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Precision Machined Body for my 1.3 GHz coaxial low pass filter 

Machining and Microwaves
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This time I'll show you how I machined the socket mountings and body cavity of the microwave coaxial low pass filters to exacting tolerances using a lathe, mill, superglue and a blowtorch. Precision is critical to ensure that the filter performs to spec and the contacts are gas-tight. That means they won't leak microwave energy from any gaps. Machining tiny parts to within a few ten-thousandths of an inch on a 1980s manual Colchester lathe and a '60s Bridgeport milling machine is nicely challenging, but it's good fun chasing those microns!
This is part 4 of the series about machining a 1.3 GHz high power low pass coaxial filter to suppress harmonics from a high powered 23 cm band microwave transmitter. The rest of the videos are in this playlist: • 1.3 GHz Coaxial Low Pa...
Getting a near gas-tight pressure joint between the sockets and the ends plates is vital to ensure that circulating currents are confined to the inside of the low pass filter assembly so it performs exactly like the modelled simulation.
AIMEE my Artificially Intelligent Machining and Engineering Expert system advisor gives me a hard time as usual. It's richly deserved. I'm a rubbish machinist.
AIMEE has dreams of being Quinn Dunki, or Scott from Kentucky Ballistics, but as she is merely a collection of JPEG bytes created by a Generative Adversarial Network at thispersondoesnotexist.com it is a rather unattainable dream. Assuming bytes can dream. AIMEE's role is that of The Chorus in classical Greek plays, she has 20/20 hindsight and is a mix of the big sister I never had, my primary school teacher and an old manager I worked with. "Scary" doesn't even start to describe her.
She's showing off her new Google Cloud TTS API voice which includes phoneme directives, and she now runs on Python instead of JSON. If that sounds like gibberish, try asking a teenager to explain. Ignore they way they sigh and roll their eyes, they do that anyway.
Links to tools and things. For the Amazon items, I get a tiny affiliate commission from each sale, it doesn't affect the price you pay and it helps me make more videos! First link to each item is Amazon.com, second (if there is one) is for UK/DE and some other countries if the same item is available on those sites.
Starrett 93B tap wrench amzn.to/3PQgpVX or amzn.to/3N21fLz
Edge Technology lathe chuck spider set amzn.to/3x0t5Rh
These other links are just links to good stuff, I don't get anything other than a nice warm feeling if you buy them and enjoy them as much as I do.
Sheepskin Morse Taper Wiper from Chronos www.ebay.co.uk/itm/303238601858
Music: Corncob by Kevin Macleod is licenced to RU-vid
Kerching sound by Benboncan freesound.org/people/Benbonca... creativecommons.org/licenses/...
Pixel Shades by me
Contents:
00:00 Body
03:42 Cap
09:31 Glue
15:10 DRO
20:43 Flycut

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19 июн 2024

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Комментарии : 70   
@GermanMythbuster
@GermanMythbuster Год назад
Very good intro! You know right a way what's up. Your editing style gets better and better. I think you have found your style 😊👍 Great job mate! 🙂
@MachiningandMicrowaves
@MachiningandMicrowaves Год назад
I reckon by the time I get to 100 videos, I'll be mildly competent. Long way to go....
@BravoCharleses
@BravoCharleses Год назад
@@MachiningandMicrowaves Well you're doing a good job fooling us all.
@bobwilson7684
@bobwilson7684 Год назад
@@MachiningandMicrowaves sexy lightning is crucial, it comes out good, your images are atractive to the eye.
@9h1gb
@9h1gb Год назад
Nice Neil. As alway you got me hooked till the end.
@makerspace533
@makerspace533 Год назад
I'm surprised AIMEE didn't point out that whenever you use the knee for precision movement, the last move should always be up to prevent backlash from getting you.
