Design and fabrication of lightweight additively manufactured mirrors for aviation
Songnian Tan, Quanchao Li, Yongsen Xu, Honghai Shen, Yanping Cheng, Ping Jia, Yulei Xu
Abstract
This paper proposes a design process for additively manufactured mirrors. A central support aspheric mirror and tripod support structure were manufactured via selective laser melting. To achieve substantial weight reduction, an additively manufactured body-centered cubic lattice structure was used in the mirror design. Simulation analysis showed that the mirror had good rigidity. Single-point diamond turning was applied to obtain an optical quality mirror. After assembly, the rms surface shape accuracy of the mirror was <mml:math xmlns:mml="http://www.w3.org/1998/Math/MathML" display="inline"> <mml:mrow class="MJX-TeXAtom-ORD"> <mml:mn>0.069</mml:mn> </mml:mrow> <mml:mi>λ</mml:mi> </mml:math> ( <mml:math xmlns:mml="http://www.w3.org/1998/Math/MathML" display="inline"> <mml:mi>λ</mml:mi> <mml:mo>=</mml:mo> <mml:mrow class="MJX-TeXAtom-ORD"> <mml:mn>632.8</mml:mn> </mml:mrow> <mml:mspace width="thickmathspace"/> <mml:mrow class="MJX-TeXAtom-ORD"> <mml:mrow class="MJX-TeXAtom-ORD"> <mml:mi mathvariant="normal">n</mml:mi> <mml:mi mathvariant="normal">m</mml:mi> </mml:mrow> </mml:mrow> </mml:math> ). The surface roughness (Ra) of the additively manufactured metal mirror was 8.125 nm. These findings provide a strong theoretical basis and technical support for the preparation and application of lightweight metal mirrors.