Ministry of Defence

INTERIM
Defence Standard

1336 (PART 8) / Issue 1

8 February 1991

BALLISTIC STANDARDIZATION OF GUN AMMUNITION

PART 8: CRUSHERS AND CRUSHER GAUGES

This Defence Standard supersedes Defence Standard 13-84/Issue 1 dated 23 October 1974

DEF STAN 13-36 (PART 8)/1 AMENDMENTS ISSUED SINCE PUBLICATION

AMD NO

DATE OF ISSUE

TEXT AFFECTED

SIGNATURE & DATE

Revision Note This Standard incorporates and updates the content of Def Stan 13-84/1 and provides additional information on the Mk 8 and Mk 9 crusher gauges. Historical Record Def Stan 13-84/1 dated 23 October 1974.

DEF STAN 13-36 (PART 8)/1 DEF STAN 13-36 (PART 8)/1 CRUSHERS AND CRUSHER GAUGES PREFACE

This Defence Standard supersedes and incorporates Def Stan 13-84/Issue 1, dated 23 October 1974

i This Defence Standard specifies the crushers (copper balls) and the associated gauges for measuring peak internal ballistic pressures in mortars, guns and howitzers by the Navy and Army Departments of the Ministry of Defence. ii This Standard has been agreed by the authorities concerned with its use and shall be incorporated whenever relevant in all future designs, contracts, orders etc and whenever practicable by amendment to those already in existence. If any difficulty arises which prevents application of the Defence Standard, the Directorate of Standardization shall be informed so that a remedy may be sought. iii Any enquiries regarding this Standard in relation to an invitation to tender or a contract in which it is invoked are to be addressed to the responsible technical or supervising authority named in the invitation to tender or contract. iv This Standard implements NATO STANAG 4113. A description of the analysis of results of the gun firing calculations specified in the STANAG is contained in Annex B. v This Standard has been devised for the use of the Crown and of its contractors in the execution of contracts for the Crown and, subject to the Unfair Contract Terms Act 1977, the Crown will not be liable in any way whatever (including but without limitation negligence on the part of the Crown its servants or agents) where the Standard is used for other purposes. vi This Defence Standard is being issued as an Interim standard and is provisional in order to obtain information and experience of its application. This will then permit the submission of observations and comments from users, using DGDQA form 0825 enclosed. vii A review of this Interim standard should be carried out within 12 months of publication. Based on the comments received the author and/or committee responsible for the preparation of the Defence Standard shall judge whether the Interim standard can be converted to a normal standard or decide on what other action can be taken.

DEF STAN 13-36 (PART 8)/1 CONTENTS Preface Section One. General 1 2 3 4 Scope WARNING Related Documents Definitions 3 3 3 5 PAGE 1

Section Two. Crushers (Copper Balls) 5 6 7 8 Description Annealing Calibration Packaging 6 6 7 7

Section Three. Mk 8 and Mk 9 Crusher Gauges 9 10 11 Annex Annex Annex Annex Annex Description Dimensional Drawings Method of Handling A B C D E Calibration Procedures Analysis of Results and Preparation of Tarage Tables Dynamic Test Procedure Static Test Procedure Sampling Plan 8 8 9 A-1 B-1 C-1 D-1 E-1

DEF STAN 13-36 (PART 8)/1 Section One. General 1 Scope This Defence Standard specifies requirements for the crushers (copper balls) and associated gauges used in measuring peak internal ballistic pressures in mortars, guns and howitzers. 2 WARNING This Standard calls for the use injurious to health if adequate to technical suitability and in user from statutory obligations of manufacture or use. 3 Related Documents 3.1 The following documents and publications are referred to in this Standard: BS 6017 Metals Advisory Memorandum 268/67 Ordnance Board Proceeding No 40736 Annex A Standard Operating Procedure No 59 MP 222 Copper Refinery Shapes Lot 4: 1967 Coppers, Crusher, Ball of substances and/or procedures that may be precautions are not taken. It refers only no way absolves either the supplier or the relating to health and safety at any stage

Lot 4:

1967 - Coppers, Crusher, Ball

Mk 8 and Mk 9 Crusher Gauges Measurement of Gun and Mortar Internal Ballistic Pressures - Part 1 - Gauges, Crusher, Ball Mk 8 and Mk 9 dated 10 January 1975 For Manufacture of Mk 8 Gauge For Manufacture of Mk 9 Gauge Details of Drop Guide Apparatus and the Oil Vessel Compression Rig for Testing 3/16 inch Copper Crushers

Drawing List No CM 8815 Drawing List No CM 1366A RARDE(FH) Drawing Nos GR/47340A to GR/47349 Inclusive RARDE Drawing GR/47413A

3.2 Reference in this Standard to any related documents means in any invitation to tender or contract the edition and all amendments current at the date of such tender or contract unless a specific edition is indicated.

DEF STAN 13-36 (PART 8)/1 3.3 Related documents may be obtained from:

DOCUMENT BS 6017

SOURCE British Standards Institution Sales Department Linford Wood MILTON KEYNES MK14 6LE Royal Armament Research & Development Establishment (RARDE) Fort Halstead SEVENOAKS Kent TN14 7BP Secretary, Ordnance Board Empress State Building Lillie Road LONDON SW6 1TR Director of Proof and Experimental Establishments St Christopher House Southwark Street LONDON SE1 0TD DGDQA/PSD Royal Arsenal West Woolwich LONDON SE18 6ST CDIA Royal Arsenal West Woolwich LONDON SE18 6ST RARDE Fort Halstead Sevenoaks Kent TN14 7BP

