INDUSTRIAL TRAINING REPORT

SMALL ARMS FACTORY, KANPUR

Submitted to:Department of Manufacturing Technology

in partial fulfillment of the requirements for the degree ofBachelor of Technology

inManufacturing Technology

JSS Academy of Technical Education, NOIDAU.P. Technical University

SUBMITTED BY: SUBMITTED TO:PRAKHAR BHASKER Mr. B.K. JHA (1109141035) HEAD OF DEPARTMENTVII-MT MANUFACTURING TECHNOGY

JSSATE, NOIDA

2014-15

ACKNOWLEDGEMENT

Training has an important role in exposing the real life situation in an industry. It was a great experience for me to work on training at SMALL ARMS FACTORY, KANPUR through which I could learn how to work in a professional environment.

Now, I would like to thank the people who guided me and have been a constant source of inspiration throughout the tenure of my summer training.

I am sincerely grateful to Mr. R.P. Rajput at Junior Works Manager, SMALL ARMS FACTORY who allowed me to pursue my summer training at the factory and rendered me his valuable assistance, constant encouragement and able guidance which made this training actually possible.

I wish my deep sense of gratitude to Mr. B.K. Jha (HOD: MT Department) whose guidance and encouragement made my training successful.

PRAKHAR BHASKER

TABLE OF CONTENTS

I. INTRODUCTION OF INDIAN ORDNANCE FACTORIES

II. BRIEF HISTORY OF INDIAN ORDNANCE FACTORIES

III. INTRODUCTION OF SAF KANPUR

IV. PRODUCTS OF SAF KANPURa) REVOLVER 0.32 (7.65 mm x 23)b) LMG 5.56 mm INSAS (Fixed Butt)c) RIFLE 7.62 mmd) GUN MACHINE 7.62 mm (MAG)e) SUB MACHINE GUN CARBINE 9 mm

V. MAIN DEPARTMENTS OF SAF KANPURa) QUALITY CONTROL

b) METALLURGICAL SECTOR

c) CNC

d) BARREL

e) RIFILING

VI. PROJECT CONCLUSION

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1. INTRODUCTION OF INDIAN ORDNANCE FACTORIES

Indian Ordnance Factories is a giant industrial setup which functions under the Department of Defence Production of the Ministry of Defence. Indian Ordnance Factories, headquartered at Kolkata, is a conglomerate of 39 Factories, 9 Training Institutes, 3 Regional Marketing Centers and 4 Regional Controller of Safety. Today OFB along with its 39 factories spread over India provide

a broad and versatile production base with multi-technology capabilities state of the art manufacturing facilities large reservoir of skilled and professionally qualified manpower and

managerial personnel strict adherence to  quality standard (all the units are ISO-9000 certified) original as well as adaptive research & development to make need based

refinement and modifications project engineering capability a strong base for industrial training facilities ready market access due to convenient location

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Geographical Spread

There are 39 Ordnance Factories geographically distributed all over the country at 24 different locations. A visual idea of how our factories and headquarters are distributed can be had from our location map.

Name of State/ Union Territory Number of factories

Maharashtra 10

Uttar Pradesh 8

Madhya Pradesh 6

Tamil Nadu 6

West Bengal 4

Uttaranchal 2

Andhra Pradesh 1

Chandigarh 1

Orissa 1

The 40th Factory is being set up at Nalanda in Bihar.

Factories1. Ammunition Factory Khadki (AFK)2. Cordite Factory Aruvankadu (CFA)3. Engine Factory Avadi (EFA)4. Field Gun Factory Kanpur (FGK)5. Gun Carriage Factory (GCF)6. Grey Iron Foundry (GIF)7. Gun and Shell Factory (GSF)8. Heavy Alloy Penetrator Project (HAPP)9. High Explosive Factory (HEF)10. Heavy Vehicle Factory (HVF)11. Machine Tool Prototype Factory (MPF)12. Metal and Steel Factory (MSF)13. Ordnance Clothing Factory Avadi (OCFAV)14. Ordnance Cable Factory Chandigarh (OCFC)15. Ordnance Clothing Factory Shahjahanpur (OCFS)16. Ordnance Equipment Factory Kanpur (OEFC)17. Ordnance Equipment Factory Hazratpur (OEFHZ)18. Ordnance Factory Ambernath (OFA)

