine one or more of the acts described herein. For example, in some geometries (e.g.. .223 Remington), the rim and extraction groove formation could occur before body drawing. Additionally, or alternatively, bead formation or a general thickening operation can be performed before a diameter reduction operation.

[0048] Act 201 of the flow diagram 200 includes a diameter reduction operation. Act201 can be performed on a metal tubing blank or initial stock material to form a diameter- reduced section in the metal tubing. The diameter-reduced section can have a diameter that approximates the outer diameter of an extraction groove for an ammunition cartridge case, which is formed from the initial metal tubing material. In another embodiment, the diameter-reduced section may approximate the greatest diameter of the body. For example, when a manufacturer intends to form the extraction features of an ammunition cartridge case through one or more scrap-generation steps, the diameter-reduced section may be the largest diameter along the casing, and the extraction features may then be formed through diameter-reducing cuts.

[0049] Figures 3A, 3B, and 4 conceptually depict performance and aspects of a diameter reduction operation (e.g., corresponding to act 201 of flow diagram 200). Figures 3A and 3B depict cross-sectional slices that show tooling for performing a diameter reduction operation, as well as the workpiece as it is formed. The tooling and the workpiece shown in Figures 3A, 3B, and 4 are axisymmetric about the central longitudinal axis. Figures 5A, 5B, 5C, 5D, 6A, 6B, 7A, 7B, 9A, 9B, 9C, 10A, 10B, 10C, 11A, 1 1B, 12A, 12B, 13A, 13B, and 13C similarly show axisymmetric cross-sectional slices. One will appreciate that the tooling shown herein is provided by way of example only and should not be interpreted as limiting the scope of the disclosed subject matter.

[0050] Figure 3A illustrates a metal tubing material 303 on which a diameter reduction operation (and other operations described herein) and a thickening / bead forming operation may be performed pursuant to forming an ammunition cartridge case. In the example shown in Figure 3A, the metal tubing material 303 has a through hole with an inner diameter similar to that of the desired powder chamber inner diameter of the cartridge casing to be formed from the metal tubing material 303. Furthermore, prior to the- Page 8 - Docket No. 23692.2aperformance of the acts depicted in flow diagram 200, the metal tubing material 303 can have a longitudinal length that can be greater than its outer diameter (e.g., in contrast to flat stock used as the starting material under conventional case formation techniques). This can allow the starting material to generally correspond in shape and size to the finished product.

[0051] Figure 3A illustrates the metal tubing material 303. a tool 301. and a die 302. In the example shown in Figure 3 A, the tool 301 can be positioned to force the metal tubing material 303 along the die 302 to allow the die 302 to form a diameter-reduced section in the metal tubing material 303. Die 302 can include one or more inner diameters that differ along its length. For instance, as shown in Figure 3A, the starting outer diameter of the tubing material 303 can fit within a first inner diameter of die 302 (toward the top of the die 302 from the perspective shown in Figure 3A) while not fitting within a narrower, second inner diameter of die 302 (e.g., without being forced or deformed). Figure 3A also show s tool 304, which can fit within the second inner diameter of the die 302. As the tool 301 forces the metal tubing material 303 into die 302, the metal tubing material 303 is guided into an annular space 310 defined by the inner diameter of die 302 and the outer diameter of tool 304.

[0052] Figure 3B illustrates completion of the diameter reduction operation, where the metal tubing material 303 is shown as including a diameter-reduced section 306 formed between and by the die 302 and tool 304 (e.g., within the annular space 310). The die 302 also forms an angled or curved section 308 in the metal tubing material 303, as shown in Figure 3B. The angled or curved section 308 may be formed via a segment of the die 302 where the first inner diameter transitions to the second inner diameter. The angled or curved section 308 can approximate the angle of the angled or tapered section / segment of the extraction groove 108. The outer diameter of the diameter-reduced section 306 may approximate the outer diameter of the extraction groove 108 for the finished ammunition cartridge case (e.g., the outer diameter of the innermost part of the extraction groove 1108 from the outside of the casing). The diameter reduction operation depicted in Figures 3A and 3B can involve advancing the metal tubing material 303 along the die 302 using the tool 301 until there is sufficient material at, in, or near the diameter-reduced section 306 to form the head of the case.

[0053] Figure 4 illustrates a close-up view of the angled / curved section 308 shown in Figure 3B. The compression of the metal tubing material 303 by tool 301 and the die 302 can force a portion of the metal tubing material 303 into forming the angled / curved section- Page 9 - Docket No. 23692.2a308, such that a bead or contact area 309 is formed on the metal tubing material 303 that abuts tool 301. During axial compression, the contact area 309 can abut a bottom surface or lower comer surface of tool 301, allowing axial compression forces from the tool 301 to transfer to the metal tubing material 303 in a manner that mitigates the possibility of the metal tubing material 303 pulling away from the die 302 (which could cause folding of the metal tubing material 303, rendering the part unusable). For instance, the contact area 309 can abut a bottom surface of the tool 301 during and / or as a result of the compression operation shown in Figures 3B and 4. The contact area 309 can facilitate this force transfer without causing portions of the metal tubing material 303 to pull away from die 302, which could result in folding of the metal tubing material 303. Thus, the formation of contact area 309 can improve the overall construction of the ammunition casings formed via the disclosed techniques.

[0054] With brief reference to Figure 2, act 202 of flow diagram 200 includes a bead formation operation. In some implementations, act 202 can be performed on a workpiece (e.g., metal tubing material) after or simultaneously with the performance of a diameter reduction operation (e.g., act 201). Act 202 can be performed to form a thickened region between the diameter-reduced section of the metal tubing material and a powder chamber section of the metal tubing material. In some implementations, the operations show n and described with reference to Figures 3A, 3B, and 4 achieve both diameter reduction (in accordance with act 201) and bead formation (in accordance with act 202).

