Patent Abstract:
The invention provides methods for making bunters used to form headstamp indicia into ammunition cases. The invention also provides bunter blanks that are specially configured to yield high quality bunters.

Full Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates generally to making a bunter of the type used to imprint indicia on ammunition cartridge cases. Specifically, this invention relates to methods and blanks for making such bunters. 
       BACKGROUND OF THE INVENTION 
       [0002]    The base of an ammunition cartridge case commonly has a “headstamp,” which comprises recessed lettering or other recessed indicia showing who manufactured the case. The headstamp may also indicate the caliber and year of manufacture. As is well known, the base typically also has a primer pocket. The headstamp, primer pocket, or both can be formed in the base using a hardened metal plug called a “bunter.” 
         [0003]    The bunter has raised lettering around its face. Thus, when the face of the bunter is pressed against the base of the case, the raised lettering on the bunter forms corresponding recessed letters in the base. 
         [0004]    The raised letters on bunters have been formed on the bunter&#39;s face by EDM or engraving. Unfortunately, both of these techniques leave the bunter&#39;s face with considerable surface roughness, and this roughness is transferred to the cartridge case when the bunter is used to stamp the headstamp on the case. Moreover, the EDM and engraving techniques require a substantial amount of time. Further, when using EDM or engraving, the bunter is not workhardened during the forming process. 
         [0005]    It would be desirable to provide a fast, efficient process for forming raised indicia on the face of a bunter. It would be particularly desirable to provide a process that leaves the face of the bunter with a smooth, workhardened surface. It would also be desirable to provide a bunter blank configuration that facilitates such a process. 
       SUMMARY OF THE INVENTION 
       [0006]    Certain embodiments of the present invention provide a method of producing a bunter that is configured to stamp recessed headstamp indicia into a base of an ammunition cartridge case. In the present embodiments, the method involves providing a bunter blank having a generally ring-shaped working face from which projects a radial center protrusion. The radial center protrusion is configured for receipt in a primer pocket of the cartridge case&#39;s base during stamping of the recessed headstamp indicia. The bunter blank&#39;s generally ring-shaped working face surrounds the radial center protrusion and has an outwardly rounded configuration. The method comprises providing a hub having a generally ring-shaped contact face that defines indicia recesses. The generally ring-shaped contact face of the hub surrounds a central pocket. The method includes assembling the generally ring-shaped working face of the bunter blank against the generally ring-shaped contact face of the hub such that the bunter blank&#39;s radial center protrusion is received in the hub&#39;s central pocket and applying enough force to the thus assembled bunter blank and hub that material defining the outwardly rounded configuration of the bunter blank&#39;s working face is deformed into the hub&#39;s indicia recesses so as to form raised indicia on the working face. 
         [0007]    Other embodiments provide a bunter blank to be machined into a bunter for stamping recessed headstamp indicia into a base of an ammunition cartridge case. In the present embodiments, the bunter blank preferably comprises metal and includes both a base and a generally ring-shaped working face from which projects a radial center protrusion. The radial center protrusion preferably has a cylindrical shape and is configured for receipt in a primer pocket of the cartridge case&#39;s base during stamping of the recessed headstamp indicia. In the present embodiments, the bunter blank&#39;s generally ring-shaped working face has a hump that encircles the radial center protrusion, and this hump has an aspect ratio of greater than 7. Preferably, the hump is located radially outside of an inwardly radiused section adjacent to a base portion of the radial center protrusion. 
         [0008]    In certain embodiments, the invention provides a method of producing a bunter that is configured to stamp recessed headstamp indicia into a base of an ammunition cartridge case. The method involves providing a bunter blank having a working face from which projects a radial center protrusion. The radial center protrusion is configured for receipt in a primer pocket of the cartridge case&#39;s base during stamping of the recessed headstamp indicia. In the present embodiments, the bunter blank&#39;s working face has a hump that encircles the radial center protrusion. The method includes providing a hub having a contact face that defines indicia recesses. The contact face of the hub surrounds a central pocket. The present method embodiments comprise assembling the working face of the bunter blank against the contact face of the hub, such that a peak of the hump is aligned with the indicia recesses and such that the radial center protrusion is received in the central pocket, and applying enough force to the thus assembled bunter blank and hub that material defining the hump is deformed into the indicia recesses so as to form raised indicia on said working face. 