Metals Advisory Memorandum 268/67

Ordnance Board Proceeding No 40736 ANNEX A

Standard Operating Procedure No 59

MP 222 and drawings

Drawing List No CM 8815 Drawing List No CM 1366A

RARDE(FH) Drawing Nos GR/47340A to GR/4734 inclusive RARDE Drawing GR/47413/A

DEF STAN 13-36 (PART 8)/1 4 Definitions For the purpose of this Defence Standard the following definitions apply: 4.1 Accuracy of a gauge is its ability to record or measure the true pressure without systematic error or bias. It may depend on pressure level, temperature or both. For the purposes of this Standard the calibration curves obtained under annex B for use at -46C, -33C, -5C, 21C, 52C and 63C shall be regarded as accurate in that any systematic errors due to the crusher gauges have been removed. The deviation of any individual results from these curves is then due to random variation in the crusher gauge, random variations in the transducer system or systems, and curve fitting errors. Any systematic error associated with the transducer systems will result in a displacement of the calibration curve from the "true" pressure curve but unfortunately the amount of this displacement cannot be assessed. 4.2 Precision indicates firstly the consistency of output of an individual gauge throughout its life and secondly the consistency of output of several gauges of the same type. It is also called reproducibility. With good precision there will be little spread of results from several gauges of the same type subjected to the same pressure cycle. Precision shall be assessed as the standard deviation of results from several gauges of the same type in one round, about their mean. When several rounds of one type are fired, an average value of precision shall be calculated by taking the root mean square of the standard deviations from all these rounds weighted according to their individual degrees of freedom. S = (ml + m2 + - - - mt)-t
2

(ml -1)S1

+ - - - +(mt l)S t

------------ (1)

where S1 to St = standard deviation for rounds 1 to t S = average standard deviation for all rounds 1 to t

m 1 to mt = number of gauges for rounds 1 to t

= number of rounds

4.3 True pressure. Is that value of maximum gas pressure which actually exists and would be obtained from an ideal measuring system. For present purposes modern transducer systems which record pressure as a time function are accepted as giving the best available estimate of true pressure.

DEF STAN 13-36 (PART 8)/1 Section Two. Crushers (Copper Balls) 5 Description 5.1 The crushers used in the UK crusher gauge are precision balls made from oxygen-free copper. Before firing, a crusher, enclosed in a crusher gauge, is inserted in the chamber of the gun. After firing, the remaining length of the deformed crusher is measured and from this the pressure developed in the chamber of the gun can be determined. 5.2 Material. The crushers shall be manufactured from oxygen-free, high conductivity copper containing: (a) Not less than 99.95% copper (b) Not more than 0.005% oxygen (c) Not more than 0.003% silver or, alternatively, in accordance with BS 6017. 5.3 Dimensions. The crushers shall be spherical and conform to the following dimensions: The lot mean ball diameter may be between 4.7244 mm and 4.7752 mm. spread about the mean shall not exceed 0.0051 mm. The

5.4 Dimensional inspection. The crushers shall be measured in accordance with a sampling plan prepared by the Contractor, based on the defect classification list shown in annex E. 5.5 Lot and batch size. The number of crushers constituting a lot shall be not less than 250,000 to be delivered in batches of approximately 25,000. The complete lot of crushers shall be produced from the same cast of copper. 5.6 Identification of lots and batches. Each batch shall be allotted a serial number.The first digit or two digits shall be the lot number and the last two digits shall be the number of the batch; thus batch No 507 will be the seventh batch in lot No 5. 6 Annealing 6.1 Pre-annealing treatment. If the copper crushers are finished to size in conjunction with steel balls they shall be pickled in ambient 10% sulphuric acid solution for two minutes, then washed and dried. Otherwise they may be pickled after annealing to remove any discolouration.

DEF STAN 13-36 (PART 8)/1 6.2 The crushers shall be annealed in batches of approximately 25,000 in a controlled temperature heating chamber at a temperature of 425C + 3C for 30 minutes. The heating time shall not start until a thermocouple housed in the vessel indicates that balls at the centre of the vessel have reached this temperature. To assist in this, the vessel may be of any convenient shape (annular, rectangular, cylindrical, spherical, etc) but care shall be taken that dimensions are such that geometry of the vessel allows relatively quick heating of balls at the centre of mass. The balls shall be housed in a vessel purged of air and filled with an inert gas (argon) at a pressure of two atmospheres. After heat treatment the vessel shall be removed from the heating chamber, re-pressurized immediately with the inert gas and allowed to cool in still air to room temperature. 6.3 The copper balls may be cleaned by pickling in cold 10% sulphuric acid for two minutes, then washed in water and dried, if they have become discolored during their manufacture. NOTE: To ensure the closest inter-batch hardness comparisons, the equipment and procedure described in Metals Advisory Memorandum 268/67 (see section 3.1) should be followed. 7 Calibration Each new lot of crushers (copper balls) shall be calibrated with the object of producing a set of tarage tables for use with that lot only. Procedures are detailed in annex A. 8 Packaging 8.1 After annealing, the copper balls are to be packed in batches (5.5) and protected against damage that may occur during handling, transportation and storage. The balls are to be packed in sub-packages of 50 balls (or as otherwise agreed by the Quality Assurance Authority which will be stated in the Contract). The packaging must be capable of storing the ball without degradation, for a minimum of 15 years. 8.2 Package marking. information: Each pack must be marked with the following

COPPER CRUSHER BALL - LOT NO: BATCH NO: . . . . . . . . . . . . . . . . . . . . . . . . . . . QTY : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTRACTORS NAME: . . . . . . . . . . . . . . . . . . CONTRACT NO: . . . . . . . . . . . . . . . . . . . . . . . .

DEF STAN 13-36 (PART 8)/1 Section Three. Mk 8 and Mk 9 Crusher Gauges 9 Description Both UK crusher gauges, (Mk 8 and Mk 9) consist of a cylindrical steel body in which a 4.76 mm diameter copper ball (the crusher) is positioned between a piston at one end and an anvil which acts as a closure cap at the other. In the Mk 8 gauge the piston slides in a bore in the gauge body, while in the Mk 9 gauge the piston slides in a bore in a second cap screwed into the other end of the body. The gauge or gauges are positioned towards the rear end of the barrel, where they are exposed to the propellant peak gas pressure which acts on the piston to compress the crusher upon firing. The deformation of the crusher, measured by its remaining length, enables the gas pressure at that position to be determined. 10 Dimensional Drawings 10.1 Mk 8 gauge. The Mk 8 gauge is manufactured to the following drawings: Drawing List No: NATO Stock No: CM 8815 5220-99-109-2864

