Photonics Research
Photonics Research
photonics
Article
The Optimization Design of a Lightweight 2 m SiC Mirror for
Ground-Based Telescopes
Zhichen Wang 1,2, *, Tao Chen 1 , Yuyan Cao 1 , Wenqiang Fan 1 , Honghao Wang 1,2 and Wenpan Wang 1,2
1 Changchun Institute of Optics, Fine Mechanics and Physics, Chinese Academy of Sciences,
Changchun 130033, China
2 University of Chinese Academy of Sciences, Beijing 100049, China
* Correspondence: [email protected]
Abstract: The weight of the primary mirror increases as the aperture of ground-based telescopes
increases, making it more challenging to maintain the positional stability and surface accuracy of the
solid primary mirror. Consequently, a 2 m lightweight silicon carbide (SiC) mirror and an optimization
method were proposed in this study. The relationship between the gravitational deformation of the
mirror and its thickness and number of supports was derived based on force analysis of the mirror; the
thickness of the mirror and the appropriate number of supports were obtained as initial parameters
for optimization. The back structure of the mirror was designed in a lotus pattern to improve its
rigidity. Numerous structural parameters were classified into major and non-major parameters
based on the results of a sensitivity analysis. The non-major and major structural parameters were
optimized using a Latin hypercube design method and a non-dominated sorting genetic algorithm,
respectively. The optimized 2 m lightweight SiC mirror had a mass of 119 kg and an areal density
of 38.7 kg/m2 . The surface figure error root-mean-square (RMS) in the vertical state of the optical
axis and the first modal resonance of the mirror assembly calculated using finite element analysis
were 11.3 nm and 76.5 Hz, respectively. Modal tests of the mirror assembly were conducted using
the hammering method, achieving a maximum relative frequency error of 7.4% compared with the
simulation results. The optimized 2 m SiC mirror was over 50% lighter than traditional passive
Zerodur mirrors of the same size.
approximately 221 kg/m2 [4,5]. A 2 m lightweight silicon carbide (SiC) PM with an annular
pattern on the back produced by CIOMP achieved a weight of 333 kg and an areal density
of 105 kg/m2 [6]. Corning used abrasive waterjetting and other technologies to produce
lightweight cores. These were then bonded to the front and back plates to manufacture
sandwich-structure ULE mirrors. This technology was used to fabricate a 1.3 m secondary
mirror weighing 185 kg for the Subaru telescope [7,8]. Composite Mirror Applications,
Inc. (CMA) produced a 1 m carbon fiber-reinforced polymer (CFRP) PM using composite
replication technology, achieving a weight of 27 kg and an areal density of 37 kg/m2 [9].
Zerodur, ULE, and SiC are commonly used materials for fabricating mirrors. In
addition to optical performance, the mechanical and thermal properties of lightweight
mirrors should be considered [10]. SiC, which has a high Young’s modulus and a low
density, is an ideal candidate for lightweight mirrors. During the early years, SiC mirrors
were expensive and used primarily for space mirrors; however, with the improvement in
production technology, the cost of SiC mirrors has decreased considerably, and they have
been used in ground-based telescopes [11,12]. SiC mirrors are produced via a reaction-
bonding process akin to casting, which enables the creation of an intricate structure that is
highly advantageous for lightweight mirrors. In light of the aforementioned advantages
of SiC, this study focuses on the structural design of a 2 m lightweight mirror using
SiC materials.
The structural design of lightweight mirrors mainly aims to eliminate mirror body
components with minimal deformation resistance contribution, thus reducing the weight
of the mirror without compromising its optical performance. Topology and parameter
optimization have been extensively utilized in the lightweight mirror design. Liu et al.
used a topology optimization technique to design a 2 m lightweight SiC primary mirror
of a space telescope [13]. Zhai et al. conducted a lightweight design for a 2.02 m SiC
mirror using parameter optimization, resulting in a model weight of 228 kg [14]. Wang
et al. employed structural and parametric optimization to develop a 2 m ultralight SiC
mirror weighing only 105 kg with an areal density of 34 kg/m2 [15]. Topology optimization
seeks to attain the most optimal structural topology, while parameter optimization aims to
determine the optimal dimensions of a given structure. This study employs a combined
approach of topology and parameter optimization to achieve the lightweight design of a
2 m SiC mirror.
3ρgr4
δ= (1)
16Et2
1.5r2 ρg
r
N= (2)
t Eδ
where δ denotes the maximum deformation of the mirror; t and r denote the thickness and
radius of the mirror, respectively; ρ and E denote the density and Young’s modulus of the
material, respectively; and N denotes the number of axial supports.
The parameters adjusted by different designers can vary considerably, which signifi-
cantly affects the design of the mirror structure. Consequently, a theoretical analysis of the
mirror thickness and the number of axial supports is necessary.
