:L J

WVT- QA- 7201

FATIGUE BEHAVIOR OF THICK-WALLED CYLINDERS(7.62MM RIFLED SPECIMENS)

TECHNICAL REPORT¢X

fbe

JUNE 1972

QUALITY ASSURANCE DIRECTORATE

U.S. ARMY WEAPONS COMMANDWATERVLIET ARSENAL

0,, WATERVLIET- NEW YORK

AMCMS NO. 4931.OM.6350

PRON M7-O.P3381

DISTRIBUTION OF THIS DOCUMENT IS UNLIMITED

Reproduced byNATIONAL TECHNICALINFORMATION SERVICE

I1 S Deportment of CommerceSpringfield VA 22151

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Ar

04U1

DISPOSITION

Destroy this report when it is ne longer needed, Do not return it

to the originator,

I

IDISCLAIMER

The findings in t,.his report are not to be construed as an officialDepartment of the Army position unless so designated by other authorized Jdocuments.

bcud DOC4ENT COKMRLDVATA. - t & D

t~~~~~~~ . W11SATIITC#)MREPORT 3ccuaITV CLaseeVICAflO04

WATEMMI~ AUE viA Th.eIaaifted

Fatigu Beairof Thick Wus4d CYlindars

Vincent T. Chodlcowski and Peter Go GOUtos

S. CPOVVT VATK PAL TOTAL 1N0. OWr PA9S A?. No. of nEit

114t. CONTRACT OR GRNTN NO. 84. 1~T0WX OW-ORT NUM11EROfl

Ais ,io. 493l.om.63501%~ PROJECTNMO- uvT - QA - 7201

- PRON H7-O-P3381 Sb. OTHER REPORT NO(S) CAW' .ffiIN840 1609 MV bO 0600i-0i

I0. OISTRISIJTIOM STATEMENT

Distribution of this documcat is unlimited.

o I I. SUPPLEMENHTARY NOTES I.SpONSOMINS MILITARY ACTIVITY

Army materials and Research centerWatertown, Masse

Thil. report deals with fatigue life testing employing 7fr62MKh rifled barrels

in order to secure information on the rel.ationship of specimen life achieved

through cyclic hydraulic pressure stregging and that achieved by firing of service

type ammnition. liaterials used inc~luded standard M14 rifle barrel stckl from

several suppliers and 175HM M113EJ. cannon tube forging material from chree suppliers.

The report also addresses the problem of "life" reliability predicticra anddewnstrates the potential usefulness of small barrel specimen testing in pro-

* viding insight to "'big gunfl research, development, manufacturing, field support

and quality engineering type problems.

I DC) ,~'.,1473 N~LACK$ D@ FORMI 1471D.IJAN 64. WHIEN Ia nlssfe

8jp09TFOR RMYUSX

14 LIMIC A UIN a LIEE3 C

R OLZ INT ROLE WT RONLE, IFT

'Fatisue FaibreIFired LifeFiring DaaSe,

Cann~on Tube Material

Rteliability Prediction/'verificationCorrelation Hydrauilic SilzlatianIFlring

LI.

Security Clamslfication

MW 2

N40LC1 MY~ I I X

Pressure Cyclinzfired Lifefiring Dzzag-

Cannon -5be MArterisl7.62M Barrel Mater~zJ.Rliability 2Pretion#erifiation

Correlatiot2 Hydraulic Siz1ationixfing

Se-CUrit ClasifiatiI

t I

WVT- QA- 7201

oFATIGUE BEHAVIOR OF THICK-WALLED CYLINDERS j(7.62MM RIFLED SPECIMENS)

TECHNICAL REPORT

BY

VI'%'CE~iT T. CHtZOK&o'.SKl Dl D~ CA'%D L

PETER G. GOUTOS S 1. 19T2

- -' °: ""-D.yJUNE 1972

QUALITY ASSURANCE DIRECTORATE

U.S. ARMY WEAPONS COMMANDWATER VLIET ARSENAL

WATERVLIET- NEW YORK

AMCMS .o. 4931 .OM. 6350 Detaf" 6f fulustraiion- ;i'P.this documerit may be better

PRON M7-O.P3381 Studied on microfiche

DISTRIBUTION OF THIS.DOCUMENT IS UNLIMITED

- . "d.. o,

FATI(ZE EMLVII2 Q-:T flI WI1M CYLT-M2?S

This report deals with fatiEie Fatigue Tailurelif-e zesting e6plong 7.62 ! Pressure Cg clim

rifled L-arrels in order to se- Fired Life

cure Inforazri n Gn the relation- Firing age;e

ship of speci en life achieved Cannorn Tube l!aterial

chrough cyclic hydrauIlc pres- 7.62!1 Barrel .tateri l

sure stressinr and that achieved Re-lability Prediction/Verification

by firing of service tyie a,=ni-Correlation Hydraulic

tion. Uaterials used included Siculation/Firing

standard '.314 rifle barrel stock

froz several suppliers and 175MC!

Mhl3AI cannon tube forging mater-

al from three suppliers.

The report also addresses the

problem of "life" reliability

prediction and demonstrates t.he

potential usefulness of small

barrel specimen testing in pro-

viding insight to "bin gun" re-

search, development, manufactur-

ing, field support and quality

engineering type problems.

~id.

2 Oijectives3 Aproacih 24 .Z-e ts a d liscssi= &5 Conclusi n 76 Pec~edztcc

APPE ICES

(PHASE i-AIPX P.)

Estabfdslsmnt of Test Terhniques

A 9-16

(PHASE II-APPXs B T-1'I Z)Correlation of lI,,draulic Pressure Q-cled Life to Fired Life

D 17-20C 21-23D 24-30E 31-36

F Application of Yalti-Leve1 Testing to 37-41Standard Cannon

(PIHASE III-APPXs G THRU L)Comparison of 1751DI Tube Forging MaterialProduced by Three Contractors X,Y,Z.

