A method of manufacturing a vee waveguide

Abstract

A manufacturing method of a V-shaped waveguide, the blank of the V-shaped waveguide comprises a rectangular flange blank, a rectangular V-shaped pipe body blank and a rectangular V-shaped cover plate blank, the rectangular V-shaped pipe body blank and the rectangular V-shaped cover plate blank are convenient for clamping rough machining and finish machining, the machining of the V-shaped pipe body is completed through a three-stage process of "rough machining-aging treatment-finish machining", the two ends of the V-shaped pipe body are blocked during the rough machining and the finish machining, the deformation amount of the inner cavity during the machining process and the deformation amount of the inner cavity during the subsequent welding process are reduced, low-temperature alloy is injected into the inner cavity of the V-shaped waveguide during the finish machining to improve the strength and the anti-vibration performance of the V-shaped pipe, the machining vibration is effectively inhibited, the V-shaped pipe can also be prevented from being clamped and deformed during the machining, the V-shaped pipe is clamped through a V-shaped positioning seat and a supporting seat, the fast positioning and clamping are realized, and the machining efficiency is improved.

Description

Technical Field

[0001] This invention belongs to the field of microwave communication device manufacturing technology, and particularly relates to a method for manufacturing a V-shaped waveguide. Background Technology

[0002] As 5G communication technology moves towards the millimeter-wave band, higher requirements are placed on the processing precision of waveguides. In particular, the precision requirements for the waveguide cavity are high; even small deviations can increase transmission loss and affect performance. Due to the small wall thickness of waveguides, existing waveguide cavity processing methods are prone to causing deformation of the V-shaped waveguide cavity cross-section, uneven wall thickness, surface damage, or springback angles that affect precision, resulting in low yield, long processing cycles, and significantly increased processing costs. Summary of the Invention

[0003] This invention provides a method for manufacturing a V-shaped waveguide to overcome the shortcomings of the prior art.

[0004] The technical solution adopted in this invention is: a method for manufacturing a V-shaped waveguide, wherein the V-shaped waveguide includes a flange, a V-shaped tube body, and a V-shaped cover plate that are integrally formed, and the method includes the following steps:

[0005] S1, Processing V-shaped tube semi-finished products;

[0006] S1.1, Use rectangular aluminum plates as blanks for processing V-shaped tube semi-finished products, and cut the material according to the external dimensions of the V-shaped tube and leave an appropriate allowance;

[0007] S1.2, the blank is clamped on a milling machine. First, the upper end of the blank is rough milled to form an open V-shaped inner cavity with an open upper end, according to the inner cavity size of the V-shaped tube. Then, according to the outer dimensions of the V-shaped tube, and with appropriate allowances reserved at both ends of the outer contour of the V-shaped tube, the side contour of the V-shaped tube is rough milled to form the side contour of the V-shaped tube. After the side contour is rough milled, its lower end remains connected to the blank, and the two ends of the open V-shaped inner cavity are not penetrated; thus, the first semi-finished product of the V-shaped tube is obtained.

[0008] S1.3, the first semi-finished product is subjected to aging treatment at a temperature between 150-200°C and a holding time of 6-8 hours to eliminate the stress generated during processing and obtain the second semi-finished product of V-shaped tube body;

[0009] S1.4, re-clamp the second semi-finished product, first fine mill the open V-shaped inner cavity, then according to the outer dimensions of the V-shaped tube, and with a suitable allowance reserved at both ends of the outer contour of the V-shaped tube, fine mill to form the side contour of the V-shaped tube, and separate the V-shaped tube from the blank, with the two ends of the open V-shaped inner cavity not penetrating; to obtain the third semi-finished product of the V-shaped tube.

[0010] S1.5 After flipping the third semi-finished product 180 degrees and re-clamping it, the bottom surface of the third semi-finished product is precision milled to make the height of the third semi-finished product reach the design size, thus obtaining the V-shaped tube semi-finished product.

[0011] S2, Processing V-shaped cover plate semi-finished products;

[0012] S2.1, Use rectangular aluminum plates as blanks for processing V-shaped cover plates into semi-finished products, and cut the material according to the external dimensions of the V-shaped cover plates and with appropriate allowance.

