Here an enormous steel ingot, forged solid, heated again and again in a huge furnace and beaten by steam-hammers, or pressed by hydraulic power between each heating till it is brought to the desired size and shape, is having its centre bored through by a special drill which takes out a solid core. This operation is termed “trepanning,” and is applied to guns not exceeding eight inches; those of larger calibre being rough-bored on a lathe, and mandrils placed in them during the subsequent forgings. The tremendous heat generated during the boring processes—we may recall how Benjamin Thompson made water boil by the experimental boring of a cannon—is kept down by streams of soapy water continually pumped through and over the metal. We notice this flow of lubricating fluid in all directions, from oil dropping slowly on to the small brass-milling machines to this fountain-play of water which makes a pleasant undertone amidst the jangle of the machines. But these machines are less noisy than we anticipated; in their actual working they emit scarcely the slightest sound. What strikes us more than the supreme exactness with which each does its portion of the work, is the great deliberateness of its proceeding. All the hurry and bustle is above us, caused by the driving-bands from the engine, which keeps the whole machinery of the shed in motion. Suddenly, with harsh creakings, a great overhead crane comes jarring along the bay, drops a chain, grips up a gun-barrel, and, handling this mass of many tons’ weight as easily as we should lift a walking-stick, swings it off to undergo another process of manufacture.
We pass on to the next lathe where a still larger forging is being turned externally, supported on specially devised running gear, many different cutters acting upon it at the same time, so that it is gradually assuming the tapering, banded appearance familiar to us in the completed state.
We turn, fairly bewildered, from one stage of manufacture to another. Here is a gun whose bore is being “chambered” to the size necessary for containing the firing charge. Further along we examine a more finished weapon in process of preparation to receive the breech-plug and other fittings. Still another we notice which has been “fine-bored” to a beautifully smooth surface but is being improved yet more by “lapping” with lead and emery powder.
In the next shed a marvellous machine is rifling the interior of a barrel with a dexterity absolutely uncanny, for the tool which does the rifling has to be rotated in order to give the proper “twist” at the same moment as it is advancing lengthwise down the bore. The grooves are not made simultaneously but as a rule one at a time, the distance between them being kept by measurements on a prepared disc.
Now we have reached the apparatus for the wire-wound guns, a principle representing the ne plus ultra of strength and durability hitherto evolved. The rough-bored gun is placed upon a lathe which revolves slowly, drawing on to it from a reel mounted at one side a continuous layer of steel ribbon about a quarter of an inch wide. On a 12-inch gun there is wound some 117 miles of this wire! fourteen layers of it at the muzzle end and seventy-five at the breech end. Heavy weights regulate the tension of the wire, which varies for each layer, the outermost being at the lowest tension, which will resist a pressure of over 100 tons to the square inch.
We next enter the division in which the gun cradles and mounts are prepared, where we see some of the heaviest work carried out by electric dynamos, the workman sitting on a raised platform to keep careful watch over his business.
Passing through this with interested but cursory inspection of the cone mountings for quick-firing naval guns, some ingenious elevating and training gear and a field carriage whose hydraulic buffers merit closer examination, we come to the shell department where all kinds of projectiles are manufactured. Shrapnel in its various forms, armour-piercing shells, forged steel or cast-iron, and small brass cartridges for the machine-guns may be found here; and the beautifully delicate workmanship of the fuse arrangements attracts our admiration. But we may not linger; the plant for the machine-guns themselves claim our attention.
Owing to the complexity and minute mechanism of these weapons almost a hundred different machines are needed, some of the milling machines taking a large selection of cutters upon one spindle. Indeed, in many parts of the works one notices the men changing their tools for others of different size or application. Some of the boring machines work two barrels at the same time, others can drill three barrels or polish a couple simultaneously. But there are hundreds of minute operations which need to be done separately, down to the boring of screw holes and cutting the groove on a screw-head. Many labourers are employed upon the lock alone. And every portion is gauged correctly to the most infinitesimal fraction, being turned out by the thousand, that every separate item may be interchangeable among weapons of the same make.
Look at the barrel which came grey and dull from its first turning now as it is dealt with changing into bright silver. Here it is adjusted upon the hydraulic rifling machine which will prepare it to carry the small-arm bullet (.303 inch). That one of larger calibre is rifled to fire a small shell. Further on, the barrels and their jackets are being fitted together and the different parts assembled and screwed up. We have not time to follow the perfect implement to its mounting, nor to do more than glance at those howitzers and the breech mechanism of the 6-inch quick-firers near which our guide indicates piles of flat cases to keep the de Bange obturators from warping while out of use. For the afternoon is waning and the foundry still unvisited.