         [0009]    Some embodiments of the invention provide a method of producing a bunter that is configured to stamp recessed headstamp indicia into a base of an ammunition cartridge case. In the present embodiments, the method comprises providing a bunter blank having a working face with a hump defined by a generally toroidal surface (in the present embodiments, the radial center protrusion is optional and may be omitted). The method involves providing a hub having a contact face that defines indicia recesses (the contact face of the hub is not required to have a central pocket, though, it is preferred). The method comprises assembling the working face of the bunter blank against the contact face of the hub, such that a peak of the hump is aligned with the indicia recesses, and applying enough force to the thus assembled bunter blank and hub that material defining the hump is deformed into the indicia recesses so as to form raised indicia on the working face. 
         [0010]    Certain embodiments provide a bunter blank to be machined into a bunter for stamping recessed headstamp indicia into a base of an ammunition cartridge case. In the present embodiments, the bunter blank preferably comprises metal and includes both a base and a working face (in the present embodiments, the radial center protrusion is optional and may be omitted). Preferably, the bunter blank&#39;s working face has a hump defined by a generally toroidal surface. In the present embodiments, the hump has an aspect ratio of greater than 3.5, greater than 5, or even greater than 7. Preferably, the hump is located radially inside of (e.g., is encircled by) a planar perimeter surface (or “flat”). 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1A  is a side view of a conventional ammunition casing. 
           [0012]      FIG. 1B  is a bottom view of the casing of  FIG. 1A . 
           [0013]      FIG. 2A  is a front view of a bunter produced in accordance with certain embodiments of the invention. 
           [0014]      FIG. 2B  is a cross-sectional side view of the bunter of  FIG. 2A , the cross section being taken along lines B-B of  FIG. 2A . 
           [0015]      FIG. 3A  is a side view of a bunter blank in accordance with certain embodiments of the invention. 
           [0016]      FIG. 3B  is a cross-sectional view of a leading end region of the bunter blank of  FIG. 3A , the cross section being taken along lines C-C of  FIG. 3A . 
           [0017]      FIG. 3C  is a detail view of the leading end region shown in  FIG. 3B . 
           [0018]      FIG. 4A  is a perspective view of a hub used in forming raised indicia on the working face of a bunter in accordance with certain embodiments of the invention. 
           [0019]      FIG. 4B  is a front view of the hub of  FIG. 4A . 
           [0020]      FIG. 4C  is a side view of the hub of  FIG. 4A . 
           [0021]      FIG. 4D  is a front view of another hub used in forming raised indicia on the working face of a bunter in accordance with certain embodiments of the invention. 
           [0022]      FIG. 4E  is a cross-sectional view of the hub of  FIG. 4D , the cross section being taken along lines A-A of  FIG. 4D . 
           [0023]      FIG. 5  is a broken away cross-sectional side view showing a leading end region of a bunter blank in engagement with a working end of a hub in accordance with certain embodiments of the invention. 
           [0024]      FIG. 6A  is a perspective view of a fixture mounted on a press with a ram of the press spaced above the fixture in accordance with certain embodiments of the invention. 
           [0025]      FIG. 6B  is a perspective view of the fixture mounted on the press of  FIG. 6A , with the ram of the press engaging stops on the fixture in accordance with certain embodiments of the invention. 
           [0026]      FIG. 7A  is a cross sectional side view of a bunter blank assembled together with a hub inside a retainer in accordance with certain embodiments of the invention, the assembly being shown prior to cold forming. 
           [0027]      FIG. 7B  is a cross sectional side view of the assembly of  FIG. 7A , the assembly being shown after cold forming. 
           [0028]      FIG. 8  is a cross sectional view of the cold forming system of  FIG. 6B , the ram of the press being shown in engagement with both of the illustrated retainers. 
           [0029]      FIG. 9  is a partially broken-away schematic cross-sectional view of a bunter in accordance with certain embodiments of the invention. 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0030]    The following detailed description is to be read with reference to the drawings, in which like elements in different drawings have like reference numerals. The drawings, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of the invention. Skilled artisans will recognize that the given examples have many useful alternatives, which fall within the scope of the invention. 
         [0031]    The invention provides a cold forming process for producing a bunter configured to stamp recessed headstamp indicia into a base of an ammunition cartridge case. The invention also provides a bunter blank configuration that facilitates this process. 