@dennishall9173
@dennishall9173 Год назад
Love it when you set them little chips free , weeeeeee
@tacticalrabbit308
@tacticalrabbit308 Год назад
I like hearing Amy speak to clarify what you said . LoL 😂😂😂
@MachiningandMicrowaves
@MachiningandMicrowaves Год назад
Indeed, she speaks the truth. In my head, she sounds like an ex-colleague. She was a force of nature, and not to be trifled with. Scared the h*ck out of me.
@graemebrumfitt6668
@graemebrumfitt6668 Год назад
Awesomeness in a vid Dude! TFS, GB :)
@dumdidumdumification
@dumdidumdumification Год назад
I understood some of these words, but you're an excellent presenter :)
@MachiningandMicrowaves
@MachiningandMicrowaves Год назад
[blush] I need a lot more practice and I have a huge number of software tools and machining things to learn. Once I reach 100 videos that are not too embarrassing to watch, I might start to get the hang of this 'Choob lark.
@smash5967
@smash5967 Год назад
I've been able to get really good surface finishes in aluminum with a 5 insert face mill on Bridgeport with an R8 spindle, the trick is light cuts and plenty of cutting fluid. Having seen videos of fly cutters explode/fly through machine enclosures and multiple walls, plus being aware of how they aren't the best for the spindle bearings I tend to avoid them.
@MachiningandMicrowaves
@MachiningandMicrowaves Год назад
I do have a really nice end mill with inserts that makes an excellent finish, but it cost about five time what the cheap shell mill did. Actually I got if FREE when I bought 20 inserts. The cheapie has a variance in cutting edge height or at least 100 micrometres, which is enough to leave multiple lines. Two of the pockets are accurate to 5 um, so I sometimes run with a pair, but there's still the impacts and the large variation in tool pressure because of the missing inserts. What I need is a high quality 125 mm face mill which can take inserts that are perfect on aluminium and copper. Those beasts tend to be expensive, and then there's what to do when the heatspreader or case is wider than the cutter. Always end up with a faint herringbone pattern.
@AlessioSangalli
@AlessioSangalli Год назад
I'm so happy you uploaded, thanks
@MachiningandMicrowaves
@MachiningandMicrowaves Год назад
This is from four weeks ago, I'm still trying to catch up with the backlog. Four more filmed but not edited videos are in progress. I'm working full time at the day job to cover for an absent colleague and that leaves no time for editing videos or playing with microwave things. I just bought some 40 GHz active multiplier devices to get a bit of power at 76 GHz, 122, 241 and 248 GHz, but I must try to clear my backlog of work before doing ANYTHING new!
@AlessioSangalli
@AlessioSangalli Год назад
@@MachiningandMicrowaves I once tried to put down the gantt chart for my home projects and it's ridiculous, the dependency list is so deep - and I am not even running a RU-vid channel, that I know takes much more time and resources. However, let me say again, I am always so happy when you can finally upload. Thanks!
@paullang1961
@paullang1961 Год назад
hey long time sub love this channel mate cheers from Down Under
@MachiningandMicrowaves
@MachiningandMicrowaves Год назад
I just wish I had more time for making videos, Real Life is getting in the way of having fun!
@WhiskeyDale
@WhiskeyDale Год назад
let me say it....... tappy tap tap facing off as is tradition YAHTZEE !
@MachiningandMicrowaves
@MachiningandMicrowaves Год назад
Heh heh, AIMEE didn't feel inspired enough to channel Quinn this time, so thanks for the assistance!
@rogeronslow1498
@rogeronslow1498 Год назад
I love the machining. I find it very theraputic. However, many of the microwave precision machined filters have been superseded by SAW and BAW filters nowadays, and very often they're dirt cheap, but not tune-able.
