ABSTRACT
In the process of manufacturing the world's largest silicon carbide (SiC) aspheric mirror, the primary difficulties are mirror blank preparation, asphere fabrication, and testing, as well as cladding and coating. Specifically, the challenges include the homogeneity of the complicated structure casting, accuracy and efficiency of the fabrication process, print-through effect, fidelity and precision of test procedure, stress and denseness of cladding process, the dynamic range of interferometric measurement, and air turbulence error due to the long optical path. To break through such a barrier of difficulties, we proposed the water-soluble room temperature vanishing mold and gel casting technology, homogeneous microstructure reaction-formed joint technology, nano-accuracy efficient compound fabrication, gravity unloading technology, high-denseness low-defect physical vapor deposition (PVD) Si-cladding technology, test data fusion method, and time-domain averaging method, etc. Based on the proposed technologies and methods, we have accomplished the world's largest SiC aspheric mirror with a size of â4.03 m. The impressive performance of the SiC aspheric mirror is validated by the characteristics of the fabricated SiC aspheric mirror. The aerial density of the SiC blank is less than 120 kg/m2, surface shape test accuracy is better than 6 nm RMS, thickness inhomogeneity of the cladding layer is less than 5%, and the final surface figure error and roughness are 15.2 nm RMS and 0.8 nm RMS, respectively.
ABSTRACT
The swing arm profilometer (SAP) has been widely used to test large aspheric optics by measuring the asphericity from its best-fitting sphere (BFS). To further improve the test accuracy, we propose a pose-varied test mode for the SAP with a shorter-range probe to measure off-axis aspheric surfaces with stronger asphericity. In contrast to the classical SAP mode in which the air-table is fixed in a stationary position during measurement, we adjust the pose of each scan arc to match the local BFS and the measurement range of the probe decreases to half that of the global asphericity. To verify the effectiveness, we conduct experiments on an off-axis asphere with a diameter of 3 and 2 m. Compared with a classical SAP mode, it achieved an improved performance of 50% higher repeatability and 32% higher accuracy.
ABSTRACT
Pentaprism scanning technology (PPS) is an absolute testing method that has the advantages of a simple structure and absolute testing without an extra reference flat, as well as being able to provide in situ surface measurements, and more. It plays an important role in the manufacturing process of large flat mirrors. For calibrating the PPS's uncertainty, this paper describes a multi-mode scanning method to implement the measurement of low-order aberrations and introduces the concept of an autocorrelation coefficient to evaluate the data processing progress. These improvements were applied to the measurement of a large flat mirror (1630 mm in diameter), which demonstrates that the measuring uncertainty of PPS can be about 20 nm rms. Furthermore, in regard to the special requirements of M3MP, the prototype mirror of M3M (the tertiary mirror) in the Thirty Meter Telescope project with a non-circular aperture, we analyzed the slope distribution of low-order aberrations, power, and astigmatism. The sample route lines of PPS are then reorganized and a new data process algorithm is implemented. This work was performed in order to improve the PPS's performance in measuring low-order aberrations of large flat mirrors.
ABSTRACT
Off-axis parabolic parts (OAPs) or quasi-OAPs are mostly frequently used in large optical telescopes. Compared to the stressed mirror polishing, computer-controlled optical surfacing (CCOS) or other computer-controlled subaperture tools provide more flexibility. However, the fabrication efficiency needs to be promoted in tactical ways. In this paper, we present a large aperture CCOS lap equipped with a compound motion unit and go through the grinding and pre-polishing with its figure errors. A CCOS-based heterocercal tool is first used in large optics to restrain the edge effects. In the fine polishing stage, corrective polishing, smoothing, and ion beam figuring are applied in combination to finish. We experimentally test this strategy on an Ø1.5 m OAP, as a part of giant steerable science mirror (GSSM) in the Thirty Meter Telescope. Finally, the surface error of Ø1.5 m OAP is better than 1/50λ RMS (full aperture), and the mid-spatial frequency part is better than 0.64 µrad in slope RMS (effective aperture). The effective fabrication duration is reduced to 2 months.
ABSTRACT
Edge effect is regarded as one of the most difficult technical issues in a computer controlled optical surfacing (CCOS) process. Traditional opticians have to even up the consequences of the two following cases. Operating CCOS in a large overhang condition affects the accuracy of material removal, while in a small overhang condition, it achieves a more accurate performance, but leaves a narrow rolled-up edge, which takes time and effort to remove. In order to control the edge residuals in the latter case, we present a new concept of the 'heterocercal' tool influence function (TIF). Generated from compound motion equipment, this type of TIF can 'transfer' the material removal from the inner place to the edge, meanwhile maintaining the high accuracy and efficiency of CCOS. We call it the 'heterocercal' TIF, because of the inspiration from the heterocercal tails of sharks, whose upper lobe provides most of the explosive power. The heterocercal TIF was theoretically analyzed, and physically realized in CCOS facilities. Experimental and simulation results showed good agreement. It enables significant control of the edge effect and convergence of entire surface errors in large tool-to-mirror size-ratio conditions. This improvement will largely help manufacturing efficiency in some extremely large optical system projects, like the tertiary mirror of the Thirty Meter Telescope.