         [0032]    The present cold forming process forms raised indicia on the working face of a bunter. The process starts with a bunter blank having a working face with a special outwardly rounded configuration.  FIGS. 3A-3C  depict an exemplary bunter blank  10 B in accordance with certain embodiments of the invention. Here, the bunter blank  10 B has a working face  15  from which projects a radial center protrusion  17 . The illustrated working face  15  is generally ring shaped, although this is not strictly required. The radial center protrusion  17  is configured for receipt in a primer pocket PP of the cartridge case&#39;s base  100 B (see  FIGS. 1A and 1B ) during stamping of the recessed headstamp indicia  100 HS. The bunter blank&#39;s working face  15  surrounds the radial center protrusion  17  and has an outwardly rounded configuration  19 . In the embodiment illustrated, the working face  15  is generally ring shaped and encircles the radial center protrusion  17 . While this will typically be preferred, the working face  15  can be provided in different shapes. 
         [0033]    Applicants have discovered that by providing the working face  15  of the bunter blank  10 B with an outwardly rounded configuration  19  having a high aspect ratio, particularly good results can be obtained. For example, it is possible to obtain fully formed letters (and/or other indicia) on the working face of the resulting bunter without objectionable distortion. In contrast, when the working face of the bunter blank is flat, the flat geometry does not allow the desired raised indicia to readily form into the recesses of the hub. Moreover, when the working face of the bunter blank is flat, the high tonnage required to get any forming of the desired indicia can deform the fixture. Further, when the working face of the bunter blank has a raised non-rounded rectangular or square projection, an outline of the desired raised indicia may be formed, but ridges will commonly be left in the working face of the resulting bunter. 
         [0034]      FIG. 3C  shows one exemplary shape for the outwardly rounded configuration (or “hump”)  19  on the working face  15  of the bunter blank  10 B. Here, the outwardly rounded configuration  19  has a width HW that is greater than its height HH. Thus, the illustrated hump  19  has a high aspect ratio. The aspect ratio is defined as the width HW of the hump  19  divided by its height HH. Preferably, the aspect ratio is greater than 3.5, greater than 5, greater than 7, or even greater than 9. In one exemplary embodiment, the aspect ratio is about 9.3. 
         [0035]    When the aspect ratio of the hump  19  is within the noted ranges, the cold forming process can provide particularly good results in terms of creating fully formed raised indicia on the working face of the bunter while minimizing distortion of the bunter blank during the cold forming process. 
         [0036]    In one group of embodiments, the hump  19  has a height of between 0.005 inch and 0.015 inch. However, this is not required. For example, when the bunter is intended to form headstamps in larger caliber cases, the desired height of the hump may be larger. Similarly, when the bunter is intended to form headstamps in smaller caliber cases, the desired height of the hump may be smaller. When the hump  19  has a height within the noted range, it preferably has an aspect ratio within one or more of the ranges taught above. For the noted height range, for example, the width HW of the hump  19  preferably is between about 0.017 inch and about 0.053 inch, between about 0.025 inch and about 0.075 inch, between about 0.035 inch and about 0.105 inch, or between about 0.045 inch and about 0.135 inch, such as between about 0.046 inch and about 0.140. 
         [0037]    In some cases, the height HH of the hump  19  is between 0.006 inch and 0.013 inch, such as from 0.007 inch to 0.010 inch. These exemplary ranges, however, are by no means required. When the hump&#39;s height HH is within one or both of these ranges, the hump&#39;s width HW can optionally be within any one or more of the ranges that are obtained by multiplying the noted top and bottom ends of the height range by 3.5, 5, 7, or 9. 
         [0038]    In the embodiment of  FIGS. 3A-3C , the outwardly rounded configuration  19  of the bunter blank&#39;s working face  15  is defined by a generally toroidal surface. Preferably, this toroidal surface is defined by a single hump  19  encircling the radial center protrusion  17 . Particularly good results can be obtained when using a single hump of this nature. For example, the resulting raised letters (and/or other indicia) can be well defined on both their inner and outer sides, and the tops of the letters can be flat. 
         [0039]    As best seen in  FIG. 3C , the working face  15  of the illustrated bunter blank  10 B defines a planar surface (or “flat”)  11  that surrounds the generally toroidal surface defining the hump  19 . While this planar surface  11  is not strictly required, it can provide particular advantages. For example, having a small perimeter flat (which can optionally border an outer edge  14  of the working face  15 ) can make it possible to use a smaller radius hump. This can reduce the overall tonnage needed to form the desired indicia. It can also increase the formability of the hump without impacting the finished product. The illustrated perimeter surface  11  is generally ring shaped and encircles the hump  19 , although this too is optional. 