@MachiningandMicrowaves
@MachiningandMicrowaves Год назад
Indeed, and they are zero fun as a result! A bit like electric cars. Boring consumer products that work suoerbly and are easy to maintain and cheap to build and completely lacking soul and character. Efficient, profitable, quiet and sensible. Now and then it's nice to play with steam external combustion engines and big old V8 petrol burners. Same with 3D printers and CNC. Hugely effective and performant, but feels like work instead of messing about on manual machines and using hand tools. I wouldn't want to be without all of that tech, but it doesn't quite scratch the same itch that my old clunkers and hand tools have. It's about the journey, not the destination
@rogeronslow1498
@rogeronslow1498 Год назад
@@MachiningandMicrowaves I suppose it depends on your perspective. I do it for a living and machined RF parts are simply not an option for the products I work with. I want to know that when the products roll off the end of the production line that every one will be perfectly tuned and meet spec. It may be boring but I sleep well knowing they are repeatable and no labout intensive tuning is required.
@MachiningandMicrowaves
@MachiningandMicrowaves Год назад
@@rogeronslow1498 Yep, if I was doing it for anything other than entertainment I would be doing everything very differently.
@joaopaulocoelho5401
@joaopaulocoelho5401 Год назад
I believe that your videos could become much better if the actual RF project, and some theory behind what you are doing, would be provided. Even if metal machining is fun to watch, I would be very much interested in its driving reasons and prototyping details (maybe in an extended version). Showing the final HF test results of the microwave parts you made would also be nice! Nevertheless, I really love your content!
@MachiningandMicrowaves
@MachiningandMicrowaves Год назад
The next episode of the low pass filter series will show the results of the filter when it's in use and carrying about a quarter of a kilowatt. I'm 6-8 weeks behind with editing and I have four videos partially complete, three of which have either a technical deep dive or some practical results and comparisons with the theoretical model. Working five days a week at the day job and managing a 1.6 acre garden and woodland, plus a large backlog of machining jobs means I have very little time for editing videos at the moment. I hope to go back to part time working from next week, then I should be able to get up to my target of at least one video per week. I have a part-completed video on the theory of coaxial low pass filters and how that translates into practical designs, looking at the require precision and the effects of the insulating "pips" and the transitions. I'm trying to learn Manim (originated by 3 Blue 1 Brown) so I can present the results in an animated graphical form. I've been talking to the distributor of Sonnet software to see if there's any way I can get an affordable licence to run larger designs in Sonnet. Also I've got the free versions of Antenna Magus and CST and I'm trying to learn those as well. I'm tied up 100% this week on putting together ninety transverter kits for 10 GHz that have been waiting for my attention for more than 18 months. At some point I'll get caught up and (hopefully) have a small stock of completed videos that I can release on a regular schedule, a nd with more of a mix of machining, practical experiments and theory. I'm a total beginner at all of this and it's going to take me AGES to get efficient and fast.
@joaopaulocoelho5401
@joaopaulocoelho5401 Год назад
@@MachiningandMicrowaves Thank you for your kind response. Please accept my apologies. It was not my intention to put any kind of pressure on you. I think your content is so singular and wonderful that I'm sure many of us would like to dive deeper into the engineering side of many of your videos (i.e. be able to learn from your vast knowledge on the subject :) ). RF design is so strange and counterintuitive that seeing first-hand the matching between the design and the final implementation would be fantastic. My remark was only to highlight the fact that microwave engineering is very fascinating and showing only the machining of the component, even if very entertaining, does not provide the whole story. However, I understand that you may have many different occupations that need your attention. I will be patient and wait for your upcoming videos :D!
@squelchstuff
@squelchstuff Год назад
Your filter is shaping up quite nicely. I do hope you plan to share your results when you characterise it. On a side note, is it me or is Amiee off her bytes and giving less sass than usual? I am aware she's off her bits, but that's another story. Great video as ever. I'm hooked.