[0013] S2.2, The blank is clamped on a milling machine, and the V-shaped cover plate is precision milled according to its external dimensions and with appropriate allowances reserved at both ends to form a semi-finished V-shaped cover plate.

[0014] S3, Welding: Weld the V-shaped cover plate semi-finished product to the open V-shaped inner cavity of the V-shaped tube semi-finished product, so that the upper end of the V-shaped tube semi-finished product is closed, resulting in a V-shaped tube with both ends sealed.

[0015] S4, clamp the V-shaped tube with both ends blocked on the milling machine, first fine mill the left end face of the V-shaped tube to make the left end of the blocked V-shaped tube pass through and the length L1 of the V-shaped tube reach the design size, and then fine mill the left end stop of the V-shaped tube to the design size.

[0016] S5. After fitting the flange onto the stop at the left end of the V-shaped tube and welding them together, the outer end face of the flange is then precision milled to obtain a semi-finished V-shaped waveguide.

[0017] S6. Using the outer end face of the flange as the reference surface, clamp the V-shaped waveguide semi-finished product. First, finely mill the right end face of the V-shaped tube to make the right end of the blocked V-shaped tube pass through and the length L2 of the V-shaped tube reach the design size. Then, finely mill the right end stop of the V-shaped tube to the design size to obtain the finished V-shaped waveguide.

[0018] In S1.2, when rough milling the open V-shaped inner cavity, leave a 1 mm allowance for the width W1 and depth of the inner cavity, and the length does not penetrate to the two ends of the outer contour lengths L1 and L2 of the V-shaped tube; when rough milling the side contour of the V-shaped tube, leave a 1 mm allowance for the width W2, and leave a 4 mm allowance at both ends of the lengths L1 and L2.

[0019] In S1.4, the open V-shaped inner cavity finish milling includes semi-finish milling and finish milling. When semi-finish milling the open V-shaped inner cavity, the inner cavity width W1 and depth each have a allowance of 0.15mm, and the length does not penetrate to both ends of the outer contour lengths L1 and L2 of the V-shaped tube. When finish milling the open V-shaped inner cavity, the inner cavity width W1 and depth reach the design dimensions, and the length does not penetrate to both ends of the outer contour lengths L1 and L2 of the V-shaped tube. When finish milling the side contour of the V-shaped tube, the width W2 reaches the design dimensions, and the lengths L1 and L2 each have a allowance of 3mm.

[0020] In S4, the V-shaped tube is clamped by a V-shaped positioning seat; the V-shaped positioning seat includes an L-shaped base and a positioning block and a swing block sitting on the L-shaped base, and one end of the swing block is hinged to one end of the positioning block; the upper ends of the positioning block and the swing block are both equipped with clamping grooves that are adapted to the V-shaped tube; the left end of the V-shaped tube is clamped in the clamping groove at the upper end of the positioning block and the right end is clamped in the clamping groove at the upper end of the swing block, and the positioning block is pressed by a wedge-shaped clamping device set on the L-shaped base, and the V-shaped tube is pressed by a pressure block set on the L-shaped base.

[0021] In S6, the V-tube is preheated before precision milling. Then, liquid cryogenic alloy is injected into the V-tube from the flange end to fill the inner cavity of the V-tube. The liquid cryogenic alloy is then processed after it solidifies.

[0022] The V-shaped waveguide semi-finished product is clamped by a support base. First, the support base is fixed on a milling machine. Then, the outer end face of the flange sits on the support base, and the V-shaped tube is fitted onto the positioning table on the support base. Finally, the flange is pressed tightly by a pressure plate set on the support base.

[0023] Compared with the prior art, the present invention has the following beneficial effects:

[0024] 1. This invention uses rectangular blanks that are easy to clamp, and completes the processing of V-shaped tubes through a three-stage process of "rough machining - aging treatment - fine machining". This overcomes the problems of deformation of the inner cavity cross section, uneven wall thickness, surface damage or springback angle affecting accuracy during the processing of V-shaped tubes. It reduces the risk of part failure due to deformation by more than 80%, improves the yield rate and reduces costs.

[0025] 2. During the processing of the waveguide inner cavity of the present invention, both ends are always in a closed structure, which reduces the amount of deformation of the inner cavity during processing and the amount of deformation of the inner cavity during subsequent welding.