         [0040]    In the illustrated embodiment, the bunter blank&#39;s radial center protrusion  17  has a cylindrical configuration. While this will typically be preferred, it is not strictly required. The radial center protrusion  17  preferably is an integral projection of (e.g., is defined by the same body as) the bunter blank&#39;s working face  15 . 
         [0041]    In certain preferred embodiments, the outwardly rounded configuration  19  of the bunter blank&#39;s working face  15  is located radially outside of an inwardly radiused section  13  adjacent to a base portion BP of the radial center protrusion  17 . Reference is made to  FIG. 3C . Here, the inwardly radiused section  13  comprises a surface that defines an interior radius located between (e.g., extending between) the hump  19  and a side surface  17 S of the radial center protrusion  17 . In other words, the illustrated inwardly radiused section  13  is located where the working face  15  comes together with the side  17 S of the radial center protrusion  17 . When provided, this interior radius is advantageous in that it can form a finished radius that is tangent between the working face  15  and surface  17 S. 
         [0042]    Thus, one group of preferred embodiments provides a bunter blank  10 B to be machined into a bunter  10  for stamping recessed headstamp indicia  100 HS into a base  100 B of an ammunition cartridge case  100 . Preferably, the bunter blank  10 B comprises metal and includes both a base  100 B and a generally ring-shaped working face  15  from which projects a radial center protrusion  17 . In the present embodiments, the radial center protrusion  17  has a cylindrical shape and is configured for receipt in a primer pocket PP of the cartridge case&#39;s base  100 B during stamping of the recessed headstamp indicia  100 HS. In these embodiments, the bunter blank&#39;s generally ring-shaped working face  15  has a hump  19  (preferably a single hump) that encircles the radial center protrusion  17 , and this hump preferably has an aspect ratio of greater than 3.5, greater than 5, greater than 7, or even greater than 9. The hump  19  in these embodiments is located radially outside of an inwardly radiused section  13  adjacent to a base portion BP of the radial center protrusion  17 . Optionally, these embodiments can include a planar perimeter surface  11  encircling the hump  19 . 
         [0043]    In the bunter blank embodiments of the invention, the bunter blank  10 B preferably is formed of metal (e.g., steel) and its base BA preferably has a generally cylindrical configuration. The base BA can alternatively have other configurations. However, a cylindrical base configuration will generally be convenient for the present cold forming process. 
         [0044]    In one particular non-limiting example, the height HH of the hump  19  is about 0.009 inch and the width HW of the hump is about 0.084 inch. In this example, the bunter blank&#39;s radial center protrusion  17  is a cylinder projecting from the bunter blank&#39;s working face  15  and having a diameter of about 0.175 inch. In the present example, the bunter blank  10 B has the configuration shown in  FIGS. 3A-3C . Here, the height of the radial center protrusion  17  is about 0.125 inch, and the width of the working face  15  is about 0.060 inch. The planar surface  11  encircling the hump  19  has a width of about 0.015 inch. The bunter blank  10 B is formed of annealed CPMM4 and its base has a diameter of about 0.508 inch. Finally, an interior radius of about 0.015 inch is provided where the working face  15  meets the side  17 S of the radial center protrusion  17 . These details, however, are merely exemplary; they are by no means limiting to the invention. 
         [0045]    Exemplary methods for fabricating the bunter blank will now be described. In one method, the bunter blank is formed of annealed tool steel, such as CPMM4 material, although other suitable materials can be used, including high speed steel. Another exemplary method for fabricating the bunter blank involves the blank being derived from cold work tool steel formed by powder metallurgy processing. The bunter blank is machined using a lathe turning center from a solid billet to the geometry shown in  FIGS. 3A and 3C . The details of these fabrication methods, however, are not limiting to the invention. 