G 42-44H 45-47I 48-50. 51-54K 55-58L 59-63

M Application of 7.62MM Barrel Specimens 64-67to a Field Failure Problem

N 7.62MM Ammunition Calibration 68-69

0 Miscellaneous References 70-71

,- nf

...

Zsta _Ils!mct cf safe c=== fe t7y ce fr c! a-=Ifrc

Is C5e S:Esfr, PartIC22hry Vb deefi alr ssccuae

V-4t, Metal fatlip-e c~f a clItfcal crP = =C2 as a CM MIb.-

Cl-~Fiiz sL!_1c I55-M2I bcwftzer *=e to It-; 1.2tJe I!Ie fer a pr-h

of cr-e mdl1k4a dcl!as Is cc~s1idcre a Zesz==I= cl a

s=[ficIe=t~re ef ="-,es L-y UIf iri to ac~ iewe a szatszLcal1

51deratIon to nmeral Issces zd 7refessiotal etis. Iopicatfr=

t - f if I:; mdtbi atte~azt extremes I= tereraturcs, Fres-

sure, azd ezerq7 Iteimg develope& I inl:-Anal t!:r Is diffIcalt If

nor :poss1le. Therefore In order to SaIn a Itettr cmderstzndimg;

of lIfe testizcg, s-=11 size specim erfrIezrztn apeared as a

logical approach for gmeratIon of data I'v uich to look Into the

theoretical, statistical aad experimental =ethods now tein;. ex-

plored by =any investigators.

2, OBJECTIVES

The irediate goals of this study are:

a. To correlate a~unition firing pressure fatigue effects to

hydraulic pressuire cycling fatigue effects using thick Valled gun

barrels.

b. To determine fatigue life performance of cannon tube

material furnished by different contractors, produced to a co~on

specification but by proprietary processes,

2--- rare gr of- eis xs=37y aml sti- res1fci

Zc ~ c z mere sf maer121 tes= ctark r

E:! C =5e fc--%! t7 1Ife

3. An4 LV

ihmse z - CT~m~ ir e=z~ e'

ne 7..6-O mfe = Ls SaeIre as a zess 'wellac bt,ea.e c:!

I=w =~s= 2= a ara&z!My ef =21 rlf!,e Bazre~s. Stf-m

t!r, fat4;=e lIfe cf a ztezlA rfLe Barel was e~fLmze! Ift

Im c4=-zrLT= WWIr tl: of a trr'!= ca=n, I= =5dzs mei mm

dr~m theC ,arreI J-st or=- th cr4I ef rifl-- =c a fccz t'o sa

1-mx douxM bai-r~a Im cr--Ie cc cciic~ arlier fmAizre. MmIcI

tests Ukerc X= UIdth tarrels =ekb~ t- a 1A4 :u-A rzxI~ (=xclo CfI

ccts!Ze 1mDze t cfr rhffrI- Vrcre dilameer). A te ef fire

of six (6) rc=n3s p=r rnlIntr ns slected as en rcau--aa~e. Even

at this Ilw rate, barrel heatL.6 scrIcusly d~e~r~zd! lI-fe (Eazrels

ttzrced blune) azd a decision 'as made t3 T-mer cool the remalin--Z

1.4, 1.6, and 1..8 vfl ratio sein d~fr fring (See AJ-ptdIx

A for infornation =d data prtain-g to this pillse of =rk).

Phlase 11 - "Crrelation of H-ydraulic 'ressure C-7c'Ied: Life to

Fired Life -

The follcu-ng decisions w-ere r-ade based on Phase 1 restilts:

a. Use a standard proof fired I-l4 barrel rodified to a 1.8v-afl

xai- o In the vit~inity of the origin of rifling.

b. Fire at 6 rmuds per mimilta.

2

- - -. *-. - - -

sx-~~~- -.:c7'-y S

Mole~ -,ta -,=m=

; m fnutr. T- :± 14= m a li

S-tc 11 " afr Z-!: 41:7' - _

scf ted ee ls if cJ2me C=1I se-.i. S

-? ces s.-e--=--.Ve f

4-'4

im71W- :2. 7vt ell Z:.! c

-- A ":-Ire

7:= t'wX-vgr=r T- e =='

fps!'-"

'I T II

Ally.SM

TCsr PER TIM-

3 2VCCfl 7,416 78=,2 C, 1)' 5,5• "'

3.'a'D 2,9733LCCO 7,C46 6,373

3, 0 2,9395 4,C 2,174 20666

16cT-rD 2,5375,63 0

6 6,20 0 Avg 6,1446,4S7 0 EdS

are s=4 in AppenIx C and yields a relationsh p between hydraulic

pressure cy'ed specinen life to fired specimetn liWe of

Y(r'cIes) ' - 2.21 X(rcurds) +12,122

or 2.21 hydraulic ce are equal to one fired round.

It sh=uld be noted tbat. although large differences are e:Ident

among individual specifen lives at any ne level, the average life

at eaeb level, closely adheres to the straight line relationship.

The fired to destruction barrels (test level 6) c,nfirn the

validity of the resultant equations raver in predicting mean

fatigue or catastrophic failure.

An analysis of variance vas perforned on the six (6) levelr., Ithree (3) replicates per level and there appears to be no

significant difference among the nean equivalent lives at each

Nr.

-?7

level. See Appendix D for details.

A reliability life determination is shown in Appendix E Slong

with photographs of failed 114 rifle specimens.

ti application of the life predicticn technique, used with the

2114, to standard cannon i3 shown in Appendix F. The concept 6f re-

tiring 1000 or more safe still usable tubes to prevent a single

accident as a result of metal fatigue has in recent years become

an acceptable practice. Additional safeguards are also provided

as a result of other rearons for condemnation sach as bore wear

(origin or =uzzle), rifling damage, rust or pitting, transportation

hazards, eneny action etc.

