DLA MIL-HDBK-660 B-2012 FABRICATION OF RIGID WAVEGUIDE ASSEMBLIES (SWEEP BENDS AND TWISTS).pdf
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1、AMSC N/A FSC 5985 MIL-HDBK-660B 21 August 2012 SUPERSEDING MIL-HDBK-660A 7 July 1972 MILITARY STANDARDIZATION HANDBOOK FABRICATION OF RIGID WAVEGUIDE ASSEMBLIES (SWEEP BENDS AND TWISTS) This handbook is for guidance only. Do not cite this document as a requirement. INCH-POUND Provided by IHSNot for
2、ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-660B FOREWORD 1. This handbook is approved for use by all Departments and Agencies of the Department of Defense. 2. This document provides information on methods of fabricating waveguide assemblies for rigid RF trans
3、mission lines. It provides information and guidance to personnel concerned with the fabrication of waveguide assemblies to fix equipments and circuits in the field. The handbook is not intended to be referenced to purchase specifications except for informational purposes, nor should it supersede any
4、 specification requirements. 3. Comments, suggestions, or questions on this document should be addressed to DLA Land and Maritime, ATTN: VAT, Post Office Box 3990, Columbus, OH 43218-3990, or emailed to Tubesampsdla.mil. Since contact information can change, you may want to verify the currency of th
5、is address information using the ASSIST Online database at https:/assist.dla.mil. ii Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-660B CONTENTS SECTION Page 1. SCOPE 1 1.1 Scope 1 1.2 Purpose of handbook . 1 1.2.1 Purpose of handbook 1 1.
6、2.2 Design 1 1.2.3 Part or identifying number (PIN) 1 1.2.4 Marking 3 2. APPLICABLE DOCUMENTS . 5 2.1 General 5 2.2 Government documents . 5 2.2.1 Specification, standards, and handbooks 5 2.2.2 Other Government documents, drawings, and publications . 5 2.3 Non-Government publications . 5 2.4 Order
7、of precedence 5 3. DEFINITIONS (not applicable) . 7 4. GENERAL REQUIREMENTS (PREPARATION FOR BENDING AND TWISTING) . 7 4.1 Fabrication of template 7 4.1.1 Template materials 7 4.1.2 Conforming template shape . 7 4.2 Annealing . 7 4.2.1 Annealing brass waveguide . 8 4.2.2 Filling with gas before anne
8、aling( optional) 8 4.2.3 Annealing aluminum waveguide 8 4.3 Filling . 8 4.3.1 Alloy method 8 4.3.2 Rosin method . 9 4.4 Bending fabrication 9 4.4.1 Pines bending machine 10 4.4.1.1 Draw bending . 11 4.4.1.2 Metal mandrel . 11 4.4.1.2.1 Plug mandrel 11 4.4.1.2.2 Formed mandrel . 12 4.4.1.2.3 Ball man
9、drel 12 4.4.1.2.4 Cable mandrel 12 4.4.1.2.5 Universal mandrel . 13 4.4.1.2.6 Small line mandrel 13 4.4.1.3 Mandrel selection . 13 4.4.1.4 Improper tooling and setting . 13 4.4.1.5 Lubrication 15 iii Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MI
10、L-HDBK-660B CONTENTS Continued. SECTION . Page 4.4.1.6 Twisting and bending . 15 4.4.1.7 Mandrel material and finish 15 4.4.1.8 Polytetrafluoroethylene mandrel . 15 4.4.2 Wallance bending machine 16 4.4.3 Hydraulic push press and portable hydraulic bender method 19 4.4.4 Hand bending machine . 21 4.
11、4.5 Bench vise 22 4.5 Twisting of the waveguide 22 5. DETAILED REQUIRMENTS (PRE-ASSEMBLY, ASSEMBLY, FINISHING OPERATIONS) 25 5.1 Removal of filling 25 5.1.1 Alloy method 25 5.1.2 Rosin method . 25 5.2 Removal of dents and wrinkles from waveguide 26 5.3 Cutting . 26 5.3.1 Hacksaw 26 5.3.2 Power saw .