         [0046]    For the cold work, powder metallurgy-derived steels, from which bunter blanks of the invention can be manufactured, in certain embodiments, the tool steel is formed so as to contain not greater than about 4% tungsten by weight, and preferably not greater than about 2% tungsten by weight. For heavy duty stamping operations, in certain embodiments, the cold work tool steel is formed to contain from about 0.2 to about 4% (and preferably from about 0.5% to about 2%) of tungsten by weight and, preferably, contains from about 5% to about 10% (and most preferably from about 7% to about 9%) of chromium by weight. In a preferred embodiment, the invention provides a durable, wear-resistant bunter blank derived from cold work tool steel formed by powder metallurgy processing and containing tungsten in an amount not greater than about 2% by weight, at least about 7% (and preferably at least about 7.3%) chromium by weight, and not over about 2% of molybdenum by weight. 
         [0047]    In addition to the foregoing bunter blank  10 B embodiments, the invention provides cold forming methods for forming raised indicia  25  on the working face  15  of a bunter  10 . The method involves providing a hub  50  having a contact face  55  (optionally a generally ring-shaped contact face) that defines indicia recesses  52 . The contact face  55  of the hub  50  surrounds a central pocket PP.  FIGS. 4A-4E  depict two exemplary hub configurations. The present methods involve assembling the working face  15  of a bunter blank  10 B against the contact face  55  of the hub  50  such that the bunter blank&#39;s radial center protrusion  17  is received in the hub&#39;s central pocket  58 . Sufficient force is applied to the thus assembled bunter blank and hub that material defining the outwardly rounded configuration  19  of the bunter blank&#39;s working face  15  deforms into the hub&#39;s indicia recesses  52  so as to form raised indicia  25  on the working face  15  of the resulting bunter  10 . 
         [0048]    The force applied in this cold forming process preferably is supplied by a press (e.g., a cold forge press). This forming of the raised indicia on the working face preferably is initiated while the bunter blank  10 B is at room temperature. The method may involve operating the press such that a force of at least 12 tons is applied to the assembled bunter blank and hub. The amount of force used will, of course, vary depending upon a number of factors, including the desired height of the raised indicia  25 , the material from which the bunter blank  10 B is formed, and the press used. 
         [0049]    During this forming of the raised indicia  25  on the working face, the outwardly rounded configuration  19  is generally flattened. In more detail, after the cold forming process, the working face  15  of the bunter  10  has a plurality of raised letters, numbers, and/or other indicia, but it preferably is otherwise generally planar. Reference is made to  FIG. 2B . 
         [0050]    The height of the raised indicia  25  on the bunter&#39;s working face  15  will depend upon the depth desired for the recessed headstamp indicia  100 HS. In certain embodiments, the height of the raised indicia  25  formed on the bunters working face  15  is between about 0.002 inch and about 0.003 inch. This, however, is merely an exemplary range. Larger or smaller caliber cases may require a different height for the raised indicia  25 . 
         [0051]    The present cold forming process is advantageous in that it can create a particularly smooth surface on the working face of the resulting bunter. For example, after forming the raised indicia  25 , the working face can have an average surface roughness R a  of less than 50 microinches, less than 25 microinches, or even less than 10 microinches. The surface is measured using a stylus moving a radial motion from the center side of the working face  15  to the outer edge  14  of the working face. The measurement excludes the raised indicia  25 . The measurement is taken by a CNC surface roughness measurement machine having a resolution of less than 0.1 microinch. 
         [0052]    Since the invention involves a cold forming process rather than an EDM process, the working face  15  of the resulting bunter  10  does not have a so-called white layer (or “recast layer”). When EDM is used, the processed surface is left with a white layer, which has a different metallurgical structure (e.g., contains considerably more carbon) than the base material. This surface layer (which extends from the surface to a certain depth below the surface) can be more brittle than the base material. Thus, when the working face of a bunter blank is fabricated by EDM, the working face of the resulting bunter (including the raised indicia on the working face) has a white layer, which can cause the raised indicia to be more brittle than the base material. The present cold forming process is advantageous in that it produces a working face devoid of such a white layer. 
         [0053]    Thus, in certain embodiments, the bunter blank  10 B comprises a steel base material (the bunter blank  10 B can optionally consist essentially of the steel base material), and after forming the raised indicia  25  on the working face  15 , a surface region SUR (see  FIG. 9 ) of the working face does not have a carbon-enriched surface layer (e.g., contains substantially the same amount of carbon as the steel base material). 