ITEM NAME Body, gauge Anvil, crusher Piston Frame, centring gauge Spring

DRAWING NO CM CM CM CM CM 9111 9112 9113 8816 8817

10.2 Mk 9 gauge. The Mk 9 gauge is manufactured to the following drawings: Drawing List No: NATO Stock No: CM 1366A 5220-99-963-1055

ITEM NAME Body, gauge Piston Cap, piston guide Anvil, crusher Frame, test piece Washer, non-metallic

DRAWING NO CM CM CM CM CM CM 8888 8889 8890 8891 8892 8893

DEF STAN 13-36 (PART 8)/1 10.3 Gauge Inspection

10.3.1 For calibration firings of a new lot a more rigorous dimensional check of the bore and the piston over their engaged length shall be carried out. Only those gauges shown to be within manufacturing tolerance will be used. A measuring system having a resolution of 2 microns or better shall be used for these requirements. 10.3.2 During routine use gauges shall be visually inspected (Piston/Bore) for signs of erosive wear. Gauges which show signs of erosive wear should no longer be used. 11 Method of Handling Detailed handling instructions for the two gauge types are specified in Standard Operating Procedure No 59. It should be noted that a crusher gauge is a precision scientific instrument and should be handled as such. Where possible the gauge body, piston and screw cap(s), should remain unique to each gauge and not intermixed between gauges. Gauge assembly should be done in a clean room with a dust-free atmosphere, as dirt inside a gauge may cause deterioration or actual damage leading to obturation failure of the gauge.

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DEF STAN 13-36 (PART 8)/1 ANNEX A Calibration Procedures A.1 Procedures A.1.1 Stages. Each new lot of crushers (copper balls) shall be calibrated with the object of producing a set of tarage tables for use with that lot only. The work shall be carried out in three stages as follows: (a) Static loading of a number of crushers from each batch so that a Standard Batch may be nominated as representative of the lot. In this, test balls from all batches will be subjected to similar static loads when the hardness of the balls from each batch will be indicated by the remaining length of the deformed balls. The balls from the Standard Batch will have a remaining length in the middle of the overall range for the whole lot. (b) Dynamic loading of a number of crushers from each batch in turn together with an equal number of crushers from the Standard Batch (see (a) above) to enable the variation in dynamic compressibility between the batches to be established. (c) Gun firings using crushers from the Standard Batch in Mk 8 and Mk 9 gauges to obtain data from which the tarage tables will annex B). NOTE : Stages (b) and (c) may take place concurrently.

A.1.2 Static loading. One of the following static loading tests shall be used: A.1.2.1 Twenty crushers from each batch shall be individually subjected to static loads of 400 kg 0.4 kg between parallel faces at a compression rate of not more than 0.5 mm per second in a suitable compression machine. The remaining length of each compressed crusher shall be measured to an accuracy of 0.0025 mm. The mean remaining length and standard deviation about the mean for each batch and the lot mean (average of the batch means) shall be calculated. Alternatively, the procedure detailed in A.1.2.2 may be used. A.1.2.2 For this test a reference batch shall be selected at random. Using the apparatus described in annex D, a set of nine crushers from the batch under test shall be subjected to the same load in a suitable compression machine able to deliver loads of 4 tonnes at a compression rate of not more than 0.5 mm per second. Four such tests shall be performed on each batch in turn, ie 36 crushers of the Test Batch. The remaining lengths of all the compressed crushers (Test and Reference Batches) shall be measured to an accuracy of 0.0025 mm. For each individual test the mean remaining length and the standard deviation about the mean of the Test and Reference Batches shall be calculated and the average difference test mean - reference mean for the tests determined and recorded. The average mean difference for the whole lot shall also be calculated. A.1.2.3 The Standard Batch shall then be selected as follows: For test A.1.2.1 the batch whose mean is closest to the lot mean remaining length is taken; or for test A.1.2.2 the batch whose mean difference is closest to the lot mean difference is chosen. If the lot mean difference is zero then the Reference Batch shall be taken as the Standard Batch. A-1

DEF STAN 13-36 (PART 8)/1 ANNEX A (Continued) A.1.3 Dynamic laboratory loadings. The equipment and procedure described in annex C shall be used to provide simultaneous dynamic loadings of Standard Batch crushers and crushers from each of the other batches in turn to provide a comparison of the dynamic compressibility of the Standard Batch with each of the other batches. The results of these tests will be examined by the Ministry of Defence Approving Authority (RARDE Fort Halstead) who will recommend which batches can be represented by the Standard Batch and a procedure for dealing with any other batches (such as by the formation of a new lot or lots with their own modified tarage tables). A.1.4 Gun firing calibrations. Gun firings shall be carried out using Standard Batch crushers in Mk 8 and Mk 9 crusher gauges as detailed in A.1.4.1. The chamber gas pressure-time histories shall be recorded for each round fired using two transducer pressure measuring systems operating as independently as possible from one another. A common voltage or charge calibration may be used for the two systems. {If two systems using transducers based on different physical principles are available this would be preferred.} The measuring systems shall have a frequency response from DC to at least 20 kHz 3dB. The transducers shall be located in the chamber such that there is no expected difference in their recordings, ie at the same distance from the breech face. The mean value of the two readings will be accepted as the true pressure if they do not differ by more than 2%. Should the values differ by more than 2%, the crusher gauge results may be used only to establish crusher gauge precision. An allowance shall be made for pressure gradient when necessary if the crusher gauges and the transducers are not located in the same section of the chamber. The crusher gauge shall be carefully dismantled without delay following a firing and the remaining length of the copper crusher measured in units of 0.0025 mm with a measuring instrument having a resolution of 0.0025 mm or better. The transducer chamber pressures will be recorded against the remaining length of the crushers in tabular form. A.1.4.1 Firing programme. For each temperature (see A.1.4.2 and A.1.4.3) the firing programme shall be: (a) Mk 8 gauge. Rounds shall be fired in a suitable weapon with four Mk 8 gauges per round at pressure levels from 200 bars to 2200 bars in approximately 100 bar increments. If two weapons are required to achieve this pressure range there shall be an overlap of 200 bars of pressure between the two weapons. A total of 21 to 24 rounds shall be fired. (b) Mk 9 gauge. Rounds shall be fired in a suitable weapon with six Mk 9 gauges per round at pressure levels from 1500 bars to 6250 bars in approximately 250 bar increments. These rounds shall be fired in two different weapon types (eg an artillery gun and a high performance tank gun) with a pressure overlap of approximately 500 bars. A total of 23 rounds shall be fired. NOTE 1: Additional rounds may need to be fired if any pressure interval between adjacent rounds exceeds 12.5% of the pressure range for the gauge. In this event the appropriate Ministry of Defence Approving Authority (RARDE Fort Halstead) should be informed and they will advise. A-2

