Precision forming technology and application for high-precision sandwich reflector panels

Aiming at the precision forming manufacturing issues of high-precision, wide-range, undevelopable hyperbolic reflector panels, this paper further developed high-precision reflector panels forming technology based on "discrete nail die, vacuuming pressure, honeycomb sandwich, stress release and spring back", built a mechanical model for hyperbolic sandwich forming, determined the simulation algorithm of the forming process and summarized the main influence factors reflected panel precision. The shape precision of panels was increased by slotting stress release and spring back compensation, while the edge precision was assured by accessing developed panel by iterative strain energy releasing method. The precision-forming CAE system, environmental control and laser tracker measurement were used as the panel quality control methods. The shape precision and edge precision of panels manufactured by this technology totally met the design requirements. The technology can be successfully applied in large compact antenna test range (CATR) and the manufacture of millimeter wave antenna.