         [0054]    The present cold forming process is perhaps best understood with reference to  FIGS. 5 ,  6 A, and  6 B.  FIGS. 6A and 6B  depict embodiments in which a fixture FX is provided on a lower table LT of a press. Here, the fixture FX has two stops STP configured to limit the downward movement of the ram RA (which occurs during the cold forming process). The number and type of stops used can, of course, be varied. The illustrated fixture FX includes a cold forming mount HM and a removal mount SE. The cold forming mount HM is configured to stably secure a retainer  80  in a cold forming position. The retainer  80  has an interior opening in which the bunter blank  10 B and hub  50  can be positioned. Preferably, the bunter blank  10 B and hub  50  are assembled together inside the retainer  80  in the manner depicted in  FIG. 5 . Here, the working face  15  of the bunter blank  10 B is positioned against the contact face  55  of the hub  50  such that the bunter blank&#39;s radial center protrusion  17  is received in the hub&#39;s center pocket  58 . In the embodiment illustrated, a peak of the hump  19  is aligned with the hub&#39;s indicia recesses  52  when the bunter blank and hub are so assembled within the retainer  80 . Preferably, the peak of the hump  19  extends in a circle, the hub&#39;s indicia recesses  52  are arranged in a circle, and both of these circles have substantially the same radius, such that when the working face  15  of the bunter blank  10 B is properly positioned against the hub&#39;s contact face  55  (as shown in  FIG. 5 ), the peak of the hump is aligned with the hub&#39;s indicia recesses. The ram RA of the press is used to apply enough force to the thus assembled bunter blank  10 B and hub  50  that material defining the hump  19  is deformed into the indicia recesses  52  of the hub so as to form raised indicia  25  on the working face  15 . In the embodiment illustrated, force is applied so as to press the hub  50  against the bunter blank  10 B; the bunter blank is mounted such that it does not move substantially in response to this application of force other than by having material forming its hump  19  deform into the hub&#39;s indicia recesses  52 . In the present method, the hub  50  moves slightly (during pressing) as the hump  19  on the bunter blank  10 B is generally flattened. If desired, the positioning of the hub  50  and the bunter blank  10 B could be reversed (using a different retention system) such that force from the ram is applied so as to press the bunter blank against the hub. 
         [0055]    In  FIG. 6A , an end surface  59 S of the hub&#39;s base  59  is spaced upwardly from the uppermost surface  81  of the first retainer  80 . As a result, when the ram RA descends, it contacts the base  59  of the hub  50 , thereby pressing the hub downwardly against the bunter blank  10 B. This causes the hump  19  on the bunter blank&#39;s working face  15  to be generally flattened while some of the material from the hump deforms into the hub&#39;s indicia recesses  52 . Thus, the working face  15  of the resulting bunter  10  defines raised indicia  25  but is otherwise generally flat. The descent of the ram RA is stopped at the appropriate position when the ram contacts the stop surfaces TP of the stops STP. 
         [0056]    The fixture FX shown in  FIGS. 6A and 6B  is advantageous in that it enables a single stroke of the ram RA to accomplish two operations. Specifically, it accomplishes the cold forming of a bunter blank in a first retainer while simultaneously removing a completed bunter from a second retainer. As shown in  FIG. 6A , the second retainer  80  has a plunger PL that is engaged by the downwardly moving ram RA and is thereby moved forcibly in a downward direction, such that once a bottom end of this plunger contacts the base BA of the completed bunter  10  in the second retainer, this bunter is forced downwardly and out of its retainer along with the hub  50  in that retainer.  FIG. 6B  shows a bunter  10  and hub  50  dropping out of the second retainer  80 . The present cold forming process is by no means limited to use of such a dual-purpose fixture. However, it is currently preferred. 
         [0057]    The retainer  80  preferably is formed of A8 material, although other suitable materials include tool steel or high speed steel. The hub  50  preferably is formed of tool steel, such as CPMM4 material, although other suitable materials include high speed steel. In certain preferred embodiments, the hub  50  has a Rockwell C hardness of at least 56. Preferably, the hub  50  is heat treated to at least this minimum hardness. The hub  50  can optionally also include a surface treatment, such as a CVD, PVD, or diffusion type coating. 
