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Zhejiang Machinery and Electrical Group

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Topological optimization design of space mirror based on additive manufacturing
Published:2022-09-22 author:LIU Duo, JIANG Yu-han, DONG De-yi, et al. Browse: 264 Check PDF documents
Topological optimization design of space mirror based on additive manufacturing

LIU Duo1, JIANG Yu-han1, DONG De-yi2, SUN Bao-yu1, GUAN Ying-jun1

(1.School of Mechanical and Electrical Engineering, Changchun University of Technology, Changchun 130012, China; 
2.Changchun Institute of Optics, Fine Mechanics and Physics, Chinese Academy of Sciences, Changchun 130033, China)

Abstract:  The traditional space mirror has the problems of long development cycle and high cost. In order to shorten the development cycle of the mirror and save the cost, the topology optimization and additive manufacturing technology were combined. On the premise of meeting the requirements of the shape accuracy of the mirror, the topology optimization design and additive manufacturing of the mirror structure with high lightweight rate were carried out. Firstly, the mathematical model of the topology optimization was established after determining the material and initial parameters of the mirror, and the manufacturability constraint was introduced into the optimization, the innovative stiffener structure at the back of the mirror meeting the requirements of surface accuracy was obtained. Then,the finite element analysis was carried out. The equivalence between the reduced scale model and the original size model was studied. Finally, the fabrication experiment of mirror scale model additive was carried out with AlSi10Mg aluminum alloy powder by selective laser melting (SLM) technology. The results indicate that the shape accuracy of the bare mirror in the vertical direction of the optical axis reaches peak value(PV)= 164.3 nm, root mean square (RMS)= 27.6nm under the self weight load, the optimized mirror mass is 4.75kg, and the lightweight rate reaches 85%, the high lightweight design of the mirror is realized according to the finite element analysis. After adopting additive manufacturing technology, the effect of highly restoring topology optimization mirror structure is achieved, which provides a new way for the efficient and rapid development of space mirror.

Key words:  large aperture space mirror; shape accuracy; topological optimization; mathematical model;selective laser melting (SLM) technology; manufacturability constraint
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