Topological optimization of lightweight aluminum mirror

Aluminum mirrors are widely used in aerospace and space remote sensing satellites. In order to improve the lightweight rate of aluminum mirrors and reduce the launch cost of commercial remote sensing satellites, a lightweight aluminum mirror with open back, triangular hole structure and three-point support was designed. Based on this structure, firstly, with the minimum mass as the optimization objective, the thickness and layout of the stiffener on the back of the mirror as the optimization object, and the minimum flexibility as the response constraint, the finite element method was used to optimize the size of the thickness of the stiffener on the back of the mirror and the topology optimization of the layout of the stiffener, and the lightweight rate of the aluminum mirror exceeded 63%. Then, the fixture was designed to carry out the single point diamond turning test. Finally, the surface shape accuracy of the mirror was measured by laser interferometer. Surface accuracy PV(peak to valley)can reach 1.48 μm, which can meet the requirements of commercial remote sensing satellites.

Topological optimization is a mathematical method that aims to find the optimal distribution of material within a given design space to achieve specific mechanical or physical properties. For lightweight aluminum mirrors, the primary goal is to reduce the weight while maintaining or even improving the mirror's optical performance.

The process of topological optimization for aluminum mirrors typically starts with the establishment of a finite element model. The design space is defined, which includes the regions where the mirror's structure can be modified. Boundary conditions and loadings, such as gravitational forces, thermal loads, and mechanical stresses during operation, are carefully considered.

One of the significant advantages of topological optimization in lightweight aluminum mirrors is the improvement in the mirror's surface accuracy. By optimizing the material distribution, the mirror can better withstand external forces and thermal variations, resulting in a more stable optical surface. This is crucial for applications such as astronomy, where high - precision imaging is required.

Another advantage is the reduction in manufacturing costs. By using topological optimization, the amount of material used in the mirror can be minimized without sacrificing performance. This not only reduces the cost of raw materials but also simplifies the manufacturing process in some cases.

3D model after topology optimization

In conclusion, topological optimization offers a promising approach for the design of lightweight aluminum mirrors. It enables the creation of more efficient, accurate, and cost - effective mirror structures, which will undoubtedly contribute to the development of various optical applications.

MG-Optics is professional in aluminum mirror lightweight manufacturing and polishing. Just send us your requirements, we will offer you designing and quotation.