         [0058]    Exemplary methods for fabricating the hub  50  will now be described. In one method, the hub  50  is formed of tool steel, such as CPMM4 material, although other suitable materials can be used, as noted above. Another exemplary method for fabricating the hub  50  involves the hub  50  being derived from cold work tool steel formed by powder metallurgy processing, similar to that already described herein with respect to the bunter blank. The hub  50  is machined in a lathe turning center to near net finish diameter of 0.750 inch, with a depth of 0.175 inch for pocket  58 , and a diameter of 0.875 inch for the base  59 . The recessed indicia  52  are then hard milled using a milling center to a depth of 0.0025 inch. Then the hub  50  is heat treated to a minimum hardness of 56 Rockwell C. The hub is then turned in a lathe turning center to the finish diameter of 0.750 inch and the base  59  to a diameter of 0.875 inch. The final step is to break the edges of the recessed indicia using polishing technology. These exemplary details are by no means limiting to the invention. 
         [0059]    One exemplary method for fabricating the retainer  80  will now be described. In the present method, the retainer  80  is formed of A8 material, although other suitable materials can be used. The retainer  80  is turned out of an A8 material blank on lathe and most of the features are added and some material is left for finishing. Then, an air release nip is added in a mill. 0.094 inch dia. 0.015 inch deep. Next, the part is sent to heat treat and the part is drawback to RC 52-54. After heat treat, the part is put on a grinder and the outside diameter is ground to 1.525 inches and there is a clean-up grind on the ends to square the part up. The retainer then goes to a jig grinder and the two inside diameters are ground out to 0.750 inch and 0.508 inch and the bottom of the holes are cleaned up. Finally, the ends of the retainer are ground so there is 0.500 inch from bottom of 0.508 hole and bottom of retainer and the overall length is ground to 3.362 inches. Here again, the noted exemplary details are not limiting to the invention. 
         [0060]    One exemplary method for fabricating the fixture FX will now be described. In the present method, the fixture FX is formed of A2 material, although many other suitable materials can be used. The fixture FX is made out of an A2 material block. The block is put in a mill squared up and all the desired features are added. It is then heat treated and the two counter bores are jig ground to size. The fixture is 6.5 inches wide, 6 inches deep, and 3.25 inches high. There are two tapped holes to hold the stops STP. There is a 1.530 inch diameter by 0.485 inch deep counter bore with a 1.015 inch diameter through-hole in the center of the fixture FX. Feature SE has a 1.530 inch diameter counter bore that is 0.880 inch deep and 1.000 inch cut out of the side of the part. Again, the details given here are not limiting to the invention. 
         [0061]    In one exemplary embodiment, the bunter  10  is designed for use with 5.56 mm caliber ammunition cases, the bunter blank  10 B is of the nature described above in the non-limiting example, the hub  50  is fabricated in the manner described above, the retainer  80  is fabricated in the manner described above, the fixture FX is fabricated in the manner just described, and a hydraulic or mechanical cold forge press is used for the cold forming process. In the present embodiment, the cold forming process happens when the ram RA is moved down vertically and comes into contact with surface  59 S of the hub  50 . The contacting surface CS of the ram RA continues moving downward vertically until it comes into contact with surfaces TP of the stops STP. Once surfaces CS and TP are flush, the cold forming process is complete, and the ram RA is moved upward vertically to its home position. 
         [0062]    The raised indicia  25  on the working face  15  can comprise letters, numbers, and/or other indicia. Commonly, the raised indicia  25  will include manufacturer indicia (i.e., indicia identifying the company that manufactured the case  100 ). In some cases, the raised indicia  25  will also include year indicia (i.e., indicia identifying the year in which the case  100  was manufactured), caliber indicia (i.e., indicia identifying the caliber or gauge of the case  100 ), or both. 
         [0063]    The raised indicia  25  on the bunter&#39;s working face  15  preferably define raised surfaces (i.e., surfaces spaced forwardly of the generally flattened part of the working face) that are planar and generally parallel to the flattened part of the working face. In many cases, the indicia  25  will include a plurality of individual (e.g., separate or “discrete”) raised letters, numbers, or both. In such cases, the raised surfaces of the different letters and/or numbers preferably are substantially flush to one another. If desired, the raised surfaces of the indicia  25  can be substantially parallel to a planar leading surface  17 L of the radial center protrusion  17 . This, however, is not required. 
         [0064]    The bunter  10  can optionally have a groove SL formed in, and extending entirely around, the base BA of the bunter. Reference is made to  FIG. 2B . Here, the illustrated bunter  10  is defined by a single integral body. However, this is not required. For example, the bunter  10  can alternatively comprise multiple bodies. This can be appreciated by referring to  FIG. 3A , which depicts an embodiment in which the bunter is to be formed by two generally cylindrical bodies BA 1 , BA 2  joined together in an end-to-end fashion. Other variants of this nature are also possible. 
