Antenna reflector surface forming method and device

Abstract

The present invention discloses a method and device for forming an antenna reflector surface, the method comprising: placing a blank into a concave cavity of a forming die, installing an upper die cover, and performing air pressure forming to obtain a semi-finished blank; the diameter of the blank is greater than the diameter of the opening of the concave cavity; the semi-finished blank is clamped on a lathe, and a flanging roller is used to roll and flanging the semi-finished blank to form a skirt structure; after the rolling and flanging is completed, the skirt structure is trimmed with a cutter to obtain an antenna reflector surface; the present invention adopts an air pressure forming process to form the shape of the antenna reflector surface in a one-step process in the forming die, and accurately presses out the semi-finished blank, and then the skirt structure is finely processed on the semi-finished blank. The process flow of the present invention solves the problem that the antenna reflector surface is easy to deform during mechanical processing, enhances the overall structural strength, and greatly improves the accuracy of the antenna reflector surface.

Description

Technical Field

[0001] The invention belongs to the technical field of antenna reflector surface processing, and in particular relates to an antenna reflector surface forming method and device. Background Art

[0002] In modern radar antenna systems, the reflector is an important component of the antenna system, and the accuracy it can achieve directly affects the indicator level of the entire system. Traditional manufacturing methods mostly use mechanical processing, using metal sheets or block materials as blanks and CNC processing equipment. Through precise programming and tool path control, the blanks are cut and processed to gradually remove excess materials.

[0003] However, antenna reflectors manufactured by mechanical processing often have the problem of workpiece deformation, thereby affecting the surface accuracy of the antenna reflector. Summary of the invention

[0004] The object of the present invention is to provide a method and device for forming an antenna reflective surface, so as to improve the surface accuracy of the antenna reflective surface.

[0005] The present invention adopts the following technical solutions: A method for forming an antenna reflector surface comprises the following steps: The blank is placed in the concave cavity of the forming die, the upper die cover is installed, and air pressure forming is performed to obtain a semi-finished blank; the diameter of the blank is larger than the diameter of the opening of the concave cavity; The semi-finished blank is clamped on a lathe, and a flanging roller cutter is used to perform a roller flanging process on the semi-finished blank to form a skirt structure; After the roll-flanging is completed, the skirt structure is trimmed with a cutter to obtain the antenna reflector surface.

[0006] Furthermore, after cutting the skirt structure with a cutting knife, the following steps are further performed: The inner surface of the antenna reflector is polished.

[0007] An antenna reflector forming device includes a pneumatic forming die for pressing a blank into a semi-finished blank; The pneumatic forming die includes a forming concave die and an upper die cover; A concave cavity is provided inside the forming die, the concave cavity matches the shape of the antenna reflector surface, and an exhaust port is provided at the bottom of the forming die; A cavity is provided at the bottom of the upper mold cover, and the cavity is adapted to the upper surface of the forming die to reserve space for the air pressure forming process. An air filling port is provided at the center of the upper mold cover.

[0008] Furthermore, a flange ring is arranged on the top of the upper mold cover, the flange ring is arranged coaxially with the upper mold cover, and a lifting rod is symmetrically arranged on the top of the flange ring.

[0009] Furthermore, a positioning hole is provided at the edge of the top of the forming die, and a positioning pin is provided at the edge of the bottom of the upper die cover, and the positioning pin matches the positioning hole.

[0010] Furthermore, a sealing ring is arranged around the edge of the concave cavity.

[0011] Further, a lathe and a punch are also included; The lathe is used to clamp the semi-finished blank and provide the rotation speed for processing the semi-finished blank; The punch is used to load the semi-finished blank and assist in clamping the semi-finished blank on the lathe; The punch comprises a first annular component and a second annular component, the second annular component is arranged on one side of the first annular component, and the first annular component and the second annular component are arranged coaxially; The inner diameter of the first annular component is smaller than the inner diameter of the second annular component, and the outer diameter of the second annular component is smaller than the outer diameter of the first annular component; The total height of the first annular component and the second annular component is equal to the vertical distance from the vertex to the center of the aperture plane of the antenna reflection surface.

