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A method of manufacturing a monobloc gun barrel by calculating an optimal residual stress profile and then applying tailored autofrettage mandrels which are mechanically pressed down the bore of a large caliber barrel, the mandrel size optimized to create a residual stress distribution on the interi

A method of manufacturing a monobloc gun barrel by calculating an optimal residual stress profile and then applying tailored autofrettage mandrels which are mechanically pressed down the bore of a large caliber barrel, the mandrel size optimized to create a residual stress distribution on the interior of the bore within the design constraints imposed by the worst-case heat flux scenario.

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1. A method of manufacturing a thick walled large caliber gun barrel, wherein the barrel requires active cooling to maintain a rate of fire, comprising the steps of:calculating a thermal profile for the barrel based on barrel geometry, barrel material and heat flux produced from a maximum fire rate

1. A method of manufacturing a thick walled large caliber gun barrel, wherein the barrel requires active cooling to maintain a rate of fire, comprising the steps of:calculating a thermal profile for the barrel based on barrel geometry, barrel material and heat flux produced from a maximum fire rate scenario;calculating a barrel yield strength of the barrel based on the thermal profile;calculating a maximum residual stress profile based on the barrel yield strength;forging the barrel;mapping the inner diameter of the barrel;testing the yield strength of the barrel forgings;constructing a mandrel, wherein said mandrel is sized according to the inner diameter of the barrel, yield strength of the forging and residual stress profile;pressing the mandrel through the barrel;machining the outer diameter of the barrel to its finished dimensions; andmachining the inner diameter of the barrel to its finished dimensions. 2. The method of claim 1 wherein the barrel is housed within a multizone cooling chamber containing a circulating liquid. 3. The method of claim 2 wherein the barrel cooling requirements are greatest at a breech end of said barrel. 4. The method of claim 1 wherein the barrel is a monobloc design. 5. The method of claim 1 wherein the mandrels are shaped with constant diameter lengths ranging from 0.25 to 0.75 inches. 6. The method of claim 1 wherein the diameter of the mandrels varies in increments of 0.001 inches. 7. The method of claim 1 wherein said barrel is subjected to service temperatures of up to 783°. 8. The method of claim 1 wherein pressing the mandrel down the barrel results in a favorable residual compressive stress distribution including a plastic deformation of less than the thickness of the barrel. 9. The method of claim 8 wherein 25% of the barrel wall thickness will be plastically deformed at a breech face. 10. The method of claim 8 wherein 10% of the barrel wall thickness will be plastically deformed at an origin of the rifling. 11. The method of claim 1 wherein an internal pressure due to firing the gun is up to 64,500 psi. 12. The method of claim 1 wherein the yield strength of the barrel is in the range of 160,000 to 180,000 psi. 13. A method of subjecting a gun barrel to autofrettage wherein the inner bore of said barrel is subjected to pressure resulting in a plastic deformation of less than the thickness of the barrel wall, said method comprising;establishing a thermal profile for the barrel based on barrel geometry and heat input from a worst-case scenario fire rate;calculating an autofrettage stress that the barrel can support based on the thermal profile;measuring a yield strength of each barrel forging;mapping the inner bore diameter;constructing a mandrel sized to produce the autofrettage stress based on the yield strength and dimensions of an individual barrel; andapplying said autofrettage stress by ramming said mandrel in a single pass through the inner bore of the barrel. 14. The method of claim 13 wherein the barrel is constructed of a high-strength alloy steel. 15. The method of claim 14 wherein the barrel is constructed according to ASTM A 723 for alloy steel forging. 16. The method of claim 13 wherein a mandrel yield strength is greater than the yield strength of the barrel. 17. The method of claim 16 wherein the mandrel is constructed of tungsten carbide. 18. The method of claim 13 wherein ramming the mandrel requires a press force with a range of 400 to 700 kip.