RU1787633C - Process of manufacture of tape helix for delay lines of travelling wave tubes - Google Patents

Abstract

Usage: in slowing lines of traveling wave tubes. SUMMARY OF THE INVENTION: A tape is made of a material with different ductility. In this case, several wires are taken as a material with less ductility, which are interconnected with a material with a higher ductility. The connection of the wires is carried out in a forming die. 5 ill.

Description

FIELD OF THE INVENTION This invention relates to methods for manufacturing tape spirals used as moderating systems in traveling wave lamps.

The traditional method of winding a tape spiral is that a wire is fed onto a rotating core by means of a stacker and fed from a reel to form a spiral. The spiral pitch is defined by the ratio of the core rotation speed and the translational motion of the stacker. In this case, the inner diameter of the spiral is determined by the outer diameter of the core, and the outer diameter of the spiral is equal to the outer diameter of the core plus twice the thickness of the wound flattened. A conditioner of the required geometric dimensions is obtained by flattening a round wire. After winding, the spiral is taut, if necessary, grinding of the outer surface is carried out to obtain the size of the required accuracy, and it is subjected to heat treatment in order to relieve internal stresses. Last remove operation

spirals from the core either corrode the core or twist the spiral from the core.

The dimensions of the finished spiral should satisfy the requirements for pitch, inner and outer diameters, and the cylindricality of the outer surface should ensure good thermal contact with the squeezing racks in the future.

A disadvantage of the existing technological process is that due to the elastic-plastic deformation, the cross section of the flattening is distorted, while the outer layers of the flattening are stretched in the longitudinal direction and compressed in the transverse, while the inner ones are compressed in the longitudinal and increase in the transverse. In addition, it is known that during the winding of the spiral, the angle of rotation of the conditioner relative to the axis of the core should be equal to the angle of elevation of the spiral. Deviation of the angle of rotation of the flattened from optimal when winding the spiral leads to a parallelism obel

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developing coil with respect to the core axis. This effect increases with increasing winding pitch and elastic modulus of the spiral material. As a result, the outer diameter of the spiral increases and the contact in the spiral-bead system deteriorates sharply, which subsequently leads to a sharp increase in the thermal load on the spiral. This disadvantage can be avoided in some cases by increasing the tension of the tape during winding, however, the internal stresses in this case increase, which affects the temperature of the subsequent annealing. In addition, the amount of tension is limited by the stiffness of the core for twisting, and with a decrease in core diameter the allowable value sharply decreases.

A known method of manufacturing a tape spiral from a wire, in which the formation of a tape spiral is carried out by flattening the wire into a tape with the energy of ultrasonic vibrations while winding it onto a rotating core. Flattening is carried out in two stages, with the first stage creating a static pressure of the tool and deforming the tape with a compression ratio of 40-80% with a urilium tension of 10-60N, in the second stage the static pressure of the tool is removed and calibration is carried out the cross section of the coils of the spiral with a compression ratio of 1-5% with a tension force of 5-40N.

A device that implements this method of manufacturing a tape spiral from a wire comprises a striking tool fixed in an ultrasonic vibrations concentrator and driven by a magnetostrictive transducer into oscillatory motion. The wire, wound on a rotating core, passes in the deformation zone under the hammer, where it is formed into a conditioner with the required dimensions,

From a comparison of the accuracy characteristics of the spirals obtained by the traditional method and with the application of ultrasonic vibrations, it was found that in the manufacture of spirals with ultrasound, step accuracy is comparable to the accuracy of winding in the traditional method.

The accuracy with respect to the outer diameter of the coils obtained by superposition of ultrasonic vibrations is less than t5 MKM, which is much better than with the traditional method of winding.

Ultrasonic flattening of the spiral can significantly reduce the amount of parallelism of the forming coil relative to the core axis in comparison with traditional technology and achieve

legans of the spiral coil to the core practically over the entire plane.

However, this method contains a number of significant disadvantages.

As a result of the action of the striker on the spiral material, core deformation occurs on which the spiral is wound. In this case, the deepening of the coils of the spiral into the core, depending on the degree of reduction, can be 20-30 microns for a tungsten spiral on a molybdenum core, and the inner diameter of the spiral is reduced by an appropriate value, which levels out the achieved accuracy in the outer diameter.