Photonics 2024, 11, x FOR PEER REVIEW 3 of 14
The parameters adjusted by different designers can vary considerably, which sig-
Photonics 2024, 11, 581 3 of 14
nificantly affects the design of the mirror structure. Consequently, a theoretical analysis
of the mirror thickness and the number of axial supports is necessary.
The elastic deformation of mirrors due to gravity is the primary factor influencing
The elastic deformation of mirrors due to gravity is the primary factor influencing their
their surface figure error. To minimize the gravitational deformation of mirrors, two
surface figure error. To minimize the gravitational deformation of mirrors, two methods
methods have been adopted: first, the stiffness of the mirror can be changed by selecting
have been adopted: first, the stiffness of the mirror can be changed by selecting materials
materials (such as SiC) with a high Young’s modulus or by altering the geometric di-
(such as SiC) with a high Young’s modulus or by altering the geometric dimensions of
mensions of the mirror (such as increasing the thickness of the mirror) to increase the
the mirror (such as increasing the thickness of the mirror) to increase the area moment of
area moment of inertia; second, the number of axial supports for the mirror can be in-
inertia; second, the number of axial supports for the mirror can be increased. Reducing
creased. Reducing the distance between the supports by increasing their number can
the distance between the supports by increasing their number can effectively reduce the
effectively reduce
gravitational the gravitational
deformation deformation
of the mirror (Figure 1).of the mirror (Figure 1).
= REI
( R R M( x)
δ= dx + Ax + B
k (3)
= "
!
M ( x ) = 0 qxdx (3)
where I denotes the area moment of inertia, q denotes the uniformly distributed gravita-
whereload,
tional I denotes the area
k denotes moment between
the distance of inertia,theq denotes the uniformly
two supports, distributed
M(x) denotes gravita-
the bonding
tional load, k denotes the distance between
moment, and A and B denote integral constants. the two supports, M(x) denotes the bonding
moment, and A anddistributed
The uniformly B denote integral constants.
gravitational load and the area moment of inertia can be
The uniformly
expressed as follows:distributed gravitational load and the area moment of inertia can be
expressed as follows: q = ρbhg (4)
= #$ℎ&
Z h/2
I= 2
z bdz (4)
(5)
+/*
−h/2
' = ( )*$ )
where b and h denotes the width and thickness of the structure between the two sup-
(5)
ports, respectively. -+/*
The number of axial supports can be expressed as follows:
where b and h denotes the width and thickness of the structure between the two sup-
ports, respectively. 2 2
π D2 − π d2
The number of axial supports can be expressed as follows:
N= (6)
π./02k1 -./21
2
= 3
./ 1
(6)
where D denotes the diameter of the mirror, and d denotes the diameter of the center hole
in the mirror.
where D denotes the diameter of the mirror, and d denotes the diameter of the center hole
From
in the Equations (3)–(6), the thickness of the mirror can be calculated as follows:
mirror.
From Equations (3)–(6), the thickness of the mirrorcan be calculated as follows:
5ρg D2 − d2
r
ℎ = 32Ev
4 ∙ N
h= − · 78 -9 : (7)
* 5 ;
(7)
For the 2 m SiC mirror, 18, 36, and 54 supports were selected, and the maximum
For the 2 m SiC mirror, 18, 36, and 54 supports were selected, and the maximum
gravitational deformations of mirrors with different thicknesses could be calculated using
gravitational deformations of mirrors with different thicknesses could be calculated us-
Equation (7). The deformation curves of the mirrors shown in Figure 2 indicate that the
ing Equation (7). The deformation curves of the mirrors shown in Figure 2 indicate that
gravitational deformation of the mirror is considerably reduced by increasing the number
of supports and the mirror thickness. However, as the number of supports and mirror
thickness increase, their impact on the gravitational deformation of the mirror becomes
less evident. Consequently, indiscriminately increasing the number of supports or mirror
sign complexity and complicates the support structure. Similarly, excessively increasing
the thickness of the mirror results in a minimal change in its gravitational deformation
but increases both its weight and manufacturing costs.
The gravitational deformation of the 36-supported ULE mirror is shown in Figure 2.
Photonics 2024, 11, 581 Even with 36 supports, the maximum deformation of the ULE mirror was slightly lower 4 of 14
than that of the SiC mirror with 18 supports, owing to the high specific stiffness (elastic
modulus/density) of SiC, which offers unparalleled advantages in lightweight mirrors.