[0055] In another embodiment, an act of thickening metal tubing material at or near a preformed diameter-reduced section can be performed. The preformed diameter-reduced section may be formed by forcing the metal tubing material into a die (or a space defined thereby) via another tool. This die may comprise characteristics similar to die 302 described above. The diameter-reduced section may then be performed prior to the thickening operation(s). In this embodiment, then, a tool and die may hold the metal tubing material in place w hile another tool axially compresses the metal tubing material to create a thickened region between the diameter-reduced section and a powder chamber section of the metal tubing material. A manufacturer may advantageously choose to form the diameter-reduced section and the thickened region in separate acts, which may lower the needed force tonnage. Reduced force, weight, or tonnage referenced throughout the application can increase tool or die working life, lower power requirements, and / or speed up the overall time investment for forming ammunition cases.

[0056] Referring again to Figure 2, act 203 of flow diagram 200 includes one or more- Page 10 - Docket No. 23692.2aprimer pocket and flash hole formation operations. In some implementations, act 203 can be performed on a workpiece (e.g., metal tubing material 303) after performance of a bead formation operation (e.g., act 202). Act 203 can be performed to form a primer pocket, a web, and a flash hole for the ammunition cartridge case using the diameter-reduced section of the metal tubing material.

[0057] Figures 5A-5D conceptually depict performance and aspects of a primer pocket, web, and flash hole formation operation (e.g.. corresponding to act 203 of flow diagram 200). Figure 5 A illustrates the metal tubing material 303 (on which the operations described with reference to Figures 3A through 4 were performed), including the diameter- reduced section 306, the angled or curved section 308, and a powder chamber section 506 (e.g., similar to powder chamber 104). Figure 5A illustrates the metal tubing material 303 arranged to be acted on by tool 701 (which may correspond to tool 301), tool 704, and die 302. In the example shown in Figure 5A, tools 701 and 704, and die 302 are positioned to compress the metal tubing material 303, substantially or at least partially forming a primer pocket, a web. and a flash hole in the metal tubing material 303.

[0058] Figure 5B illustrates completion of the primer pocket 706 and flash hole 708 formation operation, where tool 701 and die 302 are shown as having held the metal tubing material 303 in place while tool 704 axially compressed the metal tubing material 303 to shape the material in the diameter-reduced section 306 and or the thickened section of the metal tubing material 303 to generally form a primer pocket 706, a web 712, and a flash hole 708. In some instances, the contact area 309 (see Figure 4) acts as a temporary structure that contributes to the metal tubing material 303 resisting becoming folded or pulled away from the walls of the die 302 during axial compression to form one or more features of the head section 710 (e.g.. the web 712, the primer pocket 706, etc.). In some instances, the contact area may be regarded as a precursor structure that is superseded by the partially or fully formed w eb 712 after the compression operation(s) represented in Figures 5A through 5D.

[0059] It should be noted that the primer pocket 706, web 712, and flash hole 708 may, in some instances, not be fully formed during this operation, and may be further refined in one or more subsequent operations. Accordingly, tool 704 may be configured to assist in generally forming these elements (i.e., having fewer extensions). Figure 5B illustrates the primer pocket 706, the web 712, and the flash hole 708 as being arranged on or adjoining a head section 710 of the metal tubing material 303 (e.g.. adjacent to the powder chamber section 506).- Page 11 - Docket No. 23692.2a

[0060] The profiles of tools 701 and 704 can be shaped such that the general dimensions of the primer pocket 706. web 712, and flash hole 708 are formed during the compression shown in Figures 5A and 5B. For instance, tool 704 comprises a stepped cylindrical structure with concentric cylindrical protrusions, with a first cylindrical structure (the bottom cylinder from the perspective shown in Figure 5A) being shaped to advance through the second inner diameter of the die 302. a second cylindrical structure extending from the first cylindrical structure and with a smaller outer diameter than the first cylindrical structure (e g., to form a primer pocket 706), and a third cylindrical structure extending from the second cylindrical structure and with a smaller outer diameter than the second cylindrical structure (e.g., to form a flash hole 708). The tool 701 may comprise an opening for receiving the third cylindrical structure of the tool 704 during compression, as well as for allowing for the release of pressure or fluids (as shown in Figure 5B). In one embodiment, a corresponding extension or cylindrical structure may extend instead from the tool 701 and act in place of the third cylindrical structure of tool 704. The dies and tools of the present disclosure may incorporate one or more draft angles configured to assist in the removal of the material after completion of operations. These draft angles may extend partially or fully along the length of the tools and dies.

[0061] In some instances, the formation of the primer pocket, the web, and the flash hole can be achieved through multiple compression steps with different tooling (e g., rather than a single compression step with a single tooling arrangement as shown in Figures 5A and 5B). In some implementations, the primer pocket 706, web 712, and / or the flash hole 708 are further refined (after their general formation) through one or more subsequent operations. As noted hereinabove, the tooling shown is provided by way of example and can be varied within the scope of the present disclosure. For instance, the extension of tool 704 that forms the flash hole (the third cylindrical structure described above and shown in Figure 5B as residing within the flash hole 708) could, in some variants, be replaced by a pin that extends through tools 701 and 704. Although the present example focuses on an instance in which the same die 302 can be used for both the diameter reduction operation (described with reference to Figures 3A through 4) and the primer pocket, web. and / or flash hole formation operations (described with reference to Figures 7A and 7B), different dies having various inner diameters can be used for the different operations (e.g., dies with at least slightly different shape, length, or inner diameter).

