CN110137655B - Manufacturing process method for special-shaped double-ridge sealing coaxial waveguide conversion - Google Patents
Manufacturing process method for special-shaped double-ridge sealing coaxial waveguide conversion Download PDFInfo
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- CN110137655B CN110137655B CN201910494154.3A CN201910494154A CN110137655B CN 110137655 B CN110137655 B CN 110137655B CN 201910494154 A CN201910494154 A CN 201910494154A CN 110137655 B CN110137655 B CN 110137655B
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- 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
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Abstract
The invention relates to the technical field of coaxial waveguides, and discloses a manufacturing process method for special-shaped double-ridge sealed coaxial waveguide conversion. The method comprises the following steps: reconstructing and splitting a process structure of coaxial waveguide conversion into a ridge cavity and a ridge cover; arranging a fusion welding kerf at the seam; the fixing structure is designed on the ridge cavity surface, and the lead-in surface is designed on the ridge cover; cutting and processing the coaxial waveguide to convert the inner shape and polishing; cleaning and drying the ridge cover and the ridge cavity; positioning, combining and assembling the welding turning tool and the coaxial waveguide conversion, and realizing the symmetrical welding of all welding seams of the coaxial waveguide conversion through the turning tool; removing welding residual stress by adopting thermal aging; the coaxial waveguide transition is chemically surface treated. The method realizes the technical requirements of the special-shaped double-ridge coaxial waveguide conversion such as tightness, dimensional accuracy, surface roughness and the like, and has the advantages of high and stable product quality consistency and obvious production efficiency and manufacturing cost advantages.
Description
Technical Field
The invention relates to the technical field of coaxial waveguides, in particular to a manufacturing process method for special-shaped double-ridge sealed coaxial waveguide conversion.
Background
The double-ridged surface of the coaxial waveguide conversion is special-shaped and is an exponential curved surface, and the traditional technological method is to divide the coaxial waveguide conversion into two parts, respectively cut and process the two parts, and then use a fastener to combine and screw the two parts together. In order to meet the sealing performance, the joint of the sealing rubber is filled and sealed by using the rubber, the sealing rubber can be influenced by external severe environments such as ultraviolet rays, high heat, extreme cold and the like for a long time, the rubber can be aged and adhered to a surface to form a layer, the outdoor sealing is caused to lose effectiveness, and the normal reliability and the service life cycle of equipment are influenced. In the traditional process method, the coaxial waveguide is selectively transformed to be integrally and precisely cast and formed, but the ridge surface is irregular, the ridge distance size is too small, the integral casting and forming precision is difficult to realize, the product quality consistency is poor, the qualification rate is only less than 50%, the production period is longer, and the cost is higher.
Disclosure of Invention
The technical problem to be solved by the invention is as follows: the special-shaped double-ridge coaxial waveguide is produced by the traditional process, the size precision and the surface finish degree can not meet the design electrical performance requirement, and the sealing use requirement of the product in outdoor severe environment for a long time and the requirements of users on high efficiency, low price, high quality and stable quality can not be met. The invention provides a manufacturing process method for special-shaped double-ridge sealed coaxial waveguide conversion, which can realize high-efficiency and low-cost production of the double-ridge special-shaped coaxial waveguide conversion with a large number of sealing requirements and greatly improve the product yield.
The technical scheme adopted by the invention is as follows: the manufacturing process method of the special-shaped double-ridge sealed coaxial waveguide conversion comprises the following steps:
step 1, reconstructing a process structure of coaxial waveguide conversion and splitting the coaxial waveguide conversion into a ridge cavity and a ridge cover;
step 2, opening a fusion welding kerf at the seam;
step 3, designing the fixing structure on the ridge cavity surface, and designing the lead-in surface on the ridge cover;
step 4, cutting and processing the inner and outer shapes of the coaxial waveguide conversion, and polishing;
step 5, cleaning and drying the ridge cover and the ridge cavity;
step 6, positioning, combining and assembling the welding turnover tool and the coaxial waveguide conversion, and realizing the symmetrical welding of all welding seams of the coaxial waveguide conversion through the turnover tool;
step 7, removing welding residual stress by adopting thermal aging;
and 8, carrying out chemical surface treatment on the coaxial waveguide conversion.
Further, the step 1 includes the following processes: step 11, converting and splitting the coaxial waveguide into a ridge cavity and a ridge cover at a middle position of a distance between two ridges; step 12, reconstructing the ridge cover and the ridge cavity into a stepped structure; step 13, reconstructing the small end of the ridge cavity into a flange structure; and step 14, arranging a positioning structure on the matching surface of the ridge cover and the ridge cavity.
Furthermore, in the step 2, two sides of the joint are respectively inverted to form 45-degree cross sections, and the depth is one half of the thickness of the ridge cover.
Further, in step 3, the fixing structure adopts a positioning pin structure.