DEF STAN 13-36 (PART 8)/1 ANNEX A (Concluded) A.1.4.1 (Contd) NOTE 2: Rounds with pressures in the range 1500 bars to 2200 bars may be used for Mk 8 and Mk 9 gauges simultaneously. A.1.4.2 21C tarage table. The basic pressure versus remaining length function shall be calculated as given in annex B using data from the programme rounds fired at 21C and a tarage table prepared. A.1.4.3 Temperature corrections. The firing programme (A.1.4.1) shall be repeated using gauges conditioned to -46C, -33C, -5C, 52C and 63C to enable the gauge/crusher performance to be established throughout the operational temperature and pressure range. The charges will be conditioned to 21C. The gauges must be maintained at the required conditioned temperatures after loading into the weapon chamber up until fired. Using the data from these rounds and the rounds fired at 21C, tarage tables shall be calculated for the full range of temperatures at 10C intervals (from -40C to 60C) as well as at the individual fired temperatures as given in annex B. Further, if the gun/charge system permits, two or three sets of gauges conditioned to different temperatures may be used in single rounds. This will allow either a substantial saving in ammunition costs or additional temperature levels to be examined, or both. The data obtained in subclauses A.1.2, A.1.3 A.2 Preparation of tables. and A.1.4 above shall be forwarded to the appropriate Ministry of Defence Approving Authority (RARDE Fort Halstead) who shall act as advisers as required throughout the production, calibration and analysis processes.

A-3

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DEF STAN 13-36 (PART 8)/1 ANNEX B Analysis of Results and Preparation of Tarage Tables B.0 The following analytical procedures for the dynamic firing tests are in general agreement with annex D of STANAG 4113 where appropriate. B.1 Regression Functions Using a least squares regression technique, third order regression functions of remaining length of crusher on corrected piezo pressure, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (2) will be calculated using all valid piezo pressures and the for all fired temperatures. corresponding remaining lengths where = = = = fired temperature 1, 2,........,n and n = number of rounds 1, 2,........,m and m = number of gauges per round the mean recorded transducer pressure corrected for pressure gradient = the crusher remaining length for temperature round No i and gauge No k.

B.2 Outlier Test The standard deviation of the observed remaining lengths about the regression function, defined as

shall also be calculated for each temperature. Individual results which do not satisfy the following test

fitted remaining length using in regression equation (2), where shall be designated outliers and shall not be used in calculating the corrected regression functions below. B.3 Corrected Regression Functions Third order regression functions of remaining length on corrected piezo pressure using and excluding outliers) data,
. . . . . . . . . . . . . . . . . . . . . . . . . . .

(5)

will be calculated. B-1

DEF STAN 13-36 (PART 8)/1 ANNEX B (Continued) B.4 Tarage Tables (at Fired Temperatures) B.4.1 Tarage tables of crusher pressure PCR against crusher remaining length will be constructed for the full pressure range of the crusher gauge at intervals of 0.01 mm for the Mk 8 gauge and 0.0025 mm for the Mk 9 gauge in remaining length from the corrected regression functions above for each of the fired temperatures. B.4.2 Tarage tables (10C intervals). Using the corrected regression functions (equation 5) obtain remaining lengths (L ) at each of 300 to 500 pressure levels equally spaced through the working pressure range of the gauge. Then for each pressure level calculate third order regressions of L as: ................................. on (6)

From this equation obtain the fitted remaining lengths at each temperature, from -40C to 60C in 10C steps, and at each fired temperature, are only indirectly related to the main The fitted remaining lengths corrected regression functions. To avoid inconsistencies between the two sets of tarage tables finally obtained (ie at the fired temperatures and at 10C intervals) each fitted remaining length is to be corrected or adjusted by interpolation and a pro-rata basis as follows: RL . . . . . . . . . . . . . . . . . . . . . . . (7) where is the temperature under consideration, and are the fired are the fitted remaining and temperatures on either side of lengths equation(6)or temperatures and respectively, is the are the and fitted remaining length at temperature and remaining lengths obtained from the corrected regression function equation (5) for temperatures and respectively. This process is to be repeated at each pressure level to obtain an array of for each temperature and presure level P. From remaining lengths, these simple interpolation for each 10C temperature pressures can be obtained for the remaining lengths of the tarage table at intervals of 0.01 mm for the mark 8 gauge and of 0.005 mm for the mark 9 gauge.

B-2

DEF STAN 13-36 (PART 8)/1 ANNEX B (Continued) B.5 Accuracy Tests For the purpose of assessing the overall accuracy of the final tarage are assumed to be true pressures. tables the transducer pressures The tarage table values (or the stored PCR values if versus L and for rounded suitably) shall be used to obtain crusher pressure PCR each crusher remaining length obtained in the trials including the outliers and hence the individual errors (crusher pressure-piezo pressure) can be obtained. For each gauge the pressure range shall be divided into four equal zones and a variation coefficient shall be calculated for each zone and fired temperature using all the individual errors in the zone as

variation coefficient = 100 . . . . . . . . . . . (8)

The piezo pressures shall be used to determine in which zone an individual result lies. B.6 Glossary of Terms a b c and d coefficients in remaining length on regression equation (2) coefficients in corrected remaining length on regression, equation (5) round number equations (2), (3), (4), (5) and (8) crusher gauge number equations (2), (3), (4), (5) and (8) remaining length (RL) used generally with suffix length variable in RL on pressure regression equation (2) recorded RL for temperature round number i and gauge number k equations (2), (3) and (4) L L
corr

A B C and D i k L L

fitted RL using

in equation (2)

length variable used in corrected RL on pressure regression (excluding outliers) equation (5)

