How we do it...
case inspection
When we start a batch of 5.56mm cases, the first thing we do is run them through the tumblers to remove any dirt and sand. Then they are run through a Scharch inspection machine where they are deprimed, checked for cracks and splits, and inspected for berdan and broken primers.
size and trim
They are then run through a "taper and plug." This is an arsenal piece of equipment used to form the body taper, neck, and shoulder on new GI cases. We use carbide dies made specifically for these machines, so our cases are the same size as when they were originally manufactured. These cases are sized, then neck expanded, and trimmed to 1.755" length, with .002" tolerance, at 100 pieces per minute.
primer pocket swaging
The sized and trimmed cases are now ready for primer pocket swaging. This removes the crimped edge left on military cases after depriming. We swage the cases rather than ream, because a swage gives us a smooth radius on the primer pocket entrance, and we have control of these dimensions with a swaging tool over a reamer. This machine loads the cases onto the support stem, lubricates the pocket, inspects the pocket, then runs a punch into the pocket forming the entrance radius. All at 100 pieces per minute!
Priming
The cases to be primed are run through this priming machine. Once again, we use arsenal equipment to closely duplicate the quality of GI cases. This machine feeds the cases onto the work rail open end down. As they go across they are checked for length, primer pockets are probed for foreign material, and flash holes are checked for blockage. The primers are inserted into the pocket, and then checked to insure the primer went in properly. If the case and primer failed any of the earlier inspections it is ejected from the work rail. If it passed all checks, then it proceeds to the next station where the primers are seated to the proper depth and lightly crimped. It is then lacquer sealed, counted, and put out on a drying rack for 40 seconds to dry. All this happens at 106 pieces per minute!
And that's how we do it.
As for "how we get it done," well, that sometimes remains a mystery...
My crew...