@MachiningandMicrowaves
@MachiningandMicrowaves Год назад
I'm making eight of these, so it'll be interesting to see how similar they are to each other and how closely they conform to the modelled performance. I think we're both a little distracted at the moment, several big projects all about to happen at the same time. I need to finish the vid about the detailed design process and how that constrains the machining of the physical filter. This is a busy time for radio contesting/sport radio and I've had to make a lot of parts for antenna systems, azimuth rotator couplings and mountings. Sadly, it was all rush jobs, so I didn't get to film much of it, but I'll post a few photos of the finished items. For the next few days I'm finally collating all of the items for some 432 MHz to 10 GHz transverters. I ran a group purchase for the parts and enclosures and circuit boards and I have NINETY kits here, which cost me £7500 and I need to get them boxed and shipped. There are over 800 component sheets, each with up to ten surface-mount component strips which have to be cut to length then taped in the right place on each sheet. Then all of the other parts of the kit need to be bagged and boxed, then shipped. I think it will take less than 40 hours in total, but that is a huge proportion of my non-working time for the next week. The project is 18 months late so I just have to get on with it. Caroline was helping me with it before she died and somehow I was totally unable to restart work on the project. Now it's a year since we buried her, I have psyched myself up to complete the job. I might do a video about making one of the transverters. Perhaps I'll include a time-lapse of me making up component sheets....
@jimsvideos7201
@jimsvideos7201 Год назад
Great fun. RF is bananas but machining I more or less understand.
@MachiningandMicrowaves
@MachiningandMicrowaves Год назад
Different type of bananas from those in the CEE Australia videos that Kurtis makes!
@wilcojuffer5940
@wilcojuffer5940 Год назад
Hello in the early days (40y) I work also bindind a Bridgeport and I used some fix blocks for the deph control, can you show a drawing what you make ? Nice video 👍👍
@MachiningandMicrowaves
@MachiningandMicrowaves Год назад
Exploded model of the filter is at ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-S4LBXHngG1o.html
@wilcojuffer5940
@wilcojuffer5940 Год назад
Tanks a lot I know now what you turning and milling 👍👍😊
@SexyEarHair
@SexyEarHair Год назад
I know this is over 2 months old, but was that deflection and wobbling of the reamer at 2:08 not caught or just not a big worry in the end? Or third option, im just going crazy
@MachiningandMicrowaves
@MachiningandMicrowaves Год назад
I saw that, but it stopped wobbling after about 2 mm, I wonder if I deburred the hole carelessly? The top few mm of the hole might have been oval or oversized after that reamer wobble, but of course the top few mm were removed but a subsequent operation. The alignment of the socket is defined by the stepped ring on the read face mating with the stepped hole. If the central hole was actually off centre by 0.1 mm or so, there would be a very minor impact on the characteristic impedance of the nominally 50 ohm section of line. Having the same ratio of centre conductor size to bore size and a few percent offset of the centre conductor has an extremely low impact on the surge impedance as the inductance per unit length is constant but the capacitance is reduced on one side and raised on the other, almost balancing out. Measuring the error is rather tricky, as I'd need to make a 30mm diameter mandrel, centre it precisely then push the body over it, then use a dial test indicator on the bore. Well spotted anyway! I'll run a simulation usint ATLC2 to see what the impact on the impedance would be for say 0.5 mm off-centre positioning.
@SexyEarHair
@SexyEarHair Год назад
@@MachiningandMicrowaves Yeah i figured that even if it did wobble, when you put it all together Aimee would have noticed and not let you hear the end of it.
@aleksandarvasilevski7410
@aleksandarvasilevski7410 Год назад
Favorite machinist, since he is not using wd40 as lubricant for aluminium.
@MachiningandMicrowaves
@MachiningandMicrowaves Год назад
That cutting fluid is about 10% WD40, 5% IPA and the rest is an ester-based cutting oil (Millicut J40). Sorry!
@BravoCharleses
@BravoCharleses Год назад
I'm a big dummy. What's the benefit of using the face mill with one insert instead of with all the inserts?
@MachiningandMicrowaves
@MachiningandMicrowaves Год назад
It's a cheap shell mill and the precision of the pockets is poor, so if you use multiple inserts, you get a rotten finish with raised lines. Great for bulk removal when roughing, but hopeless for finishing. Also the mill only has an R8 collet. If it had something stiffer like an ISO40 or 50 it might be worth using an expensive face mill with multiple inserts. I need to make a dedicated flycutter which can take lathe tooling and that's super stiff with a lot of rotational inertia to get a mirror finish on copper and aluminium at least. Basically, it's a bodge, but it works!