[0062] As noted above, the formation of flash hole 708, primer pocket 706. and web 712 can be done in multiple steps or in a single step. Figure 5C illustrates an example in- Page 12 - Docket No. 23692.2awhich the metal tubing material 303 comprises a partially formed head section 714 (e.g., with a partially formed primer pocket and flash hole) that was partially formed via one or more intermediate steps using different tooling than that shown in Figures 5 A through 5C. Figure 5C illustrates the tools 701 and 705 and the die 302 positioned to further form or finalize the head section 710 following the intermediate step(s), with the further forming being shown in Figure 5D. By utilizing multiple compression steps to form the head section 710. a manufacturer can alter the tooling forces (e.g.. tonnage) and allow for specific flash hole geometries, which can improve or alter ignition performance. Similarly, varied tooling types, sty les, and configurations can alter the specific flash hole geometries that are possible to form.

[0063] Although the operations shown and described with reference to Figures 5A through 5D are depicted in relation to the metal tubing material 303 on which operations shown and described with reference to Figures 3A through 4 were performed, the operations shown and described with reference to Figures 5A through 5D may be performed on metal tubing material shaped in accordance with the operations shown and described within various processes of the present disclosure.

[0064] With brief reference to Figure 2, act 204 of flow diagram 200 includes one or more powder chamber elongation operations. Act 204 can be performed on a workpiece (e.g., metal tubing material 303) after performance of one or more primer pocket, web, and / or flash hole formation operations (e.g., act 203). Act 204 can be performed to elongate the powder chamber section of the metal tubing material to form a powder chamber for the ammunition cartridge case.

[0065] Figures 6A and 6B conceptually depict performance and aspects of a powder chamber elongation operation (e.g., corresponding to act 204 of flow diagram 200). Figure 6A illustrates the metal tubing material 303, including the powder chamber section 506 (prior to elongation) and the head section 710 (e.g., after performance of the primer pocket, web, and / or flash hole formation operation(s) described above with reference to Figures 5A through 5D). Figure 6A illustrates the metal tubing material 303 arranged to be acted on by the tool 902 and the die 901. Tool 902 can include a profile or outer diameter that is similar to the desired interior profile or inner diameter of the powder chamber for the finished ammunition cartridge casing. The tool 902 may be inserted into the powder chamber section 506, thereby allowing tool 902 to abut a portion of the head section 710 (e.g., part of the web). The tool 902 and die 901 may then be positioned to facilitate the drawing of the metal tubing material 303 through die 901, thereby extending the length of- Page 13 - Docket No. 23692.2athe powder chamber section 506 and reducing the wall thickness of the material. For instance, the die 901 can comprise a raised rim 906 with a smaller inner diameter than other portions of the die 901. The raised rim 906 may be positioned about the head section 710 of the metal tubing material 303, as shown in Figure 6A, and the metal tubing material 303 may be drawn through the die 901 (by movement of the tool 902, the die 901 or both), allowing the raised rim 906 to elongate and reduce the wall thickness of the powder chamber section 506 as shown in Figure 6B.

[0066] Figure 6B illustrates the completion of the powder chamber elongation operation, where the metal tubing material 303 is shown as having been drawn through die 901 using tool 902 to form the powder chamber 904 extending upwards from the head section 710 (from the perspective shown in Figure 6B). Because the initial metal tubing material can have a diameter that closely corresponds to the desired powder chamber diameter for the finished ammunition cartridge casing, the final wall thickness for the powder chamber can be achieved with a small number of draw s (e.g., tw o draws or even one draw). Implementation of one or more of the methods of the present disclosure may advantageously leave the portion of the metal tubing material outside the head section 710 in a relatively low-strain state because it is not subjected to significant deformation during the head-forming operations. As a result, this material can retain much of its ductility and can be drawn to elongate the body of the cartridge case without intermediate annealing. This can enable a more efficient manufacturing process, reduce thermal processing steps, and help preserve material integrity throughout the forming sequence. In some instances, some portion of the draw n material may be left in such a low state of strain that it does not meet the hardness or strength requirements of the final case. In these instances, additional forming steps (e.g., steps not explicitly required to form the geometry of the case) or temporary features in the metal tubing material can be implemented to work additional strain into portions of the material prior to drawing.

[0067] In at least one embodiment, the body material can be drawn or elongated before the final head-forming steps described herein. This approach may be particularly advantageous for ammunition cases with wide rims or head sections (e.g.. rimmed, semirimmed, or belted cases), where the geometry of the base requires material exceeding the diameter of the body. In such cases, the body of the cartridge case can first be extruded or drawn to its approximate final length, allowing the wall thickness and internal diameter to be established with minimal strain. Following this elongation, a secondary forming operation can be employed to radially expand the base region of the case, increasing its- Page 14 - Docket No. 23692.2adiameter to accommodate the desired extraction features such as the rim and other features such as the belt.

[0068] The order of operations for forming ammunition cases may be modified or selected to effectively manage material flow, such as where the head of the finished casing is to be larger than the drawn body. One or more machining or deformation operations may be performed to define the extraction groove, rim, and / or primer pocket. This order of operations may be beneficial for cartridge types such as the .45-70 Government, 7mm Remington Magnum, 7-30 Waters, and 220 Swift, where the head geometry is radially larger than the body profile.

[0069] Referring again to Figure 2. act 205 of flow diagram 200 includes a rim and extraction groove formation operation. In some implementations, act 205 can be performed on a workpiece (e.g., metal tubing material) after performance of one or more powder chamber elongation operations (e.g., act 204). Act 205 can be performed to form a rim and an extraction groove for the ammunition cartridge case.