Phase III - "Comparison of 175M Tube. Forginp M.aterial Produced

by Three Contractors X, YZ Z."

Data generated from this experiment and a graphical portrayal of

this data is shown in Appendix 11.

Comparing 14 rifle material plot to 175M-1 gun material plot

shows more variation in IL14 rifle material llfe. This may be attri-

buted to the fact that all 1751M specimens were manufactured by one

machinist on common m chinery while the 1114 rifle barrels were drawn

from stock and involve a variety of manufactures.

In both the IL14 test and the 175M material test, hydraulic pres-

sure cycling was performed at about 3000 PSI less than the average

firing pressure. This might account for the 1114 2:1 hydraulic cycles

per firing cycle but then it does not account for the 1:1 relation-

ship shown with 175MM material with specimen fired beyond the 500

6

Q ^--- I - -

round level. See Appendix N for ammunition calibration inforwation.

The 175IM! material appears to be very seriously affected by

firing damage as demonstrated on the graph with the pure (unfired)

hydraulically pressure cycled specimens versus those fired to

destruction. Also the combination fired/cycled 5 rd., 50 rd., and

100 rd. specimens show a sizable drop in life as compared with the

unfired specimens. The 1114 material did nt exhibit this effect

although proof of one round may promote sufficient firing damage

to account for this condition.

In order to perform a comparison of life data within a forging,

among forgings from a particular supplier, and among forgings from

different suppliers, data was transformed to a common base as shown

in Appendix 1. The difference among forging life data are considered

normal and acceptable fatigue behavior irrespective of forging

supplier. Material properties and quality are considered to be

effectively the same. Appendix J contains life/reliability infor-

mation. Appendix K shows life and material properties data and pots

while Appendix L contains photos of specimens fired to destruction.

Appendix M shows information on a field failure and specimen

test results. W1hile the results cover a wide range, from 1676

rounds through 7810 rounds, the three out of four low life values

indicate cause for concern about material behavior.

S. CONCLUSION

The multi-level testing technique and 7.62WM bore fatigue spec-

imens, as demonstrated by these studies, are each considered useful

tools and reasonable (cost/effective) methods for problem exploration.

7

Typical problems for possible application being:

Swage tule vs hydraulic autofrettage tube life

Rate of fire effects

Effects of pressure levels

Changes in chemistry

Changes in heat treat

Changes in forging practices

Chrome or other type plating effects

Refractory liners

Cooling effects

Aging and rest between firing effects

lydrogen _mbrittlement

Long term storage chemical effects

Straightening

* Thermal treatment effects

Dirt size and ccunt

6. RECOMIENDATYON JContinued funding of projects using specimens of the type em-

ployed in this study in order to promote knowledge for production

of superior cannon tubes and safely exploiting maxinum life from

these tubes.

8

APPENDIX A

MrFABLIS!fI23E0 OF TEST TECHN7IUES

NO. PACE

1. Firing Fixture Used for Preliminary Investigations 10

2. 1.4 Wall Ratio Specimens - Air Cooled During Firing !3. 1.4 Wall Ratio Specimens - Water Cooled During Firing 12

4. 1.6 Wall Ratio Specimens - Water Cooled During Firing 135. 1.8 Wall Ratio Specimens - Water Cooled During Firing 14

6. Graph - Wall Ratio vs Fired Life 15

7. Specimen #5 Heat Check Pattern 16

9

9 A

I..

I it

CL

:1E 0

07A:

. fikI

7-62iM Ihdified M4l1 Ria-le Barrel~s-'-4 Wall Ratio FP-tigue Specimens

Air Co-oled, Rate of Fix-e 6 RdazzlinPioJectile Travel jic*u Ammmiition LOt LO .13023

Projeot N!o. 4332-1., Negative No, 29-c4-.69

4pec~nen #Life 87 rd

'NM I '1I

Li fe 389 rds

A-2i

7.621v2 I Mdified Nib Rifle Barre'l.s1.4j 1,441 Ratio Fatigue Specimens

Water Cooled, Rate of Fire 6 Rds/MinProject No. 0332-1. Negative No. '197-2--69

:pecimen #3Life 829 rds.,rnmiition Lot LC-13023Projectile Travel 10O-2-

3pecimefl #710Life U93 rdsAzmunition Lot tNRA-227l3Projectile T1ravel. 19 "e

Znecirnen gi11

Lire-OL*1 rds

? rojecti~e Tra~vel 1914A'

A-3?

7.6221 Modified MAlJ Ri-fle Biarrels1.6 Wall Ratio Fatigue .'-pecimens

W~ater Cooled, Rlate of Fire 6 Rds/fti?Prcjectil' Travel 0" Atiminition Iot LC 13023

Project 1b. la332-l,. Negative No. 1L97-1-69

Znecimen lLife 2756 rds

Dtt ienf

S',ecizen #6

13 A-4

~A

7.62i -bdified 1h Rifle Barrels1.8 Wall Ratio Fatigue Specimens

Water Cooled, Rate of Fire 6 Rds/KinProjectile Travel 19 ', Project No. h332-1

Negative No. 197-3-69

-r

Spenimen #7Life 547h rdsArlnmnition Lot LC-13023

Sp,,cimen #8Life 5093 rdsAmmunition Lot LC-13023

Specimen #9Life 707 rdsAmmunition Lot WRA-22713

A-5 14

L 11

7-62 MH M14 Rifle BarrelSpecimens,4achined to1.4,1.6,1.8 Wall RatioFired at 6 Rds I Min.Water cooledAir Cooleu'

I I t III I l l 1 , .: 1 - .1 - t i ll7

58 7 1 RDS ImG.