         [0065]    In the illustrated embodiments, the working face  15  of the bunter blank  10  has a generally ring-shaped configuration, the contact face  55  of the hub  50  has a generally ring-shaped configuration, and the bunter blank&#39;s radial center protrusion  17  has a cylindrical configuration. While these configurations will commonly be most convenient, they are not strictly required. For example, the contact face of the hub could be square, hexagonal, or various other shapes. The same is true of the working face of the bunter blank. In most cases, though, the noted configurations will be used. 
         [0066]    In some embodiments, the working face  15  of the bunter  10  is provided with a coating  1300 . One exemplary embodiment is shown in  FIG. 9 . When provided, the coating  1300  can optionally be over the entire working face  15  of the bunter  15 . In  FIG. 9 , the coating  1300  is over the working face  15 , including the raised indicia  25 , and it is also over the radial center protrusion  17 . If desired, the coating  1300  can be over the entire bunter  10 . Thus, in some method embodiments, after the formation of the raised indicia  25 , the method further includes forming a coating  1300  on the working face  15  of the bunter  10 . 
         [0067]    The coating  1300  can optionally be a dry lubricant coating. For example, the coating  1300  can comprise nickel (e.g., nickel alloy) and/or a low friction polymer. In some cases, the coated surface has one or more of the following features: (i) a coefficient of static friction below 0.35, below 0.3, or even below 0.2; (ii) a coefficient of dynamic friction below 0.3, below 0.25, below 0.18, or even below 0.1. Useful dry lubricant coatings are available commercially from, for example, General Magnaplate Corporation (Linden, N.J., USA) and Poeton Industries, Ltd. (Gloucester, England). As one example, the coating can be a NEDOX® coating. 
         [0068]    In certain embodiments, the coating  1300  comprises a nitride and/or a carbide. One commercially available nitride coating is the Nitrex® coating, which is a high endurance surface enhancement available commercially from Nitrex, Inc. (Aurora, Ill., USA). Particularly useful nitriding and nitrocarburizing enhancements are described in U.S. Pat. No. 6,327,884, the salient teachings of which are incorporated herein by reference. 
         [0069]    Nitriding and nitrocarburizing processes are known in the field and need not be described in great detail. Reference is made to U.S. Pat. Nos. 4,790,888 and 4,268,323, the teachings of which regarding such enhancements are incorporated herein by reference. The latter patent refers to the use of a fused salt bath to enable nitrogen and carbon to diffuse into the surface of a steel piece suspended in the bath to form a carbonitride case. Reference is made also to U.S. Pat. No. 5,234,721 (referring to methods of forming carbonitride coatings), the teachings of which regarding such coatings are incorporated herein by reference. 
         [0070]    Nitriding processes, both plasma (ion) nitriding and liquid nitriding, are described in detail in the ASM Handbook prepared under the direction of the ASM International Handbook Committee, Revised vol. 4 : Heat Treating , pp. 410-424 (1994), the teachings of which concerning nitriding enhancements are incorporated herein by reference. Plasma or ion nitriding involves the use of glow discharge technology to provide nascent nitrogen to the surface of a heated steel part. Here, the part is subjected to a nitrogen plasma in a vacuum chamber. Nascent nitrogen diffuses into the surface of the part to form an outer “compound” zone containing γ (Fe 4 N) and ε (Fe 2,3 N) intermetallics, and an inner “diffusion” zone which may be described as the original core microstructure with some solid solution and precipitation strengthening. Liquid nitriding involves immersing a steel part in a molten, nitrogen-containing fused salt bath containing cyanides or cyanates, e.g., NaCN or NaCNO. Steel components can be enhanced by liquid nitriding through a wide variety of commercial coating manufacturers, such as Metal Treaters Inc. of St. Paul, Minn., USA. As used herein, the term coating includes discrete coatings on the surface of a part, diffusion of material into the part so as to enhance its surface, etc. 
         [0071]    While the coating  1300  may be advantageous in some embodiments, it is by no means required. Thus, the bunter  10  need not have any coating(s). While a preferred embodiment of the present invention has been described, it should be understood that various changes, adaptations and modifications may be made therein without departing from the spirit of the invention and the scope of the appended claims.

Technology Classification (CPC): 1