[0012] Furthermore, it also includes a flanging roller cutter, which is used to perform roller flanging processing on the semi-finished blank on a lathe to form a skirt structure; The flanging roller cutter comprises a roller cutter rod, one end of which is provided with a U-shaped cavity, a roller shaft is arranged in the U-shaped cavity, the roller shaft passes through two side walls of the U-shaped cavity, and the shaft body of the roller shaft is connected to the roller through a bearing.

[0013] Furthermore, it also includes an air compressor, the air supply port of the air compressor is connected with the air charging port, and is used to provide compressed air to the pneumatic molding mold.

[0014] Furthermore, a cutter is included for cutting the skirt structure on a lathe.

[0015] The beneficial effects of the present invention are as follows: the present invention adopts a pneumatic forming process to form the shape of the antenna reflecting surface in a forming die in one step, accurately presses out a semi-finished blank, and then performs fine processing of the skirt structure on the semi-finished blank. The process flow of the present invention not only effectively avoids the risk of deformation of the antenna reflecting surface during processing, but also enhances the overall structural strength, thereby greatly improving the surface accuracy of the antenna reflecting surface. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 is a flow chart of the method of the present invention; Figure 2 is a cross-sectional view of the gas pressure forming mold of the present invention; Figure 3 A top view of the upper mold cover of the present invention; Figure 4 It is a cross-sectional view of the flanging roller cutter of the present invention; Figure 5 is a cross-sectional view of the male mold of the present invention; Among them, 1. roller arbor, 2. roller shaft, 3. bearing, 4. roller, 5. cotter pin, 6. gasket, 7. forming die, 8. upper die cover, 9. flange ring, 10. lifting rod, 11. sealing ring, 12. positioning pin, 13. inflation port, 14. concave cavity, 15. exhaust port, 16. first annular component, 17. second annular component. DETAILED DESCRIPTION

[0017] The present invention is described in detail below with reference to the accompanying drawings and specific embodiments.

[0018] A method for forming an antenna reflector surface, such as Figure 1 As shown, the following steps are included: S110, placing the blank into the concave cavity 14 of the forming die 7, installing the upper die cover 8, and performing air pressure forming by using an air compressor to obtain a semi-finished blank; the diameter of the blank is larger than the diameter of the opening of the concave cavity 14; S120, clamping the semi-finished blank on a lathe, and performing roller flanging processing on the semi-finished blank using a flanging roller cutter to form a skirt structure; S130, after the rolling and flanging is completed, a cutter is used to cut the skirt structure to a required size to obtain an antenna reflector surface; S140, removing the antenna reflector from the lathe, and polishing the inner surface of the antenna reflector.

[0019] The antenna reflector obtained by air pressure forming has higher surface accuracy than that obtained by mechanical processing, and the operation is simple and efficient.

[0020] The skirt structure can increase the strength of the product itself, and can be rolled during the rotation of the lathe to make the skirt structure beautiful in appearance. There is no need to make a separate mold to process the skirt structure, thereby reducing production costs.

[0021] Compared with cutting with scissors, the cutting with a cutter is simpler and faster, and the edges of the finished product are neat and beautiful.

[0022] After polishing, the inner surface accuracy can be further improved to a level comparable to that of mechanical processing, while having a better surface finish. Compared with mechanical processing, polishing has lower costs and shorter cycles while ensuring the inner surface accuracy and roughness.

[0023] Specifically: Prepare a 1060 pure aluminum plate with a thickness of 1 mm and a diameter of 500 mm as a blank; The blank is placed in the concave cavity 14 of the forming die 7, the upper die cover 8 is installed, and compressed air of 0.6-0.8 MPa is introduced by an air compressor for air pressure forming to obtain a semi-finished blank; The punch is clamped on the chuck of the lathe, the semi-finished blank is tightly pressed in the punch, the lathe speed is ≤20 rpm, and the flanging roller cutter is manually operated to roll and flanging the semi-finished blank to form a skirt structure; After the roll flanging is completed, a cutter is used to cut the skirt structure to the required size to obtain the antenna reflector surface. The diameter of the antenna reflector surface is 400 mm. Fix the antenna reflective surface on the convex mold and polish the inner surface of the antenna reflective surface with a scouring pad.