11 -it -

t m I

I TT I I I

2458 RDS PANG. 1 4 1 1 1 1 1 it zi

L

t i l l i tI I I it 1022 RDS AVG.I IT lilt IVw1 . I ' I _ f i l l -iL4I f I l l f i l i ! , t i l l : f l : t I i l l 1 1 l i l t e I l i t i f l .1 I i t

: 1 1 ; 11 1 11 I t l i l l , i f f i t 1 . J ; . I t , I t - I .1 1 1 1 -i f ;1 1 1 1 4 1 1 1 1 I l l .I ' ? I ' 1 - 1 1 1 , l i l f , , I l i l I L L L III

I f f i l l i t t I f f i l ' i t i l ! .f $ I t t I I ! i I I I j jj j I ' _.L I._LL1 1 l i l t 1 1 1 1 1 1 1 t t f i l l I t 1 1 .1 ; I .! I j t I I l i l ti f l i l l i l i l l I j i f i I I I , -I II f 1 1 1 1 1 ! 1 f ; -1_ --i. I I I I I l l j l_1 1 .1 mi t I f i l -I i t I l i ! 1 1 L S ' . I f i l l ' t 1 f l i f o li t L , -t i l l 1 : I f f i l l 1 ! l l i f l ! f f ! l I f i f i l i t

- -_ I l l 'i l -i i I I . I l i f f t l i l I f i l l 1 .-LL I till

fit L tI J I ' l l f t l ' I l i f i t , l i l t f i t

f l i f t l ! I l i f f : 1 : 1 1 .1 1 1 I l l i lI I f i t i 1 I i i i ; f i t : 1 i f II ! I i l l l l -l .. I I - -I- I ! . 11111 1 1 I L I I i L

f I I I I I I I 1--w I I - It I I i f t i f ' ! f - l i f o l l fl i f f i t t l l l l l l f l I ------ v t 4 l f ff i l l I l l t i ll I l . .1 . t l l l i l

If

ifi J T_ i

jqL

A

,I

:11

It

A-7 16

C --

~.4t -!

'it ~ rr ~ IC?

*- ---- itA - 7 1 6 F

1

:r '1tr .- -. 4, if 'js

-r * - -

-,-Z - -m

2 r ill G= -- o et c c

3. E-3ra~c Pe-=z Te=Sm=

[17

-U, / ,__ _ _ _ _ _h

i .,

T4

4-0

I - III

I TA

Aft'.jo R-2

44

B- -)

(PEASE II)

C(dIILATION OF HDRt=IC HMESSIRE- GC LIFE TO FIRM- LIFE

NO. PACE

1. Graph , -vydrPMulic. Cycles vs1Rounds Fired 2i

2. Graph - Avg HydrAulic Cycles vs Rounds Fired 21

o0

-14

2

21 C

= --( _-Z I .)

] -~

TT LL 1

or=Umm cmLms MM,01 Htil

7.621WO 1.8,,WAU UT3Ds, 104 RMFLR Nuir-M smb1m

M= AT 6100NDSMN COM COOLED)MIMMM= =WAT 7 ==/=

.- Rm. loW MMU=FUND crcm

1, Htt 11 1-' 1 Ll 0 12,3914, 0 15v582

0 8s552Tit M.

4- -A-LLL I sopo 02069V 1 12000

'1,000 110552,90DO 10s4622,000 7j416

TH ,..Ooo 5,5463,006 2s973

3sCM, 7;04691 3sOOO idi -M90

lilt, 4,oDo 2$939

t 4,000 2,,474

4,000 2,,587-Ll I

-2.21 X + 12,122

CORR, COXF. - -. 830............ BrWTM FROOF

Hm4R11SSwp& 44,309 PSI -

STD. DIV. PRE33M - 1,000 PSI

MN LOT WA-2k731lvii +A4+ + F -=m-l

I-FT-1- A I I 4-H4+

liltIf

71

M A-1JJ i I+

22

APPENDIX C

(PHASE II)

CORRELATION OF HMDRAULIG PRESSURE CYCLED LIFE TO FMRIMD LIFE

NO. PAGE

1. Graph - Hydraulic Cycles vs Rounds Fired 22

2. Graph - Avg Hydraulic Cycles vs Rnunds Fired 23

21 C

.... .i ... ..i l .I..[ : . - -: I--.-- - -- , - ,- -- i - • . . . .. . .

" .!"CORRETION OF AVERAGE HhRAULIC CYCL. VanuS ROM1,)S: -; FIRE ON't 7.62M4, 1.8 WiT., RATIO, Mlh RIFLE MERREL TEST

- ........

.

i . ........

A: ... . .. .

* . .. .. t " ' " AVERJAGE

... .. ... . " - - ..... .LES PER

A: ...... .... TES L-... Egn1_:L:__: ,h0•

..................................................... ....... .... ..- ,o .

* :::::::::: 7,808

L3 Ll.4 -1-.-4 .-1_.. 6 ,1h 4 -

4- 1. --

- "L -fT z :__'._ 4 -S....4 .

-____ . -j. --- i4 e- 4 - '+ 4 4 * -I

=. .-- : . ..'i, . . ... ........ * .- L , ... t j j .. , .... .- .L..4 .. ..

-4- FIRED O. . . . ... .. . .

~.** 4.4...4i~ 444 444 -4* 4 .

