CN110112529B - Integrated integral manufacturing method for multi-port millimeter wave bent rectangular waveguide array body - Google Patents
Integrated integral manufacturing method for multi-port millimeter wave bent rectangular waveguide array body Download PDFInfo
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- CN110112529B CN110112529B CN201910490695.9A CN201910490695A CN110112529B CN 110112529 B CN110112529 B CN 110112529B CN 201910490695 A CN201910490695 A CN 201910490695A CN 110112529 B CN110112529 B CN 110112529B
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01P—WAVEGUIDES; RESONATORS, LINES, OR OTHER DEVICES OF THE WAVEGUIDE TYPE
- H01P11/00—Apparatus or processes specially adapted for manufacturing waveguides or resonators, lines, or other devices of the waveguide type
- H01P11/001—Manufacturing waveguides or transmission lines of the waveguide type
- H01P11/002—Manufacturing hollow waveguides
Abstract
The invention relates to the field of millimeter wave bent rectangular waveguides, and discloses an integrated integral manufacturing method of a multi-port millimeter wave bent rectangular waveguide array body. The method comprises the following steps: manufacturing an outline mold of the waveguide array body and a water-soluble core forming mold of a waveguide inner cavity; preparing a water-soluble core of the inner cavity of the waveguide; the water-soluble core and the outline mold are integrated into a pressed piece; a water-soluble core of the dissolved waveguide inner cavity; assembling a module; preparing a refractory mixture; manufacturing a casting shell by vacuum vibration grouting; roasting in a casting mold; smelting molten metal, and maintaining pressure, crystallizing and solidifying; carrying out sand removal, shaping and heat treatment; performing liquid polishing treatment on the waveguide inner cavity; and removing the flange mounting end face processing of the waveguide array body, and carrying out chemical treatment on the inner surface and the outer surface of the waveguide array body. The product which has smooth surface and accurate size and meets the assembly precision requirement and the waveguide transmission performance is prepared by the method, and the qualification rate reaches 80 percent.
Description
Technical Field
The invention relates to the field of millimeter wave bent rectangular waveguides, in particular to an integrated integral manufacturing method of a multi-port millimeter wave bent rectangular waveguide array body.
Background
The millimeter wave rectangular waveguide requires closed transmission due to high microwave frequency transmission, has high requirements on manufacturing precision and inner cavity roughness, and has strict requirements on position precision of a plurality of external waveguide ports in an array. The traditional process method of the single millimeter wave rectangular bending waveguide generally adopts a tool mold to bend and form a waveguide section, and an end face flange is formed into a whole by manual brazing, so that the process method is not applicable to a multi-waveguide array integrated structure. If the method of integrally splitting, machining and screwing by using the fastening piece is adopted, the sealing cannot be realized, the risk of energy overflow exists, and the sealing requirement cannot be met during outdoor use. If the method of integrally splitting, machining and welding into a whole is adopted, the welding flux can enter the waveguide inner cavity to influence transmission, the thin wall of the part is easy to weld and deform, the dimensional precision cannot meet the use requirement, and the qualification rate is less than 20%. The multi-port millimeter wave rectangular bent waveguide array body is produced by the traditional process, and cannot meet the requirements on the size precision, the roughness and the closure of an inner cavity and the requirement on the designed electrical performance.
Disclosure of Invention
The technical problem to be solved by the invention is as follows: aiming at the existing problems, the integrated integral manufacturing method of the multi-port millimeter wave bent rectangular waveguide array body is provided, and the integrated integral manufacturing of the millimeter wave bent rectangular waveguide array body product with a plurality of ports is successfully realized.
The technical scheme adopted by the invention is as follows: the integral manufacture method of the multiport millimeter wave bent rectangular waveguide array body comprises the following steps:
step S1, manufacturing an outline mold of the multi-port millimeter wave rectangular bent waveguide array body and a water-soluble core forming mold of the waveguide inner cavity;
step S2, preparing a water-soluble core of the waveguide inner cavity;
step S3, assembling the water-soluble core in the cavity of the outline mold, closing the mold and locking the outline mold;
step S4, pressing the millimeter wave rectangular bending waveguide array body by using an outline mold to obtain a millimeter wave rectangular bending waveguide array body pressing part;
step S5, the mould pressing piece is put into clean water to dissolve the water-soluble core of the waveguide inner cavity;
step S6, arranging runners in the pouring system at two ends of the flange, and completing module assembly by adopting a bottom pouring type pouring mode;
step S7, preparing a refractory mixture;
step S8, completing vacuum vibration grouting to manufacture a casting shell in vacuum vibration stirring grouting equipment;
step S9, drying, hardening, baking and roasting the casting shell, wherein the baking temperature is carried out in a step heating and heat preservation mode;
step S10, smelting molten metal, injecting the molten metal into the casting shell under the vacuum condition, and maintaining pressure, crystallizing and solidifying;
and step S11, opening the casting shell, carrying out sand removal and shaping on the multi-port millimeter wave rectangular bent waveguide array blank, and then carrying out heat treatment.