The maximum
thickness might not be gravitational deformation
beneficial. Excessively of the 2 the
increasing m SiC mirror
number with 18 minimally
of supports axial sup-
ports is limited to 39.6 nm (λ/16, λ = 632.8 nm). The thickness of the solid mirror
affects the gravitational deformation of the mirror but increases the design complexity derived
and
complicates the support structure. Similarly, excessively increasing the thickness ofopti-
from Equation (7) is 122 mm, which serves as the initial parameter for lightweight the
mization.
mirror The in
results 18 asupports
minimalcan be arranged
change in inner and
in its gravitational outer ring configurations,
deformation withits6
but increases both
supports
weight andin manufacturing
the inner ring and 12 supports in the outer ring.
costs.
the number
Figure 2. Effect of the number of
of axial
axial supports
supportsand
andmirror
mirrorthickness
thicknesson
ondeformation
deformationofof22mmmirrors.
mirrors.
3. BackTheStructure
gravitational
of thedeformation
2 m SiC Mirrorof the 36-supported ULE mirror is shown in Figure 2.
Even with 36 supports, the maximum deformation of the ULE mirror was slightly lower
Many pa<erns can be used on the back of a lightweight mirror, the most commonly
than that of the SiC mirror with 18 supports, owing to the high specific stiffness (elastic
used being triangular, hexagonal, and annular pa<erns.
modulus/density) of SiC, which offers unparalleled advantages in lightweight mirrors.
In this
The study, agravitational
maximum triangular pa<ern with a of
deformation spacing
the 2 mofSiC
k between adjacent
mirror with ribs supports
18 axial was first
is limited to 39.6 nm (λ/16, λ = 632.8 nm). The thickness of the solid mirror derivedthe
used for the 2 m SiC mirror (Figure 3a). The location of the support should be at rib
from
intersections; consequently, the inner and outer rings are not independent but
Equation (7) is 122 mm, which serves as the initial parameter for lightweight optimization. are inter-
related
The as a function
18 supports can beofarranged
k. A finite element
in inner andmodel
outer of the
ring 2 m SiC mirror
configurations, was
with developed
6 supports in
using
the thering
inner ANSYS parametric
and 12 supports in design language
the outer ring. (APDL). The surface figure error RMS
varies with distance k under a gravitational load (Figure 3b). When the distance k is 200
mm,
3. Back theStructure
minimum of surface
the 2 m figure error RMS of the mirror is 19 nm. The deformation
SiC Mirror
cloudManymap patterns
of the mirror is shown in
can be used on the Figure
back3c.
of a lightweight mirror, the most commonly
used being triangular, hexagonal, and annular patterns.
In this study, a triangular pattern with a spacing of k between adjacent ribs was first
used for the 2 m SiC mirror (Figure 3a). The location of the support should be at the
rib intersections; consequently, the inner and outer rings are not independent but are
interrelated as a function of k. A finite element model of the 2 m SiC mirror was developed
using the ANSYS parametric design language (APDL). The surface figure error RMS varies
with distance k under a gravitational load (Figure 3b). When the distance k is 200 mm, the
minimum surface figure error RMS of the mirror is 19 nm. The deformation cloud map of
the mirror is shown in Figure 3c.
The 2 m SiC mirror was also tested using an annular pattern where the inner and outer
rings were independent of each other (Figure 4a). A finite element model of the mirror
was developed using the APDL. Different outer ring radii (rout ) were set and the inner ring
radius (rin ) was varied from 330 to 400 mm. The surface figure error RMS of the mirror was
computed under a gravitational load, with the variation curve of surface figure error RMS
indicated in Figure 4b. The minimum surface figure error RMS of the mirror is 19.5 nm
when rin and rout are 380 and 840 mm, respectively. A deformation cloud map of the mirror
is shown in Figure 4c.
Photonics 2024, 11, x FOR PEER REVIEW 5 of 14
Photonics 2024, 11, 581 5 of 14
The 2 m SiC mirror was also tested using an annular pa<ern where the inner and
outer rings were independent of each other (Figure 4a). A finite element model of the
mirror was developed using the APDL. Different outer ring radii (rout) were set and the
inner ring radius (rin) was varied from 330 to 400 mm. The surface figure error RMS of the
mirror was computed under a gravitational load, with the variation curve of surface fig-
(a) ure error RMS indicated (b) in Figure 4b. The minimum surface figure (c) error RMS of the
mirror is
Figure3.3.(a)19.5
(a)Thenm when
Thetriangular r and
triangular patternr
pa<ern on are
on the 380 and
the back 840 mm, respectively. A deformation cloud
back of
of the
the 22 m
m SiC
SiC mirror.
mirror. (b)
(b)The
Thecurve
curveofofsurface
surfacefig-
in out
Figure figure
map of the mirror is shown in Figure 4c.
ure error RMS versus distance k. (c) The deformation cloud map of the mirror when distance k is
error RMS versus distance k. (c) The deformation cloud map of the mirror when distance k is 200 mm.
