Forming closely spaced annular internal corrugations in circular waveguides

1. A method of forming corrugations on an interior surface of a cylindrical tube:

inserting a cutter head into the cylindrical tube;

inserting, after the inserting the cutter head, a mandrel into the cylindrical tube following the cutter head;

directing the cutter head to a furthest position within the cylindrical tube at which said corrugations are to be formed;

spinning the cutter head;

misaligning an axis of rotation of the cutter head and a longitudinal axis of the cylindrical tube while maintaining the axis of rotation parallel to the longitudinal axis, wherein cutting teeth of the cutter head are brought into contact with the inner surface;

orbiting the axis of rotation of the cutter head around the longitudinal axis while maintaining the axis of rotation parallel to the longitudinal axis, wherein the cutting teeth of the cutter head traverse the circumference of the inner surface, wherein first corrugations of uniform depth and spacing are formed in an annular pattern around the interior surface;

moving the axis of rotation toward alignment with the longitudinal axis while maintaining the axis of rotation parallel to the longitudinal axis, wherein the cutting teeth of the cutter head are brought out of contact with the inner surface;

pulling, after the moving, the cutter head toward the mandrel to a position adjacent to the first corrugations;

again misaligning, after the pulling, the axis of rotation of the cutter head and the longitudinal axis of the circular tube while maintaining the axis of rotation parallel to the longitudinal axis, wherein cutting teeth of the cutter head are brought into contact with the inner surface;

again orbiting the axis of rotation of the cutter head around the longitudinal axis while maintaining the axis of rotation parallel to the longitudinal axis, wherein the cutting teeth of the cutter head traverse the circumference of the inner surface, wherein second corrugations of uniform depth and spacing are formed in an annular pattern around the interior surface at the position adjacent to the first corrugations.

2. The method of claim 1 wherein said spinning comprises spinning a drive shaft.

3. The method of claim 2 wherein said spinning comprises spinning a universal joint interposed in said drive shaft.

4. The method of claim 1 wherein said misaligning comprises:

rotating an inner control tube relative to an outer control tube.

5. The method of claim 1 wherein said misaligning comprises:

rotating an inner bellows interposed in an inner control tube relative to an outer bellows interposed in an outer control tube.

6. The method of claim 5 wherein said spinning comprises spinning a universal joint interposed in a drive shaft, wherein said universal joint, the inner bellows and the outer bellows cooperate to form a flexible region.

7. The method of claim 1 wherein said orbiting further comprises cutting said corrugations with cutting teeth.

8. The method of claim 7 wherein said orbiting further comprises cutting said corrugations with said cutting teeth, wherein said cutting teeth are on a plurality of carbide bars positioned about the circumference of the cutter head.

9. The method of claim 1 wherein said spinning said cutter head spins hundreds of times during each orbit of said cutter head around the longitudinal axis.

10. The method of claim 1 wherein said spinning includes forming grooves free of burrs.

11. The method of claim 1 wherein said spinning includes forming grooves comprising bottoms that are concentric with the inner diameter of the cylindrical tube.

12. The method of claim 1 wherein said spinning includes forming grooves that are annular and equally spaced.

13. The method of claim 1 further comprising orienting the circular tube vertically, and exiting cutting fluid from the circular tube in a downward direction.

14. The method of claim 13 wherein said inserting said cutter head comprises inserting said cutter head into a top of the circular tube.

15. The method of claim 14 wherein said pulling, after the moving, said cutter head comprises pulling said cutter head in an upward direction.

16. The method of claim 1 further comprising flowing cutting fluid through a plurality of cutting fluid exit holes.

17. The method of claim 1 further comprising flowing cutting fluid through a plurality of cutting holes from a cutting fluid manifold.