Step S12, performing liquid polishing treatment on the waveguide inner cavity;
and step S13, removing redundant metal on the flange mounting end surface of the waveguide array body, and chemically treating the inner surface and the outer surface of the waveguide array body.
Further, carrying out mold splitting by using Pro/E aiming at the three-dimensional part of the waveguide array body, determining the total shrinkage rate, and creating a waveguide cavity; the die cavity is divided into the following parts: (1) the waveguide cavity of the main mould forming the outline structure is divided into two parts, (2) the core mould cavity forming the waveguide cavity structure is divided into two parts; generating a model entity by using an Extract function in the Mold Comp; correspondingly generating a simulation piece, and analyzing and detecting whether the design of the die is correct; and transmitting the model data to a numerical control machining center for forming to obtain an outline mold and a water-soluble core forming mold.
Further, in step S1, a positioning groove is designed in the inner cavity of the metal mold in the shape of the millimeter wave rectangular curved waveguide array body, and is used for positioning the soluble core in the inner cavity of each waveguide during the preparation of the mold pressing piece.
Further, in step S2, when the water-soluble core of the waveguide cavity is prepared, a stainless steel sleeve is inserted into both ends of the water-soluble core for positioning.
Further, in the step S4, a mold material is prepared and stirred for mixing and melting, the millimeter wave rectangular curved waveguide array mold pressing member is prepared by using an outline metal mold under the conditions of a mold temperature of 30 ℃, an injection temperature of 65 ℃ and an injection pressure of 5-6 MPa, and the mold pressing member is taken out after pressure maintaining of 4-5 MPa for 10S.
Further, the leaching process in step S5 is as follows: the water temperature is kept at a set temperature, then the solution loss soaking is carried out, and finally the cleaning is carried out repeatedly.
Further, in the step S7, 30% of alpha hemihydrate gypsum and 70% of a refractory filler are mixed, and the mesh number of the mixed refractory material is 200-280 meshes.
Further, in the step S8, the vacuum degree is 6x10-2Grouting under MPa, controlling the rotating speed of a motor at 700r/min, controlling the stirring time within 1-3 minutes, and controlling the vibration frequency at 200 times/min.
Further, in step S11, a frequency harmonic vibration device is used during sand cleaning, the maximum exciting force is 25KN, and the rated rotation speed is 8000 rpm.
Further, in step S12, liquid polishing is performed by using 140 mesh mold fluid.
Compared with the prior art, the beneficial effects of adopting the technical scheme are as follows: by designing and manufacturing a multi-port millimeter wave rectangular bent waveguide array external forming die and a waveguide cavity core die, preparing a high-precision water-soluble core through a die, positioning, assembling and integrally pressing, combining a material precision forming manufacturing process method and waveguide inner cavity liquid polishing post-treatment, the roughness of a waveguide inner cavity integrally formed by the multi-port millimeter wave rectangular bent waveguide array integrally reaches Ra1.6-Ra3.2, the size of the waveguide inner cavity reaches the tolerance of +/-0.03 mm, the tolerance of the adjacent size of a waveguide opening reaches +/-0.05 mm, the assembly precision requirement and the waveguide transmission performance are well met, and the qualification rate reaches 80%.
Drawings
FIG. 1 is a simplified flow diagram of an integrated integral manufacturing process of a multi-port millimeter wave rectangular curved waveguide array body.
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings, but the embodiments of the present invention are not limited thereto.
As shown in fig. 1, the method for integrally manufacturing the multi-port millimeter wave bent rectangular waveguide array body comprises the following steps:
(1) manufacturing an outline mold of a multi-port millimeter wave rectangular bent waveguide array body and a water-soluble core forming mold of a waveguide inner cavity;
performing mold splitting by using Pro/E aiming at the three-dimensional part of the waveguide array body, determining the total shrinkage rate, and creating a waveguide cavity; the die cavity is divided into the following parts: (1) the waveguide cavity of the main mould forming the outline structure is divided into two parts, (2) the core mould cavity forming the waveguide cavity structure is divided into two parts; generating a model entity by using an Extract function in the Mold Comp; after the Mold design is finished, simulating the Mold manufacturing process by using the Create function in the Mold, correspondingly generating a simulation piece, and analyzing and detecting whether the Mold design is correct or not; and transmitting the model data designed in the process to a numerical control machining center for forming and processing to obtain an outline mold and a water-soluble core forming mold.
In addition, in order to position the soluble cores in the inner cavities of the waveguides during preparation of the die-pressed part, positioning grooves are designed in the inner cavity of the metal die in the shape of the millimeter wave rectangular curved waveguide array body.