[0026] 3. This invention completes the processing of both ends of the waveguide by designing a special fixture, which can control the dimensional accuracy of the waveguide within ±0.01mm. Furthermore, the special fixture can automatically align the waveguide, achieving rapid positioning and clamping, thereby improving processing efficiency.

[0027] 4. The present invention improves the strength of the V-shaped tube by injecting liquid low-temperature alloy into the inner cavity of the V-shaped tube, thereby increasing the vibration resistance by 40%, effectively suppressing processing vibration, and also preventing the V-shaped tube from being clamped and deformed during processing. Attached Figure Description

[0028] Figure 1 , 2 This is a schematic diagram of the V-shaped waveguide structure of the present invention;

[0029] Figure 3 This is a roughing process diagram of the V-shaped tube body of the present invention;

[0030] Figure 4 This is the flange process diagram of the present invention;

[0031] Figure 5 This is a process diagram of the V-shaped cover plate of the present invention;

[0032] Figure 6 This is a process diagram of the V-shaped tube body semi-finished product of the present invention;

[0033] Figure 7 This is a schematic diagram of the V-shaped positioning seat structure of the present invention;

[0034] Figure 8 This is a diagram showing the usage state of the V-shaped positioning seat of the present invention;

[0035] Figure 9 This is a schematic diagram of the support structure of the present invention;

[0036] Figure 10 This is a diagram showing the usage state of the support base of the present invention. Detailed Implementation

[0037] The following is in conjunction with the appendix Figure 1-10 The present invention will be described in detail below with reference to specific embodiments.

[0038] A method for fabricating a V-shaped waveguide, comprising a V-shaped tube and a flange 1. The V-shaped tube is composed of a V-shaped tube body 2 and a V-shaped cover plate 3. The V-shaped tube body 2 has an open V-shaped cavity with an open upper end. The V-shaped cover plate 3 is fixed to the upper end face of the open cavity. The flange 1 has a central rectangular hole and is fitted onto the left end of the V-shaped tube, forming an integral structure with the V-shaped tube (see...). Figure 1 , 2 );

[0039] The processing steps are as follows:

[0040] The first step is to cut the materials. The blanks for V-shaped tube 2, flange 1 and V-shaped cover plate 3 are all rectangular aluminum plates (3A21 aluminum plates). The blanks for V-shaped tube 2 are prepared with a height allowance of 1 mm and a length and width allowance of 5 mm. The blanks for flange 1 are prepared with a length, width and height allowance of 1 mm. The blanks for V-shaped cover plate 3 are prepared with no height allowance and a length and width allowance of 5 mm.

[0041] The second step is rough milling;

[0042] The V-shaped tube blank is clamped on both sides with a vise (see process). Figure 3Mill the cavity at the upper end of the V-shaped tube 2, leaving a 1 mm allowance for width W1 and depth, and ensuring that the length does not penetrate the contour lengths L1 and L2 of the V-shaped tube 2, leaving a 1.5 mm wall thickness; mill the contour of the V-shaped tube 2, leaving a 1 mm allowance for width W2, and connect its lower end to the blank with a connection thickness of 1.5 mm, leaving a 4 mm allowance at both ends of the contour lengths L1 and L2; thus obtaining the first semi-finished product of the V-shaped tube 2;

[0043] The first semi-finished product of the V-shaped tube body 2 is subjected to aging treatment at a temperature between 150-200°C and a holding time of 6-8 hours to eliminate the stress generated during rough processing and obtain the second semi-finished product of the V-shaped tube body 2.

[0044] Clamp the blank end face of flange 1 with a vise, mill the outer length and width of flange 1 to the design requirements and chamfer it. Then, clamp both sides of flange 1 with a vise and mill one end face of flange 1 to a smooth surface, using it as a reference surface. Cut the central rectangular hole to match the size of the left end stop of the V-shaped tube; see process. Figure 4 ,

[0045] Mill the V-shaped cover plate 3, leaving a 3mm allowance at both ends of the outline length. Mill the V-shaped cover plate 3 to the design width; see process. Figure 5 ,

[0046] The third step is semi-finish milling. The second semi-finished product, V-shaped tube 2, is clamped on a milling machine. The cavity width W1 of V-shaped tube 2 is milled, with a depth allowance of 0.15mm. The cavity length is milled to match the contour length L1 and L2 of V-shaped tube 2, but not through the ends, leaving a wall thickness of 1.2mm.

