RFQ - CNC Lathe parts - Aluminium - Metric - RADAR feed Horns


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Thread: RFQ - CNC Lathe parts - Aluminium - Metric - RADAR feed Horns

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    Default RFQ - CNC Lathe parts - Aluminium - Metric - RADAR feed Horns

    Hi all,

    I'm working on a RADAR project that requires tiny aluminium feed horns.

    The zip file enclosed gives the mechanical detail.

    The info is all there but it's buried in different places. The 3D drawings are from the EM simulator that we use which is not a

    mechanical drafting program and has very limited dimensioning abilities. It won't let us put dimensions on hole centres for

    example.

    Prototypes were hand made but they really need to be done by CNC for repeatability.


    The diagrams show two types of horn and a coupler that secures either horn to a PCB.

    I need a quote for 20 couplers, 10 of the large horn and 10 of the small Chaparral feed.

    thanks

    Tim

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    Default

    Hi Tim , I didn't see the zip file you attached. Where should I find it?
    East



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    Default Re: RFQ - CNC Lathe parts - Aluminium - Metric - RADAR feed Horns

    Its an attachment at the bottom of the post.



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    Default Re: RFQ - CNC Lathe parts - Aluminium - Metric - RADAR feed Horns

    Quote Originally Posted by TSL;2313748)


    I need a quote for 20 couplers, 10 of the large horn and 10 of the small Chaparral feed.

    I need to revise the quantity
    10 couplers
    10 Chapperal feeds
    2 large horns.

    Additional detail just supplied by our designer

    Material = Aluminium 6082 T6 AL6082

    Interior surface roughness Ra = 0.02um or better.

    Tolerance = 0.01mm


    thanks

    Tim



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    Default Re: RFQ - CNC Lathe parts - Aluminium - Metric - RADAR feed Horns

    Material = Aluminium 6082 T6 AL6082
    Not a problem.

    Interior surface roughness Ra = 0.02um or better.
    Tolerance = 0.01mm


    Um - the tolerance of 10 microns is doable, but the surface finish spec of 20 nanometres is REALLY pushing it!!!
    As they stand, your specs would permit a surface waviness of 10 microns, which is 500x rougher than the spec'ced roughness.

    I may of course be off with the fairies, but are you SURE?

    Cheers
    Roger



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    Default Re: RFQ - CNC Lathe parts - Aluminium - Metric - RADAR feed Horns

    Quote Originally Posted by RCaffin View Post
    Material = Aluminium 6082 T6 AL6082
    Not a problem.

    Interior surface roughness Ra = 0.02um or better.
    Tolerance = 0.01mm


    Um - the tolerance of 10 microns is doable, but the surface finish spec of 20 nanometres is REALLY pushing it!!!
    As they stand, your specs would permit a surface waviness of 10 microns, which is 500x rougher than the spec'ced roughness.

    I may of course be off with the fairies, but are you SURE?

    Cheers
    Roger
    Hi Roger,

    Yeah its because these are operating at 122GHz where surface roughness becomes a loss inducing concern.

    At 100GHz the skin depth of the signal in Aluminium is 0.28um, so the Ra needs to be better that that to avoid too much attenuation of the signal.

    I know 0.02um can be achieved with a diamond drill directly and/or interior magnetic polishing but we may have to settle for less dependent on cost of manufacture.

    regards

    Tim



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    Default Re: RFQ - CNC Lathe parts - Aluminium - Metric - RADAR feed Horns

    I see. That high in frequency. OK.
    All the same, I think you need some different specs than what you have given. A surface waviness of 5 um is within your specs, but I suspect it might not suit the actual needs.

    Have you considered a plastic injection moulding with a heavy metal plating over the plastic? That might meet your Roughness requirements, and you could of course silver-plate the interior afterwards as well.

    I would not bother with the diamond drill bit: that is not the right application for it. For machining hard glass or hard rock, yes, and I have machined up to Mohr 9 that way (Ruby, Basalt, carbide). Polished HSS would be more than enough with aluminium.

    Al 6082 T6 - not so common. 6061 or 6060 would meet your requirements quite well, and they are more readily available in many sizes.

    Your RFQ is not simple.
    * First one would have to generate properly dimensioned drawings. They don't need to be 3D models: 2D drawings would be enough for programming.
    * Then one would have to make some machining jigs to hold the parts, and they would have to be made very carefully. I think you would still need jigs with a 5-axis machine.
    * Then one would get around to machining the parts. Anti-climax: automated.
    * Then one might have to polish some of the surfaces to meet your Roughness specs. That is likely to be a manual job.

    Or one could knock up some plastic parts and have them vacuum-coated. But that only shortens some of the steps.

    Cheers
    Roger
    PS: if anyone tries to sell you on 3D printing - forget it. A dimensional tolerance of maybe 0.5 mm and a surface roughness not much better than that.



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    Default Re: RFQ - CNC Lathe parts - Aluminium - Metric - RADAR feed Horns

    Sounds like the requester needs to go back to the drawing board, literally. Asking the bidders to do his designing does not seem fair.

    Retired Master Electrician, HVAC/R Commercial. FLA Saturn 2 4x4 CNC Router Mach4 Kimber 1911 45ACP


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RFQ - CNC Lathe parts - Aluminium - Metric - RADAR feed Horns

RFQ - CNC Lathe parts - Aluminium - Metric - RADAR feed Horns