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19. Ordnance Factory Ambajhari (OFAJ)20. Ordnance Factory Bhandara (OFBA)21. Ordnance Factory Bhusawal (OFBH)22. Ordnance Factory Bolangir (OFBOL)23. Ordnance Factory Kanpur (OFC)24. Ordnance Factory Chandrapur (OFCH)25. Ordnance Factory Dumdum (OFDC)26. Ordnance Factory Dehu Road (OFDR)27. Ordnance Factory Dehradun (OFDUN)28. Ordnance Factory Itarsi (OFI)29. Ordnance Factory Khamaria (OFK)30. Ordnance Factory Katni (OFKAT)31. Ordnance Factory Muradnagar (OFM)32. Ordnance Factory Project Nalanda (OFN)33. Ordnance Factory Project Medak (OFPM)34. Ordnance Factory Tiruchirapalli (OFT)35. Ordnance Factory Varangaon (OFV)36. Opto Electronics Factory (OLF)37. Ordnance Parachute Factory (OPF)38. Rifle Factory Ishapore (RFI)39. Small Arms Factory (SAF)40. Vehicle Factory Jabalpur (VFJ)

Our Product RangeItems produced in Ordnance Factories are highly sophisticated and complex in nature. Also the range of products is simply astonishing. Our products, as is evident from the list below, span across a wide and exhaustive range of requirements of any armed forces.

TechnologyOur products must be safe in handling, reliable and perform consistently

during actual operation with equal efficiency under varying and extreme conditions of climate. The plant and technologies have been so chosen as to ensure high degree of quality and reliability and is a unique blend of old and the most modern stae-of-the-art CNC technologies. The manufacturing process covers wide spectrum of engineering - Mechanical, Electrical, Metallurgical, Chemical, Textile, Leather, Optics and Electronics.

It is our Endeavour to manufacture world class products without compromising with the safety aspects of products and processes. Adherence to safety standards is given highest priority and a well laid down safety norm as well as disaster management plan exists in the organisation.

Customers

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The prime customers of Indian Ordnance Factories are the Indian Armed Forces. Apart from supplying armaments to the Armed Forces, Ordnance Factories also meet the requirement of other customers viz. Central Paramilitary Forces and State Police Forces in respect of Arms, Ammunition, Clothings, Bullet Proof Vehicles and Mine Protected Vehicles etc. Increase in volume of Export, as an extension to its functioning remains an important objective of Ordnance Factories.

2. BRIEF HISTORY OF INDIAN ORDNANCE FACTORIES

The BeginningThe history and development of Indian Ordnance Factories is directly linked

with the British reign in India. East India company of England for their economic interest in India and to increase their political hold considered military hardware as vital element. During 1775 British authorities accepted the establishment of Board of Ordnance in Fort William, Kolkata. This marks the official beginning of the Army Ordnance in India. In 1787 a gun powder factory was established at Ishapore which started production from 1791 ( at which location Rifle Factory was established in 1904). In 1801 a Gun Carriage Agency at Cossipore, Kolkata (presently known as Gun & Shell Factory, Cossipore) was established and production started from 18th March, 1802. This is the first Industrial establishment of Ordnance Factories which has continued its existence till date.

Growth of Indian Ordnance FactoriesThe growth of the Ordnance Factories leading to its present setup has been

continuous but in spurts. There were 18 ordnance factories before India became independent in 1947. 21 factories have been established after independence - mostly, in wake of defence preparedness imperatives caused by the three major wars fought by the Indian Armed forces. 40th Factory is under establishment at Nalanda, Bihar.

Main EventsMain events in the evolution of Ordnance Factory can be listed as below:

1801 - Establishment of Gun Carriage Agency at Cossipore, Kolkata. 1802 - Production started from 18th March 1802 at Cossipore.

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1906 - The Administration of Indian Ordnance Factories came under a separate charge as 'IG of Ordnance Factories'.