B-3

DEF STAN 13-36 (PART 8)/1 ANNEX B (Concluded) m m1 to mt n PCR number of gauges per round equations (2) and (3) number of gauges for rounds 1 to t equations (1), (3) and (8) number of rounds at each temperature (3)
e,i, k

equations (2) and

crusher gauge tarage table pressure for temperature o round number i and gauge number k using original recorded remaining lengths equation (8). corrected piezo pressure in RL on pressure regression equation (2) and (5) piezo-electric pressures corrected for pressure gradient for temperature and round number i equations (2) and (5) pressure from equation (5) for RL = L (incremented RL value) Temperature (in particular fired temperature)

P P

and

Adjacent fired temperatures equation (7) Tarage table temperature, -40C to 60C at 10C intervals

L L L Lp

and

Fitted remaining lengths for fired temperatures equation (7) Fitted remaining length for temperature

and

equation (7)

Remaining lengths for assumed pressure P equation (7) Remaining length variable in temperature regression for pressure P equation (6) Coefficients in remaining length on temperature regression equation (6) Remaining length calculated using equation (7) for temperature and pressure P average standard deviation for rounds 1 to t equation (1) standard deviation for individual rounds 1 to t equation (1) number of rounds to be averaged equation (1) standard deviation of the observed remaining lengths about the regression function B-4

QP,RP,SP, and TP RL S S1 to St t

DEF STAN 13-36 (PART 8)/1 ANNEX C Dynamic Test Procedure C.1 Apparatus C.1.1 The dynamic test apparatus comprises a 11.34 kg weight which falls vertically in a drop guide onto a piston in the top of an oil vessel which is positioned centrally between the guide rails. The impact of the weight on the piston produces in the oil in the vessel a pressure pulse of roughly known intensity and duration. The drop guide apparatus and the oil vessel are detailed in RARDE(FH) Drawing Nos GR/47340A to GR/47349 inclusive. C.1.2 The oil vessel contains two sets of six outwards facing pistons, each set identical in size, which2 are exposed to the oil pressure. The 2 upper set of pistons are of 81 mm cross -section and the lower set 37 mm . A copper ball attached by a rubber sleeve to the base of a screwed-in anvil is held in contact with the head of each piston. The pressure pulse acting via the pistons compresses the balls between the piston and anvil faces with transient loads which are identical within each set. With three balls from each of two different batches of crushers loaded with a set, the relative dynamic compressibility of the two batches can be established at that load level by comparing the remaining lengths of the balls. C.1.3 To reduce any effect due to differences between pistons another drop is made from the same height with balls from the two batches interchanged in position, Two more pairs of drops are made from the same height - six in all. A further six drops (three pairs) are made from a greater height. Altogether in the 12 drops, 144 balls will be compressed, 72 from each of two batches, one of which will be the Standard Batch and the other designated the Test Batch in the 12 drop test series. C.2 Filling the Vessel with Oil C.2.1 It is important that the oil volume in the vessel be filled with oil free from any air bubbles as trapped air can produce undesirable pressure oscillations. The following procedure is designed to achieve this. C.2.2 After loading the vessel with 12 uncompressed copper balls (see clause C.3) and inserting Piezo electric Quartz Transducer (see clause C.4) remove the bleed plug adjacent to the Piezo electric Quartz Transducer and carefully pour oil into the vessel. The use of a syringe may help to reduce air bubbles. This is best done with the vessel clamped in a vice with its operating piston downwards and fully extended. Before inserting the closure plug any trapped air can be expelled by gently moving the operating piston in and out until no further bubbles appear. If any air is trapped in the channel below the Piezo electric Quartz Transducer the vessel should be tilted further to help it to escape. When all the air is removed ensure that the operating piston is fully extended and that there is surplus oil in the filling hole. Screw in the closure plug slowly to avoid a build-up of pressure in the oil that might distort the copper balls and then tighten. The vessel is now ready for use. At this stage the piston should not move into the vessel when lightly pressed. C.2.3 Between drops, after the vessel has been reloaded with a further 12 balls, the piston should be examined to see whether any significant amount C-1

DEF STAN 13-36 (PART 8)/1 ANNEX C (Continued) C.2.3 (Contd) of oil has escaped; the piston protrusion being less than normal by 3 mm or more. If more has escaped the vessel should be topped up with oil as above. C.3 Re-loading the Vessel with Balls C.3.1 Following a drop test the compressed balls are to be removed and a new set of balls inserted as follows. Lay the vessel on its stand with screw caps 1 and 2 uppermost. Remove cap No 1 and the compressed ball and place the ball in the first column in the ball tray in the row appropriate to the drop number. Insert a new ball into the retaining sleeve of the cap and screw the cap back into the vessel to a torque of 8 to 10 Nm. Repeat with cap No 2 and ball. Turn vessel until screw caps 3 and 4 are uppermost and repeat the procedure until all 12 balls have been replaced by new balls, with the 12 compressed balls in the tray. C.3.2 For the odd number drops, balls from the Test Batch will be loaded into holes 1 to 6 and balls from the Standard Batch in holes number 7 to 12. For the even number drops this order will be reversed ie Standard Batch balls in holes 1 to 6. This will enable any difference in behaviour between the holes to be removed in the subsequent analysis. It should be emphasized that the correct balls must be used where required, otherwise the test becomes valueless. After all 12 balls have been loaded, check the piston protrusion and refill vessel if necessary (see C.2.3) before putting the oil vessel in the drop rig. C.4 Inserting the Piezo electric Quartz Transducer (see Note 1) The vessel is designed to take a Piezo electric Quartz Transducer (see Note 1). Before the transducer is screwed into the vessel, ensure that the seating in the vessel is clear and clean and that the sealing washer is in position at the base of the transducer. Screw the transducer into the vessel using the correct box spanner and tighten it to manufacturers recommended torque. NOTE 1: The Kistler Pressure Transducer type 6211 using seal 1101B, has been used and found suitable for this application. C.5 The Drop C.5.1 Ensure that the release pin through the weight eye and lifting shackle is properly inserted before resetting the weight catching pawl mechanism. If this mechanism is not reset damage may be caused should the weight be released. Raise the weight to its required height (approximately 1.8 m for the high pressure and 0.9 m for the low pressure drops). Connect the Piezo electric Quartz Transducer lead to the transducer and position the vessel centrally between the guide rails making sure that the cable is not trapped. Set or connect the triggering device for the electrical pressure recording gear. C.5.2 Place a small piece of soft metal (a waste copper ball is ideal) onto the top of the closure piston to help reduce the initial transient pressure shocks that might otherwise occur with the steel to steel contact C-2