200 mm.
The 2 m SiC mirror was also tested using an annular pa<ern where the inner and
outer rings were independent of each other (Figure 4a). A finite element model of the
mirror was developed using the APDL. Different outer ring radii (rout) were set and the
inner ring radius (rin) was varied from 330 to 400 mm. The surface figure error RMS of the
mirror was computed under a gravitational load, with the variation curve of surface fig-
ure error RMS indicated in Figure 4b. The minimum surface figure error RMS of the
mirror is 19.5 nm when rin and rout are 380 and 840 mm, respectively. A deformation cloud
map of the mirror is shown in Figure 4c.
Figure 5. (a) A lotus pa<ern on the back of the 2 m SiC mirror. (b) The curve of the surface figure
error RMS versus the inner ring radius Rin for different outer ring radii Rout. (c) The deformation
cloud map of the mirror when Rin and Rout are 370 and 830 mm, respectively.
Comparing three different pa<erns for the 2 m SiC mirror, the lotus pa<ern mirror
has surface figure error RMS of 17.7 nm, which is superior to those of the triangular and
annular pa<erns.
A topology optimization method was employed to improve the lightweight of the 2
m SiC mirror. The surface plate and support locations were designated as non-optimized
regions, whereas the remaining parts of the mirror were designated as optimized re-
gions. The result of the topology optimization is shown in Figure 6a, with red indicating
the parts to be retained and blue indicating those that can be removed. Based on the op-
(a) timization results, the (b) height of the outer edge of the mirror was (c) reduced. Considering
the grinding process, auxiliary reinforcing ribs were added to the back of the surface
Figure 5. (a) A lotus pa<ern on the back of the 2 m SiC mirror. (b) The curve of the surface figure
Figure
plate to (a) A lotus
5. enhance itspattern on the
rigidity. back of the
To enhance the2m SiC mirror.
natural (b) The
frequency ofcurve of the surface
the mirror figure
and position
error RMS versus the inner ring radius Rin for different outer ring radii Rout. (c) The deformation
error
the RMS versus
center of the inner
gravity ring radius
behind the Rin forplate,
surface different outer ring
semi-open back Rout . (c)
radiiplates Thedesigned
were deformation
on
cloud map of the mirror when Rin and Rout are 370 and 830 mm, respectively.
cloud map of the mirror when
the back of the mirror. The final Rin and R are
structure
out 370 and 830 mm, respectively.
of the 2 m SiC mirror is shown in Figure 6b.
Comparing three different pa<erns for the 2 m SiC mirror, the lotus pa<ern mirror
has surface figure error RMS of 17.7 nm, which is superior to those of the triangular and
annular pa<erns.
A topology optimization method was employed to improve the lightweight of the 2
m SiC mirror. The surface plate and support locations were designated as non-optimized
regions, whereas the remaining parts of the mirror were designated as optimized re-
gions. The result of the topology optimization is shown in Figure 6a, with red indicating
the parts to be retained and blue indicating those that can be removed. Based on the op-
timization results, the height of the outer edge of the mirror was reduced. Considering
the grinding process, auxiliary reinforcing ribs were added to the back of the surface
plate to enhance its rigidity. To enhance the natural frequency of the mirror and position
the center of gravity behind the surface plate, semi-open back plates were designed on
(a) (b)
the back of the mirror. The final structure of the 2 m SiC mirror is shown in Figure 6b.
Figure6.6.(a)
Figure (a)The
Thetopology
topologyoptimization
optimizationresult
result
ofof the
the 2m2m SiC
SiC mirror.
mirror. (b)(b)
TheThe final
final structure
structure of the
of the 2 m2
m SiC mirror with a lotus pa<ern.
SiC mirror with a lotus pattern.
4.
4. Optimization
Optimization of of Mirror
Mirror Structure
StructureParameters
Parameters
Optimization
Optimizationof of the
the structural
structuralparameters
parameterscould couldbe beperformed
performedafter afterdetermining
determiningthe the
structure of the 2 m SiC mirror. A 1/6 mirror was selected for
structure of the 2 m SiC mirror. A 1/6 mirror was selected for optimization to enhance optimization to enhance
computational
computational efficiency.
efficiency. The The mirror
mirror isisan
anaxisymmetric
axisymmetric geometric
geometric body,
body,evenly
evenlydivided
divided
into six sections at 60 ◦ intervals. Each section includes three axial supports, with one on
into six sections at 60° intervals. Each section includes three axial supports, with one on
the
the inner
inner ring
ring and
and twotwoon onthetheouter
outerring.
ring. The
The radial
radial stiffness
stiffness of of the
the mirror
mirror significantly
significantly
exceeds its axial stiffness, and the radial support positions
exceeds its axial stiffness, and the radial support positions are related are related to the mirror’s center
to the mirror’s
of gravity, remaining insensitive to variations in specific structural
center of gravity, remaining insensitive to variations in specific structural parameters. parameters. Meanwhile,
the axial support (a)positions significantly impact the optimization(b) of structural parameters.