(2) Preparing a water-soluble core of the inner cavity of the waveguide;
(a) uniformly mixing water-soluble raw materials and a plasticizer according to the proportion of 5:1, and putting the mixture into a stainless steel container; (b) heating, gradually heating to 120 deg.C, and stirring while melting to obtain molten liquid; (c) cleaning the surface of a core mold, ensuring no dirt, and positioning and combining the core mold; (d) preheating to 30 ℃, and injecting 120 ℃ molten liquid into the core die cavity; (e) cooling to 30 ℃, opening the core cavity die, exerting appropriate force, taking out the water-soluble core, and carrying out micro-modification treatment on the surface.
In order to accurately position the position of the water-soluble core, when the water-soluble core of the inner cavity of the waveguide is prepared, a stainless steel sleeve is embedded into two ends of the water-soluble core for positioning.
(3) Assembling the water-soluble mold core in a cavity of the outline mold through positioning devices at two ends of the water-soluble mold core, closing the mold and locking the outline mold;
(4) preparing a mold material, stirring and melting, pressing by using an outline mold under the conditions that the mold temperature is 30 ℃, the material injection temperature is 65 ℃ and the injection pressure is 5-6 MPa to obtain a millimeter wave rectangular bending waveguide array mold pressing part, maintaining the pressure at 4-5 MPa for 10 seconds, and taking out the mold pressing part;
(5) placing the molded piece into clean water to dissolve the water-soluble core in the inner cavity of the waveguide;
when dissolving, the water temperature is kept at 25 + -3 deg.C, then the solution is soaked for 2 hours, and finally the washing is repeated for several times (3 times).
(6) The inner runner of the pouring system is arranged at two ends of the flange, and the module assembly is completed by adopting a bottom pouring type pouring mode;
(7) preparing a refractory mixture;
the refractory mixture is mixed according to the weight ratio of 3:7, namely 30% of alpha semi-hydrated gypsum and 70% of refractory filling material are proportioned, and the mesh number of the proportioned refractory mixture is 200-280 meshes.
(8) Completing vacuum vibration grouting to manufacture a casting shell in vacuum vibration stirring grouting equipment;
at vacuum level 6X10-2Grouting under MPa, controlling the rotating speed of a motor at 700r/min, controlling the stirring time within 1-3 minutes, and controlling the vibration frequency at 200 times/min.
(9) Drying, hardening, baking and roasting the cast shell in a box-type resistance furnace, wherein the baking temperature is carried out in a step heating and heat preservation mode;
(10) smelting molten metal, injecting the molten metal into a casting shell under a vacuum condition, and carrying out pressure maintaining, crystallization and solidification;
(11) opening the casting shell, carrying out sand removal and shaping on the multi-port millimeter wave rectangular bent waveguide array blank, and then carrying out heat treatment;
during sand cleaning, frequency harmonic vibration equipment is adopted, the maximum exciting force is 25KN, and the rated rotating speed is 8000 rpm.
(12) Liquid polishing treatment is carried out on the waveguide inner cavity, and 140-mesh mold material fluid can be adopted for liquid polishing;
(13) and removing redundant metal on the flange mounting end surface of the waveguide array body, and chemically treating the inner surface and the outer surface of the waveguide array body.
The invention is not limited to the foregoing embodiments. The invention extends to any novel feature or any novel combination of features disclosed in this specification and any novel method or process steps or any novel combination of features disclosed. Those skilled in the art to which the invention pertains will appreciate that insubstantial changes or modifications can be made without departing from the spirit of the invention as defined by the appended claims.
