Microwave Component Mechanics

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”.

DetailedCAD manufacturing documents help you ensure immediate start-up manufacturingand enable direct CNC-control of CNC machines. Based on real industrialprojects, the book helps you create effective project plans and utilizeefficient design methodologies for your varied projects in microwave mechanicsand manufacturing. This practical book includes over 100 illustrations and morethan 110 equations.

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

Contents:

Listof Symbols. List of Abbrevations. Acknowledgements. Introduction.

Part1: Design for Manufacturability and Assembly of Mechanical MicrowaveComponents.

SpecialRequirements for MW-Mechanics - Fundamentals of Microwaves. DeminsionalUncertainties. Material Problems. Connection Philosophies. Typical User andApplication Profiles.

SystematicFlowchart Model for DFMA of Microwave Mechanics - Principles of SystematicDesign. Advanced Methodology for Designing Microwave Mechanics.

MaterialSelection for Microwave Mechanics - Basic Guidelines for Microwave Designers.Effects of the Product’s Operating Frequency. Effects of the OperatingEnvironment. Metallic Components. Use of Plastics. Utalization of CeramicMaterials and Powder Metallurgy.

ComputerAided Environment for Design Work - Intergration of Basic CAD Tools. TypicalSimulation Software Solutions for Microwave. Integration Problems of CurrentCAD Applications.

Instructionsfor Technical Documentation and Dimensioning - The Relationship Between RF andMechanical Parameters. Differences Between DFMA and Performance OrientedApproach. On the Suitability of General Manufacturing Tolerances forMW-Mechanics.

Effectsof Production Volume and Related Topics - General Aspects Related to TheEvaluation Production Costs. Relationship Between Manufacturing Costs andSurface Finish. Relationship Between Manufacturing Costs and DimensionalTolerance. Design for Manufacturability. A Cross-Technical Approach. ConcurrentEngineering Design. Manufacturing Costs of Prototypes. Quality Aspects. CostEvaluation by Utilizing Parametric Component Design. Cost Accumulation in LaserProcessed Components. Manufacturing Costs of Other Manufacturing Processes. AMulti-Level Optimizing Approach for Cost-Effective Production.

Part2: Manufacturing Technologies for Some Passive Microwave-Components.

WeldedComponents - Welding Processes for the Topic Area. Laser Welding in General.Laser Welded Stripline Filter. Utilizing Ultrasonic Welding in FilterConstructions. Welded Joint Geometries of Microwave Cavity Resonators andWaveguides. Welded Radiating Elements of Patch Antennas. A Comparison ofWelding Processes for Encapsulating Electronics.

OtherJoining Technologies - Assembly Rules for Screw Joints to Obtain Reliabilityand Required Microwave Performance. Glued Joints. Applications of Fits.

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

CuttingProcesses - Sheet Metal Cutting in General. Water Jet Cut Striplines andMicrostrips. Laser Processed Feeding Strips. Tuning Coaxial Transitions.

FormingProcesses - Extrusion Processes for Metallic Profiles. Selected Processes forShaping Plastics. Drawing Processes for Wires. Forming Processes for SheetMetals. Electroforming Process for Corrugated waveguides.

Coating- Basics of Coating Technology. Requirements for Coating Quality. CoatingMaterials for Microwave Mechanics. Case Examples of Coated MicrowaveComponents.

Part3: Examples of Requirements for Mechanical Accessories in Microwave Assemblies.

AMicrowave Measuring System for Wood Quality - Description of the TestArrangement. Transducer Arrangements. Mechanical Requirements for theMeasurement System Assembly

AntennaConstructions - Basics for the Design of Antenna Constructions. Wind and IceLoads.

Part4: Test Arrangements and Results of Microwave Components Manufactured withAlternative Technologies.

MechanicalMeasuring Equipment - Dimensional Uncertainties. Joint Reliability. SurfaceProperties. Tests for Hermetic Enclosures.

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

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

Summary

AppendixA: Detailed Manufacturing Documents. Appendix B: Material Data and ComponentSheets. Appendix C: List of Standards.

HarriEskelinenis a senior research scientist in the laboratory of manufacturing technology atthe Lappeenranta University of Technology, Finland, where he receivedhis M.Sc.and D.Sc. in mechanical engineering.

PekkaEskelinen isa professor in the radio laboratory and head of the Institute of DigitalCommunications at the Helsinki University of Technology, Helsinki, Finland,where he received his M.Sc. and D.Sc. in electrical engineering.