[0024] During the machining process, cutting force can cause elastic and plastic deformation of the workpiece. In particular, for antenna reflector skirts with thin walls and slender structures, cutting force is more likely to cause deformation, affecting the surface accuracy of the antenna reflector. For example, when milling thin-walled skirts, cutting force may cause the skirt to bend or twist, requiring multiple corrections and finishing, increasing machining costs and time. At the same time, cutting processing will produce residual stress inside the workpiece, and the presence of residual stress may cause the workpiece to deform after machining or during use. For components such as antenna reflectors that require extremely high surface accuracy, deformation caused by residual stress may reduce the surface accuracy of the reflector and affect the performance of the antenna.

[0025] The present invention adopts a pneumatic forming process to form the shape of the antenna reflecting surface in one step in the forming die 7, accurately press out a semi-finished blank, and then perform fine processing of the skirt structure on the semi-finished blank. This process flow not only effectively avoids the risk of deformation of the antenna reflecting surface during the processing, but also enhances the overall structural strength, thereby greatly improving the surface accuracy of the antenna reflecting surface.

[0026] After the air pressure forming is completed, the skirt structure is processed immediately, so that the final processed antenna reflector has a skirt structure. The skirt structure enhances the overall structural strength of the antenna reflector and can effectively reduce the deformation of the antenna reflector when facing external interference, maintain the stability of the shape, and thus improve the surface accuracy of the antenna reflector. At the same time, the antenna reflector is polished to further improve the surface accuracy of the antenna reflector. It has the advantages of low cost, short cycle, and light weight, and can be widely used in the processing of reflectors of radar antenna systems.

[0027] An antenna reflector shaping device, such as Figure 2 As shown, it includes a gas pressure forming die for pressing a blank into a semi-finished blank; The pneumatic forming mold includes a forming die 7 and an upper mold cover 8; A concave cavity 14 is provided inside the forming die 7, and the concave cavity 14 matches the shape of the antenna reflector surface. An exhaust port 15 is provided at the bottom of the forming die 7; A cavity is provided at the bottom of the upper mold cover 8, and the cavity is adapted to the upper surface of the forming die 7. The area and shape of the cavity are the same as the area and shape of the upper surface of the forming die 7, and the cavity completely covers the upper surface of the forming die 7, which is used to reserve space for the air pressure forming process. A lifting rod 10 is provided at the top of the upper mold cover 8, and an inflation port 13 is provided at the center of the upper mold cover 8; The edges of the forming die 7 and the upper die cover 8 are provided with mounting holes. When working, the upper die cover 8 is mounted on the forming die 7 through the mounting holes and bolts.

[0028] The present invention uses pneumatic forming to make the pressure on the blank more uniform, avoiding the stress concentration caused by traditional mechanical stamping, and making the blank fit precisely with the concave cavity 14; the inflation port 13 is located at the center of the upper mold cover 8, ensuring the symmetry of the air pressure distribution, reducing the risk of forming deviation, and also avoiding deformation of the workpiece caused by mechanical processing.

[0029] The lifting rod 10 is used to quickly load and unload the mold, which reduces the intensity of manual operation.

[0030] For antenna reflector surfaces with complex internal structures, it is often difficult for mechanical processing to reach certain internal areas for processing, and special processing methods such as electrospark processing may be required to assist, which increases the complexity and cost of the processing technology. The present invention can design a forming die 7 that matches the shape of the antenna reflector surface according to the different shapes of the antenna reflector surface, thereby reducing the process complexity and saving processing time and cost.

[0031] like Figure 3 As shown, the upper mold cover 8 is circular, and a flange ring 9 is arranged on the top of the upper mold cover 8. The flange ring 9 is arranged coaxially with the upper mold cover 8, and a lifting rod 10 is symmetrically arranged on the top of the flange ring 9.

[0032] In the present invention, the flange ring 9 is coaxially designed with the upper mold cover 8, which can enhance the overall structural strength of the mold and prevent the upper mold cover 8 from being deformed when the air pressure is loaded; the symmetrically distributed lifting rods 10 realize balanced lifting of the mold and avoid damage to the mold or workpiece due to uneven force during transportation.

[0033] A positioning hole is provided at the edge of the top of the forming die 7 , and a positioning pin 12 is provided at the edge of the bottom of the upper die cover 8 , and the positioning pin 12 matches the positioning hole.