12、 26 5.3.3 Squareness of cut 26 5.3.4 Modification of flanges and heavy wall waveguides for proper fit 26 5.3.4.1 Cover flange . 26 5.3.4.2 Choke flange 27 5.4 Cleaning . 28 5.5 Attachment of flanges 28 5.5.1 Assembly of contact or cover flange to waveguide 28 5.5.2 Assembly of choke or socket flange
13、s to waveguide . 29 5.5.3 Clamps and jigs . 30 5.6 Silver brazing brass waveguide . 30 5.7 Brazing flanges on aluminum waveguide . 35 5.7.1 Torch tips . 36 5.7.2 Brazing rod 36 5.8 Dip brazing aluminum waveguide 36 5.8.1 Brazing flux 36 5.8.1.2 Preparation of parts 36 5.8.1.2.1 Cleaning . 36 5.8.1.2
14、.2 Chemical dipping 36 5.8.2 Assembly . 37 5.8.2.1 Final cleaning . 37 5.9 Dry air piping connections 37 5.9.1 Air connection completion 37 5.10 Finishing operation. 37 5.10.1 Finishing operation. 37 5.10.1.1 Machining . 37 5.10.1.2 Smoothing 37 5.10.2 Cleaning waveguide 37 iv Provided by IHSNot for
15、 ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-660B CONTENTS continued SECTION . Page 6. NOTES . 39 6.1 Intended use 39 6.2 Subject term (key word) listing . 39 6.3 Changes from pervious issue 39 v Provided by IHSNot for ResaleNo reproduction or networking permi
16、tted without license from IHS-,-,-MIL-HDBK-660B ILLUSTRATIONS Figure . Page 1. Waveguide side and bend identification 2 2. Electrical length of bend 4 3. Wooden waveguide template 6 4. Wire template 6 5. Template for waveguide twist 7 6. Wall distortion of bend. 10 7. Draw bend . 11 8. Types of mand
17、rels 12 9. Undersize plug mandrel setting . 12 10. Wrinkling caused by tapered mandrel . 14 11. Mandrel setting too deep. 14 12. Inherent gap between tangent point and lip of wiper die . 14 13. Depth of support of plug, form, and ball mandrels 15 14. Details of bending forms for Wallace bending mach
18、ine 17 15. Bending forms for edgewise bend for 3 x 1.5 inch guide. 17 16. Detail of bending forms for edgewise bends for 3 x 1.5 inch guide . 18 17. Bending form for sideways bend for 3 x 1.5 inch guide . 18 18. Detail of forms for sideways bend . 18 19. Greenlee hydraulic bender, model 775 . 20 20.
19、 Bending waveguide in simple hydraulic press . 20 21. Waveguide dies used with Greenlee bender . 21 22. Waveguide hand bending tool . 22 23. Twisting machine for waveguide . 22 24. Twisting machine detail . 23 25. Cross section of clamps for 3 x 1.5 inch waveguide twisting machine 24 26. Waveguide t
20、wisting tool for 3 x 1.5 inch waveguide 24 27. Tool for use with twisting machine 25 28. Modifying standard RG-95/U heavywall aluminum waveguide for use with standard US-406A/U choke flange 27 29. Modification of standard UG-406A/U choke flange for use with standard RG-95/U heavywall Aluminum wavegu
21、ide . 28 30. Through flange on waveguide . 29 31. Concentricity of waveguide and flange . 30 32. Squareness of flange face with waveguide . 31 33. Waveguide and flange assembly-butt design 32 34. Waveguide squareness. 33 35. Torch brazing 34 36. Jig for through flange 34 37. Silver soldering wavegui
22、de and flange-sleeve design . 35 38. Directing flame on contact or cover flange 35 39. Brazing waveguide and flange-butt design . 37 40. Fitting for air connection 38 vi Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-660B TABLES Table I Wav
23、eguide bend values 2 II. Surface toughness tolerances of waveguides . 38 vii Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-660B 1 1. SCOPE 1.1 Scope. This handbook is intended for the electronic installations technician to be used as a gui
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