Theoretical Justification and Analysis of Technology for Manufacturing Waveguide-and-Distribution Systems of Spacecraft Communication Devices

Manufacturing of extended thin-walled waveguide-and-distribution system (WDS) by soldering separate elements is associated with force, strain and temperature impacts leading to undesirable deformations both in local areas as well as in the whole structure. Each element and the system in general are subjected to local thermal exposure that results in temperature stresses and strains. The stresses that occur due to heating can cause irreversible deformations of the structure manifested as local deflections and distortions of the cross section geometry. When assembling waveguide-and-distribution systems, even minor angular and linear displacements in the places where the elements are joined result in disruption of the overall geometry of the structure and therefore, a displacement of the mounting points relative to the desired location. Forced alignment of these points would create internal stresses, which combined with external impacts, could violate the conditions of strength, rigidity and location of the control mounting points. To achieve the required strength, rigidity and accuracy parameters of the system, it is necessary to perform a theoretical and calculation analysis of the manufacturing process parameters, steps, actions and methods. The paper presents a method of calculating waveguide-and-distribution systems that can be used to promptly determine the stress-strain state with a required accuracy in order to ensure strength, rigidity and sufficient geometrical accuracy of the WDS structure. The WDS is treated as a rod model in the global formulation and as a shell structure when a separate local area is analyzed in detail. This approach enables the assessment of the stress-strain state in general and more precise calculations of the stresses and strains in defined local areas with nearly any required accuracy. An example showing calculations of the dynamics of variation of the gap between thin-walled elements in the process of soldering is given. An analysis of the stress-strain state of the mounting soldered seam between the elements is performed. The results obtained using the proposed two-step calculation method provide the required quality throughout the whole process of manufacturing an extended waveguide-and-distribution system for a spacecraft.

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