CN103177913A - Mold and forming method for high-precision helical lines - Google Patents

Abstract

A mold and forming manufacturing method for high-precision helical wires, belonging to the field of vacuum electronic devices, including chucks placed at both ends of the helical wire precision winding machine tool, a core rod placed in the middle, and two ends of the core rod are arranged A hollow core rod fixing fixture is provided with a card slot; the core rod is welded together with the ends of both sides of the fixing fixture. Its forming manufacturing method operates according to a-f6 process manufacturing steps. This method realizes the winding of the high-precision helix of the space traveling wave tube, the operation is convenient, the finished product rate of the winding is greatly improved, and the tolerance of the helix winding is not greater than 2 μm; after the process is used, the surface finish of the helix is obvious Increase, the strength and flexibility of the helix are significantly better, which is conducive to the assembly of the helix.

Description

Tool and mold used for high-precision spiral wire and its forming manufacturing method

technical field

The invention belongs to the field of vacuum electronic devices, and in particular relates to a mold and a forming manufacturing method for a high-precision helix used in a high-frequency space traveling wave tube.

Background technique

The high-frequency space traveling wave tube will be mainly used for interstellar satellite communication in the future. Due to the special requirements of space applications, the space traveling wave tube has to improve the efficiency of the whole tube to save power consumption. According to reports, if the overall efficiency of the space traveling wave tube is increased by one percentage point, the energy consumption of the entire space load system will be significantly reduced, and the economic benefits will reach tens of millions of dollars. Therefore, it is very important to improve the efficiency of the space traveling wave tube.

The key factor determining the efficiency of the space traveling wave tube is the interaction efficiency, that is, the electronic efficiency, and the pitch accuracy of the helix in the traveling wave tube directly affects the improvement of the electronic efficiency. Less than 0.3mm; the inner diameter is less than 0.4mm, and the outer diameter is less than 0.5mm. In order to obtain higher electronic efficiency, the pitch accuracy of the helix is required to be no more than 2um.

Using the traditional manufacturing method, the two ends of the winding core rod are directly fixed in the chuck of the winding equipment, as shown in Figure 1. Since the diameter of the winding core rod for high-frequency space traveling wave tubes is generally less than 0.4mm, for such winding When the wire core rod and the helical wire strip are wound and rotated on the surface of the core rod, the core rod is deformed due to force, which cannot guarantee the normal winding of the helix wire. Even if the winding is barely completed, the qualified rate of the product is less than 1/10, and The measurement found that the pitch accuracy exceeds 7um. For high-frequency space traveling wave tubes, the pitch of the helix is usually less than 0.3mm. If the accuracy exceeds 7um, it will seriously affect the improvement of the electronic efficiency of the traveling wave tube and the efficiency of the whole tube. Therefore, a higher process is proposed for the process. Require.

This invention aims at the above problems. In order to ensure the smooth winding of the small pitch and high-precision helix, first design and process a specific winding mold, and then weld the mold and the core rod into one, and use the integrated structure of the core rod and the mold to complete the high-speed winding. The winding of the precision helix requires strict process treatment for the finished helix to ensure the strength and toughness of the helix for the assembly of the helix. Therefore, the invention has strong practical application value.

Contents of the invention

The technical problem to be solved in the present invention is that it is difficult to wind high-precision helical wires for high-frequency space traveling wave tubes, and the winding yield is extremely low, which affects the manufacture of space traveling wave tubes. rate and pitch accuracy, the purpose of the present invention is to provide a high-precision helical tool mold and forming manufacturing method, the method includes helical winding and winding process after the completion of the process.

In order to realize the purpose of the present invention, the technical solution adopted is as follows, a tool and mold for high-precision helical wires, including chucks placed at both ends of the helical wire precision winding machine tool, and a core rod placed in the middle, characterized in that, The two ends of the core rod are provided with two hollow core rod fixing fixtures, and the clamps are provided with card slots; the core rod is welded together with the ends of both sides of the fixing fixtures.

According to the process method of above-mentioned mold winding and forming, it is characterized in that, operate according to the following process steps:

a. The finished helical wire is placed in a hydrogen furnace for shaping, heated to 1000°C, and kept for 20 minutes;

b. After setting the shape, remove the helix from the core rod, and carry out electrochemical polishing, two-way polishing inside and outside, and the polishing time is 20 seconds;

c. Burn the polished helix with hydrogen in a hydrogen furnace to remove the oxide layer at a temperature of 800°C and keep it warm for 10 minutes;

d. Fix multiple helical wires on the mold, and use ion sputtering to plate copper on the surface of the helical wires, with a sputtering thickness of 5-10um;

e. Heat treatment in a helical hydrogen furnace after sputtering, the temperature is raised from 780°C to 850°C, and kept for 15 minutes;

f. Use special testing equipment to measure the helix pitch, belt thickness and bandwidth.