.fu 1 +~ 4,I .. .. . . I,,, ,,. .L4. , ,,,.=.,.D ROUNS (THOUSANDS) -

23 ('-2

• 0

APPNDIX D

(PHIASE UI)

CORRELAIION OF )IYDRAUJLIC PRESSURE CYCLED LIFE MM LIj

NO. PNCE

1. Conversion to Equivalent Rotmds 25

2. Graphs - Average Equivalent Rounds vs Test Level 26and Frequency vs Equivalent Rounds

3. Analysis of Variance 27-3C

D 24

i-i

-- : x~(2oi) = c'e)CWMMIT 2.2311A-F~

2 3 h 5 6

AVG SO lzw AVG MJS/CrImZ-1-S AM EZ7"

CMM~ Cmw-s- 1=69_ FPXLW%, FARMS

0 12,37-1 5,600 15,4R2 12,1 7,75 5,5%0 6,552 3,867

I,oo 3.,69 hva-32 1,Oo 8,9.B 9,h7o 5,G& 5,283

1,CcrG 11,355 6,135

2,Co 10,462 6,73,C3 2.,Coo 7shi6 7,28o8 5,,354 5,531

2,600 5,51 6 b,5

3j,0:) 2,973 ls,0jh3AW ~ 7,0&6 6,373 6,186 5,n82

3,00 9,101 7,115

5 1,ooo 2,h714 2,666 5,119 5,206h,0o 0 2,58? 5,1 70

5,683 0 5,6836 6,263 0 6,lh 6,263 6,114

,8 6,187

5= 25 -

D _ _ _ _ _

TS- LWE7A 1 2 ..L....4 .. 6* -

-711O 7,0b6 5,o64s ,554 6,186 5,,119 6,263-.4

4AV AE 520 5,p283 5j,531 5,882 5,206 6,1ri :

....................L FREDf-

fa26

I

ANALYSIS OF VARIANCE (ANOVA)

In general, there are three AhOVA classifications:

(i) FIXED EFFECTS - Wihere particular levels of a factor are

studied and the result is a comparison of mean effects of THOSE

particular levels.

(ii) RAIOM EFFECTS - Where levels of each factor axe randomly

chosen from a large finite or infinite population of levels and the

resulting analysis estimates the component of variance contributed by

each factor to the total variance rather than the main effects and

interactions at particular levels of each factor.

(iii) MI

The combination of (i) and (ii) resulting in a more

complicated analyses.

The analysis of variance technique enables L- to partition

the variance of the measured variable into portions caused by the

factors, singly or in combination, and an experimental error component.

ONE FACTOR ANALYSIS

PURPOSE ...

To compare 1L" different levels of a single factor having

I'M" replicates (repeat experiments) per level.

ASSLd>TIONS ...

(i) The "1' replications for any level represent a sample

dravm at random from a normal population.

27 D-3

DI

° (ii) (a) FIXED MFES

The "L( levels are systematically chosen as the

important (or only) levels of the factor.

(b) RANDOM EFFECTS

The "L' levels are randomly chosen from a normal

population cf levels of the factor.

ANALYSIS ...

Let . Level of S!Eificance

L - Number of Levels

M Number of Replicates

N (L)(M)5. Sample Size

Xi-- Replication t of Level iit7

Then, the partitioning of the total sum of squares

(S.S.) of deiiations from the mean into its components is as follows:

Source of Variation:

Among Levels I - 1 M )2,

S.S,(AMM)1) = L !0 (9J "ij Z

... associated degrees of freedom = (L-1)

Within Levels

S.S.(WITHIN) = SoS.(TOTAL) - S.S.(AMNG)

... associated degrees of freedom =(N-L)

Total Sum of Squares:

S.S.(TOTAL) At x N... associated degrees of freedom = (N-i)

I

D-3 (Cont) 28

--

The Mean Squares (variance estimates) are formed by

dividing the Sum of Squares by their associated degrees of freedom.

If the null hypothesis (H) of no difference among

levels (equal means) is true, then the mean squares (M.S.), among and

within, are independent estimates of the same quantity and should be

approximately equal (except for iampling error) with a ratio (among

M.S. to rithin M.S.) near unity. A ratio greater than or equal to the

tabled value for (L-1, N-L) degrees of freedom would occur in rrndom

sampling with probability 0c if H were true. Therefore, we would

reject the null hypothesis and say there is a difference among levels

(ioe., averages).

if an F - ratio loss than unity is calculated, considera-

tion should be given to its reciprocal being statistically significant

rather than accepting Ho imediately. If the reciprocal is significant,

possibly the postulated model is inadequate (Reference 2).

ANDVA, FIXED EFFETS, LEVELS 6, REPLICATES 3

LEVEL 1 2 3 4 5 6EQUIVALMIE 5603 4649 6731 434j4 5329 5683ROUND 7o46 5o64 535h 6186 5119 6263REPLICATES 3867 6135 4508 7115 5170 6487

SOURCE OF SUM OF DBGREES OF MEANVARIATION SQUARES FREEDOM SQUARE

Among 1,934,A9 5 386,890Within 13 106 290 12 1,092,190Total 17

29 D-3 (Cont)

D

Resulting F ratio is .354 which is less than the table

value 3.11 and therefore there is no significant difference amozig the

mean lives of the six (6) levels considered.

Similarly the reciprocal of the F ratio, 1/F is 2.82,

which is less than the table value of 4.68, and the model can be

considered adequate. (Reference 3, tables).

References:

1. STATISTICS MANUAL by E. Crow, F. Davis, M. Maxfield, Dover Publications

2. STATISTICS IN RESEARCH by B. Ostle, Iowa State University Press

3. EIiRIN3 STATISTES by A. H. Bowker and G. J. Lieberman

D3

D-3 (Cant) '3D

APPenDIX E

(PHASE 11)

CaREIATION OF HDRAULIC PRESSURE CYCLED LZ TO FIRED LIFE

NO. PAGE

1. Graph - Reliability vs Equivalent Rounds to Failure 32

2. Photos of Failed M14 Rifle Specimens 33-36

3

4N

VF

.31 E z

IE

ALL- u, -T

- ,- %= U ,-.re - ............_-_-, .

.1 1S-f1il 41 U .~alll t7

++. M '"ILI___ W .,

r - ---sgS*..

.- ,+

_ _. - , . .. -I :

,I,4;1~,: "-" ] " ..