1933 - Charged to 'Director of Ordnance Factories'. 1948 - Placed under direct control of Ministry of Defence. 1962 - Dept. of Defence Production was set up at Ministry of Defence. 1979 - Ordnance Factory Board came into existence from 2nd April.

3. INTRODUCTION OF SAF KANPUR

SAF was built in 1942 as part of the strategic plan to have a shadow factory of RFI at Kanpur to undertake manufacture of small arms as a sequel to threat on the eastern border during world war-II.

The factory was known as Transplantation Project -1.   After independence, the factory was renamed as Small Arms Factory in the

year 1949. SAF is engaged in consistently supplying small arms to MOD & Paramilitary

forces. Manufacturing facilities built over an area of 103 acres. The organization possess highly skilled, qualified and dedicated team of 2200

personnel

4. PRODUCTS OF SAF KANPUR

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Revolver 0.32 (7.65 mm x 23)

ROLE : Light weight, easy to handle weapon, suitable for personal safety.

FUNCTION : 32 (7.65 mm) Revolver is capable of firing 6 rounds, loaded in revolving chamber. Misfiring of a round does not affect next firing.

SAFETY :

Positive location of main spring eliminates malfunctioning and additional safety feature provided to prevent accidental firing General Characteristics of Revolver 0.32 (7.65 mm) :   I. Simple in design & sturdy in constructionII. Positive location of main spring eliminates malfunctioningIII. During non-functioning of weapon, springs are not under fatigueIV. Misfiring of a round does not effect next firingV. Accuracy aimed at high standardsVI. High grade of alloy steel with heat treatment achieve durabilityVII. Interchangeability of parts ensuredVIII. Provided with additional feature of safety to prevent accidents

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SPECIFICATION:

Nomenclature Revolver 0.32 (7.65 mm)Calibre 7.65 mmWeight (Without Ammunition)

0.7 kg

Length of Revolver 177.8 mmEffective length of Barrel Bore

76.2 mm

Rifling Six Grooves R.H. 1 Turn/380 mmSights Fore Sight Blade

Back Sight 'U'Feed Revolving Chamber, 6 Rounds

LMG 5.56 mm INSAS (Fixed Butt)

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ROLE:The weapon is used for providing covering fire during assault by infantry.

FUNCTION:LMG 5.56 mm is a gas operated weapon with rotating bolt locking system which can fire in S.S./Auto system. LMG:

SPECIFICATION:   Nomenclature Unit LMG 5.56 mm INSAS (Fixed Butt)

Calibre mm 5.56Wt. w/o Magazine kg 6.23Wt. w/loaded Magazine kg 6.73Length Overall mm 1050Barrel length mm 535Sight Radius mm 475Magazine Capacity Rds 30Fire selection Rds SS/AutoRate of fire (cyclic) Rpm 650Effective range m 700Muzzle velocity m/s 925Muzzle energy J 1780Recoil energy J 2.75

SAFETY:

The system is provided with mechanical & applied safety.   General Characteristics of LMG 5.56 mm INSAS  

i. Light weight weapon

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ii. Commonality of parts amongst the LMG and Rifle, 5.56 mm INSAS.iii. Weapon is very compact, easy to handle, operate and simple to maintain.iv. Weapon robust enough to withstand rough usage.v. Furniture made of Plastic materialsvi. Foldable Butt version also available to suit paratroopers.vii. Barrel Bore Chrome plated for high Barrel life and ease of maintenance.viii. Provided with mount for day light telescope & passive night sight.

ix. Provision for mounting on tripod on armed vehicles for Anti-Air Craft role & Monopod for fixed line firing.

Rifle 7.62 MM

This is a self-loading gas operated and air-cooled rifle. A gas cylinder and an adjustable gas regulator are fitted on the top of the barrel. The amount of gas acting on the piston is controlled by the gas regulator to ensure smooth functioning of the Rifle. A flash eliminator is fitted on the muzzle end on which a bayonet can be fitted. A projector grenade can also be fitted for grenade firing. A fully auto version of the Rifle is also available.