[0070] Figures 7A and 7B conceptually depict performance and aspects of a rim and extraction groove formation operation (e.g., corresponding to act 205 of flow diagram 200). Figure 7A provides a view of the head section 710 of the metal tubing material 303 (e.g., after performance of the powder chamber elongation operation(s) described above with reference to Figures 6A and 6B). Figure 7A illustrates the metal tubing material 303 positioned to be acted upon via tool 1101, tool 1103. and die 1102, which are arranged to deform the metal tubing material by performing axial compression of the metal tubing material 303. Tools 1101 and / or 1103 may be shaped to facilitate further refinement of the primer pocket 706 and / or the flash hole 708 of the head section 710 during the axial compression (as indicated above). For instance, the tool 1101 may include a stepped cylindrical structure with concentric cylindrical protrusions, similar to tool 704 described above. The tool 1103 may be positioned within the metal tubing material 303, allowing tool 1103 to exert direct force on the head section 710 (e.g., by interfacing with the web 712). In order to release the part after rim formation, the die 1102 may be an open (or segmented) die. For clarity, the die 1102 is depicted here as a solid piece, while die 1102 may be an open or multipiece die.

[0071] Figure 7B illustrates the completion of the rim and extraction groove formation operation, where the metal tubing material 303 is shown as having been compressed by the tools 1101 and 1103 and the die 1102 to form a rim 1107 and an extraction groove 1108 at the head section 710. Although Figures 7A and 7B focus on an example in which- Page 15 - Docket No. 23692.2aaxial compression using segmented die is implemented to form the rim and the extraction groove, a rim and extraction groove formation operation as disclosed herein can implement alternative techniques, such as a rolling operation or machining (e.g., where the head section 710 is formed thicker, allowing the extraction groove to be cut into the head section 710, see Figures 13B and 13C). The formation of the rim and extraction groove through axial compression can reduce or limit the number of scrap-producing steps or actions (e.g., no more than one or no more than two scrap-producing steps or actions), which can result in cost savings and more streamlined processes.

[0072] Figures 8A and 8B illustrate a close-up recreation of a portion of the rim and extraction groove formation operation discussed with reference to Figures 7A and 7B. Figure 8 A illustrates that tool 1101 can define a recess 1110 (e.g., adjacent to and extending about the first cylindrical structure of the tool 1 101 in an annular manner) for forming the rim 1107 when the tools 1101 and 1103 and the die 1102 compress the metal tubing material 303. Figure 8A furthermore illustrates that the die 1102 may include a diameter-reduced region 1112 with a smaller inner diameter than other portions of the die 1102 and than the outer diameter of the powder chamber 904 defined by the metal tubing material 303 (the die 1102 may include a tapered region 1114 adjacent to the diameter- reduced region 1112). The inner diameter of the diameter-reduced region 1112 may correspond to or approximate the outer diameter of the extraction groove 1108 (e.g., the outer diameter of the innermost part of the extraction groove 1108 from the outside of the casing). Figure 8A illustrates the die 1102, further including a radial surface 1 116 that interfaces with the axially-extending diameter-reduced region 1112 edge 1118 of the die 1102. The diameter-reduced region 1112, the tapered region 1114, the radial surface 1116, and / or the edge 1118 may form the extraction groove 1108 when the tools 1101 and 1103 and the die 1102 compress the metal tubing material 303. Figure 8B illustrates the tools 1101 and 1103 and the die 1102 having compressed the metal tubing material 303 to form the rim 1107 and the extraction groove 1108.

[0073] With brief reference to Figure 2, act 206 of flow diagram 200 includes one or more neck formation operations, which can be performed to form a neck for the ammunition cartridge case. Act 206 can be performed on a workpiece (e.g., metal tubing material) after performance of a rim and extraction groove formation operation (e.g., act 205).

[0074] Figures 9A, 9B, and 9C conceptually depict performance and aspects of neck formation operations (e.g., corresponding to act 206 of flow diagram 200). Figure 9A- Page 16 - Docket No. 23692.2aillustrates the metal tubing material 303, including the powder chamber 904 (e.g., after performance of the powder chamber elongation operation(s) and / or the rim and extraction groove formation operation). Figure 9A illustrates the metal tubing material 303 arranged to be acted on by tool 1302 and die 1301. The profile of the die 1301 can correspond to the desired neck, shoulder, and body shape for the finished ammunition cartridge case. For instance, the die 1301 can comprise a first segment 1312 with an inner diameter corresponding to the desired outer diameter of the case body 109 for the finished ammunition cartridge case, a tapered segment 1314 with a shape corresponding to the shoulder 105 for the finished ammunition cartridge case, and a second segment 1316 with an inner diameter corresponding to the desired outer diameter of the neck 110 of the finished ammunition cartridge case. It should be noted that in some embodiments of the present disclosure, the inner diameters of the dies can be tapered. Tool 1302 and die 1301 can be arranged to force the metal tubing material 303 into the die 1301 to form the neck for the finished ammunition cartridge case. An additional tool 1304 can be used in conjunction with the die 1301 to form the neck and / or shoulder of the finished ammunition cartridge. The tool 1304 may include an end 1318 (e.g., a rounded end) that comprises an outer diameter (or an outermost diameter) that corresponds to the desired inner diameter of the neck 110 of the finished ammunition cartridge case. The outer diameter of the end 1318 of the tool 1304 may be greater than the outer diameter of a shaft 1320 of the tool 1304 (where the shaft 1320 may reside within the space defined by the second segment 1316 of the die 1301 , as shown in Figure 9A). Figure 9A furthermore illustrates the tool 1302 as including a stepped cylindrical structure with concentric cylindrical protrusions (e.g., similar to tools 704 and / or 1101), which may facilitate surface contact between the tool 1302 and the metal tubing material 303 (e g., the head section 710 thereof) for neck formation operations (and / or to further shape the features of the head section 710).