Claims (2)
1. The integral manufacturing method of the multi-port millimeter wave bent rectangular waveguide array body is characterized by comprising the following steps of:
step S1, manufacturing an outline mold of the multi-port millimeter wave rectangular bent waveguide array body and a water-soluble core forming mold of the waveguide inner cavity; performing mold splitting by using Pro/E aiming at the three-dimensional part of the waveguide array body, determining the total shrinkage rate, and creating a waveguide cavity; the die cavity is divided into the following parts: (1) the waveguide cavity of the main mould forming the outline structure is divided into two parts, (2) the core mould cavity forming the waveguide cavity structure is divided into two parts; generating a model entity by using an Extract function in the Mold Comp; correspondingly generating a simulation piece, and analyzing and detecting whether the design of the die is correct; transmitting the model data to a numerical control machining center for forming and processing to obtain an outline mold and a water-soluble core forming mold; a positioning groove is designed in the inner cavity of a metal mold in the shape of the millimeter wave rectangular curved waveguide array body and is used for positioning the soluble core in the inner cavity of each waveguide during preparation of a mold pressing piece;
step S2, preparing the water-soluble core of the waveguide inner cavity, which comprises the following steps:
(a) uniformly mixing water-soluble raw materials and a plasticizer according to the proportion of 5:1, and putting the mixture into a stainless steel container; (b) heating, gradually heating to 120 deg.C, and stirring while melting to obtain molten liquid; (c) cleaning the surface of a core mold, ensuring no dirt, and positioning and combining the core mold; (d) preheating to 30 ℃, and injecting 120 ℃ molten liquid into the core die cavity; (e) cooling to 30 ℃, opening the core cavity die, exerting appropriate force, taking out the water-soluble core, and carrying out micro-modification treatment on the surface;
step S3, assembling the water-soluble core in the cavity of the outline mold, closing and locking the outline mold: assembling the water-soluble mold core in a cavity of the outline mold through positioning devices at two ends of the water-soluble mold core, closing the mold and locking the outline mold;
step S4, pressing by using an outline mold to obtain a millimeter wave rectangular bending waveguide array mold pressing part: preparing a mold material, stirring and melting, pressing by using an outline mold under the conditions that the mold temperature is 30 ℃, the material injection temperature is 65 ℃ and the injection pressure is 5-6 MPa to obtain a millimeter wave rectangular bending waveguide array mold pressing part, maintaining the pressure at 4-5 MPa for 10 seconds, and taking out the mold pressing part;
step S5, putting the mould pressing piece into clean water to dissolve the water-soluble core in the waveguide inner cavity, when dissolving, firstly keeping the water temperature at 25 +/-3 ℃ by using the set temperature, then soaking for 2 hours in a dissolving loss way, and finally repeatedly cleaning for 3 times;
step S6, arranging runners in the pouring system at two ends of the flange, and completing module assembly by adopting a bottom pouring type pouring mode;
step S7, preparing a refractory mixture: mixing the refractory mixture according to the weight ratio of 3:7, namely proportioning 30% of alpha hemihydrate gypsum and 70% of refractory filling material, wherein the mesh number of the proportioned refractory mixture is 200-280 meshes;
step S8, completing vacuum vibration grouting to manufacture casting shell in the vacuum vibration stirring grouting equipment: grouting under the vacuum degree of 6x10-2MPa, controlling the rotating speed of a motor at 700r/min, controlling the stirring time within 1-3 minutes, and controlling the vibration frequency at 200 times/min;
step S9, drying, hardening, baking and roasting the cast shell in a box-type resistance furnace, wherein the baking temperature is carried out in a step heating and heat preservation mode;
step S10, smelting molten metal, injecting the molten metal into the casting shell under the vacuum condition, and maintaining pressure, crystallizing and solidifying;
step S11, opening the casting shell, carrying out sand removal and shaping on the multi-port millimeter wave rectangular bent waveguide array blank, and then carrying out heat treatment; during sand cleaning, frequency harmonic vibration equipment is adopted, the maximum exciting force is 25KN, and the rated rotating speed is 8000 rpm;
step S12, performing liquid polishing treatment on the waveguide inner cavity, and performing liquid polishing by using 140-mesh mold material fluid;
and step S13, removing redundant metal on the flange mounting end surface of the waveguide array body, and chemically treating the inner surface and the outer surface of the waveguide array body.
2. The method for integrally manufacturing the multiport millimeter wave bent rectangular waveguide array body according to claim 1, wherein in the step S2, when the water-soluble core of the waveguide cavity is prepared, stainless steel sleeves are embedded into two ends of the water-soluble core for positioning.
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| CN1223913A (en) * | 1999-01-27 | 1999-07-28 | 苏凯蒂 | Mould material for investment casting and mould forming method |
| US6101705A (en) * | 1997-11-18 | 2000-08-15 | Raytheon Company | Methods of fabricating true-time-delay continuous transverse stub array antennas |
| CN106180561A (en) * | 2016-08-03 | 2016-12-07 | 桐城市宇洁机动车尾气检测有限公司 | Cavity construction car exhaust treatment system parts hot investment casting quick molding method and the detection device of foundry goods |
| CN107855467A (en) * | 2017-11-22 | 2018-03-30 | 扬州峰明光电新材料有限公司 | The model casting system and investment casting method of U-shaped magnesium alloy member |
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Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6101705A (en) * | 1997-11-18 | 2000-08-15 | Raytheon Company | Methods of fabricating true-time-delay continuous transverse stub array antennas |
| CN1223913A (en) * | 1999-01-27 | 1999-07-28 | 苏凯蒂 | Mould material for investment casting and mould forming method |
| CN106180561A (en) * | 2016-08-03 | 2016-12-07 | 桐城市宇洁机动车尾气检测有限公司 | Cavity construction car exhaust treatment system parts hot investment casting quick molding method and the detection device of foundry goods |
| CN107855467A (en) * | 2017-11-22 | 2018-03-30 | 扬州峰明光电新材料有限公司 | The model casting system and investment casting method of U-shaped magnesium alloy member |
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