Meanwhile, the axial support positions significantly impact the optimization of structur-
Consequently,
Figure 6. (a) Thethe lightweight
topology optimization
optimization process
result of the 2 m SiCincluded
mirror. (b)axial support
The final positions
structure of the 2and
excluded radial
m SiC mirror withsupport positions. Symmetrical constraints were applied to the connecting
a lotus pa<ern.
surfaces. A flowchart for the structural parameter optimization of the 2 m SiC mirror is
4. Optimization
shown in Figure 7. of Mirror Structure Parameters
Numerous structural parameters
Optimization of the structural of the 2 mcould
parameters SiC mirror could beafter
be performed further optimized,
determining theand
changes to certain parameters may have minimal effects on the
structure of the 2 m SiC mirror. A 1/6 mirror was selected for optimization to enhancesurface figure error RMS
and mass of theefficiency.
computational mirror. Simultaneous
The mirror isoptimization
an axisymmetric of these parameters
geometric body,would
evenlysignificantly
divided
reduce
into sixcomputational
sections at 60° speed, particularly
intervals. Each sectionfor includes
structural parameters
three with minimal
axial supports, with one impacts
on
onthethe
inner ring figure
surface and two on RMS
error the outer ring. The
and mass, radial in
resulting stiffness
a wasteofofthe mirror significantly
computational resources.
exceeds itsitaxial
Therefore, was stiffness,
imperative andtothe radial support
differentiate thesepositions
parameters are related
to discern to the
themirror’s
sensitivity
ofcenter of gravity,
the surface figureremaining
error RMS insensitive
and mass to variations
to parameter in specific structural
variations. parameters.
A parametric study
Meanwhile,
method the axial support
was employed positions
to conduct significantly
a sensitivity impact
analysis on thetheeleven
optimization of structur-
structural parameters.
Each factor (parameter) independently varied from low to high across 30 specific levels
(parameter values) within the experimental space, while the other factors were constant at
their baseline values. A total of 331 analytical calculations were conducted to identify the
Photonics 2024,11,
Photonics2024, 11,581
x FOR PEER REVIEW 77 of
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Figure7.7.Flowchart
Figure Flowchartfor
forthe
thestructural
structuralparameter
parameteroptimization
optimizationofofthe
the2 2mmSiC
SiCmirror.
mirror.
Figure 8a shows
Numerous that the
structural outer ringof
parameters radius
the 2 (rm2 )SiC
has mirror
the greatest
couldimpact on the
be further surface
optimized,
figure error RMS,
and changes followed
to certain by the main
parameters mayrib thickness
have minimal (tr ),effects
surface
onplate thickness
the surface (tf ), error
figure and
inner
RMS ring and radius
mass of(rthe 1 ). mirror.
Figure 8b shows that optimization
Simultaneous the main rib of thickness (tr ) has thewould
these parameters greatest sig-
impact
nificantly on the mirrorcomputational
reduce mass, followedspeed,by the particularly
surface platefor thickness
structural(tf ), back plate width
parameters with
(w b ), and mirror
minimal impacts thickness
on the (h). The remaining
surface figure errorstructural
RMS and parameters, including
mass, resulting in athe
wasteouterof
edge height
computational (h ), auxiliary rib height
o resources. Therefore, it (h ), outer edge thickness
s was imperative to differentiate (to ), auxiliary rib thickness
these parameters
(tto
s ), discern
and back theplate thickness
sensitivity (tb ),surface
of the were defined as theRMS
figure error non-major
and mass structural parameters
to parameter varia-
because
tions. Athey cause less
parametric thanmethod
study 10% variation in the surface
was employed figure error
to conduct RMS and
a sensitivity mass within
analysis on the
the
elevenexperimental
structuralspace. The Latin
parameters. Eachhypercube design (LHD)
factor (parameter) method was
independently employed
varied from low forto
non-major structural parameters, and the function can be expressed
high across 30 specific levels (parameter values) within the experimental space, while the as follows:
other factors were constant at their baseline values. A total of 331 analytical calculations
were conducted to identify the impact of each factor on the outcomes. The surface figure
error RMS and mass variations with respect to the structural parameters are shown in
Figure 8a and 8b, respectively. The greater the surface figure error RMS and mass varia-
tions, the more sensitive they are to changes in the structural parameters.