SPECIFICATION :

1. Length of Rifle with normal butt 44.85 in/1139.19 mm2. Length of Barrel 21 in/533.4 mm3. Bore dia L 0.297 in/7.5436 mm H 0.299 in/7.5946

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mm4. Number of Grooves 65 Twist R.H.6. Pitch of Rifling 1 turn in 12 inch / 304.8 mm

7. Weight of rifle with full magazine Sling and bayonet

12 lbs 2 oz /5.50 kg.

8. Weight of rifle with empty Magazine 10 lbs 4 oz /4.649 kg.9. Weight of rifle without magazine 9 lbs 11 oz /4.396 kg10. Fore sight Adjustable Pole type

11. Back sight Aperture Graduated 200-600 yds./182.88 - 548.64 M

12. Maximum effective range 600 yds /548.64 M13. System of operation Gas14. Type of Magazine Box15. Weight of full Magazine 1 lb 9 oz /0.708 kg.16. Weight of empty magazine 9 oz / 0.255 kg.17. Magazine capacity 20 rounds18. Rate of fire 60 rounds per minute

19. Capability of being fitted with Projector grenade

Can be fitted

20. Type of Bayonet Bayonet, 2 A, having 10" long blade/254 mm

21. Muzzle velocity 822. 93 M /s ± 9.14M/s22. Sight radius 21.77 - 552.95 mm23. Trigger Pull 6 to 9 lbs / 2.72 to 4.08 kg.24. Ammunition Cartg. SA ball 7.62 mm NATO.

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GUN MACHINE 7.62 mm (MAG)

The weapon is designed to serve the role of a medium machine gun and is fired from a tripod mounting. It is fully automatic, air cooled, belt fed, gas operated weapon capable of a sustained high rate of fire in bursts. The gun fires from open breech thus preventing any explosion of a cartridge (cook off) after prolonged firing. The gun is provided with a heavy/light barrel, the bore and chamber of which are chromium plated. The weapon is supplied with a gun barrel and a spare barrel which can be quickly and easily changed to avoid over heating which causes cook off and reduction in barrel life. The gun is fed from left to right with belts of disintegrating link which are ejected to the right. Empty cartridge cases are ejected downwards.

SPECIFICATION:

Calibre 7.62 mmWeight of Gun 11 KgsOverall length 1048 mmRate of Fire Adjustable

600 to 1000 rounds /Minute

Max Range 1800 MBelt Disintegrating

LinkTotal No of Components 219Sight Rear Aperture Graduated Steps of 100

MFolded Down 200 to 800 MExtender 800 to 1800

MBarrel :i) Length of Barrel 545 mm

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ii) Bore Dia H 7.655/L 7.61mm

iii) Number of Grooves 4iv) Pitch of Rifling 1 Turn in 305

mmv) Twist of Rifling Right Hand

SUB MACHINE GUN CARBINE 9 mm

A short range personal weapon capable of being used upto 183 m. It is operated by spent case projection or blow back action and is capable of firing in fully automatic or single shot modes. It is fitted with a hinged collapsible butt and may be fired with the butt in the extended or folded position. The casing is in one piece and carries a bayonet boss at the forward end for fitting of bayonet.

SPECIFICATION :

Calibre 9 mmLength of the Weapon with Butt Extended 685.8 mm

Length of the Weapon with Butt Folded 482.6 mmWeight of the Weapon with Loaded Magazine & Sling

3.82 Kgs

Weight of the Weapon with Empty Magazine

3.06 Kgs

Type of the Magazine BoxMagazine Capacity 34 RoundsWeight of the Empty Magazine 0.226 KgsWeight of Magazine (Loaded) 0.680 KgsType of Sight used with Range Setting:Fore Sight Adjustable Blade Type

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Back Sight Aperture Peep TypeRange Setting 91.44 meters to 182.88 metersEffective Range 27.43 metersMaximum Range 182.88 metersSystem of Operation Blow Back Self Loading TypeAmmunition Cartridge SA 9 mm Ball Mk.2ZCyclic Rate of Firing per minute 550 RoundsRate of Firing Single per minute 68 RoundsType of Bayonet used Blade TypeTotal number of Components 109Total number of Assy / Sub Assy. 19 