[0075] Figure 9B illustrates the metal tubing material 303 after being forced or compressed into die 1301 by tool 1302. As shown in Figure 9B, after forcing the metal tubing material 303 into the die 1301 via the tool 1302, an end of the metal tubing material 303 (e.g., the upper end, from the perspective shown in Figure 9B) may form a shoulder 1310 and a neck region 1311 by reducing the diameter of part of the metal tubing material 303. Tool 1304 may be positioned to assist in guiding the metal tubing material 303 into the die 1301 such that the metal tubing material 303 resists pulling away from the die 1301. Forcing the metal tubing material 303 into the die 1301 via the tool 1302 may cause at least part of the metal tubing material 303 at the neck region 1311 to pull away from the- Page 17 - Docket No. 23692.2adie 1301 (e.g., away from the second segment 1316 of the die 1301), as illustrated in Figure 9B. Under such a configuration, the tool 1304 may be urged through the neck region 1311 (e.g., from the position shown in Figure 9B to the position shown in Figure 9C), allowing the neck region 1311 to be shaped / straightened by the end 1318 of the tool 1304 and the second segment 1316 of the die 1301, resulting in a neck 1322 as show n in Figure 9C. After diameter reduction, the wall thickness of the neck material may be greater than desired, as the wall thickness may increase during the necking forming operations. The outermost diameter of tool 1304 can be sized to simultaneously draw the neck material to the desired thickness.

[0076] Figure 9C illustrates completion of the neck formation operation, where the metal tubing material 303 is shown as having been forced into die 1301 to form the neck 1322, shoulder 1310, and final body shape of the finished ammunition cartridge case. In some implementations, neck formation can be achieved through the performance of multiple forming steps. In some embodiments, the mouth of the finished ammunition cartridge case is formed at the end of the neck 1322 without trimming operations. In some implementations, a post-forming trimming operation can be performed to finalize the mouth at the end of the neck 1322. Where a post-forming trimming operation is performed, it may, in some instances, be the only scrap-generating operation performed (starting with the initial piece of metal tubing material) to generate the finished ammunition cartridge case. As used herein, a “scrap-generating operation7’ refers to any operation that generates waste material and / or new' surfaces, such as machining, trimming, pinching, punching, or other methods.

[0077] In some instances, a post-forming stress relief treatment can be performed on the ammunition cartridge case. Where such a stress relief treatment is performed, it can, in some instances, be the only heat treatment operation performed (starting with the initial piece of metal tubing material) to generate the finished ammunition cartridge case.

[0078] In some instances, a post-forming annealing treatment can be performed on the ammunition cartridge case in order to obtain a desired neck hardness, hardness profile, hardness gradient along the longitudinal axis of the case, or some combination thereof. Where such an annealing treatment is performed, it can, in some instances, be the only annealing operation performed (starting w ith the initial piece of metal tubing material) to generate the finished ammunition cartridge case.

[0079] Figures 10A, 10B. and 10C conceptually depict performance and aspects of a partial thickening operation pursuant to forming an ammunition cartridge casing. In some- Page 18 - Docket No. 23692.2aimplementations, a partial thickening operation can be performed before a diameter reduction operation. The partial thickening operation can be used to increase the wall thickness of a portion of the metal tubing material 1530 (e.g., similar to metal tubing material 303). During such an operation, the metal tubing material 1530 may remain within a substantially straight die (e.g., a die having a continuous or nearly continuous (e.g., a small draft angle) interior diameter along at least a section of its length that is greater than the length of the metal tubing material 1530).

[0080] Figure 10A illustrates the compressed metal tubing material 1530 positioned within a substantially straight die 1502 and proximate to tool 1501. Tool 1501 can be configured to axially compress the metal tubing material 1530 within the die 1502 and against tool 1504. In this configuration, die 1502 does not include a substantially tapered or stepped interior profile or diameter, and thus does not cause a substantial reduction in the outer diameter of the metal tubing material 1530 during this operation. Axially compressing the metal tubing material 1530 via the tools 1501 and 1504 within the die 1502 can form a thickened region 1510 in the metal tubing material 1530, which may comprise a substantially uniform diameter throughout its axial length. Performing partial thickening as described with reference to Figure 10A may reduce the required tooling force (tonnage) for future operations to form an ammunition cartridge case by redistributing the portions of the metal tubing material 1530 to different locations. For instance, by thickening portions of the metal tubing material 1530 as shown in Figure 10A, future operations for forming the head section can be performed with less tonnage. Partial thickening prior to diameter reduction may also reduce the number of required intermediate steps to form an ammunition cartridge case, as it imparts rigidity to the material and thus more stability (e.g., less tendency to form folds) during subsequent compression operations.