DEF STAN 13-36 (PART 8)/1 ANNEX C (Continued) C.5.2 (Contd) of the weight onto the piston. Note that a length of copper wire (10 to 14 SWG) may serve to reduce these shocks and also provide a suitable trigger (if insulated from earth) for the recording gear. C.5.3 Pull the release pin allowing the weight to fall. After it has struck the piston, the weight should rebound to approximately half its original height. If the weight is not caught by the rachet and strikes the piston a second time, the test should be regarded as invalid and repeated. C.6 Pressure-time Recording Using the Piezo electric Quartz Transducer (see Clause C.4 Note 1) and appropriate electronic apparatus a pressure-time pulse for each drop is to be obtained. This is not intended to provide an accurate measurement of the peak pressure although such information may be of value later. The main purpose is to confirm that the pressure-time pulse is smooth and free from spurious oscillations, particularly near to peak pressure. Such oscillations, which would probably be due to air trapped in the vessel, could affect the compression of the copper balls and in particular the consistency of results. The analysis of results relies on consistency between drops to permit the elimination of the between hole differences that may be present with the vessel. C.7 Measuring the Compressed Balls C.7.1 The remaining lengths of the compressed balls shall be measured as detailed in Standing Operating procedure No 59. Because of the relatively small sample of balls to be tested from each batch compared with the batch size (ie 72 of 25 000) and accepting that the dynamic calibration is a one-off process it is important that a reliable measurement of the ball is used in the analysis. Hence unless an automated digitized measuring system is used, then the remaining length of each compressed ball shall be measured by two operators independently. The first measurement can conveniently be made as each ball is unloaded from the vessel and a second set of measurements made later. If any pair of measurements differ by more than 0.0050 mm then the ball shall be re-measured and an agreed figure used in the subsequent analysis. C.7.2 The compressed balls shall be stored in suitable containers identified as to batch number, drop number and hole number until the analysis of results has been completed to the satisfaction of the Ministry of Defence Approving Authority. C.8 Analysis of Results C.8.1 In a complete test of one batch against the Standard Batch 72 balls of each batch will have been compressed in four sets of load levels (two oil pressure levels and two piston areas) in the 12 drops. Each load level comprises 18 balls of the Standard Batch and 18 balls of the batch under test, ie six drops with three balls of each batch per drop. Within each set of results a comparison between the 18 Standard Batch and the 18 Test Batch balls shall be made as follows:

C-3

DEF STAN 13-36 (PART 8)/1 ANNEX C (Continued) C.8.2 The results may be represented by the following table (eg for the first six drops using the larger pistons 1 to 6, now numbered Hole 1 to 6 for the convenience of the following table below:

Hole Drop 1 2 3 4 5 6

1 2 3 4 5 6

T1 S4 T7 S10 T13 S16

T2 S5 T8 S11 T14 S17

T3 S6 T9 S12 T15 S18

S1 T4 S7 T10 S13 T16

S2 T5 S8 T11 S14 T17

S3 T6 S9 T12 S15 T18

where Tx and Sx are the means of the two readings of the remaining lengths of the Test Batch and Standard Batch balls respectively. A further three sets of data will be provided by the set of smaller pistons (drops 1-6) and drops 7 to 12. C.8.3 The results above will be influenced by: (a) the between batch difference, which we are seeking to establish.

(b) the effect of any hole difference and any hole-remaining length interaction. (c) the effect of any pressure difference between drops and any pressure-remaining length interaction. (d) the within batch variability in compression. (e) measurement errors. (f) other unspecified experimental errors. The hole differences and the pressure differences can be removed to first order after which the other errors are accepted as part of the within-batch errors rather than perform a full analysis of variance. For each hole subtract the column mean from each of the entries in the column in turn and then for each drop subtract the new row mean from each of the modified entries in the row in turn. A new array will result in and each which each Test Batch result can be represented by Standard Batch result by Where and are the indiviual random errors with

C-4

DEF STAN 13-36 (PART 8)/1 ANNEX C (Concluded) C.8.3.1 Modified array:

Hole Drop
1

2 3 4 5 6

etc

the Standard Batch mean From these, the Test Batch mean and the standard deviations about these means are to be calculated giving and the Test and Standard Batch standard deviations. Four estimates of together with four estimates of the Test Batch and Standard Batch deviations are to be calculated and a mean and RMS value of Test Batch and Standard Batch standard deviations obtained. C.8.3.2 The results for all batches are to be summarized as a table:

Drops 1 to 6 Batch Number larger holes smaller holes Test Std sd sd Test Std sd sd

Drops 7 to 12 Combined larger holes smaller holes Test Std sd sd Test Std sd sd Test Std sd sd

C-5

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DEF STAN 13-36 (PART 8)/1 . ANNEX D Static Test Procedure D.1 Introduction The apparatus is used to subject two sets of nine copper ball crushers from different batches to identical static loads so that the relative compressibility of the batches may be assessed from the remaining lengths of the compressed crushers. One batch, designated the Reference Batch, is to be compared with each other batch in turn. D.2 Apparatus The apparatus consists of an anvil and a pair of plates held between the jaws of a compression machine. The anvil, a 12.70 mm thick by 50.80 mm square steel plate, has a set of nine 6.35 mm diameter cylindrical posts on each side back to back, onto each of which a copper crusher is secured. The base plate, a 25.40 mm thick by 196.85 mm by 69.85 mm steel plate carries a pair of vertical steel columns 25.40 mm diameter. The similar sized top plate has a pair of holes allowing it to slide freely up and down the columns. The plates are normally held apart by a pair of strong compression springs located around the columns. The movement of the plates when forced together in the press is limited by a pair of hollow rigid steel stops which themselves fit around the springs. The apparatus is to be used in a compression machine which can provide a load in excess of 4.064 tonnes at a compression rate of not more than 0.5 mm per second. The apparatus is detailed in RARDE drawing GR/47413/A entitled Compression Rig for Testing 3/16 inch Copper Crushers. D.3 Experimental Technique For a single compression of eighteen balls, designated a round, nine balls from one Batch are attached to the upper posts of the anvil using short lengths of rubber tubing and nine balls from another Batch to the lower posts. Care should be taken to ensure that the balls are located centrally on their posts. The upper set are designated numbers 1 to 9 and the lower set 11 to 19 with 1 opposite 11 etc. The anvil is inserted between the plates near to, but not touching the locating pins. When the press is operated the plates are forced together until the plates are in hard contact with the stop columns hence compressing all the balls to approximately the same remaining length. The final load will be of order 4.064 tonnes when the meter monitoring the compressing load will indicate the load to be increasing more rapidly. Applying the load in two phases, firstly up to approximately 1.524 tonnes, releasing the load, then applying up to the full load after checking that the anvil is clear of the locating pins, helps reduce the tilt plane effect see later (D.5.2.1).