@BravoCharleses
@BravoCharleses Год назад
@@MachiningandMicrowaves Sounds a lot like my own misadventures; working around limitations and making due with what I've got! Cheers from The Rubber City, Akron, Ohio, USA.
@MachiningandMicrowaves
@MachiningandMicrowaves Год назад
That's the secret of success, if you can't buy a thing, and can't make it, you can always repurpose something else. All you need is a plentiful supply of cunning and a sufficiently warped mind.
@petevenuti7355
@petevenuti7355 Год назад
Ever do anything in the terahertz gap?
@MachiningandMicrowaves
@MachiningandMicrowaves Год назад
Nothing yet. I used to play with big CO2 lasers, and I'm watching closely what's going on with fast photodiodes and mixing a pair of tunable dye lasers to generate beat frequencies in the hundreds of GHz range, but the area above 300 GHz and below 10 micrometres is very tough to get into unless you have a University lab or similar at your disposal. Some of the locals are doing interesting things with comms at 30 THz, but they are using bolometers and FLIR sensors for detection, and sometimes using a sun-tracking mirror as the thermal source to save on battery power when they are on a hilltop. I've been looking at germanium lenses and first surface mirrors for 30 THz, but not done anything more than drooling at old Melles Griot catalogues (now Thorlabs) and browsing the Edmund Optical website. I've played with long distance visible light comms using LEDs putting out about 15 watts of red light into a 300 mm square Fresnel lens, but finding sites in the UK with a long enough free-space path is close to impossible. However, I want to try cloud-bounce over 200+ km, but using LEDs and lasers is like using spark transmissions on radio, very 1900s. There are some Japanese experimenters doing interesting things at 800 GHz, but the practical limit for me at the moment is probably 288 GHz using harmonic mixer diodes and cavities on receive and multiplier diodes in flip-chip packages on transmit. I have more than enough projects to fill the next two or three years without trying to get hold of a die bonder. My aunt used to be an expert wire-bonding operator at a specialist semiconductor fab, so I could get a collab going with her if I can find an old bonder.
@petevenuti7355
@petevenuti7355 Год назад
@@MachiningandMicrowaves that was more than I expected and a lot to digest 😁. Do you remember ricochet wireless? Or, Do you remember Ronja or ever hear of Digital Atlantic? Both involved free space optic communication.Ronja was a hobbyist Russian project that I likely misspelled that used car tail light LEDs and telescopes. The second was a failed startup out of poolesville Maryland , if you look up their patent, the six smaller lenses to be used for tracking and alignment were my contribution.. the main optic was very much like the Huygens optics monolithic from his videos. The whole unit was intended to fit in the size of a soda can doing multigigibit at 1000ft.. after my friend Steve the CEO died it seemed like everything got run by the marketers not the engineers and the company fell apart.. This was back in the 90s when I was trying to start my own wireless ISP, but I was intentionally avoiding microwaves.. preferring optical or the 915 megahertz ISM... I was fascinated how strategic placement of rebar in the trees in the woods could create beneficial Fresnel effects to get around line of sight issues... I still have some free world dialup VoWiFi phones made by Utstarcom from near the end when I gave up..(cable broadband came out) My interest now in the terahertz range is much like when I was a child playing with old radios fascinated with trying to pick up or send signals in otherwise empty spectrum not having any idea what I was doing....( I wish I kept my tube collection) terahertz technology is so much untapped potential, if it could ever be practically and affordably figured out.. well it's not going to be by me because now all I got is a germanium window and $20 bucks
@mincukspuncuks8694
@mincukspuncuks8694 Год назад
Is there final assembly and measurements? Can't find them.... :(
@MachiningandMicrowaves
@MachiningandMicrowaves Год назад
Not yet sorry, Real Life is getting in the way right now!