U~ ~ T 7 J~ -L

""".!j - -g - -. 32 -

"" " .. t - --U . -- ' " .'

5 U.... U,, ..-.,+• * * +~ a * - . - .. + + , . ': ' f . t 1 ' ..

"

9., --i,. -4.+

.I- + ' -'- -++

S . U U ."- +-. *- .- . .. ."45++ ..

++ + -: - 5- 4 - - - .- +L.

._-. .-.,a ;.+ -__J _ - U 11..... +. . : " _+ . ' , ------ :..- --. . . . :+ ..-+ --'-

F-1 3?

NEW

tied;'!-- -I

r-eq

V3

~ 3 Fie :ds -amic Cycles 15,552

z

-- lw .2; Fed Rts 7y Tyle3 7,41

'Now___________

Icert

IF G&,-A ANI LX r 111 1

'P4~ Fired Pds 0 Hydrawlic cycies 8,55,

jjI

zecL~ijl7 Fie Ed ,O ydraulic Cycles 11,355

L

Speen #27) Fired Rds 2,000 Hfydraulic Cycles 5,546

i:3 Firel ?-Is 3,7"j- Hyrdraulic CyclIes ,

Reproduced ffom (best available copy.

35 F-2 (cant)I

ITI

EJ

9-0

ut

ia E0Z r..

U.2.

~~0

M :1 l . v l4 r V4X r

F-2 (ct 36

0 C, i .

az 0

r -

,.. . o

" > F

APPENDIX F

APPLICATION OF MU;LTI-LEVEL TE-TRIi.J TO STANDARD CANNON

NO. Pl.GE

1. Cannon 155"24 Howitzer HIAI Graph -Hydraulic Cycles vs Rounds Fired 38

2. Cgnnon 15511 owitzer MIAl Graph -Ieliability Predictions 39

3. Cannon 175'P1 Guns M113 & 11113AI Graph -Hydraulic Cycles vs Rounds Fired 40

4. Cannon 175MM Ouns M113 & Ml13Al Graph -Reliability Predictions 41

37 F

.__.a ,

4'

I CAWW, 155WH )m-irm XXIM

0 -MAUIM .i-a=a V.TM VMS MU MM A73-4PS

5,006 9,

o 16,553 -

~18~- *0 16,700

0 20,"91

0 22.632

400

i- lob it* 1 'iPm RO= 4'~dsks

r,- 381

CT Ea= W-TCEE1

4T4 ti~--

L ,:i

_1 1 7

_________ _________ Zs~

-A, ki4 -=T ElA

1373 Y--- .5_%

ft-A- -

-- T. -- 6,-5 35

11-73 1 r - 'r-

*** ~ ~F~1~_____0.5-* -44 *~

I .358

Jt 1 ~~E',TAI MUMS TO.~ _____ ___________

3,Y

F

, _:= .... ..: 6-n23 (GM I t--- ELFs-s.LI s M-. .. ..... - .... .. .' .. ..... ...-- -- .nl2A, '2? -

, ......., .. .. .. .. ... .... i .. .. , . . . . .[=---:-- !!:-.:.. ~~~~...... .: ........ 7 )h l a 86...... :::: : :: : C ..S CYCS Pz3s F. .... .... :331) 9322 1330 65 ':

__38_____16213 7586

- -- ;---4-- 3~ 1~o 330:::-!

.- :r .::: -:::::: :::3:::: :: z 1270 6317 ....... : _ _= ......... .... 2~.3 V4-. 9 = a o -?a . .

A21 73-

....... ...... :.T 231 W17 I27 2 5 69 .-

- --=G... .. .. .-- - %. ...... - -- ,--'--.4... .. . .. . . ...

27. 6 ..... 1270= 63 .

.... .... 57.6 . . _. . . . . .. . . .. . . .2:1 3157 1327.. ..

_ _ _ _" 30 ... h749

256 "M3 " L615===K !,.2.XP3, ... .. -1... ..a+7978i :......... ;. : : : . . . - : .. : : :.... :.: : : : : 2

-3 40

- T1

... .

n ..... ... ... .A .... ...

0 C' 0 0 OLsC 0 -C 0 F %0 r-C %C 4"- 4 0 4 -l r -

A-

0I WLll i LC% 0%- I - n0- c . .*0 .Ta

I i C -) L %0_ _ r - % R % C% C Qf---0 C%"- C 4r c) ,co 4 0 CO I -M -

0 1i

-I C-4 -

1 ~ ~ ~ ~ ~ ~ T cn_____________

411~~11 C% I ;d2 ~ wC241 ID

0 IV C!_______III C> IT

ci0.~-4-O~r.' ;;

U'

U44

APPENDIX G

(PHASE III)

COHPARISON OF 1751.0 TUBE ZORGING MATERIAL PRODUCED

- BY THREE CONTRACTORS X, Y, Z.

NO. PAGE

1. Specimen Selection 175f HI3A1 Forging [aterial 43

2. Phase III Test Plan 44

G 4

itt

C 42

1-1-4 %C 4M* t : ,( c nI n

r-4 4 ' N JwUI N IN N IN" tn IN

E > 0HE0

CU,

cnrX :u) o-H 4=

OC4% I Ln C4e DN0 Ar4C1C4 r%0z on %D rlDUO r- %D D D rz 4r r o lr a

E- ElZ)-

w (: raE-4'-

H / 0HO .. Cz

E,() ,

It c.J .C0 ' co %0 - Coj r44 3 tnn cr N-4tITcn O C a r4C UIA'Q C14 '

Nr 4 cot %0 4MC4IH0 % ot o CIn %D x % I'D X o %0 Ixo %D% 14I D X% r n %

.cr4 > - '

