MECH690 MECHANICAL DESIGN PROJECT, SUMMER 2010 MID-SEMESTER REPORT INTEGRATED CLIP CARRYING CASE-M240B PROJECT MANAGER: SIGNATURE: DATE:

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1 Final Report Format DEPARTMENT OF ELECTRONICS AND MECHANICAL MECH690 MECHANICAL DESIGN PROJECT, SUMMER 2010 MID-SEMESTER REPORT INTEGRATED CLIP CARRYING CASE-M240B CLIENT: Department of Defense CLIENT CONTACT: U.S. Marine George Geddis PROJECT MANAGER: SIGNATURE: DATE: PROJECT ADVISORS: Department of Electronics and Mechanical Wentworth Institute of Technology 550 Huntington Ave, Boston, MA ( )

2 TABLE OF CONTENTS SUMMARY OF PROJECT EXECUTIVE SUMMARY 1. INTRODUCTION 5 2. NEED ASSESSMENT 5 3. SPECIFICATIONS 5,6 4. DESIGN OPTIONS 7-10 a. Design Options b. Analysis of Design Options c. Decision Matrix d. The Design of the Project e. Analysis of Design Options 5. REFERENCES APPENDIXES a. Team Qualifications b. Resume of Team Members 7. BREAKDOWN OF TASKS 16 a. Group Schedule and Progress

3 INTEGRATED CLIP CARRYING CASE-M240B SUMMARY OF THE PROJECT The ICCC-M240B will directly replace the current way to transport ammunition for the M240B Medium Grade Machine Gun during a patrol. The current method to carry the 7.62mm rounds for the 240B is the standard ammunition box that the military has had since the need to carry ammunition was a necessity and the other current method is to wrap the ammunition rounds over your shoulder. The Aluminum container is bulky, hard to carry and does not offer any protection for the bullets other than keeping them out of the direct rain or snow. To have the bullets fed into the weapon, the container must be completely open leaving the bullets open to the elements of nature. The other method is where soldiers carry the ammunition Rambo Style ; wrapping the rounds around their body over their shoulder; however, this method does not protect the ammunition from their surroundings. They are directly exposed to the elements of nature and can get dirt, water, clothe, and other various pieces to jam the bullets in the weapon. Our proposed idea for the ICCC-M240B (Integrated Clip Carrying Case) is to build a new ammunition storage case for the M240B that can be easily attached and detached to the current design specifications of the M240B. The case will incorporate a dual compensation method which allows the container to attach to the gun like a magazine and gives the operator capability to clip extra rounds directly to the ammunition chain which will provide longer uninterrupted firing time. While the weapon is not in use, it will clip to the soldiers gear and keep the rounds out of the elements with a weatherproof seal. This case will keep the rounds water proof so they will not rust, and it will also keep the rounds out of direct contact with mud, dirt, and dust. We have set a budget on the project of $ The main costs behind the project like this are the costs on labor and material. This case has to be affordable so it could be mass produced to outfit all the M240B s that are being used by the military today. The tooling for this case will not be too extensive; we will design it using Solid-Works 2009 in order to obtain correct measurements and FEA analysis calculations where applicable. We are going to order all the clipping devises for the case from engineering supply companies such as McMaster-Carr which also make it easier for mass production.

4 INTEGRATED CLIP CARRYING CASE-M240B EXECUTIVE SUMMARY At this point in our project we have completed most of our work as a group rather than in individual tasks. The few assessments that we have completed on our own are as follows, Aaron Bronshtein has been contacting companies in which we could gather information on the military issue weapon, Filip Shosho has be planning and building schedules in order to keep ourselves on track, Andrew Cammorata and Justin Bruyn have both been working on feasible design scenarios and preparing report data/information to clearly state our ideas to the prospective audience. All members of the group are working very well together, completing tasks on time, and communicating ideas with one another. PROJECT MANAGER: SIGNATURE: DATE:

5 INTRODUCTION INTEGRATED CLIP CARRYING CASE-M240B Today the military has two real methods of carrying their ammo for the M240B Machine Gun; the ammunition case. The case is cumbersome and not weather tight, leaving the rounds exposed to moisture and grime that will cause the rounds to rust and become dirty. If this happens, the rounds could potentially jam in the gun leaving the soldiers vulnerable to the enemy. Currently, the military also has a canvas bag that clips onto the gun but it only holds 30 rounds, so it is only useful while the gunner is in motion, it also does not protect the rounds what so ever from outside conditions. We came up with this idea after talking to a friend that just came home from his tour of duty in the war in Afghanistan; he told me that they did not have a way to easily carry the ammunition that kept it dry, clean, and easily accessible. When we looked further into the operation of this weapon in a war time scenario we realized that the ammunition delivery system and transport options drastically need improvement. NEED ASSESSMENT Our attachment to the M240B Machine Gun would increase efficiency in reload time and would provide reassurance to a soldier operating it. They would not have to worry about a jam due to dirty or rusty ammo. The ammunition stored in the case would be protected from shock and weather conditions outside of the case. This product would hopefully be used by the United States Military. They would not see any profit (money) from this product. However, because this does not already exist they will see an increase in efficiency and decrease in casualties due to a down gun for ammo issues. SPECIFICATIONS The ICCC-M240B will keep the 7.62 round required for the gun, out of the elements. It will keep them free from mud, dirt and grime. This case will also be waterproof so the rounds will not rust. The case will also be able to clip directly into the gun just like a magazine already being used in other applications. The case will have to hold up its integrity in a battle situation, being dropped/fumble, and knocked around. This product is based on ease of use because the soldiers using it must be able to clip it into the gun fast, so the gun can be in operation with the least amount of down time. The case also has to allow the bullets to flow freely with ease so they do not jam the gun, it must also be easy to reload so the operating soldier can do it efficiently during a battle situation. Another specification for the case is the ability to clip rounds into the previously loaded rounds in the ICCC via some sort of hinged door or access point. Right now there is no way available to keep the rounds water proof. If they are carried in the metal ammunition box they are not safe from water damage that leads to rust and more gun jams. We propose an integrated clip carrying case that is totally water proof so