Photonics 2024, 11, 581 8 of 14
f ind ( X ) = (to , ho , ts , hs , tb ) T
min( RMS, mass)
S.T
3 ≤ to ≤ 6
(8)
30 ≤ ho ≤ 70
≤ ts ≤ 6
3
20 ≤ hs ≤ 50
3 ≤ tb ≤ 6
The optimization objective was to minimize the surface figure error RMS and mass
of the mirror, using a sample size of 100. The level distribution of each factor is shown
in Figure 9, demonstrating that the LHD method uniformly samples the factors within
the design matrix. The responses of the surface figure error RMS and mass are shown in
Photonics 2024, 11, x FOR PEER REVIEW 8 of 14
Figure 10. The preferred values of non-major structural parameters are summarized in
Table 1.
(a) (b)
Figure 8.
Figure 8. (a)
(a) Curves
Curves of
of surface
surface figure
figure error
error RMS versus the
RMS versus the structural
structural parameters
parameters of
of the
the 22 m
m SiC
SiC
mirror. (b) Curves of mass versus the structural parameters of the 2 m SiC mirror.
mirror. (b) Curves of mass versus the structural parameters of the 2 m SiC mirror.
Figure
After 8a shows that
completing the outer
the design ring radiusstructural
of non-major (r2) has the greatest impact
parameters, furtheron the surface
optimization
figure error RMS, followed by the main rib thickness (t
was required for the six major structural parameters, including the outer ring radius
r), surface plate thickness (tf), (r
and2 ),
inner ring radius (r ). Figure 8b shows that the main rib thickness
main rib thickness (tr ), surface plate thickness (tf ), inner ring radius (r1 ), mirror thickness
1 (t r) has the greatest
impact
(h), and on theplate
back mirror
widthmass,(wfollowed by the surface plate thickness (tf), back plate width
b ). The mass of the 1/6 mirror was limited to 21 kg. The
(wb), and mirror
optimization thickness
function can be(h). The remaining
expressed as follows: structural parameters, including the outer
edge height (ho), auxiliary rib height (hs), outer edge thickness (to), auxiliary rib thickness
T
(ts), and back plate thickness (tf bind
), were definedh, t f ,as
tr , the
r1 , rnon-major structural parameters be-
( X) = 2 , wb
cause they cause less than 10% variation in the surface figure error RMS and mass within
min( RMS, mass)
the experimental space. The
Latin hypercube design (LHD) method was employed for
S.T
non-major structural parameters, and the function can be expressed as follows:
110 ≤ hC≤ =
@AB 140DE , ℎE , DG , ℎG , DH I
mass ≤ 21
⎧
JAB K L, JMNN
⎪
(9)
⎪ 3L.≤
⎪ O tr ≤ 6
3 ≤ t f ≤ 6
≤3r1≤≤DE400 ≤6
30r≤ ℎ ≤ 70
⎨
300
E
(8)
⎪40 ≤ 3w≤ D ≤6
760 ≤ ≤ 850
⎪
2
b ≤G 80
⎪ 20 ≤ ℎG ≤ 50
Structural Parameters Initial Value (mm) Optimized Value (mm) Selected Value (mm)
Outer edge thickness (to ) 4 3.4 3.5
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edge FOR PEER
(ho ) REVIEW 45 50.6 50 9 of 14
Auxiliary rib thickness (ts ) 4 3.0 3
Auxiliary rib height (hs ) 40 28.2 28
Back plate thickness (tb ) 5 4.2 4
(d) (e)
(d) (e)
Figure 9. Distribution of the non-major structural parameters. Red indicated infeasible (constraint
Figure 9. Distribution
Figure 9. black
Distribution of the non-major
of thefeasible
non-major structural parameters.
structuralmet),
parameters. Red indicated
Red indicated infeasible
infeasible (constraint
violations), indicated (constraint blue indicated feasible-tie (as(constraint
good as previ-
violations), black indicated feasible (constraint met), blue indicated feasible-tie (as
violations), black indicated feasible (constraint met), blue indicated feasible-tie (as good as previ-good as previous
ous best), and green indicated feasible better (best so far). (a) Outer edge height (ho). (b) Auxiliary
best),ous best),
and (h and
green green indicated feasible be<er (best so far). (a) Outer edge height (h ). (b) Auxiliary
indicated feasible better (best so far). (a) Outer edge height (ho ). (b) Auxiliary rib
o
rib height s). (c) Outer edge thickness (to). (d) Auxiliary rib thickness (ts). (e) Back plate thickness
rib height (hs). (c) Outer edge thickness (to). (d) Auxiliary rib thickness (ts). (e) Back plate thickness
height
(tb). (h s ). (c) Outer edge thickness (to ). (d) Auxiliary rib thickness (ts ). (e) Back plate thickness (tb ).
(tb).
(a) (b)
(a) Figure 10. (a) Response of the surface figure error RMS. (b) Response(b)
of the mass.
