Weapon barrel manufacturing ranks among the most demanding challenges in long-part machining. Extreme length-to-diameter ratios, tight concentricity tolerances, hard-to-machine materials, and the unique internal geometry with rifling and lands present unique challenges at every process step. This article describes the complete process chain from the sawn raw-part to the barrel ready for installation. Comparing a hammered tube to one machined with ECM highlights the machining and process requirements needed for reliable production. This example doesn’t cover other rifling methods, like button rifling or cut rifling.
