MIL-HDBK-660 Fabrication Of Rigid Waveguide Assemblies Sweep Bends And TwistsThis handbook is intended for the electronic installations technician to be used as a guide for fabricating rectangular waveguide bends and twists used in the microwave region of the electronic spectrum.

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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 mandrels ................................................................................................................................ 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 machine ........................................................................ 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.        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 twisting 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 waveguide......................................................................................................................... 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 waveguide 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