Research and Experimental Verification on Topology-Optimization Design Method of Space Mirror Based on Additive-Manufacturing Technology

• Published in: Machines (Basel) 2021-12, Vol.9 (12), p.354
• Main Authors: Fan, Yanchao, Dong, Deyi, Li, Chao, Sun, Yuxin, Zhang, Zhiyu, Wu, Fanlu, Yang, Liwei, Li, Quhao, Guan, Yingjun
• Format: Article
• Language: English
• Subjects: Accuracy; Additive manufacturing; additive-manufacturing technology; Aluminum; Aperture; Apertures; Cameras; Configuration management; Critical components; Deformation; Design optimization; Design techniques; Diamonds; Lightweight; Machinability; Manufacturing; Mechanical properties; modal test; Optimization; Product development; Production methods; Reflectors; Resonant frequencies; single-point diamond-turning; space mirror; Structural design; Topology optimization; Verification
• ISSN: 2075-1702; 2075-1702
• DOI: 10.3390/machines9120354

As one of the most-critical components in space optical cameras, the performance of space mirrors directly affects the imaging quality of space optical cameras, and the lightweight form of mirror blanks is a key factor affecting the structural quality and the surface-shape accuracy of mirrors. For the design requirements of lightweight and high surface-shape accuracy with space mirrors, this study proposes a design and manufacturing method that integrates topology-optimization with additive-manufacturing technology. This article firstly introduced the basic process and key technologies of space-mirror design and analyzed the superiority of combining a topology-optimized configuration design and additive-manufacturing technology; secondly, the topology-optimized design method of a back-open-structure mirror was used to complete the scheme design of a Φ260 mm aperture mirror; finally, the laser selective-melting manufacturing technology was used to complete the Φ260 mm aperture mirror blank. The mirror and its support structure were assembled and tested in a modal mode; the resonant frequencies of the mirror assembly were all over 600 Hz; and the deviation from the analytical results was within 2%. The optical surface of the mirror was turned by the single-point diamond-turning (SPDT) technique. The accuracy of the optical surface was checked by a Zygo interferometer. The RMS accuracy of the mirror surface was 0.041λ (λ is the wavelength; λ = 632 nm). In the test of the influence of gravity on the surface-shape accuracy, the mirror was turned over, which was equivalent to twice the gravity, and the RMS of the mirror surface-shape accuracy was 0.043λ, which met the requirement. The verification results show that the mirror designed and fabricated by the additive-manufacturing-based mirror-topology-optimization method can be prepared by the existing process, and the machinability and mechanical properties can meet the requirements, which provides an effective development method for improving the structural design and optimizing the manufacturing of space reflectors.