Further, the step 4 includes the following processes: step 41, processing the ridge cavity and the ridge cover inner shape in sequence; step 42, combining the ridge cover and the ridge cavity to process the shape and the small end inner shape; step 43, marking a pairing mark; step 44, disassembling the ridge cover and the ridge cavity, and lightly polishing the ridge curved surface by using abrasive cloth to process lines; and step 45, removing burrs and blunting edges.
Further, the step 6 includes the following processes:
step 61, converting the center of the small end from the coaxial waveguide to be used as an initial position, assembling, welding and overturning the tool in a combined mode, carrying out spot welding on peripheral welding seams at symmetrical intervals, and sealing and welding the straight section of the small end; step 62, extending from the small end to the side face of the large end, rotating the welding turnover tool for 90 degrees, and sealing and welding the side face; and 63, rotating the welding turnover tool, and converting all welding seams by the coaxial waveguide to alternately realize symmetrical and continuous welding of the side surface.
Further, in the step 7, the welding residual stress is removed in the box-type resistance furnace, and the welding turnover tool is disassembled after cooling.
Compared with the prior art, the beneficial effects of adopting the technical scheme are as follows: the technical requirements of the special-shaped double-ridge coaxial waveguide conversion such as sealing performance, dimensional accuracy, surface roughness and the like are met by carrying out process structure reconstruction, high-accuracy processing, high-accuracy assembling and high-energy beam welding on the special-shaped double-ridge coaxial waveguide conversion, the product quality consistency is high and stable, the advantages of production efficiency and manufacturing cost are obvious, the manufacturing cost is only 60% of that of the traditional process method, and the requirement of design parameter indexes can be met by 100% without debugging the electrical performance of the double-ridge special-shaped coaxial waveguide conversion.
Drawings
FIG. 1 is a schematic flow chart of a manufacturing process for special-shaped double-ridge sealing coaxial waveguide conversion.
Detailed Description
The invention is further described below with reference to the accompanying drawings.
The double-ridge coaxial waveguide conversion is a converter of double-ridge waveguide and coaxial radio frequency cable microwave signals. The special-shaped double-ridge sealed coaxial waveguide conversion appearance is formed by encircling four metal sheets into a horn shape, and the thickness of the metal sheets is 1 mm; the horn inner cavity comprises symmetrical double ridges, the double ridges at the small end section of the inner cavity are Z-shaped, the double ridges at the large end section are smooth exponential curves, the ridge widths are different in size, and the widths gradually extend from the small end to the large end of the horn inner cavity and are widened. The minimum dimension of ridge distance is less than 0.2mm, and the tolerance requirement is +/-0.05 mm. When the product is used outdoors, the product is required to resist vibration and have sealing performance. The embodiment provides a process method with high reliability and low manufacturing cost for the coaxial waveguide conversion product, and successfully realizes the manufacturing of the special-shaped double-ridge coaxial waveguide conversion product with high reliability, sealing resistance and high dimensional precision requirements.
Fig. 1 shows a manufacturing process method of the special-shaped double-ridge sealed coaxial waveguide conversion according to the embodiment.
1. Reconstructing and splitting a process structure of coaxial waveguide conversion into a ridge cavity and a ridge cover;
(a) the coaxial waveguide is converted and split into a ridge cavity and a ridge cover at a middle position of the distance between the two ridges; (b) the ridge cover and the ridge cavity are reconstructed into a stepped structure; (c) reconstructing the small end of the ridge cavity into a flange structure; (d) the matching surface of the ridge cover and the ridge cavity is provided with a positioning structure.
2. Arranging a fusion welding kerf at the seam; the two sides of the joint are respectively inverted with 45-degree sections, and the depth is one half of the thickness of the ridge cover.
3. High accuracy location frock structural design: the fixing structure is designed on the ridge cavity surface, and the lead-in surface is designed on the ridge cover; wherein the fixing structure adopts a positioning pin structure.
4. High-speed cutting processing of the coaxial waveguide to convert the inner shape and polishing;
(a) sequentially processing the inner shapes of the ridge cavity and the ridge cover; (b) combining the ridge cover and the ridge cavity to process the shape and the small end inner shape; (c) marking a pairing mark; (d) detaching the ridge cover and the ridge cavity, and lightly polishing ridge curved surface processing lines by using 280-300 sand cloth with the roughness of Ra1.6; (e) removing burrs and blunting edges.
5. Cleaning and drying the ridge cover and the ridge cavity;
(a) and cleaning the ridge cover and the ridge cavity in a weak base solution at the temperature of 60 ℃. (b) And cleaning the ridge cover and the residual stains on the surface of the ridge cavity in clean water at the temperature of 60 ℃. (c) And putting the ridge cover and the ridge cavity into a clean drying furnace for drying.
6. Carrying out high-precision positioning combination assembly on the welding turning tool and the coaxial waveguide conversion, and realizing symmetrical welding of all welding seams of the coaxial waveguide conversion through the turning tool;
step 61, converting the center of the small end from the coaxial waveguide to be used as an initial position, assembling, welding and overturning the tool in a combined mode, carrying out spot welding on peripheral welding seams at symmetrical intervals, and sealing and welding the straight section of the small end; step 62, extending from the small end to the side face of the large end, rotating the welding turnover tool for 90 degrees, and sealing and welding the side face; and 63, rotating the welding turnover tool, converting each welding line by the coaxial waveguide to alternately realize symmetrical and continuous welding of the side surface, and controlling welding deformation in the process.