[0081] Figures 10B and 10C illustrate operations for facilitating diameter reduction and head section formation after performance of the partial thickening operation described with reference to Figure 10A. Figure 10B illustrates the metal tubing material 1530 during compression, where tool 1508 can be used to apply axial force to the tubing material 1530 while pressing against die 1503 and tool 1501. Tool 1508 may have various extensions or structures configured to assist in the forming of the flash hole, web, and primer pocket (e.g., comprising a stepped cylindrical structure with concentric cylindrical protrusions, similar to tools 704, 1101. and / or 1302) The compression can begin to cause the formation of the flash hole, primer pocket, and web using the material from the thickened region- Page 19 - Docket No. 23692.2a1510. Unlike die 1502 of Figure 10A, die 1503 can comprise a diameter reduction region, causing a curved or angled section to form at or near the thickened region 1510. Axially compressing the partially thickened region 1510 into die 1503 by tool 1501 may further thicken and shape the thickened region 1510, which may result in a contact area 1509 similar to the contact area 309 shown in Figure 4.

[0082] Figure 10B illustrates a diameter reduction operation. The contact area 1509 that may be formed at or near the thickened region 1510 is shown in contact with the tool 1501 (e.g., with a bottom surface thereof), assisting in compressing the tubing material 1530 into the die 1503 that has a tapered or stepped interior diameter. This multi-step approach that includes a partial thickening operation can allow for more controlled material flow and reduced or varied tooling forces. As shown in Figure 10C, the operation can include the full formation of a web, flash hole, and primer pocket. As with all acts of the present disclosure, this process can be completed in multiple steps with various tools and dies to alter the overall shape and tooling force utilized.

[0083] Figures 11 A and 1 IB show a similar process to that shown in Figures 10A and 10B. However, Figure HA illustrates a full thickening operation performed on metal tubing material 1630 to form a thickened region 1610 before the diameter reduction and the formation of the head section. The full thickening operation show n in Figure 11 A can result in a thicker thickened region (relative to that shown in Figure 10A) and can cause the formation of a contact area 1609 (e.g., similar to contact area 309). Thickened region 1610 can include enough material to form the webbing, flash hole, primer pocket, and other elements of the final ammunition casing. This thickening operation can include the use of tools 1601 and 1604 as w ell as die 1602. In some implementations, tool 1604 may omit a stepped cylindrical structure with concentric cylindrical protrusions for forming a flash hole and a separate primer pocket; rather, tool 1604 may be constructed to form a generally uniform thickened region 1610. As used herein, full thickening refers to thickening of the metal tubing material to the point where further substantial thickening is not necessary to form the wall of the primer pocket. Any subsequent minor thickening may only be incidental to forming the primer pocket profile.

[0084] Figure 1 IB illustrates the completion of the head section preform within die 1603. Die 1603 can include a reduced diameter section to reduce the diameter of the casing. This action can also include fully forming the flash hole, primer pocket, and web. The sidewalls 1606, as shown in Figure 11A, may be compressed further to define the primer pocket. The full thickened casing may have its diameter reduced using die 1608.- Page 20 - Docket No. 23692.2a

[0085] In some implementations, full thickening (or any thickening step described herein) of the metal tubing material may be advantageous by providing a preformed mass of material that can resist unwanted deformation during subsequent operations. For example, the presence of a fully thickened region can help prevent bending or folding of the material when it is later subjected to diameter reduction or axial compression. Additionally, the increased volume of material in the thickened region can allow compressive forces to be distributed more evenly across a larger area, potentially reducing the formation of localized high-strain zones and improving the uniformity of the final head structure. Pre-thickening or thickening operations may result in lower peak strain in high- deformation areas. However, full thickening may utilize higher tooling forces compared to partial thickening, due to the increased volume of material being displaced and the greater resistance to deformation. As such, the choice between partial and full thickening may depend on the desired geometry of the final part, the capabilities of the forming equipment, and the specific strain management characteristic of the manufacturing process.

[0086] Figures 12A and 12B conceptually depict performance and aspects of another thickening operation that can preform a web pursuant to forming an ammunition cartridge casing. The operation shown in Figures 12A and 12B can be structurally similar to the thickening operations described with reference to Figures 10A-1 IB, but it can include the formation of web 1710 in a single operation.

[0087] Figure 12A illustrates the metal tubing material 1730 positioned within die 1702 and between tools 1701 and 1704. Tool 1701 can be configured to apply axial force to metal tubing material 1730, while tool 1704 supports the material from below (from the perspective shown in Figure 12A). As compression is applied, material can be displaced to form a thickened region that includes a preformed web 1710. Tool 1704 may omit an extension or pin to form a flash hole during this step. For example, the tool 1704 can assist in forming a contact area 1709 (similar to contact area 309 in Figure 4) that forms a part of the partially formed web 1710. Die 1702 may comprise a substantially cylindrical die that omits a diameter reduction section (as shown in Figure 12A).

[0088] Figure 12A illustrates the completion of the web-preforming thickening operation, where the preformed web 1710 is shown as having been shaped within the head region of the tubing material 1730. Figure 12B shows a diameter reduction section of die 1703, which can reduce the diameter at or around the preformed web 1710 of the metal tubing material. Tool 1708 may optionally be used to refine the geometry’ of the web, to- Page 21 - Docket No. 23692.2aprepare the material for subsequent flash hole formation, or to complete the formation the flash hole. This approach can streamline the forming process by combining thickening and web formation into a single step, potentially reducing the number of tooling stages and improving process efficiency. However, the tooling force may need to be higher than in a multistep process.

[0089] Figures 13A, 13B, and 13C illustrate various example head section configurations for an ammunition cartridge casing, in accordance wi th implementations of the disclosed subject matter. Each configuration represents a different approach to forming the head section of the casing, particularly in relation to whether and how diameter reduction is performed prior to forming the extraction features. A manufacturer can use or modify dies and tools of the present disclosure to achieve various head section geometries, including, by way of example, head sections 1810a, 1810b, and 1810c.