_z ( Ln a'-zZ 4 -1' CA

H E-4 xQE-

z ~ r, E i. E , n1-4E-40 H 0-4 r

(f)~ 1

,

0 L) -4 %0 U)

in

43 C-

G

PHASE III

TEST PLAN

FOR 7.62MM SPECIMENS, 175MM TUBE MATERIAL

CATEGORY QTY TYPE TEST

PbTRE 9 HYDRAULIC PRESSURE CYCLED

SPECIAL 1 3 RDS/CYCLED4 COMBINATION 1 50 RDS/CYCLED

2 100 RDS/CYCLED

3 500 RDS/CYCLED3 2000 RDS/CYCLED

15 COMBINATION 3 3000 RDS/CYCLED3 4000 RDS/CYCLED3 5000 RDS/CYCLED

REAL 9 FIREDTOTAL 37

r2

C,-2 44

IK

APPEN"DIX H

(PHASE III)

V COMPARISON OF 175M11 TUBE FORCING MATERIAL PRODUCED

BY THREE CONTRAC'rORS X, Y, Z.

NO. PAGE

1. Original Data - 1751 91U3E Cannon Tube aterial 46

2. Graph - Hydraulic Cycles vs Rounds Fired175MM MU3E1 Cannon Tube Material 47

44

A

St

'A

€I

S45 1'

-

H, L=7 ff -% l Io Cr Q-ZMLZ0

D-4 -M ~~~

A U >z m-; - F-

"U tm 0w_______I ~ .2 ~- ~ ~u~ Ad1cI I

_ a

Cl zaC-~- 43 cm - - (.5 Ca~ C.1 't

I3 C

46 --

_a

__- 4oM AT .v

Zf T

-MX

I A.; zi L

_ _ _ _ _ __U

_ _ _ _ _ _ _ _ _ _ _ ~1~47

2. A&ISme~ J41e M2a ~

48

CAIe-C1- 1 I -%: 0a l .rO

.= - nc .v z% a- -uan

of " rW 0 GC 4C4 l n%

%-II cl r.1 onC - - -- -4nco =-%0 " .:ri nt 0 19c

cm~

v-a 4 r ooce0000

O r C(10 CI C 10 an ON0% 3C >C ,

0 cal

n% 0 C -) C~3r.- r- SO 0

C449

-1 -4 C~ -;T%

ADJbSTED LIFE DATA

SUPPII __z

b-4R :,..I a

E-E-

ALL 1 X1 6208 13 Yl 6956 25 Z1 7433

Fl-ED 5 2 6124 17 Y2 7233 30 Z. 68699 X3 7696 21 Y3 7274 33 Z 6918

2 X1 7855 14 Y_ 5210 26 Z1 6866ALL 6 X2 6948 19 Y2 6366 31 z2 686M4CYCLED 10O A3 8199 22 Yj 7040 34 Z 3 7365

ADJUSTEDCOfIATION 3 X1 6583 15 YI 6673 27 ZI 7352

FIRED h x 6937 16 Y, 7215 28 Z, 7243

7 x2 6240 20 Y2 6281 32 z 2 645011 X i 7314 23 y- 7507 35 Z3 6964

CYCLED 12 x, 6828 24 2 7146 36 Z3 7795

ANAYSIS OF VARIANCE

F-RATIO

ALL ADJUSTED X 2.11ALL ADJUSTED v 1.81ALL ADJUSTED .009

ALL FRED xYZ .65ALL PDJ CYCLED XYZ 3.56ALL ADJ COMBO XYZ .84

TABLE VALUE 5.14

In order to simlify, adjusted combination fired andcycled X1 Is, X Is, Y s, Y Is etc. were averaged toprovide three eplicates par c-i.

1-2 50

l''i lll" i' i :1 i:+l . i I'" T

u i i--l'tT 1 i 'i 'f" il:m :€

]I

APPENDIX J

(PHASE III)

COMPARISON OF 1751M TUBE FORGING MATERIAL PRODUCED

BY THREE CONTRACTORS X, Y, Z.

NO. PAGEC--1. Life Characteristic Comparison by Material Supplier 52

(Using Adjusted Data)

2. Life Characteristics Comparison by Test Method 53(Using Adjusted Lives)

3. Graph - Rel.'ability Prediction 54(Using All Adjusted Data)

51

N~I

Z. * T COe CO CCrmnu T% 4 - --C4 r. z-- 'I m r V.',r-C-% % 3% %3%

C*4 l cl -IT -a n gl IT 11 i %3C, % C-E n* - %< n c '-l 0 C m 0 , %T i ng . 0 c o

I-I CzO C.)) 0-U 0 K39.F-4rAA Ea C 0 ~ c r'- U D' i d n mt D co r, cr~ ~ o ' o 0 <3Ad~ E-4 0 -Z01r-. n ci C n C 1--T c)CAc 7 d l 3

1. ':4% V % o 1- o % n G - C ' ~ 1 -

., F4 0 c

f-4~i-41

E- C%' C% -8C - c 3C4Lnr %

-0 0

0 c< F4

3--0 4

-4 1-4 E-4'a -4

o .- i 0 nr

0 -:4u :0Z

0 N

AN22WUd ZALLyifl34fl

J-1 52

r:;'

r-~' - C

113v P0 I. -; j

I-i A

CO*~ co C) i n C c~~C. % 0 -

0 1 1

E- E-4

'0 C-

U

53 -

110 "~i coC * 30

C;C;o:ozWoo;-iV:ic C z~OO OOOOOO ioocw;,zE!3 04- iiC --I 12- C- 1Ww 1% 04 1 iiBr mC oc*1 _ _ _ -Z_ _ _ co_ _ en M_ _%_ -c = i~ 3 .oitC2 - C'oCaa - rii'ik i %

_ __d W _ _ =_ _ %Z_ _t nc iii.U4 6 1 I %'0' . - 7C1C %a nC

VAM C6% . 0 % D4 0% 0Iiii ~ii.r CiI.Ci . r f ii iiiC.f C

lit, 1t 41 j2T_________- - r~j t~i4

a 1-zji ar

tiiif ___ ___

1 .4 4 %

in -4c 1J N1 c i

00 0 0ac .*4r 44 r4 *) . t ft00

544

iA O c

MMM F- 717MM TS-BMR~ MUERULPZWCCI

55 K

ac =Ij~f rr4 0 .

