CNC Turned Lead Projectiles for Gas-Guns
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Solution Overview
Problem
Current manufacturing methods for projectiles, particularly for gas-guns, face challenges such as high costs, low precision, and limited material options due to the use of casting or pressing, which result in deviations and reduced ballistic efficiency, especially for lead projectiles, limiting their effectiveness at long distances.
Innovation Solution
Development of machine-tool turned projectiles made from lead or its alloys with precise diameter control, utilizing carbide or high-speed steel cutters in NC or CNC machines to achieve a high ballistic coefficient and improved aerodynamics, allowing for precise shaping and reduced deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If casting or pressing methods are used to manufacture lead projectiles, then production cost is reduced, but manufacturing precision and ballistic coefficient are insufficient
Solution Approach 1:
The patent replaces traditional mechanical casting and pressing systems with a computer-controlled lathe machining system. This substitution enables precise diameter control (deviation < 1%) through automated tool paths and digital programming, eliminating the precision limitations of manual molding while maintaining cost-effectiveness through the simplicity of the machining approach for soft lead material.
2Ease of manufacture
If lead is used for projectiles in firearms, then material cost is reduced, but temperature resistance is insufficient due to low melting point
Solution Approach 1:
The patent inverts the traditional approach by designing the projectile manufacturing process around lead's low melting point rather than fighting against it. By using cold-forming machining operations on a lathe instead of high-temperature processes, the method fully exploits lead's ductility and softness at room temperature to achieve precise shaping without requiring temperature resistance or jacketing materials.
3Productivity
If traditional casting or pressing machines are used, then initial equipment cost is reduced, but productivity and adaptation to new shapes are limited
Solution Approach 1:
The patent transforms the manufacturing approach by changing the operational parameters from high-power pressing/casting to low-power precision machining. The computer-controlled lathe uses variable tool paths, speeds, and feeds programmed digitally, allowing rapid adaptation to new projectile shapes through software modification rather than physical retooling, thereby increasing productivity and flexibility simultaneously.
4Manufacturing precision
If moulds are manufactured for new projectile prototypes, then production accuracy can be maintained, but development cost and time increase significantly
Solution Approach 1:
The patent uses digital copying and simulation capabilities of computer-controlled machining systems. Projectile shapes can be designed, simulated, and programmed virtually before actual machining, allowing rapid prototyping and iteration without physical mold fabrication. The same digital model can be directly transferred to production machining, eliminating the time-consuming mold-making process while maintaining precision through digital accuracy.
Data Source
AI summary
A rotationally symmetrical lead metal-cut projectile of the caliber ranging from 0.17 to 0.50 for gas-guns comprises at least 60% by weight of lead, up to 40% by weight of tin and up to 5% by weight of admixtures selected from the following list: Ag, As, Bi, Cd, Cu, Fe, Ni, Sb, Zn, Ti or their mixtures thereof.