[0047] Step 4: Fine milling. Mill the upper end face of the V-shaped tube 2 until it is smooth. Mill the cavity width W1 and groove depth to the design dimensions. Mill the cavity length and the outline lengths L1 and L2 of the V-shaped tube 2 without penetrating at both ends, leaving a 1 mm wall thickness. Mill the outline lengths L1 and L2 of the V-shaped tube 2, leaving a 3 mm allowance at each end. Mill the outline width W2 of the V-shaped tube 2 to the design dimensions and separate the V-shaped tube 2 from the blank to form a V-shaped tube 2 with both ends sealed. This yields the third semi-finished product of the V-shaped tube 2. Turn it over and mill the lower end face of the V-shaped tube 2 to the design dimensions to obtain the semi-finished product of the V-shaped tube 2. See process details. Figure 6 The V-shaped tube's contour is sealed at both ends, effectively reducing the deformation of the inner cavity during processing and subsequent welding.

[0048] In the fifth step, after the semi-finished V-shaped tube body 2 is degreased and cleaned with hydrochloric acid, flux is applied around the weld seam to ensure full flux filling during welding. After polishing the inner end face of the V-shaped cover plate 3, it is brazed to the upper end face of the open cavity of the V-shaped tube body 2, so that the upper end of the V-shaped tube body 2 is closed, resulting in a V-shaped tube with both ends sealed. The surface roughness after polishing meets the design requirement of 0.8 or higher.

[0049] Step 6: Clamp the V-shaped tube with both ends sealed on the milling machine, mill the left end face of the V-shaped tube to make the left end of the sealed V-shaped tube pass through, leave a margin of 0.4 for the outline length L1, and mill the left end stop of the V-shaped tube body 2 to the design size.

[0050] To facilitate rapid positioning and improve efficiency, a V-shaped tube sealed at both ends is clamped onto a milling machine using a V-shaped positioning seat 4. The V-shaped positioning seat 4 includes an L-shaped base 4-1 and a positioning block 4-2 and a swing block 4-3 seated on the L-shaped base 4-1. One end of the swing block 4-3 is hinged to one end of the positioning block 4-2. Both the positioning block 4-2 and the swing block 4-3 have clamping grooves 4-4 at their upper ends that are adapted to the V-shaped tube. The left end of the V-shaped tube is fitted into the clamping groove 4-4 at the upper end of the positioning block 4-2, and the right end is fitted into the clamping groove 4-4 at the upper end of the swing block 4-3. The positioning block 4-2 is pressed against the L-shaped base 4-1 by a wedge-shaped clamping device 4-5, and the V-shaped tube is pressed against the L-shaped base 4-1 by a pressure block 4-6. (See...) Figure 7 , 8 .

[0051] In use, the positioning block 4-2 is pressed against the vertical surface of the L-shaped base 4-1 on one side. The connecting end of the positioning block 4-2 overlaps with the connecting end of the swing block 4-3 and is hinged to the horizontal surface of the L-shaped base 4-1 by a pin. Then, the swing block 4-3 is rotated to match the angle of the V-tube. Finally, the V-tube is placed into the clamping groove 4-4 at the upper end of the positioning block 4-2 and the swing block 4-3, and fixed by the pressure block 4-6 and the wedge-shaped clamping device 4-5. This eliminates the tedious alignment and simplifies the clamping, achieving rapid positioning and clamping, thereby improving processing efficiency.

[0052] Step 7: After the V-tube is degreased and cleaned with hydrochloric acid, flange 1 is fitted onto the stop at the left end of the V-tube, ensuring that the exposed end face of flange 1 is in close contact with the stop end face. Flux is applied around the weld seam to ensure full flux filling during welding. The V-tube body 2 and flange 1 are welded together using brazing. Then, the V-tube is preheated, and liquid cryogenic alloy is injected into the V-tube from the flange 1 end to fill the inner cavity of the V-tube. After the cryogenic alloy cools to a solid state, the V-tube is clamped on both sides of section L1 using a vise or by using a V-shaped positioning seat 4. The outer end face of flange 1 is milled to make the thickness B of flange 1 and the length L1 of V-tube the designed dimensions. A semi-finished V-shaped waveguide is obtained.