6 that a soldier could be on patrol with the case clipped to his pack and submerge it completely and no water enters the clip. Being water proof the clip is also protects the rounds from any other conditions outside of the case, which would include mud, dirt, dust and grime. If any of these outside conditions were to get between the M13 disintegrating links that hold the rounds together a jam will most certainly occur. This case must be able to go from the soldiers pack to the gun in seconds. When a soldier needs rounds he does not have time to fumble around in the reloading sequence. This case will allow a soldier to attach the case, load the bullets, and not have to worry about the rounds until he/she is ready for the next case. This case must also be durable. It must have to hold up to refill after refill. It must also protect the ammunition from a fumble or fall. The case should be able to perform smoothly after drops of about 5 to 10 feet. The rounds must be arranged in a horizontal layered pattern. This is to ensure that they will not snag on each other and jam the gun. Below, figure A depicts the rounds layered in a horizontal pattern allowing each layer to be pulled directly up off of the layer beneath. In figure B the rounds are layered vertically the bullets would be pulled along the adjacent layer. This would most certainly cause the gun to jam because there is a lot of friction when the bullets are pulled along other bullets.

7 DESIGN OPTIONS (3D model of our basic design concept) (Multi-part case with spring loading tray to keep rounds closer to top at all times)

8 (Multi-part case that satisfies all specifications) ANALYSIS ON DESIGN OPTION Our first design option is a multi-part case that has a trap door on the side for loading. This case has a large capacity for rounds making it bulky. The second design option is also a multi-part case with a spring loaded tray. This case holds the bullets under the gun which can interfere with firing from the ground. Our third and best design option is a side loading case that has minimal moving parts. It will be able to hole of 100 rounds. It is simple to use and easily carried.

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10 THE DESIGN OF THE PROJECT Our third design option is our best. It will be constructed of a plastic compound with some metallic parts such as hinges rivets and fasteners. The case will consist of three main parts a top, body and bottom. The body of the case will include a feature (clip) that secures it to a soldier while it is not attached to the gun. The top will allow for easy access to the rounds while keeping them safe from outside conditions. It will also secure the case to the gun. The bottom will allow for a soldier to open the case while the gun is being fired and add rounds to the already loaded chain, while this is not recommended it leaves the option open to a soldier if a situation in which this is required. ANALYSIS OF THE DESIGN OPTION All of our design options are result of direct feedback from soldiers that have used and use the M240B in combat. The need for a case to keep the rounds protected from outside conditions is long overdue. With that, we feel that a carrying case that is integrated to a clip for the gun is even better. This case must be easily carried, and very effective. This case must also protect the rounds from moisture, mud, dirt, dust and grime. When the ammunition rounds are not in use they must be kept in the same conditions as they were received. REFERENCES Mr. Eugene R. Reda President Savit Corporation (Direct) (Mobile) ereda@savitcorp.com Glenna Government Sales Director Colt Defense LLC Tel: ext Fax: (860)

11 APPENDICES TEAM QUALIFICATIONS Justin Bruyn Landscaping (3 years) Provided proper maintenance and up keep of all equipment to insure longest machine life. Manufacturing Industry (1 year) Created detailed AutoCAD diagrams of machines and machine setups. Recorded and analyzed tested data for new machine setups. Designed one off machine modifications to improve production quality. Skilled Mechanic 2 years of training at Newburgh Free Academy High School (Newburgh, NY) 1 year of experience in industry Andrew Cammorata AUV Industry (1 year) Solidworks: Designed AUV parts and systems. Assembled AUV's and troubleshooted design flaws with a design/build team. Tested AUV's in the ocean. Mechanic Self taught and apprentice at Norm's Automotive Service (Hanover, MA) Custom Car Design and Maintenance, specializing in Hot Rods. Aaron Bronshtein Business Development Built Strong Lasting Relationships with suppliers, manufacturers and Distributors. Project Management Organized the team and the project to have it done on time by constant follow up and motivation. Filip Shosho Design Solid Work drawings for cells, brackets, wire brackets and other components relating to batteries and the manufacturing process. Programming Program machines for manufacturing purposes that relates to building cells.

12 Project Timeline