[0090] Figure 13 A illustrates a head section 1810a having a reduced diameter relative to the body of the casing. This configuration may be used when the extraction groove and rim are to be formed through deformation operations. The reduced diameter can approximate the final outer diameter of the extraction groove, allowing the material to be shaped without machining or other scrap forming operations. This approach can reduce scrap and simplify downstream operations.

[0091] Figure 13B illustrates a head section 1810b having a larger outer diameter. This configuration may be used when the extraction groove and rim are to be machined rather than formed. The increased diameter provides sufficient material to allow for the cutting of the extraction features while still maintaining clearance for drawing the body of the casing. This configuration can offer flexibility but may increase machinery requirements compared with the approach illustrated in Figure 13 A.

[0092] Figure 13C illustrates a head section 1810c having a non-reduced diameter. This can mean the head section is formed without a prior diameter reduction operation. This approach can simplify the forming process, as a diameter reduction step may not be included. However, because the body must be draw n from thicker, potentially high-strain material in the region of the head, this configuration may result in increased drawing forces and higher residual strain in the head region compared with the approaches illustrated in Figures 13A and 13B. Additional tooling may be used to prevent collapse of the primer pocket or to manage material flow, and multiple drawing operations may be needed to reduce the risk of fracture. Alternatively, the extraction features may be machined before the body drawing operation, providing clearance for tooling to draw the body without- Page 22 - Docket No. 23692.2ahaving to draw the high-strain head material. Each configuration may be selected based on the desired balance between manufacturing complexity, material utilization, and the method of forming or machining the extraction features.

[0093] Disclosed embodiments include at least those represented in the following numbered clauses:

[0094] Clause 1. A method for forming a web of an ammunition cartridge case, the method comprising: obtaining a metal tubing material that defines a through hole; forming a thickened portion of the metal tubing material by axially compressing a first portion of the metal tubing material; and forming a web that defines a flash hole by axially compressing the thickened portion of the metal tubing material.

[0095] Clause 2. The method of any preceding clause, wherein the thickened portion of the metal tubing material and the web that defines the flash hole are formed via a single axial compression operation.

[0096] Clause 3. The method of any preceding clause, wherein the method further comprises, after forming the thickened portion of the metal tubing material, reducing a diameter of the thickened portion via axial compression using a tool and a die.

[0097] Clause 4. The method of any preceding clause, wherein, prior to forming the thickened portion and prior to forming the web, a longitudinal length of the metal tubing material is greater than an outer diameter of the metal tubing material.

[0098] Clause 5. The method of any preceding clause, the method further comprises forming an extraction groove by axially compressing the thickened portion of the metal tubing material.

[0099] Clause 6. The method of clause 5, wherein, prior to forming the web and forming the extraction groove, an outer diameter of the thickened portion approximates an outer diameter for the extraction groove.

[0100] Clause 7. The method of any preceding clause, wherein the thickened portion of the metal tubing material comprises a contact area configured to receive axial compressive forces from a tool used during formation of the thickened portion.

[0101] Clause 8. The method of any preceding clause, further comprising forming a primer pocket by axially compressing the thickened portion of the metal tubing material.

[0102] Clause 9. A method for forming an ammunition cartridge case, the method comprising: obtaining a metal tubing material that defines a through hole; and performing a plurality of operations on the metal tubing material to form the ammunition cartridge case, the plurality of operations comprising: reducing a diameter of a first portion of the- Page 23 - Docket No. 23692.2ametal tubing material; axially compressing the first portion to thicken the first portion and form ahead section; and drawing a second portion of the metal tubing material to elongate the second portion of the metal tubing material.

[0103] Clause 10. The method of clause 9, wherein a longitudinal length of the metal tubing material on which the plurality of operations is performed is greater than an outer diameter of the metal tubing material.

[0104] Clause 11. The method of any preceding clauses 9 through 10, wherein axially compressing the first portion of the metal tubing material comprises forming a contact area configured to receive axial compressive forces from a first tool.

[0105] Clause 12. The method of any preceding clauses 9 through 11, further comprising, prior to axially compressing the first portion to thicken the first portion and form the head section, performing an initial thickening operation.

[0106] Clause 13. The method of any preceding clauses 9 through 12, wherein the plurality of operations comprises, at most, two draw press operations.

[0107] Clause 14. The method of any preceding clause 9 through 13. wherein the plurality of operations comprises, at most, two scrap-generating operations.

[0108] Clause 15. The method of any preceding clause 9 through 14, wherein the plurality of operations comprises, at most, a single heat treatment operation.

[0109] Clause 16. The method of clause 15, wherein the single heat treatment operation comprises a post-forming stress relief treatment or a post-forming annealing treatment.

[0110] Clause 17. The method of any preceding clause, wherein the second portion of the metal tubing material forms a powder chamber for the ammunition cartridge case.

[0111] Clause 18. The method of clause 17. wherein the plurality of operations further comprises one or more neck formation operations that form a neck for the ammunition cartridge case.

[0112] Clause 19. The method of clause 18, wherein the one or more neck formation operations comprise urging a rounded tool through an inner diameter of the metal tubing material to form the neck.

[0113] Clause 20. A method for forming an ammunition cartridge case from a metal tubing material that defines a through hole, the method comprising: reducing a diameter of a first portion of the metal tubing material; axially compressing the first portion to thicken the first portion and form a head section, the head section comprising a primer pocket and web, wherein the web defines a flash hole; drawing a second portion of the- Page 24 - Docket No. 23692.2ametal tubing material to elongate the second portion of the metal tubing material to form a powder chamber; axially compressing the metal tubing material to for an extraction groove and a rim; reducing a diameter of at least part of the second portion of the metal tubing material to form a neck; and urging a tool through an inner diameter of the metal tubing material to smooth the neck.