[0034] The positioning pin 12 cooperates with the positioning hole in the present invention to realize fast and accurate alignment of the upper die cover 8 and the forming die 7, eliminating the problem of time-consuming manual adjustment; at the same time, it avoids the forming defects of the blank caused by mold misalignment during the pressurization process.

[0035] A sealing ring 11 is arranged around the edge of the concave cavity 14 .

[0036] The sealing ring 11 can effectively seal the molding cavity, prevent compressed air leakage, ensure stable molding pressure, reduce the number of repeated pressurization caused by air leakage, shorten a single molding cycle, and reduce energy consumption.

[0037] like Figure 5 As shown, the present invention also includes a lathe and a punch; The punch is used to load the semi-finished blank and assist in clamping the semi-finished blank on the lathe; The punch includes a first annular component 16 and a second annular component 17. The second annular component 17 is arranged on one side of the first annular component 16. The first annular component 16 and the second annular component 17 are arranged coaxially. The first annular component 16 and the second annular component 17 are provided with mounting holes on their circumferences. The first annular component 16 and the second annular component 17 are mounted together through the mounting holes and bolts. The inner diameter of the first annular component 16 is smaller than the inner diameter of the second annular component 17 , and the outer diameter of the second annular component 17 is smaller than the outer diameter of the first annular component 16 ; The total height of the first annular component 16 and the second annular component 17 is equal to the vertical distance from the vertex to the center of the aperture plane of the antenna reflection surface.

[0038] The three-jaw chuck of the lathe is used to clamp the first annular component 16 of the punch, the antenna reflector surface is placed in the punch, and the tailstock of the lathe is used to hold the antenna reflector surface tightly against the punch, thereby completing the clamping of the antenna reflector surface on the lathe.

[0039] The cavity formed inside the punch matches the shape of the semi-finished blank, which enables rapid clamping of the lathe and reduces the adjustment time of traditional fixtures.

[0040] like Figure 4 As shown, the present invention also includes a flanging roller cutter, which is used to perform rolling flanging processing on the semi-finished blank on a lathe to form a skirt structure; The flanging roller cutter comprises a roller cutter bar 1, one end of which is provided with a U-shaped cavity, a roller shaft 2 is arranged in the U-shaped cavity, the roller shaft 2 passes through two side walls of the U-shaped cavity, and the shaft body of the roller shaft 2 is rotatably connected to the roller 4 through a bearing 3.

[0041] A cotter pin 5 is provided on the top of the roller shaft 2, and the roller shaft 2 is fixed to the roller cutter bar 1 body through the cotter pin 5, so as to prevent the roller shaft 2 from axial movement during operation and ensure the reliability of the structure.

[0042] A gasket 6 is also provided between the roller 4 and the roller cutter bar 1 body, and the gasket 6 is used to adjust the axial clearance to ensure the stability of the roller 4 during operation.

[0043] In the present invention, the roller shaft 2 cooperates with the bearing 3 to realize the resistance-free rotation of the roller 4. The material is evenly extended during the rolling process, eliminating the wrinkle problem of traditional stamping flanging; the U-shaped cavity structure guides the roller 4 to move along the skirt edge trajectory, improving the assembly compatibility.

[0044] The present invention further comprises an air compressor, the air supply port of which is connected to the air charging port 13 and is used to provide compressed air to the air pressure forming mold.

[0045] The air compressor is used to provide a stable and adjustable compressed air source, which can adapt to the forming needs of blanks of different thicknesses or materials.

[0046] The present invention also includes a cutter for cutting the skirt structure on a lathe.

[0047] The cutter is used in conjunction with a lathe to cut the skirt edge in a rotating state, which improves the flatness of the cut and eliminates the need for secondary trimming.

[0048] To sum up, the present invention adopts the pneumatic forming process to form the shape of the antenna reflecting surface in one step in the forming die 7, accurately press out a semi-finished blank, and then perform fine processing of the skirt structure on the semi-finished blank. This process flow not only effectively avoids the risk of deformation of the antenna reflecting surface during the processing, but also enhances the overall structural strength, thereby greatly improving the surface accuracy of the antenna reflecting surface.

[0049] The antenna reflector processed by the present invention has a thickness of only 1mm and a surface accuracy of up to 0.1mm (RmS). In comparison, the antenna reflector processed by the traditional spinning method has a surface accuracy of 0.5mm (RmS), and the present invention significantly improves the surface accuracy. The antenna reflector processed by the common casting method often has a thickness of tens of millimeters. In comparison, the present invention greatly reduces the thickness of the antenna reflector and effectively reduces the weight of the antenna reflector.