D-1

DEF STAN 13-36 (PART 8)/1 ANNEX D (Continued) D.3 (Contd)

Four rounds, designated a serial, will be used in the comparison of each Batch in turn against the Reference Batch. For rounds 1 and 3 balls from the Reference Batch will be on the upper posts (Nos 1 to 9) and for rounds 2 and 3 Test Batch balls will be on these posts. D.4 Measurement of Compressed Balls The compressed balls will be measured using a micrometer with a resolution of 0.0025 mm. Extreme care must be taken at all stages during loading, removal, measurement and storage of the compressed balls to preserve the identity of the balls as regards their location and round number. D.5 Analysis of the Data D.5.1 Mean difference between Batches. The within round difference between the means of the nine Test Batch remaining lengths and the nine Reference Batch remaining lengths is a measure of the comparative compressibility of the two batches. The four rounds for each serial provide four estimates of the mean difference from which an overall mean is obtained. The first and last serials should test the Reference Batch against itself to give an evaluation of the overall accuracy of the experimental technique. D.5.2 Variability in remaining length. It has been found that the bias errors associated with the apparatus and the experimental technique contribute most to the overall error budget, that is the variability about mean remaining length. The errors are designated the tilt plane effect, the post effect and the level effect. D.5.2.1 Tilt plane effect. For each round, at full compression the anvil finished slightly non-parallel with the plates. The result is that the compressed balls on one side of the anvil range in size from larger in one corner to smaller in the other with the compressed balls on the opposite side of the anvil showing a similar but opposite pattern. The plane through the two sets of data (upper and lower) combined can be calculated and the remaining lengths modified appropriately. Due to manufacturing tolerances etc there is a bias D.5.2.2 Post effect. effect between posts. This can be allowed for by averaging for each post the observations for the four rounds of a serial and subtracting the average from the individual values. D.5.2.3 Level effect. There may be a slight difference in load level between the upper and lower positions. This can be allowed for by calculating the level averages for all upper and lower remaining lengths respectively for all serials combined and subtracting appropriately from the individual observations. D.5.2.4 Variability due to the crusher. The remaining variation after these three effects have been allowed for is assumed to be due to the crusher. The Standard Deviation for each set of nine modified observations is then calculated. D-2

DEF STAN 13-36 (PART 8)/1 ANNEX D (Continued) D.5.2.4 (Contd) The Standard Deviation of the mean difference (Test Batch remaining length - Reference Batch remaining length) for a serial is then obtained as the RMS average of the four standard deviation within the serial for the Test and Reference Batches respectively. D.6 Between Batch Difference and Selection of a Standard Batch For each Batch a (Test Batch-Reference Batch) difference will be obtained and the overall mean difference for all Batches calculated. The Standard Batch is selected whose individual mean is close to the overall mean and which does not have an unusually high Standard Deviation. As an example Table A gives the results of the Static Tests of Lot 8 crushers (1989) from which Batch 816 was selected as the Standard Batch. The Reference Batch used throughout the tests was Batch 805. Table B gives the results of the four rounds of serial No 2, Batch 801. Note, remaining lengths and differences are in imperial units of 0.0001 inch in both Tables. The imperial units in the tables will be converted to metric units when the Interim Standard is given full Defence Standard status.

D-3

DEF STAN 13-36 (PART 8)/1 ANNEX D (Continued) TABLE A STATIC TESTS OF LOT 8 BALL CRUSHERS Batch No 813 817 804 805 815 812 801 816 803 806 808 809 818 810 811 807 802 814 (all) (T-R) .44 .33 0 -.11 -.14 .17 -.50 -.64 -.72 -.86 -.89 -.94 -1.17 -1.19 -1.28 -1.31 -1.50 -2.36 -.72 s.d 1.27 1.00 1.21 .80 1.18 .87 .82 .96 1.05 1.07 .71 1.02 1.19 1.19 1.01 .90 .71 1.27 1.02 (T-M) 1.08 .97 .64 .53 .50 .47 .14 -.01 -.09 -.22 .25 -.30 -.53 -.55 -.64 -.67 -.86 -1.72 s.d 1.66 1.39 1.36 .95 1.28 .98 .83 .96 1.05 1.09 .76 1.07 1.31 1.32 1.20 1.13 1.12 2.15 1.24

Batch 805 was Reference Batch

D-4

DEF STAN 13-36 (PART 8)/1 ANNEX D (Concluded) TABLE B ANALYSIS OF STATIC COMPRESSION TESTS COMPARING BATCH NO 801 WITH REFERENCE BATCH NO 805 Original Data Matrix: Serial No: Rd No 1 2 Upper 1280 1278 1277 1282 1278 1275 1280 1278 1275 1281 1278 1276 Test Reference Test Reference 1293 1292 1291 1294 1291 1290 1293 1292 1290 1292 1290 1288 Reference Test Reference Test 1290 1294 1297 1288 1294 1299 1291 1295 1298 1285 1290 1295 Lower 1275 1280 1282 1275 1279 1284 1275 1279 1283 1273 1278 1282 1261 1264 1267 1259 1264 1269 1260 1264 1267 1262 1266 1269