BARREL : Length of Barrel 199.34 mmBore Diameter H 8.890 mm, L 8.814 mmNumber of Rifling Grooves 6Twist of Rifling Grooves Right HandLead of Rifling Grooves 1 turn in 250 mm

5. MAIN DEPARTMENTS OF SAF KANPUR

QUALITY CONTROL

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The principal factor in the performance of Field Gun Factory is attainment of qualify which purports adherence to the guiding particulars or all types of undertaken manufacture. The factory has an established procedure based on internationally recognized concepts as enunciated in ISO 9000 series specification. Growing confidence, reliability and inalienable conformance to design requirements monitor interchangeability muability, functioning safety and thus, guarantees dependable usability to thus our valued customers.

Quality control measures have a distinguished series of testing equipment, like Direct Reading spectrograph, Gas Analysers etc., essentially required for production of special High Alloy. Steels Coloured metallography Magnetic Particle Testing Ultrasonic testing equipments which enthuses reliability in the metallurgical products of the factory are used.

INSPECTION-TESTING FACILITIES :

Reicherter Hardness Testing Machine Having Integrated digital display with Milling Facilities Jarrel Ash Direct Reading Spectrograph with Teletype. Leco Gas Analyser for hydrogen, Oxygen & Nitrogen.

Chemical Laboratory functional and stagewise checking of products. 50 T Avery Denison Universal Tensile Testing Machine. Wolfred/Avery Impact Testing machine for testing at ambient and subzero

temperatures upto (-) 50 deg C Kraut Krammer/ Kari Deutsh Ultrasonic Testing Machines. Magnetic Sorting Bridge. Magnetic Crack Detector, Lathe Type.

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Leitz Metallurgical Microscope with 80-2000 magnification & Micro - photograph facilities. Metallurgical Macro & Micro analysis facilities.

Chemical analysis facilities for effluents. RockweU, Vickers & Brinell Hardness Testing Machines. Latest measuring and testing facilities for Intricate Rnish Machined-

Profiles, Internal & External on 3 co-Qrdinate measurement machine.

Ultrasonic Testing of Round Barrel to Determine Internal Raws of Material

Checking of Surface Raws in a Bore through Introscope

METALLURGICAL SECTOR

(A) STEEL MELTING 20 T Capacity Model 12 GEC Electric Arc Furnace. Argon Purging facilities with Calcium silicide core wire injections. Electric Ferro Alloy Heating Furnace. Wellman Ferro Alloy Charger. Electric insulated Evaporator for liquid oxygen with

oxygen lancing facilities Electric Stopper Rod Heating Furnace. Slide gate teeming systems Hydraulic ingot stripper

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(B) FORGING - 2650 T Capacity ZDAS Forging Press with 40 Mtr Ton

rail bound manipulator. GEC Electric Annealing and heating Furnaces 3-60 Thru

100 MT. Wesrnan Oil fired re-heating Furnaces 7-60 Thru 120

MT 2 T closed Pneumatic Hammer 2 T Die Hammer with defining arrangements. 500 Kg Pneumatic Hammer for forging of smaller cross-sections and tool

steels.(C) HEAT TREATMENT -

Vertical Pit Type Electric Hardening, Tempering & Normalising Furnaces with auto programmers & Oil;Water quenching facilities, Job length 10,000 mm . and Tubes upto 400 mm dia.

Bogie Hearth Electric Annealing, Normalising, Hardening and tempering furnaces for heat treatment of tool steel.

Salt Bath Furnace. Rame Hardening facilities. Austempering facilities for spring steels.

TOOL ROOM

A toolroom is a room where tools are stored. In a factory it includes a space where tools are made and repaired for use throughout the rest of a factory. In engineering and manufacturing, a toolroom is everything related to tool-and-die facilities in contrast to production line activity.

Originally a toolroom was literally in one room, but like emergency room, the term has been figuratively extended in both substantive and adjectival senses to all such places and the methods used there, regardless of the physical space. A broader use of the term includes a space where tools are made, repaired, inventoried (kept track of), and distributed for use throughout the rest of a factory. This extension of sense reflects the development of greater systemization in manufacturing. During the 19th century, there gradually developed the division of labor whereby the people who made, repaired, kept records of, stored, and retrieved tools were not necessarily the same people who used the tools to do the manufacturing work itself. Examples of division of labor had existed in prior centuries, but most manufacturing had been done

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on a craft basis, where there had been no need for the idea of a toolroom separate from the rest of the workshop (or a word to name it).