[0053] Preheating the V-tube can effectively prevent cracks between the cryogenic alloy and the parts. Injecting liquid cryogenic alloy into the inner cavity of the V-tube effectively improves the strength of the V-tube and prevents the V-shaped waveguide semi-finished product from being deformed by the vise or V-shaped positioning seat 4. At the same time, it avoids vibration in the eighth step of processing, thus ensuring the processing quality of the V-shaped waveguide. Cryogenic alloy (such as bismuth-based alloy or tin-based alloy with melting points of 70℃ and 92℃). After obtaining the finished V-shaped waveguide, the V-tube wall is heated by boiling water at 100℃ to make the cryogenic alloy inside liquefy and flow out from the V-tube.

[0054] Step 8: Mill the right end of the V-shaped waveguide semi-finished product. Mount the V-shaped waveguide semi-finished product on a milling machine. Using the outer end face of flange 1 as the base surface and the inner cavity of the V-shaped tube as the reference, mill the right end face of the V-shaped tube to make the right end of the cavity pass through and the V-shaped tube contour L2 reach the design size. Mill the right end stop of the V-shaped tube to the design size to obtain the finished V-shaped waveguide.

[0055] To achieve rapid positioning and improve efficiency, the outer end face of flange 1 rests on the support base, and the V-shaped tube is fitted onto the positioning table 5-1 of support base 5. The right end face of the sealed V-shaped tube is milled to ensure the right end of the cavity is open, and the V-shaped tube contour L2 is aligned to the design dimensions. The right end stop of the V-shaped tube is then milled to the design dimensions, resulting in the finished V-shaped waveguide. This achieves rapid positioning and clamping, improving processing efficiency. See [link / reference] Figure 9 , 10 .

[0056] The above embodiments are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Therefore, all equivalent variations made to the content described in the claims of the present invention should be included within the scope of the claims of the present invention.

Claims

1. A method for manufacturing a V-shaped waveguide, the V-shaped waveguide comprising an integrally formed flange (1), a V-shaped tube body (2), and a V-shaped cover plate (3), characterized in that, The method includes the following steps: S1, process V-shaped tube body (2) semi-finished product; S1.1, Use rectangular aluminum plates as blanks for processing V-shaped tubes (2) into semi-finished products, and cut the material according to the external dimensions of the V-shaped tubes (2) and leave an appropriate allowance; S1.2, the blank is clamped on a milling machine. First, the upper end of the blank is rough milled according to the inner cavity size of the V-shaped tube (2) to form an open V-shaped inner cavity with an open upper end. Then, according to the outer dimensions of the V-shaped tube (2) and with a suitable allowance reserved at both ends of the outer contour of the V-shaped tube (2), the side contour of the V-shaped tube (2) is rough milled. After the side contour is rough milled, its lower end is kept connected to the blank. The two ends of the open V-shaped inner cavity are not penetrated; the first semi-finished product of the V-shaped tube (2) is obtained. S1.3, the first semi-finished product is subjected to aging treatment at a temperature between 150-200°C and a holding time of 6-8 hours to eliminate the stress generated during processing and obtain the V-shaped tube body (2) second semi-finished product; S1.4, re-clamp the second semi-finished product, first fine mill the open V-shaped inner cavity, then according to the outer dimensions of the V-shaped tube (2) and leave a suitable allowance at both ends of the outer contour of the V-shaped tube (2), fine mill to form the side contour of the V-shaped tube (2), and separate the V-shaped tube (2) from the blank, the two ends of the open V-shaped inner cavity are not penetrated; the third semi-finished product of V-shaped tube (2) is obtained; S1.5, after flipping the third semi-finished product 180 degrees and re-clamping it, the bottom surface of the third semi-finished product is precision milled to make the height of the third semi-finished product reach the design size, and a V-shaped tube body (2) semi-finished product is obtained. S2, process the V-shaped cover plate (3) semi-finished product; S2.1, Use rectangular aluminum plates as blanks for processing V-shaped cover plates (3) into semi-finished products, and cut materials according to the external dimensions of V-shaped cover plates (3) and with appropriate allowance; S2.2, The blank is clamped on a milling machine, and the V-shaped cover plate (3) is precision milled according to its external dimensions and with appropriate allowances reserved at both ends of the V-shaped cover plate (3) to form a semi-finished V-shaped cover plate (3); S3, Welding: Weld the V-shaped cover plate (3) semi-finished product onto the open V-shaped inner cavity of the V-shaped tube body (2) semi-finished product, so that the upper end of the V-shaped tube body (2) semi-finished product is closed, and a V-shaped tube with both ends sealed is obtained. S4, clamp the V-shaped tube with both ends blocked on the milling machine, first fine mill the left end face of the V-shaped tube to make the left end of the blocked V-shaped tube pass through and the length L1 of the V-shaped tube reach the design size, and then fine mill the left end stop of the V-shaped tube to the design size. S5, after fitting the flange (1) onto the stop at the left end of the V-shaped tube and welding them together, the outer end face of the flange is then milled to obtain a semi-finished V-shaped waveguide. S6. Using the outer end face of the flange (1) as the reference surface, clamp the semi-finished V-shaped waveguide. First, finely mill the right end face of the V-shaped tube to make the right end of the blocked V-shaped tube pass through and the length L2 of the V-shaped tube reach the design size. Then, finely mill the right end stop of the V-shaped tube to the design size to obtain the finished V-shaped waveguide.