1266 1265 1263 1267 1265 1262 1265 1264 1261 1269 1267 1265

Individual Difference from Tilt Plane and the Post Effect Averages 1 2 .26 .10 -.21 -.43 .13 .79 -.18 -.46 -.22 -.42 .40 .97 .06 -.15 -.24 -.40 .06 .06 -.25 -.64 -.25 -.08 .44 .67 .03 .08 .06 .05 .40 .27 -.49 -.40 -.19 .81 -.08 -.31 .58 -.42 -.31 -.08 .08 -.22 -.73 -.41 .27 .15 .38 .48 -.19 -.19 .33 .28 -.33 -.50 .19 .42 .33 -.22 -.06 .17 -.40 .06 .13 -.02 -.15 .01 .54 .32 -.46 -.13 .07 -.21

Std Devs relative to overall means of Test and Reference Observations after correction for tilt plane and post effect and for level correction ( -.67) Drop No 1 2 3 4 ALL TEST Mean .06 .05 -.44 -.67 -.25 S.D .44 .69 .49 .71 .59 REFERENCE Mean S.D -.06 -.05 .44 .67 .25 .55 .58 .50 .63 .57 DIFF(T-R) Mean S.D .11 .11 -.89 -1.34 -.50 .71 .90 .71 .95 .82

Summary of combined results for all four drops Mean Difference Std Dev of Mean Difference -.50 .82 D-5

Blank Page

ANNEX E CONTRACT NO DEFECT CLASSIFICATION SHEET MAXIMUM BATCH SIZE: 25,000 INITIAL BATCHES - NORMAL/INSP REDUCED INSPECTION WILL NOT BE ALLOWED STORE: COPPERS, CRUSHER, BALL FOR USE IN GAUGES, CRUSHER, BALL MKS 8 & 9 INSPECTION LEVEL: II PREPARED BY: DGDQA/PS WPNS(A) DATE : COMPONENT . . . . . . . . . . . . . . . . . JANUARY 1988 STORE BRANCH: DGLFS/QA/HY AMMB SHEET 1 OF 1

CRITICAL DEFECTS A=0.01 AQL : % DEFECTIVE B=0.1 FEATURE AQL A DIAMETER 5.3 SECT (MEASURE MUTUALLY PLANES) (AS PER PARA 2) IN TWO PERPENDICULAR GAUGE NO CODE NO

MAJOR DEFECTS AQL : FEATURE

MINOR DEFECTS

% DEFECTIVE/DEFECTS 100 UNITS AQL: % DEFECTIVE/DEFECTS 100 UNITS GAUGE NO CODE NO FEATURE GAUGE NO CODE NO

AQL A AQL B MATERIAL COMPOSITION (AS PER PARA 5.2 SECT 2) AQL B

SAMPLE SIZE 1250 ACCEPTANCE No 0 REJECT No 1 SAMPLE SIZE 125 ACCEPTANCE No 0 REJECT No 1

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DIRECTORATE OF STANDARDIZATION

MINISTRY OF DEFENCE
Room Kentigern House 65 Brown Street Glasgow G2 8EX
Telephone 041 248 7890Ext Direct Dialing 041-224-Ext Telex: Your reference

Our Reference

D/D Stan/ 306/2/9

Date

January 1991

INTERIM DEFENCE STANDARD IMPROVEMENT PROPOSAL Defence Standard No:

Title:

13-36 (PART 8)/1

CRUSHERS AND CRUSHER GAUGES

The above Defence Standard has been published as an INTERIM Standard and is provisional because it has not been agreed by all authorities concerned with its
use. It shall be applied to obtain information and experience on its application which will then permit the submission of observations and comments from users. The purpose of this form therefore is to solicit any beneficial and constructive comment that will assist the author and/or committee to review the INTERIM Standard prior to it being converted to a normal Standard. Comments are to be entered below and any additional pertinent data which may also be of use in improving the Standard should be attached to this form and returned to the Directorate of Standardization at the above address. No acknowledgement will normally be sent. NAME: J O MUIR SIGNATURE BRANCH: STAN 4C

1.

Has any part of the Standard created problems or required interpretation during use:

u
a. b.

YES

NO

if yes state,

clause number/s and wording:

recommendation for correcting the deficiencies:

2.

Comments on any requirement considered too rigid:

Continued over 1
DGDQA

Form 0825

3.

Is the Defence Standard restrictive:

YES

NO (if yes in what way)

4. General comment:

5.

We agree that this INTERIM Standard (subject to amendments to take account of our comments) when published in final form will cover our requirements. Should you find our comments at variance with the majority, we shall be glad of the opportunity to enlarge upon them before final publication. Signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . Representing . . . . . . . . . . . . . . . . . . . . . . .

Submitted by (print or type name and address):

Telephone number:

Date:

Our Ref:

2 WP 38A

DEF STAN 13-36 (PART 8)/1

Crown Copyright 1989

Published by and obtainable from: Ministry of Defence Directorate of Standardization Kentigern House 65 Brown Street GLASGOW G2 8EX Tel No: 041-248 7890

This Standard may be fully reproduced except for sale purposes. The following conditions must be observed: The Royal Coat of Arms and the 1 publishing imprint are to be omitted. The following statement is to be 2 inserted on the cover: Crown Copyright. Reprinted by (name of organization) with the permission of Her Majestys Stationery Office. Requests for commercial reproduction should be addressed to MOD Stan 1, Kentigern House, 65 Brown Street, Glasgow G2 8EX

The following Defence Standard file reference relates to the work on this Standard - D/D Stan/306/2/9 (Stan 4c). Contract Requirements When Defence Standards are incorporated into contracts users are responsible for their correct application and for complying with contract requirements. Revision of Defence Standards Defence Standards are revised when necessary by the issue either of amendments or of revised editions. It is important that users of Defence Standards should ascertain that they are in possession of the latest amendments or editions. Information on all Defence Standards is contained in Def Stan 00-00 (Part 3) Section 4, Index of Standards for Defence Procurement - Defence Standards Index published annually and supplemented periodically by Standards in Defence News. Any person who, when making use of a Defence Standard encounters an inaccuracy or ambiguity is requested to notify the Directorate of Standardization without delay in order that the matter may be investigated and appropriate action taken.

90/40075