CNC

In modern CNC systems, end-to-end component design is highly automated using computer-aided design (CAD) and computer-aided manufacturing (CAM) programs. The programs produce a computer file that is interpreted to extract the commands needed to operate a particular machine via a post processor, and then loaded into the CNC machines for production. Since any particular component might require the use of a number of different tools – drills, saws, etc., modern machines often combine multiple tools into a single "cell". In other installations, a number of different machines are used with an external controller and human or robotic operators that move the component from machine to machine. In either case, the series of steps needed to produce any part is highly automated and produces a part that closely matches the original CAD design.

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BARREL

A gun barrel is the tube, usually metal, through which a controlled explosion or rapid expansion of gases are released in order to propel a projectile out of the end at a high velocity.

The first guns were made in a time where metallurgy was not advanced enough to cast tubes able to withstand the explosive forces of early cannon, so the pipe (often actually built from staves of metal) needed to be braced periodically along its length, producing an appearance somewhat reminiscent of a storage barrel.

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Gun barrels are mostly of metal construction. The early Chinese, the inventors of gunpowder, used bamboo, a naturally tubular stalk, as the first barrels in gunpowder projectile weapons. [2] Early European guns were made of wrought iron, usually several bands of the metal arranged around circular wrought iron rings and then welded into a hollow cylinder. The Chinese were the first to master cast-iron cannon barrels. Bronze and brass were favoured by gunsmiths, largely because of their ease of casting and their ability to resist the corrosion created by the combustion of gunpowder.]Early cannons were hugely thick for the caliber that they fired. Early manufacturing defects (such as air bubbles trapped in the metal) were key factors in many gun explosions; the expanding gases became too much for the weak barrel, causing it to rupture and explode in deadly fragments

RIFILING

Rifling refers to helical grooves in the barrel of a gun or firearm, which imparts a spin to a projectile around its long axis. This spin serves to gyroscopically stabilize the projectile, improving its aerodynamic stability and accuracy.

Rifling is often described by its twist rate, which indicates the distance the rifling takes to complete one full revolution, such as "1 turn in 10 inches" (1:10 inches), or "1 turn in 254 mm" (1:254 mm). A shorter distance indicates a "faster" twist, meaning that for a given velocity the projectile will be rotating at a higher spin rate.

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The combination of length, weight and shape of a projectile determines the twist rate needed to stabilize it – barrels intended for short, large-diameter projectiles like spherical lead balls require a very low twist rate, such as 1 turn in 48 inches (122 cm).[1] Barrels intended for long, small-diameter bullets, such as the ultra-low-drag, 80-grain 0.223 inch bullets (5.2 g, 5.56 mm), use twist rates of 1 turn in 8 inches (20 cm) or faster.[2]

In some cases, rifling will have twist rates that increase down the length of the barrel, called a gain twist or progressive twist; a twist rate that decreases from breech to muzzle is undesirable, as it cannot reliably stabilize the bullet as it travels down the bore.[3][4] Extremely long projectiles such as flechettes may require impractically high twist rates; these projectiles must be inherently stable, and are often fired from a smoothbore barrel.

6. CONCLUSION

The Vocational training at SMALL ARMS FACTORY, KANPUR helped me in improving my practical knowledge and awareness regarding Manufacturing of guns and its components to a large extent.I also came to know about Milling, Drilling, Grinding, Body housing etc. which used in this manufacturing process

Here I came to know about the technologies and material used in manufacturing of guns. Besides this, I also visualized the parts involved or equipments used in this manufacturing process.

Here I learnt about how the electrical equipments are being manufactured and how they tackle the various problems under different circumstances. At least I could say that the training at SMALL ARMS FACTORY is great experience for me and it really

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helped me in making or developing my knowledge about manufacturing and other technology used in manufacturing like CNC, COLD SWAYGING etc.

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