Figure 10. (a) Response of the surface figure error RMS. (b) Response of the mass.
Figure 10. (a) Response of the surface figure error RMS. (b) Response of the mass.
Table 1. Values of non-major structural parameters of the 2 m SiC mirror.
The parameters for the NSGA-II are listed in Table 2. After 241 iterations, an optimal
Structural Parameters Table 1. Values
solution Initialof
with non-major
aValue
surface structural
figure
(mm) errorparameters
RMS value
Optimized of the
Value of 211.1
(mm) m SiC
nmmirror.
and a mass
Selected Valueof 19.8 kg was
(mm)
Outer edge thickness (tobtained.
o) The optimization
4 processes for the3.4surface figure error RMS 3.5
and mass are shown
Structural Parameters Initial Value (mm) Optimized Value (mm) Selected Value (mm)
Outer edge height (hoin ) Figure 11. Histograms
45 of the major structural
50.6 parameters are shown 50 in Figure 12. The
OuterAuxiliary
edge thickness (t o)
rib thickness horizontal
(ts)
4 4
3.4
3.0
3.5
3 axis indicates the
axis represents the range of parameter values, while the vertical
OuterAuxiliary
edge height (ho) (hs)
rib height 4540 50.6
28.2 28 50
Auxiliary rib thickness (t s
Back plate thickness (tb) ) 4 5 3.0
4.2 4 3
Auxiliary rib height (hs) 40 28.2 28
Back plate thickness (tb) After completing
5 the design of non-major4.2structural parameters, further 4optimiza-
tion was required for the six major structural parameters, including the outer ring radius
lected.
Table 3.The optimization values of the major structural parameters are summarized in
Table 3.
Table 2. Parameters for NSGA-II.
Table 2. Parameters for NSGA-II.
Photonics 2024, 11, 581 Parameters Value 10 of 14
Parameters Value
Population size 12
Population size 12
Number of generations 20
Number of generations 20
Crossover probability 0.9
number of times each value was selected during the optimization process. The convergence
Crossover probability 0.9
Crossover
of distribution
the optimization objective 10
indexis more likely the more a parameter value was selected. The
Crossover distribution index 10
optimization values of the
Mutation distribution major structural parameters are 20
index summarized in Table 3.
Mutation distribution index 20
(a) (b)
(a) (b)
Figure 11.
11. Optimizationprocess
processofof objectives. Red indicated infeasible, black indicated feasible,
Figure
Figure 11. Optimization
Optimization
blue indicated process
feasible-tie, ofobjectives.
and green
Red
objectives.
indicatedRed
indicated infeasible,
indicated
feasible
black
be<er.infeasible,
indicated
black
(a) Optimization
feasible,
indicated blue
process offeasible,
the sur-
indicated
blue feasible-tie,
indicated and
feasible-tie, green indicated feasible
and green indicated better. (a) Optimization process of the surface
face figure error RMS. (b) Optimization process feasible be<er. (a) Optimization process of the sur-
of the mass.
figure
face figure RMS.RMS.
errorerror (b) Optimization
(b) Optimizationprocess of theofmass.
process the mass.
Structural Parameters Initial Value (mm) Optimized Value (mm) Selected Value (mm)
Inner ring radius (r1) 370 361.4 360
Outer ring radius (r2) 830 825.7 825
Surface plate thickness (tf) 4 3.0 3
Main rib thickness (tr) 4 3.4 3.5
Mirror thickness (h) 122 128.2 128
Back plate width (wb) 50 47.3 47
Parameters Value
Population size 12
Number of generations 20
Crossover probability 0.9
Crossover distribution index 10
Mutation distribution index 20
Structural Parameters Initial Value (mm) Optimized Value (mm) Selected Value (mm)
Inner ring radius (r1 ) 370 361.4 360
Outer ring radius (r2 ) 830 825.7 825
Surface plate thickness (tf ) 4 3.0 3
Main rib thickness (tr ) 4 3.4 3.5
Mirror thickness (h) 122 128.2 128
Back plate width (wb ) 50 47.3 47
testswere
Modal tests wereconducted
conductedonon the
the mirror
mirror assembly
assembly using
using the the hammering
hammering method
method [18].
[18]. The mirror assembly was positioned on three identical support blocks,
The mirror assembly was positioned on three identical support blocks, and two high- and two
high-precision
precision tri-axial
tri-axial accelerometers
accelerometers were were
fixed fixed perpendicular
perpendicular one toone to another
another on theon the
outer
outer edge of the mirror. The test only achieved the eigen frequency of the mirror as-
sembly, without its mode shape, owing to the limited number of accelerometers. The fi-
nite element model and modal test of the mirror assembly are shown in Figure 14b and
Figure 14c, respectively. The simulation and test results are shown in Figure 15, indicat-
ing substantial agreement between the simulation and experimental results. The largest
(a) (b) (c)
Figure 13. Surface deformation of the 2 m SiC mirror (a) The optical axis is in a vertical state. (b)
The optical axis is in a horizontal state. (c) After compensating for the tilt of 0.6”.