7. Removing welding residual stress by adopting thermal aging;
the welding residual stress can be removed in the box type resistance furnace, the temperature difference in the furnace is guaranteed to be +/-5 ℃, and the welding turnover tool is disassembled after cooling.
8. The coaxial waveguide transition is chemically surface treated.
In the embodiment, when the three-axis numerical control machining center is adopted, the rotating speed is not lower than 8000r/min, Ra1.6 is ensured, the precision is controlled to be +/-0.01 mm, a progressive cutting mode is selected, and the polishing amount of the ridge curved surface is 0.02 mm.
In the above embodiment, the positioning accuracy was designed to be 0.02 mm.
In the above embodiment, a phi 2 stainless steel positioning pin is used for static pressure assembly.
In the embodiment, the positioning tool is designed and processed to assemble and fix the workpiece, the joint is welded by high energy beams under the conditions of single-point power of 4KW and light emitting frequency of 8Hz and by using an AL4043 welding wire with the diameter of phi 0.8mm, the welding speed is 9mm/s, the fusion width is 1mm, and the fusion depth is not less than 0.5 mm.
On the basis of the embodiment, a simple airtight tool is designed, a workpiece is sealed, positive pressure air inflation is carried out for 0.02Mpa, and the water immersion tightness test is successfully realized.
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 (3)
1. The manufacturing process method for the special-shaped double-ridge sealed coaxial waveguide conversion is characterized by comprising the following steps of:
step 1, reconstructing a process structure of coaxial waveguide conversion and splitting the coaxial waveguide conversion into a ridge cavity and a ridge cover;
step 11, converting and splitting the coaxial waveguide into a ridge cavity and a ridge cover at a middle position of a distance between two ridges;
step 12, reconstructing the ridge cover and the ridge cavity into a stepped structure;
step 13, reconstructing the small end of the ridge cavity into a flange structure;
step 14, arranging a positioning structure on the matching surface of the ridge cover and the ridge cavity;
step 2, opening a fusion welding kerf at the seam; two sides of the joint are respectively inverted to 45-degree openings, and the depth is one half of the thickness of the ridge cover;
step 3, designing the fixing structure on the ridge cavity surface, and designing the lead-in surface on the ridge cover;
step 4, cutting and processing the inner and outer shapes of the coaxial waveguide conversion, and polishing;
step 41, processing the ridge cavity and the ridge cover inner shape in sequence; step 42, combining the ridge cover and the ridge cavity to process the shape and the small end inner shape; step 43, marking a pairing mark; step 44, disassembling the ridge cover and the ridge cavity, and lightly polishing the ridge curved surface by using abrasive cloth to process lines; step 45, removing burrs and blunting edges;
step 5, cleaning and drying the ridge cover and the ridge cavity;
(a) cleaning the ridge cover and the ridge cavity in weak base solution at the temperature of 60 ℃;
(b) cleaning the ridge cover and the residual stains on the surface of the ridge cavity in clear water at the temperature of 60 ℃;
(c) putting the ridge cover and the ridge cavity into a clean drying furnace for drying;
step 6, positioning, combining and assembling the welding turnover tool and the coaxial waveguide conversion, and realizing the symmetrical welding of all welding seams of the coaxial waveguide conversion through the turnover tool;
step 61, converting the center of the small end from the coaxial waveguide to be used as an initial position, assembling, welding and overturning the tool in a combined mode, carrying out spot welding on peripheral welding seams at symmetrical intervals, and sealing and welding the straight section of the small end; step 62, extending from the small end to the side face of the large end, rotating the welding turnover tool for 90 degrees, and sealing and welding the side face; step 63, rotating the welding turnover tool, and converting each welding seam by using the coaxial waveguide to alternately realize symmetrical and continuous welding of the side surface;
step 7, removing welding residual stress by adopting thermal aging;
and 8, carrying out chemical surface treatment on the coaxial waveguide conversion.
2. The manufacturing process method for the special-shaped double-ridge sealed coaxial waveguide conversion of claim 1, wherein in the step 3, the fixing structure adopts a positioning pin structure.
3. The manufacturing process method for special-shaped double-ridge sealed coaxial waveguide conversion according to claim 1, wherein in the step 7, welding residual stress is removed in a box-type resistance furnace, and a welding turnover tool is disassembled after cooling.
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| CN101281989A (en) * | 2008-04-30 | 2008-10-08 | 华东师范大学 | Co-plane waveguide based on SOI substrate and manufacturing method thereof |
| JP5390315B2 (en) * | 2009-09-11 | 2014-01-15 | 国立大学法人北海道大学 | Metal carrier manufacturing apparatus and metal carrier manufacturing method |
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