2. The manufacturing method of a V-shaped waveguide according to claim 1, characterized in that: In S1.2, when rough milling the open V-shaped inner cavity, the inner cavity width W1 and depth are each left with a 1 mm allowance, and the length does not penetrate the outer contour lengths L1 and L2 of the V-shaped tube (2) at both ends; when rough milling the side contour of the V-shaped tube (2), the width W2 is left with a 1 mm allowance, and the lengths L1 and L2 are each left with a 4 mm allowance at both ends. In S1.4, the open V-shaped inner cavity fine milling includes semi-fine milling and fine milling. When semi-fine milling the open V-shaped inner cavity, the inner cavity width W1 and depth are each left with a margin of 0.15mm, and the length does not penetrate the outer contour lengths L1 and L2 of the V-shaped tube (2) at both ends. When fine milling the open V-shaped inner cavity, the inner cavity width W1 and depth are up to the design size, and the length does not penetrate the outer contour lengths L1 and L2 of the V-shaped tube (2) at both ends. When fine milling the side contour of the V-shaped tube (2), the width W2 is up to the design size, and the lengths L1 and L2 are each left with a margin of 3mm at both ends.

3. The manufacturing method of a V-shaped waveguide according to claim 1, characterized in that: In S4, the V-shaped tube is clamped by a V-shaped positioning seat (4); the V-shaped positioning seat (4) includes an L-shaped base (4-1) and a positioning block (4-2) and a swing block (4-3) sitting on the L-shaped base (4-1), and one end of the swing block (4-3) is hinged to one end of the positioning block (4-2); the upper ends of the positioning block (4-2) and the swing block (4-3) are both equipped with clamping grooves (4-4) that are adapted to the V-shaped tube; the left end of the V-shaped tube is clamped in the clamping groove (4-4) at the upper end of the positioning block (4-2), and the right end is clamped in the clamping groove (4-4) at the upper end of the swing block (4-3), and the positioning block (4-2) is clamped by a wedge-shaped clamping device (4-5) set on the L-shaped base (4-1), and the V-shaped tube is pressed by a pressure block (4-6) set on the L-shaped base (4-1).

4. The manufacturing method of a V-shaped waveguide according to claim 1, characterized in that: In S6, the V-tube is preheated before precision milling, and then liquid cryogenic alloy is injected into the V-tube from the flange (1) end to fill the inner cavity of the V-tube. After the liquid cryogenic alloy condenses, it is then processed.

5. The manufacturing method of a V-shaped waveguide according to claim 4, characterized in that: The V-shaped waveguide semi-finished product is clamped by the support base (5). First, the support base (5) is fixed on the milling machine. Then, the outer end face of the flange (1) sits on the support base (5) and the V-shaped tube is fitted on the positioning table (5-1) on the support base (5). Then, the flange (1) is pressed by the pressure plate (5-2) set on the support base (5).

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