Figure15.
Figure 15.Modal
Modalresult
resultcomparison:
comparison:simulation
simulationversus
versustest.
test.
6.6. Discussion
Discussion
Lightweight
Lightweightmirrors
mirrorsnot
notonly
onlyreduce their
reduce own
their weight
own weightbut but
alsoalso
reduce the weight
reduce and
the weight
cost
and of theofentire
cost system.
the entire Space-based
system. mirrors
Space-based thus offer
mirrors thusa offer
highera lightweight rate owing
higher lightweight rate
to launch weight constraints. For instance, the areal density of the 3.5 m Herschel
owing to launch weight constraints. For instance, the areal density of the 3.5 m Herschel PM is
25 kg/m² [11] and that of the 2 m ultralight space mirror is 34 kg/m² [15]. By
PM is 25 kg/m² [11] and that of the 2 m ultralight space mirror is 34 kg/m² [15]. By con- contrast, the
areal
trast,densities
the arealof the 2 m andof
densities 4 mthe
SiC2PM m produced
and 4 mbySiC CIOMP PM for ground-based
produced telescopes
by CIOMP for
are 105 kg/m² and 120 kg/m², respectively [6,12]. Compared with space
ground-based telescopes are 105 kg/m² and 120 kg/m², respectively [6,12]. Compared telescope mirrors,
the
with lightweight rate ofmirrors,
space telescope mirrorsthe forlightweight
ground-based
ratetelescopes
of mirrors needs further enhancement.
for ground-based telescopes
needs further enhancement. This study focused on the capability of using SiC in intricate
structures and proposed a 2 m SiC lightweight mirror with a lotus back structure, ideal
for ground-based telescopes. The areal density of the optimized 2 m SiC mirror is 38.7
kg/m2, which is significantly lower than that of the SiC mirrors in the aforementioned
ground-based telescopes.
Photonics 2024, 11, 581 13 of 14
This study focused on the capability of using SiC in intricate structures and proposed a 2 m
SiC lightweight mirror with a lotus back structure, ideal for ground-based telescopes. The
areal density of the optimized 2 m SiC mirror is 38.7 kg/m2 , which is significantly lower
than that of the SiC mirrors in the aforementioned ground-based telescopes.
The methods for determining the number of axial supports and mirror thickness can
be applied to mirrors of various materials in ground-based telescopes. The optimization
method can be applied to SiC mirror designs for ground-based telescopes and can also
serve as a reference for designing space-based SiC mirrors. However, the proposed design
and optimization methods for lightweight structures are subject to certain limitations for
mirrors made with other materials.
7. Conclusions
This study focused primarily on the lightweight optimization of a 2 m SiC mirror
for ground-based telescopes. The mirror thickness and number of axial supports were
preliminarily selected by analyzing the gravitational deformation of the mirror. The back
structure of the mirror was designed as a lotus pattern owing to its improved rigidity.
Numerous structural parameters were categorized into major and non-major structural
parameters via a sensitivity analysis of the surface figure error RMS and mass. The non-
major structural parameters were optimized using the LHD method, whereas the major
structural parameters were optimized using the NSGA-II model. The optimized 2 m SiC
lightweight mirror weighed 119 kg, with an areal density of 38.7 kg/m2 , which was more
than 50% lighter than traditional passive Zerodur mirrors of the same size. The proposed
structure and optimization method can serve as a reference for the design of SiC mirrors.
Author Contributions: Conceptualization, Z.W.; methodology, Z.W.; software, Z.W.; validation, Z.W.,
T.C., Y.C., W.F., H.W. and W.W.; formal analysis, Z.W.; investigation, Z.W.; resources, Z.W.; data
curation, Z.W.; writing—original draft preparation, Z.W.; writing—review and editing, Z.W. and Y.C.;
supervision, Z.W.; project administration, Z.W.; funding acquisition, Z.W. All authors have read and
agreed to the published version of the manuscript.
Funding: This research was funded by the National Natural Science Foundation of China (12303084)
and the Natural Science Foundation of Jilin Province (20240101309JC).
Institutional Review Board Statement: Not applicable.
Informed Consent Statement: Not applicable.
Data Availability Statement: The original contributions presented in the study are included in the
article material, further inquiries can be directed to the corresponding author.
Acknowledgments: Authors would like to thank the National Natural Science Foundation of China
and the Natural Science Foundation of Jilin Province.
Conflicts of Interest: The authors declare no conflicts of interest.
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