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Microwave Component Mechanics

Microwave Component Mechanics by Harri Eskelinen
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Here’s a first-of-its-kind resource that offers you detailed guidance in the mechanical aspects of designing and manufacturing microwave components. The book takes an interdisciplinary approach that combines design and manufacturing, mechanical and electrical design, and microwave component performance and productivity. By exploring the immediate connection between electrical and mechanical quality, you more easily arrive at cost-effective solutions and reduce the unnecessary use of “double-tolerancing”.

Detailed CAD manufacturing documents help you ensure immediate start-up manufacturing and enable direct CNC-control of CNC machines. Based on real industrial projects, the book helps you create effective project plans and utilize efficient design methodologies for your varied projects in microwave mechanics and manufacturing. This practical book includes over 100 illustrations and more than 110 equations.

CD-ROM included! This interactive disc features several 3-D models, informative PowerPoint presentations, and dxf files of selected microwave components for direct CNC-machining.


List of Symbols. List of Abbrevations. Acknowledgements. Introduction.

Part 1: Design for Manufacturability and Assembly of Mechanical Microwave Components.

Special Requirements for MW-Mechanics - Fundamentals of Microwaves. Deminsional Uncertainties. Material Problems. Connection Philosophies. Typical User and Application Profiles.

Systematic Flowchart Model for DFMA of Microwave Mechanics - Principles of Systematic Design. Advanced Methodology for Designing Microwave Mechanics.

Material Selection for Microwave Mechanics - Basic Guidelines for Microwave Designers. Effects of the Product’s Operating Frequency. Effects of the Operating Environment. Metallic Components. Use of Plastics. Utalization of Ceramic Materials and Powder Metallurgy.

Computer Aided Environment for Design Work - Intergration of Basic CAD Tools. Typical Simulation Software Solutions for Microwave. Integration Problems of Current CAD Applications.

Instructions for Technical Documentation and Dimensioning - The Relationship Between RF and Mechanical Parameters. Differences Between DFMA and Performance Oriented Approach. On the Suitability of General Manufacturing Tolerances for MW-Mechanics.

Effects of Production Volume and Related Topics - General Aspects Related to The Evaluation Production Costs. Relationship Between Manufacturing Costs and Surface Finish. Relationship Between Manufacturing Costs and Dimensional Tolerance. Design for Manufacturability. A Cross-Technical Approach. Concurrent Engineering Design. Manufacturing Costs of Prototypes. Quality Aspects. Cost Evaluation by Utilizing Parametric Component Design. Cost Accumulation in Laser Processed Components. Manufacturing Costs of Other Manufacturing Processes. A Multi-Level Optimizing Approach for Cost-Effective Production.

Part 2: Manufacturing Technologies for Some Passive Microwave-Components.

Welded Components - Welding Processes for the Topic Area. Laser Welding in General. Laser Welded Stripline Filter. Utilizing Ultrasonic Welding in Filter Constructions. Welded Joint Geometries of Microwave Cavity Resonators and Waveguides. Welded Radiating Elements of Patch Antennas. A Comparison of Welding Processes for Encapsulating Electronics.

Other Joining Technologies - Assembly Rules for Screw Joints to Obtain Reliability and Required Microwave Performance. Glued Joints. Applications of Fits.

Machined Components - General Rules for Machining Technologies. Milled Low Loss Filters. Ring Hybrids and Other Milled Power Dividers. General Enclosures for Encapsulating Electronics. Connector Mounting Considerations. Rotary Joints. Case Examples of Precisioned Machined Components.

Cutting Processes - Sheet Metal Cutting in General. Water Jet Cut Striplines and Microstrips. Laser Processed Feeding Strips. Tuning Coaxial Transitions.

Forming Processes - Extrusion Processes for Metallic Profiles. Selected Processes for Shaping Plastics. Drawing Processes for Wires. Forming Processes for Sheet Metals. Electroforming Process for Corrugated waveguides.

Coating - Basics of Coating Technology. Requirements for Coating Quality. Coating Materials for Microwave Mechanics. Case Examples of Coated Microwave Components.

Part 3: Examples of Requirements for Mechanical Accessories in Microwave Assemblies.

A Microwave Measuring System for Wood Quality - Description of the Test Arrangement. Transducer Arrangements. Mechanical Requirements for the Measurement System Assembly

Antenna Constructions - Basics for the Design of Antenna Constructions. Wind and Ice Loads.

Part 4: Test Arrangements and Results of Microwave Components Manufactured with Alternative Technologies.

Mechanical Measuring Equipment - Dimensional Uncertainties. Joint Reliability. Surface Properties. Tests for Hermetic Enclosures.

Selecting Microwave Test Instrumentation - Vector Network Analyzers. Spectrum Analyzers. Signal Generators. Cables, Connectors and Some Accessories.

Examples of Practical Test Set-Ups - Passive Intermodulation in Welded Components. Testing the Shielding Performance of Microwave Enclosures. Experiments on the Input Impedance of Wavequide to Coax Transitions. Analyzing the Effects of Mechanical Defects on the Performance of Small Phased Array Antennas.


Appendix A: Detailed Manufacturing Documents. Appendix B: Material Data and Component Sheets. Appendix C: List of Standards.

Harri Eskelinen is a senior research scientist in the laboratory of manufacturing technology at the Lappeenranta University of Technology, Finland, where he received his M.Sc.and D.Sc. in mechanical engineering.

Pekka Eskelinen is a professor in the radio laboratory and head of the Institute of Digital Communications at the Helsinki University of Technology, Helsinki, Finland, where he received his M.Sc. and D.Sc. in electrical engineering.

Artech House; January 2003
388 pages; ISBN 9781580535892
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Title: Microwave Component Mechanics
Author: Harri Eskelinen; Pekka Eskelinen