Novel simulation technique for efficient fabrication of 2m class hexagonal segments for extremely large telescope primary mirrors

Dae Wook Kim, Sug-Whan Kim

Research output: Contribution to journalConference article

7 Citations (Scopus)

Abstract

2m class hexagonal primary mirror segments for extremely large telescopes such as OWL and EURO50 receive an I increased attention from the optics fabrication community world-wide. We report the development of a novel simulation technique offering cost-effective mass fabrication strategies for such mirrors of tight specifications. A family of static tool influence functions (TIFs) was derived using the Preston's material removal equation. We then confirmed that the mathematical TIFs can re-produce the material removal foot prints of the bulged processing tooling reported elsewhere. For fabrication simulation, these TIFs are fed into the in-house developed polishing algorithm that uses a combination of the fixed tool path patterns and the floating trajectory management based on the error grid weighting and the irregular tool paths. The algorithm also optimizes other control parameters including dwell time and tool pressure in real-time as the machine runs. Trial simulation runs using various combinations of the TIFs and the polishing algorithm showed the feasibility of producing the 2m class primary segments with the bulged precessing tooling. The details of the simulation technique together with the results and implications for mass fabrication are presented.

Original languageEnglish
Article number10
Pages (from-to)48-59
Number of pages12
JournalProceedings of SPIE - The International Society for Optical Engineering
Volume5638
Issue numberPART 1
DOIs
Publication statusPublished - 2005 Jun 14
EventOptical Design and Testing II - Beijing, United States
Duration: 2004 Nov 82004 Nov 11

Fingerprint

Extremely Large Telescopes
Influence Function
Telescopes
Hexagon
Fabrication
Mirror
telescopes
mirrors
Tool Path
fabrication
Polishing
Simulation
simulation
tooling
Dwell Time
Effective Mass
polishing
machining
Simulation Tool
Control Parameter

All Science Journal Classification (ASJC) codes

  • Electronic, Optical and Magnetic Materials
  • Condensed Matter Physics
  • Computer Science Applications
  • Applied Mathematics
  • Electrical and Electronic Engineering

Cite this

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abstract = "2m class hexagonal primary mirror segments for extremely large telescopes such as OWL and EURO50 receive an I increased attention from the optics fabrication community world-wide. We report the development of a novel simulation technique offering cost-effective mass fabrication strategies for such mirrors of tight specifications. A family of static tool influence functions (TIFs) was derived using the Preston's material removal equation. We then confirmed that the mathematical TIFs can re-produce the material removal foot prints of the bulged processing tooling reported elsewhere. For fabrication simulation, these TIFs are fed into the in-house developed polishing algorithm that uses a combination of the fixed tool path patterns and the floating trajectory management based on the error grid weighting and the irregular tool paths. The algorithm also optimizes other control parameters including dwell time and tool pressure in real-time as the machine runs. Trial simulation runs using various combinations of the TIFs and the polishing algorithm showed the feasibility of producing the 2m class primary segments with the bulged precessing tooling. The details of the simulation technique together with the results and implications for mass fabrication are presented.",
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