~ ~ ~.0- .000 -r-.0. 4 &- z~

-N ci on(

I II-E 1101 -" M -§8

%2 w .% C a- A- 1 i- - . -

0%-30 0 r-rjZ-hr - -

C-0. 0;t c: 0 ,

o 0o

ioI

F-A

in C* Is

c- C C

0 C!

c 0n 0~ In o i C.

o9 co I0.~ ~~~~~~~ .~.CIC .O-~ .O~ -A.I c .VAO . C a . .. .. .. ..

.~ ~ ~ ~ I~t--C~r'~C-%-t- C- .1A--O.O0. c'%O 0 % %0.JO

=0000 0000 IlOAIl00~00- 0tCOAs 0O*o0,

ur w .~nI IAAIU 1 IIIA

E54 ( _a = - -m e

0 It N~ C

013 -I 56 0 0 1 lc tU vIC

LIrb VS. MMUANCAL PROPERTIFS

........ . FORGM M WACT!I

Life VS.Cha.-py n A-.

.--......... ... ....

.. . . . . . . . . . . . . . ... .....

11~~ ~ ~ 717-L. .. ..

Av._ A._ .: . . .

Ufa~~~"* VS-hr ........* Ag.TS~(1~3 (PI)......... ... .. ..

~~~~~~~~ .. I ..-' .I I4 .iAg Sx1 3 P

57:

K+-:+-+: : : .... : .I-.- - .... I.... + : : ,+. . . ...:

44

, -. : .. ... . . .. .. . ... .t t 1•. o

N. - - - - -.. ..

..... .. ._ ... :..

Z ~2 . .. ...

.. .. .... . .... .. . ...... ....

.+

--.... . ... .. ... .... ... ........... ..

... .. . .... . .

_ _ _. . . . .. . ... .. .

K-3 58'

DI

APPENDIX L

(PHASE III)

COMPARISON OF 175151 TUBE FORGING MATERIAL PRODUCED

BY THREE CONTRACTORS X0 Y, Z.

NO. PAGE

1. Photos of Specimens Fired to Destruction Material 60Supplier X

2. Photos of Specimens Fired to Destruction Material 61Supplier Y

3. Photos of Specimens Fired to Destruction Material 62Supplier Z

9

Ii59 L

I REDMIZ

Repcodrea Fmavagabe coPI

[I IE ' o

low-

I-mm"

Fri i;

C, IMWS

avaulag

C; ;Ixovce 19---~---

rIED*C~114 inI~L

15ICAMNO CF 7.6ZTK S-FECUCENS TO A FIELD FAIUME PrFMBfLU

1:0. PACE

1. Field Failure Motes~ 65

2. TdIre Sectli =d Specimen tocation 66

3. Failed Specinems 67

4. !%cL=IczI Pro;,erties of ForizinF 68

63I

CqrO a be COP*'lbes'

-- :46

le .%, %b --.-

2(

0101C, I9

eI

ellgee

CA')

R SDS.1

4

9BIReroucd40o

3et3val4le0oy

14 C1

u C% c a% M

z

in n 0~c

00

*- I, *0 *

0o 0 0 0 cI-4 -* *

E-4 N c~ cEn'

67 -4

N

APPENDIX 14I 7.62Mq AIMITION CALIBRATION

NO. PAGE

1z 1. Ammunition Calibration 69

N 6

I'I

\',I N 681

N

ANIMONLi~Q CALIB.7ATION

60'% 504Eu

~3o

~20

•.5 .C 1.5 0.c

TnzM(,EC- x io-3)

TYPICAL P-7 CbU'VE

7.62121 (1114 ifle M.t'l) Test !zrno Lot 1.-'-731

Calibration Date Mean Pressure Std Dev. Mean Velocity Std Dev.Original 8/67 h4,300 1000 Uot Avail. Not Avail.1st Check 11/70 47,800 1300 2701 162nd Check 2/71 47,900 1100 2740 28

7.621I (In13El Cannon 1t'l) Test A-o Lot "Rbl 22896

Calibration Date Mean Pressure Std Dev. Mean Velocity Std Dev.Original 10/68 45,3C0 1000 2751 19.71st Check 11/70 47,500 1600 2687 282nd Check 2/71 h3,300 1200 2731 19

NOTE: Check tests were performed by Frankford Arsenal.Hydraulic cycling pressure was established on original ammunitioncontractor calibrations.

Q, Nl-1

._,- -, -_ .. ,''..,,,; , . .: , ,,':, ,:,_:<: , ,, ,, , ' 1 '' ' ..... - i' '' : o ,' , ! , , u.. .-

APPENDIX 0

MISCELLANEOUS REFERENCES

NO. PAGE

1. Miscellaneous References 71

0 70

• , f]

00

MIISCELLANEOUS REFERENCES

1. "Establishment of Cannon Life Criteria" -R. E. Weigle 1967Watervliet Arsenal (Plus additional R&E laboratory test data).

2. "Fatigue Characteristics of Open-End Thick-.Walled CylinderUnder Cyclic Internal Pressure"; T. E. Davidson, R. Eisenstadt,A. N. Reiner - 1962 Watervliet Arsenal IYVT-R1-6216.

3. "175124 MIIA Gun Tube Special Test for Service Life";B. B. Brown, T. E. Davidson, D. G. Forkas, M. E. Kraut,T. Moraczewski, A. N. Reiner, P.K. Rummel, R. Soanes Jr. -

1971 Watervliet Arsenal.

10,

S71 0-]