Fabrication of traveling wavetube barrels using precision track forming

A method of fabricating a traveling wave tube assembly, comprising the steps of

• providing a hollow cylindrical barrel having a longitudinal axis and having a bore defined by an inner wall with an inside diameter;
• providing a first elongated tool having
• a first tool body, and
• at least two first track-forming elements extending outwardly from the first tool body and elongated parallel to a direction of elongation of the tool, the at least two first track-forming elements having a first circumscribed maximum diameter greater than the inside diameter of the hollow cylindrical barrel;
• forcing the first tool through the bore in a direction parallel to the longitudinal axis to define a track in the inner wall of the hollow barrel for each of the at least two first track-forming elements;
• providing a second elongated tool having
• a second tool body, and
• at least two second track-forming elements extending outwardly from the second tool body, the at least two second track-forming elements corresponding in circumferential position to the at least two first track-forming elements, the at least two second track-forming elements having a second circumscribed maximum diameter greater than the first circumscribed maximum diameter;
• forcing the second tool through the bore in the direction parallel to the longitudinal axis to enlarge the tracks in the inner wall of the hollow barrel;
• and
• assembling a traveling wave tube circuit assembly inside the bore, the traveling wave tube circuit assembly including at least two rods, one supported in each of the at least two tracks and extending parallel to the longitudinal axis.