DFMA analysis and design optimization of a coaxial mixer module in X-band radar systems
Larson, Aaro (2025)
Kandidaatintyö
2025
School of Energy Systems, Konetekniikka
Kaikki oikeudet pidätetään.
Julkaisun pysyvä osoite on
https://urn.fi/URN:NBN:fi-fe2025033122328
https://urn.fi/URN:NBN:fi-fe2025033122328
Tiivistelmä
This thesis explores the application of Design for Manufacturability and Assembly (DFMA) principles and important aerospace design considerations in optimizing the mechanical design of a coaxial mixer module for X-band radar systems. The coaxial mixer module is a critical radio frequency (RF) component that converts a received radar signal into an intermediate frequency (IF), enabling signal processing and target identification. Operating principles of radar systems are well understood; however, limited research has addressed DFMA driven optimization of low-volume and performance-critical aerospace radar components.
A mixed-method approach was utilized: a comprehensive literature review, an expert interview, and CAD simulation to evaluate current design features, manufacturing, and material selection. Findings indicate that changing the housing material from steel to an aluminum alloy (AA 6061-T6) decreases the housing weight by 65%, translating to an 1,893.49 gram decrease in take-off weight. Additionally, a 29-38% reduction in housing manufacturing costs and a 30-40% reduction in tool wear is achievable. Critical tolerances were identified and defined, particularly surrounding the center conductor. Manufacturing techniques including various types of casting and additive manufacturing were explored; however, CNC machining is an essential step in all proposed manufacturing methods. Utilizing DFMA principles led to design proposals that could reduce the housing block parts count by 40%. This research explores transitioning from a formerly robust design to one more streamlined for modern manufacturing, assembly, and aerospace demands.
A mixed-method approach was utilized: a comprehensive literature review, an expert interview, and CAD simulation to evaluate current design features, manufacturing, and material selection. Findings indicate that changing the housing material from steel to an aluminum alloy (AA 6061-T6) decreases the housing weight by 65%, translating to an 1,893.49 gram decrease in take-off weight. Additionally, a 29-38% reduction in housing manufacturing costs and a 30-40% reduction in tool wear is achievable. Critical tolerances were identified and defined, particularly surrounding the center conductor. Manufacturing techniques including various types of casting and additive manufacturing were explored; however, CNC machining is an essential step in all proposed manufacturing methods. Utilizing DFMA principles led to design proposals that could reduce the housing block parts count by 40%. This research explores transitioning from a formerly robust design to one more streamlined for modern manufacturing, assembly, and aerospace demands.