[0114] While certain embodiments of the present disclosure have been described in detail, with reference to specific configurations, parameters, components, elements, etc., the descriptions are illustrative and are not to be construed as limiting the scope of the claimed invention.

[0115] Furthermore, it should be understood that for any given element of component of a described embodiment, any of the possible alternatives listed for that element or component may generally be used individually or in combination with one another, unless implicitly or explicitly stated otherwise.

[0116] In addition, unless otherwise indicated, numbers expressing quantities, constituents, distances, or other measurements used in the specification and claims are to be understood as optionally being modified by the term '‘about’’ or its synonyms. When the terms “about,” “approximately,” “substantially,” or the like are used in conjunction with a stated amount, value, or condition, it may be taken to mean an amount, value or condition that deviates by less than 20%, less than 10%, less than 5%, less than 1%, less than 0.1%. or less than 0.01% of the stated amount, value, or condition. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0117] Any headings and subheadings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description or the claims.

[0118] It will also be noted that, as used in this specification and the appended claims, the singular forms “a,” “an” and “the” do not exclude plural referents unless the context clearly dictates otherwise. Thus, for example, an embodiment referencing a singular referent (e.g., “widget”) may also include two or more such referents.

[0119] It will also be appreciated that embodiments described herein may also include properties and / or features (e.g., components, members, elements, parts, and / or portions) described in one or more separate embodiments and are not necessarily limited strictly to the features expressly described for that particular embodiment. Accordingly, the various features of a given embodiment can be combined with and / or incorporated into other- Page 25 - Docket No. 23692.2aembodiments of the present disclosure. Thus, disclosure of certain features relative to a specific embodiment of the present disclosure should not be construed as limiting application or inclusion of said features to the specific embodiment. Rather, it will be appreciated that other embodiments can also include such features.- Page 26 - Docket No. 23692.2a

Claims

CLAIMSWhat is claimed is:

1. A method for forming a web of an ammunition cartridge case, the method comprising: obtaining a metal tubing material that defines a through hole; forming a thickened portion of the metal tubing material by axially compressing a first portion of the metal tubing material; and forming a web that defines a flash hole by axially compressing the thickened portion of the metal tubing material.

2. The method of claim 1, wherein the thickened portion of the metal tubing material and the web that defines the flash hole are formed via a single axial compression operation.

3. The method of claim 1, wherein the method further comprises, after forming the thickened portion of the metal tubing material, reducing a diameter of the thickened portion via axial compression using a tool and a die.

4. The method of claim 1, wherein, prior to forming the thickened portion and prior to forming the web, a longitudinal length of the metal tubing material is greater than an outer diameter of the metal tubing material.

5. The method of claim 1, the method further comprises forming an extraction groove by axially compressing the thickened portion of the metal tubing material.

6. The method of claim 5, wherein, prior to forming the web and forming the extraction groove, an outer diameter of the thickened portion approximates an outer diameter for the extraction groove.

7. The method of claim 1, wherein the thickened portion of the metal tubing material comprises a contact area configured to receive axial compressive forces from a tool used during formation of the thickened portion.

8. The method of claim 1, further comprising forming a primer pocket by axially compressing the thickened portion of the metal tubing material.

9. A method for forming an ammunition cartridge case, the method comprising: obtaining a metal tubing material that defines a through hole; and performing a plurality of operations on the metal tubing material to form the ammunition cartridge case, the plurality of operations comprising: reducing a diameter of a first portion of the metal tubing material; axially compressing the first portion to thicken the first portion and- Page 27 - Docket No. 23692.2aform a head section; and drawing a second portion of the metal tubing material to elongate the second portion of the metal tubing material.

10. The method of claim 9, wherein a longitudinal length of the metal tubing material on which the plurality of operations is performed is greater than an outer diameter of the metal tubing material.

11. The method of claim 9, wherein axially compressing the first portion of the metal tubing material comprises forming a contact area configured to receive axial compressive forces from a first tool.

12. The method of claim 9, further comprising, prior to axially compressing the first portion to thicken the first portion and form the head section, performing an initial thickening operation.

13. The method of claim 9, wherein the plurality of operations comprises, at most, two draw press operations.

14. The method of claim 9, wherein the plurality of operations comprises, at most, two scrap-generating operations.

15. The method of claim 9, wherein the plurality' of operations comprises, at most, a single heat treatment operation.

16. The method of claim 15, wherein the single heat treatment operation comprises a post-forming stress relief treatment or a post-forming annealing treatment.

17. The method of claim 9, wherein the second portion of the metal tubing material forms a powder chamber for the ammunition cartridge case.

18. The method of claim 17. wherein the plurality of operations further comprises one or more neck formation operations that form a neck for the ammunition cartridge case.

19. The method of claim 18, wherein the one or more neck formation operations comprise urging a rounded tool through an inner diameter of the metal tubing material to form the neck.

20. A method for forming an ammunition cartridge case from a metal tubing material that defines a through hole, the method comprising: reducing a diameter of a first portion of the metal tubing material; axially compressing the first portion to thicken the first portion and form a head section, the head section comprising a primer pocket and web, wherein the web defines a flash hole; drawing a second portion of the metal tubing material to elongate the- Page 28 - Docket No. 23692.2asecond portion of the metal tubing material to form a powder chamber; axially compressing the metal tubing material to for an extraction groove and a rim; reducing a diameter of at least part of the second portion of the metal tubing material to form a neck; and urging a tool through an inner diameter of the metal tubing material to smooth the neck.- Page 29 - Docket No. 23692.2a

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