RU2556300C1 - Production of horn-type radiator and male die used to this end - Google Patents

Abstract

FIELD: process engineering.

SUBSTANCE: set of inventions relates to antenna hardware and can be used in production of pyramidal horn radiators incorporated with millimetre wave band antennas. Proposed method consists in forming the radiator from metal bar workpiece. First, horn inner section is formed by male die acting on workpiece end surface, male die working part shape complying with, in fact, tetrahedral pyramid sized to horn inner part. Then, spark erosion machining is used to form waveguide inner part to produce rectangular bore at workpiece centre. Then, mechanical processing is used to form the horn outer part and waveguide outer part. Said male die has working part shaped to tetrahedral pyramid with top section with two opposite faces arranged at larger angle to pyramid axis than faces of the main section and making 0.22-0.28 of said main section with sizes corresponding to those of the horn inner part.

EFFECT: simplified production, better manufacturability, accurate parameters, better radio performances.

2 cl, 3 dwg

Description

The group of inventions relates to the field of antenna technology and can be used in the manufacture of pyramidal horn emitters used in antennas of the millimeter range.

A known method of manufacturing a pyramidal horn emitter, including the formation of fragments of a horn emitter from sheet metal, their machining, bending to give the necessary shape, connecting the fragments to each other and welding (see N. Eskelinen et al. DFM (A) -Aspects for a Horn Antenna Design, Research report 55, Finland, 2004, p. 24).

The disadvantages of this method are its complexity and high cost, as well as the insufficient accuracy of the manufactured horn emitter to the required parameters, which reduces its radio technical characteristics.

In addition, there is a known method of manufacturing a conical horn emitter, which consists in extruding it from a metal bar (see, for example, Taigin V.B. et al. Composite materials in the construction of corrugated horns for spacecraft antennas (Reshetnev readings: materials of the XIV International Scientific Conference, Krasnoyarsk, November 10-12, 2010, part 1, p. 36)).

The disadvantages of this method are that it cannot be used in the manufacture of a horn emitter having a more complex geometric shape than a body of revolution, in particular a pyramidal horn emitter.

The known method is adopted as the closest analogue of the claimed method.

The objective of the claimed group of inventions is the creation of a method of manufacturing a pyramidal horn emitter, devoid of these disadvantages, and a punch used in the implementation of the claimed method.

As a result, a technical result is achieved, consisting in simplifying and increasing the manufacturability of the horn emitter, as well as improving the accuracy of its compliance with the required parameters (including increased requirements for the alignment of the socket and the waveguide, matching their transition sections), which, in turn, , improves its radio technical characteristics.

Specifically, the indicated technical result is achieved by creating a method for manufacturing a pyramidal horn emitter, which consists in forming it from a metal bar stock, in which the inner part of the bell is first formed by acting on the end surface of the workpiece with a punch, the working part of which has the shape of a substantially tetrahedral pyramid with the dimensions corresponding to the dimensions of the inner part of the bell, then by electric discharge machining form the inner part of the waveguide, Pointing through the center of the workpiece through a rectangular hole, and then machining form the outer part of the socket and the outer part of the waveguide.

Also, the specified technical result is achieved by creating a punch used in the implementation of the claimed method, the working part of which is in the form of a tetrahedral pyramid with an upper section having two opposite faces located at a greater angle to the axis of the pyramid than the edges of the main section, ranging from 0.22 to 0.28 from the main portion having dimensions corresponding to the dimensions of the inner part of the bell.

In FIG. 1 shows the technological process of forming the inner part of the bell.

In FIG. 2 shows the technological process of forming the inner part of the waveguide.

In FIG. 3 shows an image of a horn emitter (longitudinal section) made by the claimed method.

The claimed method is implemented as follows.

Preparatory operations are performed (in particular, cutting a metal (for example, aluminum) bar to a workpiece 2 of a given length, its thermal and galvanic processing).

In the center of the workpiece 2, a through hole with a diameter of 3 mm is drilled.

Further, as shown in FIG. 1, the inner part of the socket is formed by plastic deformation (see Fig. 3, item 7a), acting by the punch 1 on the end surface of the workpiece 2.

To do this, the workpiece is installed in the die matrix 3 on the base 4 and the punch 1 is lowered along the guides 5 with a force of 30-35 t. To limit the extrusion depth, restrictive rings are used that are mounted on the punch 1 from above (not shown).

The working part of the punch 1, as shown in FIG. 1, has the shape of a tetrahedral pyramid with an upper (entry) section having two opposite faces located at a greater angle to the axis of the pyramid than the faces of the main section, comprising from 0.22 to 0.28 from the main section having dimensions corresponding to the dimensions of the inner parts of the bell 7a.

Then, as shown in FIG. 2, the internal part of the waveguide is formed by electric discharge machining (see FIG. 3, item 8a), forming a through rectangular hole 6 in the center of the workpiece 2.

To do this, put the workpiece in a bath with a dielectric liquid, fix it in the holder, draw the electrode-wire with a diameter of 0.15-0.2 mm using the rollers into a hole pre-drilled in the center of the workpiece 2 (in case of a significant reduction in the size of this hole during plastic deformation workpieces 2 it re-pass drill).

They form a channel 3.4 mm high and 7.2 mm wide as a result of the destruction of the metal under the influence of electric pulses.

Then, by machining (in particular, turning and milling), the outer part of the socket 7b and the outer part of the waveguide 8b are formed, according to the requirements for their shape and size (grooves for sealing rings, holes for fasteners are made).

Claims (2)

1. A method of manufacturing a pyramidal horn emitter, which consists in forming it from a metal bar stock, characterized in that the inner part of the bell is first formed by acting on the end surface of the workpiece with a punch, the working part of which has the shape of an essentially tetrahedral pyramid with dimensions corresponding to the dimensions the inner part of the bell, then by electric discharge machining, the inner part of the waveguide is formed, forming a through rectangular hole in the center of the workpiece, and then machining form the outer part of the socket and the outer part of the waveguide. 2. The punch used in the method according to claim 1, the working part of which has the shape of a tetrahedral pyramid with an upper section having two opposite faces located at a greater angle to the axis of the pyramid than the faces of the main section, comprising from 0.22 to 0, 28 from the main portion having dimensions corresponding to the dimensions of the inner part of the bell.

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