@mincukspuncuks8694
@mincukspuncuks8694 Год назад
@@MachiningandMicrowaves I'll be waiting for it :).... Just wached BBC bugging video... it is awsome!!!
@sommersetcoker5455
@sommersetcoker5455 Год назад
i see it done regualary, but why only one insert?
@MachiningandMicrowaves
@MachiningandMicrowaves Год назад
It's a cheap shell mill and the precision of the pockets is poor, so if you use multiple inserts, you get a rotten finish with raised lines. Great for bulk removal when roughing, but hopeless for finishing. Also the mill only has an R8 collet. If it had something stiffer like an ISO40 or 50 it might be worth using an expensive face mill with multiple inserts. I need to make a dedicated flycutter which can take lathe tooling and that's super stiff with a lot of rotational inertia to get a mirror finish on copper and aluminium at least
@sommersetcoker5455
@sommersetcoker5455 Год назад
@@MachiningandMicrowaves well, that would explain why i get a rubbish finish from.my cheap shell mill! ha! i learn so much from your interesting videos. dont stop!
@AI7KTD
@AI7KTD Год назад
Procrastination is your middle name, sure, but where's the next part? It's been 7 months!
@MachiningandMicrowaves
@MachiningandMicrowaves Год назад
I must get that video finished, yes. Too many projects!
@chopper3lw
@chopper3lw Год назад
See This Old Tony... you should not have to go through life without a fly cutter.
@MachiningandMicrowaves
@MachiningandMicrowaves Год назад
The real application for the flycutter is for mirror-finishing copper heatspreaders that are 5 inches wide, so controlling chatter and avoiding resonances, tearing and edge impact ripples are critically important. I think I need a steel disk with a heavy cast-in lead infill and a 25 mm toolholder slot to be able to get the surface finish I want but with excellent damping and stiffness. If I tram the mill really well, I can get better than 5 micrometres flatness across a 100 mm copper slab using the single-cutter facemill in two passes, but I should be able to do better with a single pass of a much heavier cutter.
@chopper3lw
@chopper3lw Год назад
@@MachiningandMicrowaves I'll look forward to seeing the creation of the lead bearing beast.
@realfoggy
@realfoggy Год назад
Amy and I both love @KentuckyBallistics and nobody likes EGGPLANTS!
@MachiningandMicrowaves
@MachiningandMicrowaves Год назад
I grew some eggplants once. They withered and had mildew. Probably for the best.
@franklingomez5311
@franklingomez5311 Год назад
First again! I'm simply too quick.
@Tadesan
@Tadesan Год назад
May I be your apprentice? I want to expatriate.
@Putersdcat
@Putersdcat Год назад
This is total shit, I liked and subscribed
@ikbendusan
@ikbendusan Год назад
i guess i can't name a certain chinese supplier of goods; comment gets deleted automatically lol. have you thought about getting a monocrystalline insert or end mill from china? i bought one and was pleased with the result. they're relatively affordable (but they're not cheap per se; it's a diamond after all). i would share a picture but words are illegal in the youtube comments, much less hyperlinks
@MachiningandMicrowaves
@MachiningandMicrowaves Год назад
I don't see anything in the quarantined messages, so it must be deleted invisibly. I'll go and look. Never thought of trying monocrystalline inserts
@MachiningandMicrowaves
@MachiningandMicrowaves Год назад
Ali express part number 1005001946379849 for example. Interesting
@ikbendusan
@ikbendusan Год назад
​@@MachiningandMicrowaves that's the manufacturer i purchased my insert from. they have a bunch of different types. if you go to the baba website (let's see if this gets deleted lol) you can find sellers that sell milling sticks with the diamond directly attached to the end of them so you could try machining side walls with them too
@9h1gb
@9h1gb Год назад
By the way Neil, dropped you an email.
@NuttyforNissan
@NuttyforNissan Год назад
Ha Ha Parallax
@MachiningandMicrowaves
@MachiningandMicrowaves Год назад
...only possible explanation...
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