[0050] At the same time, the present invention also solves the problems of high cost and long cycle when preparing antenna reflector surfaces by mechanical processing, reduces the processing cost of antenna reflector surfaces, shortens the processing cycle, improves the surface accuracy of antenna reflector surfaces, promotes the improvement of antenna system indicators, and provides support for the design of high-frequency radar system products.

Claims

1. A method for forming an antenna reflector surface, characterized in that: The following steps are involved: The blank is placed in the concave cavity (14) of the forming die (7), and the upper die cover (8) is installed to perform air pressure forming to obtain a semi-finished blank; the diameter of the blank is larger than the diameter of the opening of the concave cavity (14); Clamping the semi-finished blank on a lathe, and performing a rolling and flanging process on the semi-finished blank using a flanging roller cutter to form a skirt structure; After the rolling and flanging is completed, the skirt structure is trimmed with a cutter to obtain the antenna reflector.

2. The method for forming an antenna reflector surface according to claim 1, characterized in that: After cutting the skirt structure with a cutting knife, the following steps are further performed: The inner surface of the antenna reflective surface is polished.

3. An antenna reflector shaping device, characterized in that: It includes a gas pressure forming die for pressing the blank into a semi-finished blank; The pneumatic forming mold comprises a forming concave mold (7) and an upper mold cover (8); A concave cavity (14) is provided inside the forming die (7), the concave cavity (14) matches the shape of the antenna reflector surface, and an exhaust port (15) is provided at the bottom of the forming die (7); A cavity is provided at the bottom of the upper mold cover (8), the cavity is adapted to the upper surface of the forming die (7) and is used to reserve space for the air pressure forming process, and an inflation port (13) is provided at the center of the upper mold cover (8).

4. The antenna reflector shaping device according to claim 3, characterized in that: A flange ring (9) is arranged on the top of the upper mold cover (8), and the flange ring (9) is arranged coaxially with the upper mold cover (8). A lifting rod (10) is symmetrically arranged on the top of the flange ring (9).

5. The antenna reflector shaping device according to claim 4, characterized in that: A positioning hole is provided on the edge of the top of the forming die (7), and a positioning pin (12) is provided on the edge of the bottom of the upper die cover (8), wherein the positioning pin (12) matches the positioning hole.

6. The antenna reflector shaping device according to claim 5, characterized in that: A sealing ring (11) is arranged around the edge of the concave cavity (14).

7. The antenna reflector shaping device according to claim 6, characterized in that: Also includes lathe and punch; The lathe is used to clamp the semi-finished blank and provide a rotation speed for processing the semi-finished blank; The punch is used to load the semi-finished blank and assist in clamping the semi-finished blank on the lathe; The male mold comprises a first annular component (16) and a second annular component (17), wherein the second annular component (17) is arranged on one side of the first annular component (16), and the first annular component (16) and the second annular component (17) are coaxially arranged; The inner diameter of the first annular component (16) is smaller than the inner diameter of the second annular component (17), and the outer diameter of the second annular component (17) is smaller than the outer diameter of the first annular component (16); The total height of the first annular component (16) and the second annular component (17) is equal to the vertical distance from the vertex to the center of the aperture plane of the antenna reflection surface.

8. The antenna reflector shaping device according to claim 7, characterized in that: It also includes a flanging roller cutter, which is used to perform rolling flanging processing on the semi-finished blank on the lathe to form a skirt structure; The flanging roller cutter comprises a roller cutter bar (1), one end of the roller cutter bar (1) is provided with a U-shaped cavity, a roller shaft (2) is arranged in the U-shaped cavity, the roller shaft (2) passes through two side walls of the U-shaped cavity, and the shaft body of the roller shaft (2) is connected to the roller (4) via a bearing (3).

9. The antenna reflector shaping device according to claim 8, characterized in that: It also includes an air compressor, the air supply port of the air compressor is connected to the inflation port (13) and is used to provide compressed air to the air pressure forming mold.

10. The antenna reflector shaping device according to claim 9, characterized in that: Also included is a cutter for trimming the skirt structure on the lathe.

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