Bullet forming process

A multi-stage process of forming a bullet of a predetermined caliber, the process comprising:

• providing a multi-stage die assembly, each stage of the assembly comprising:
• a stationary die comprising a die cavity extending from a first end to a second end and defining a cavity diameter, a punch configured to press into the first end of the die, and an eject stem defining a stem diameter, the eject stem configured to extend into the second end of the die;
• in one or more preliminary stages:
• forming a rear component comprising:
• a core, a jacket comprising a cylindrical jacket body portion extending axially forward of the core, a tapering boat tail shape rearward of the jacket body portion, and a rear face defining a base diameter,
• the jacket body portion defining an inner jacket diameter and an outer jacket diameter, the outer jacket diameter being substantially equal to the predetermined caliber of the bullet;
• in a loose-fit stage:
• placing the rear component in the die with the rear face toward the second end of the die, and
• assembling the bullet by inserting a penetrator into the jacket via the punch applying a loose-fit force on the penetrator, the penetrator comprising:
• a base defining a penetrator diameter sized to press-fit relative to the inner jacket diameter, an ogive portion tapering in diameter from the base, and a forward tip;
• in a press-fit stage:
• placing the bullet in the die with the rear face toward the second end of the die,
• seating the penetrator fully against the core by the punch applying a press-fit force to the penetrator, the press-fit force being greater than the loose-fit force,
• radially expanding the jacket in response to the press-fit force, the expanded outer jacket diameter being greater than the predetermined caliber, and
• supporting an annulus of the rear face of the rear component against the die, the die of the press-fit stage comprising a ledge extending radially inwardly to engage the annulus of the rear face;
• and
• in a jacket-forming stage:
• placing the bullet in the die with the rear face toward the second end of the die,
• decreasing the outer jacket diameter via the punch applying a jacket-forming force, and
• pressing a forward portion of the jacket against the ogive portion of the penetrator,
• in one or more finishing stages:
• placing the bullet in the die with the rear face toward the second end of the die, and
• the punch applying force to one or more of:
• the forward tip of the penetrator, the ogive portion of the penetrator, and the forward portion of the jacket,
• wherein, in the press-fit stage, the stem diameter is less than the stem diameter in at least one of the loose-fit stage and the jacket-forming stage.