The beneficial effect of the present invention is that the winding of the helical wire of the high-frequency space traveling wave tube can be realized, and the operation is convenient, the finished product rate of the helical wire winding is greatly improved, and the finished product rate exceeds 80%, and the winding precision is not greater than 2um; After the process method is used, the surface finish of the helix is obviously improved, and the strength and flexibility of the helix are obviously improved, which is beneficial to the assembly of the helix.

Description of drawings

Fig. 1 is a schematic diagram of a traditional helically wound core rod fixing method;

Fig. 2 is the schematic diagram of the fixed mold of the core rod used in the present invention;

Fig. 3 is a schematic diagram of the integrated structure of the core rod and the mold;

Figure 4 is a general schematic diagram of high-precision helical wire winding;

Fig. 5 is the schematic diagram of the mold used for splashing metal material on the surface of the helix;

Fig. 6 is a schematic diagram of the mold forming structure used for the high-precision helix of the present invention.

Detailed ways

Referring to Figure 1, it shows a schematic diagram of a traditional helical winding core rod fixed on a precision winding machine tool 1, the middle part is a core rod 5 for winding, and the two ends of the precision winding machine tool are symmetrically equipped with chucks 6 to hold the core The rod is clamped, and the alignment problem in the winding process has always been a difficult problem. Referring to Fig. 2 and Fig. 3, it shows the hollow core rod fixing fixture 2 adopted in the present invention, and the fixture is provided with a card slot. The core rod is welded together with the ends on both sides of the fixture. Since the centering problem in the winding process is overcome, the winding precision and product qualified rate are obviously improved. Referring to Fig. 4, it shows the overall schematic diagram of the high-precision helical scrambling forming shown in the present invention, in which 3 is a winding tension control device, and 4 is a metal strip wound into a high-precision helix. Referring to FIG. 5 , it shows a schematic diagram of a metal sputtering mold 7 on the surface of the helix, in which a plurality of helixes 8 are simultaneously fixed for metal sputtering.

Referring to Fig. 6, the flow chart of the mold forming and manufacturing method used by the high-precision helix of the present invention is shown. The mold forming manufacturing method used by the high-precision helix is as follows:

a. The finished helical wire is placed in a hydrogen furnace for shaping, heated to 1000°C, and kept for 20 minutes;

b. After setting the shape, remove the helix from the core rod, and carry out electrochemical polishing, two-way polishing inside and outside, and the polishing time is 20 seconds;

c. Burn the polished helix with hydrogen in a hydrogen furnace to remove the oxide layer at a temperature of 800°C and keep it warm for 10 minutes;

d. Fix multiple helical wires on the mold, and use ion sputtering to plate copper on the surface of the helical wires, with a sputtering thickness of 5-10um;

e. Heat treatment in a helical hydrogen furnace after sputtering, the temperature is raised from 780°C to 850°C, and kept for 15 minutes;

f. Use special testing equipment to measure the helix pitch, belt thickness and bandwidth.

Claims (2)

1. the tool and mould that uses of a high-precision spiral line, comprise the dop that is placed in the accurate winding-machine bed of helix two ends, the core bar that is placed in the middle part, it is characterized in that, core bar two ends are provided with the core bar stationary fixture of two hollow shape, and this fixture is provided with draw-in groove; Core bar and described stationary fixture both side ends are welded as a whole.

2. the high-precision spiral line uses the forming manufacturing method of tool and mould according to claim 1, it is characterized in that, by following process step operation:

A. the helix completed of coiling is placed in the hydrogen stove and finalizes the design, and is warming up to 1000 ℃, is incubated 20 minutes;

B. the rear screw line of finalizing the design is pulled down from core bar, carries out electrochemical polish, inside and outside two-way polishing, polishing time 20 seconds;

C. with polishing rear screw line annealing in hydrogen atmosphere in the hydrogen stove, the deoxidation layer, 800 ℃ of temperature are incubated 10 minutes;

D. many helixes are fixed on mould, adopt the ion sputtering mode at the helix copper coating, sputter thickness 5-10um;

E. sputter rear screw line hydrogen furnace treatment reason, 780 ℃ of temperature rise to 850 ℃, are incubated 15 minutes;

F. adopt specialized detection, measure helix pitch, tape thickness, bandwidth.

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