To eliminate this drawback, it is necessary to use a core with a higher hardness than a spiral material such as ceramic. This does produce a result, however, as the required core diameter decreases, its strength becomes less and less, and with a diameter of less than one millimeter, its strength becomes insufficient. Thus, for the manufacture of spirals with a diameter of less than one millimeter, this method is unacceptable,

The aim of the invention is to reduce residual stresses and ensure the accuracy of the specified geometric dimensions, that is, the development of a fundamentally different method that eliminates the above disadvantages and conventional equipment, using cores with a diameter of 0.3 mm, to obtain tape spirals with a plane forming a coil strictly parallel to the core plane and geometrical dimensions no worse than that of similar spirals wound from round wire.

This goal is achieved by the fact that in the method of manufacturing tape spirals of deceleration lines, comprising the steps of manufacturing the tape and winding the tape onto a rotating core, the tape is made of materials having different ductility, while the material with less ductility (for example, tungsten, molybdenum, etc.) in the form of two or more wires of circular cross-section, parallel and in a certain configuration relative to each other, are interconnected by a material with greater ductility and less ohmic resistance (for example, gold, silver, copper) by passing round cross-section wires through a forming spinneret immersed in the molten material with greater ductility.

In FIG. 1 shows a diagram of an apparatus for producing a tape of two or more wires;

in FIG. 2 shows the shape of a die for producing a tape spiral of two wires; in FIG. 3 is a longitudinal section of a tape spiral obtained in accordance with the proposed method; in FIG. 4 is a transverse section of a tape of a different configuration, obtained from three wires; in FIG. 5 shows the shape of a die for producing a ribbon blank of a different configuration of three wires.

A device for producing a tape of two or more conductors consists of coils 1 (two in the drawing, according to the number of conductors) for wires 2, guide rollers 3, 4, crucible 5 with molten metal of high ductility, die 6, receiving coil 7.

Example. Tungsten wires with a diameter of 0.1 mm from two coils 1 were simultaneously fed through guide rollers 3, 4 into a crucible 5, in which there was a melt of material with high ductility (gold). In a crucible with molten gold, the wires pass through a forming die 6 located in the lower part (see Figs. 1, 2). A ribbon was obtained at the output, the width of which is equal to twice the diameter of the initial wire 0.2 mm, and the height of the diameter of the initial wire 0.1 mm. The cross-sectional shape of the obtained ribbon is shown in FIG. 3. On it, the letter W (tungsten) denotes the material of round wires, and the letter Au (gold) denotes the material that fills the space between the round wires and fastens them into a single tape. The resulting tape was fed to the receiving coil 7, and from it to the I 4.017.0029M machine (not shown in the drawing), on which a spiral was wound on a core with a diameter of 0.5 mm. Since the stiffness of the tape in the cross section was significantly less than that of the tape made of a homogeneous material (flattening), the force required so that the forming coil of the spiral was strictly parallel to the plane of the core was reduced and twisting of the core did not occur during winding of the spiral. The cross-sectional shape of the coil (Fig. 3) corresponded to that obtained by ultrasonic treatment. The distortion of the cross-sectional shape was significantly less than when winding a ribbon from flattened.

As a result, a spiral was obtained with an accuracy of geometric dimensions no worse than when winding a spiral from a round wire, and due to the coating material (gold), with a lower ohmic resistance, which favorably affects the LEO parameters.

The application of the proposed method is not limited to manufacturing only

flat ribbon spirals. Using a different configuration of dies, it is possible to obtain a tape with a different cross-sectional profile, for example, with a profile (Fig. 4), which significantly reduces the dielectric loss in the TWT deceleration line. Three coils of tungsten wire with a diameter of 60 microns were used to produce a tape of this profile. Similar to the above example, they were passed

through the die (Fig. 5). As a result, a wire was obtained (Fig. 4), from which a spiral was wound. The dielectric loss of the deceleration line with such a spiral was less than with a spiral of a rectangular

or round section;

Using the proposed method will reduce the dispersion of the electrical parameters of the TWT (interaction voltage, phase characteristics),

and also by stabilizing the average radius of the helix, reduce rejects by gain.

Claims (1)

The claims A method of manufacturing tape spirals for slowdown lines of traveling wave lamps, which consists in manufacturing a tape from a wire of circular cross section and winding it into a spiral on a rotating core, characterized in that, in order to improve the quality of the finished product by reducing residual elastic stresses and ensuring accuracy geometric dimensions and expanding technological capabilities by obtaining a tape with a different configuration and with a smaller inner diameter of the spiral, the tape is made of two elements whose materials have different plasticity, at the same time, at least two wires that are parallel to one another are used as an element with less ductility, and a connecting wire melt from a material with greater ductility and lower ohmic resistance compared to wire material by passing through a connecting wire into a die plate immediately after passing the wires through the melt.