A feasible way to improve the manufacturing efficiency of large reaction-bonded silicon carbide optics is to increase the processing accuracy in the ground stage before polishing, which requires high accuracy metrology. A swing arm profilometer (SAP) has been used to measure large optics during the ground stage. A method has been developed for improving the measurement accuracy of SAP using a capacitive probe and implementing calibrations. The experimental result compared with the interferometer test shows the accuracy of 0.068 μm in root-mean-square (RMS) and maps in 37 low-order Zernike terms show accuracy of 0.048 μm RMS, which shows a powerful capability to provide a major input in high-precision grinding.
The swing arm profilometer (SAP) has been playing a very important role in testing large aspheric optics. As one of most significant error sources that affects the test accuracy, misalignment error leads to low-order errors such as aspherical aberrations and coma apart from power. In order to analyze the effect of misalignment errors, the relation between alignment parameters and test results of axisymmetric optics is presented. Analytical solutions of SAP system errors from tested mirror misalignment, arm length L deviation, tilt-angle θ deviation, air-table spin error, and air-table misalignment are derived, respectively; and misalignment tolerance is given to guide surface measurement. In addition, experiments on a 2-m diameter parabolic mirror are demonstrated to verify the model; according to the error budget, we achieve the SAP test for low-order errors except power with accuracy of 0.1 μm root-mean-square.
In this paper, the influence on the image quality of manufacturing residual errors was studied. By analyzing the statistical distribution characteristics of the residual errors and their effects on PSF and MTF, we divided those errors into low, middle and high frequency domains using the unit “cycles per aperture”. Two types of mid-frequency errors, algorithm intrinsic and tool path induced were analyzed. Control methods in current deterministic polishing process, such as MRF or IBF were presented.
The high precision off-axis asphere mirrors are quite usefull in the modern sapce optical system.in this paper, the
ion beam figuring is researched to accomplish the final surface accuracy. Firstly, The IBF machine we used is introduced
simplely. The correction method for the distortion in off-axis mirror interference measurement is studied. Beacasue of
the curve shape of the off-axis mirror, the changing of the removal function was analyzed simply. In order to testify the
reaserch, a 1100mm×800mm off-axis aspheric mirror is finished by ion beam figuring. After 2 times polishing, the
surface error was corrected to RMS 9nm in full aperture and achieved 6.3nm in sub- aperture.
Due to the central obscuration problem exists in most optical synthetic aperture systems, it is necessary to analyze its effects on their image performance. Based on the incoherent diffraction limited imaging theory, a Golay-3 type synthetic aperture system was used to study the central obscuration effects on the point spread function (PSF) and the modulation transfer function (MTF). It was found that the central obscuration does not affect the width of the central peak of the PSF and the cutoff spatial frequency of the MTF, but attenuate the first sidelobe of the PSF and the midfrequency of the MTF. The imaging simulation of a Golay-3 type synthetic aperture system with central obscuration proved this conclusion. At last, a Wiener Filter restoration algorithm was used to restore the image of this system, the images were obviously better.
The high precision optical mirrors are quite important for the modern optical system. In this paper, a novel
Magnetic Medium Assistant Polishing technology and device is researched for optical finishing. The key element of the
device is a designed magnetic wheel and accessorial magnetic component. The solid magnetic powder arranged with the
magnetic field distribution and became a flexible polishing brush tool. The solid magnetic medium tool working with a
high rolling speed and the polishing liquid with abrasive was injected to contact region of the optical surface. The
magnetic powder tool is reforming with the magnetic field all the time, and this feature made the removal rate and
distribution of the removal function invariable. The device is connected to the polishing machine. The fabrication
experiments were completed. The distribution of the removal function is like a raindrop and asymmetry in one
orientation. The removal stability of the tool was quite good and achieves 95% sameness of peak value in one hour. The
primary experiments shown that the technology can be used in the practical fabrication.
Design method led by high precision finite element analysis (H-FEA) and structural optimization platform is provided to obtain the support and the configuration of large aperture mirror. Firstly the mirror’s abstract model, whose configuration depends on several geometric parameters, is drawn by CAD software. Then the H-FEA is carried out to get the adequate FEM model balancing precision and computing cost. Afterward optimization of the abstract model is implemented. Finally the mirror’s detailed model is drawn and optimized parametrically. All procedures and iterations are driven automatically in an integrated flow without manual interruption. A 1.5 meter aperture mirror design example, achieving λ/12 PV and λ/56 RMS (λ=632.8nm), shows the effectiveness and practicability of the method.
Freeform surfaces provide more degrees of freedom for design of optical systems, and enhance the ability of
compensation and correction aberrations. Freeform surfaces are of advantage to balance the unsymmetrical aberrations, especially for the wide-field off-axis optical systems. This paper focus on an off-axis reflective optical system, which focal length is 550mm, F# is 6.5 and field of view (FOV) is 76°. The system adopts some freeform surfaces. We discuss the problems we noticed in processes of design, manufacture, measurement and alignment, and the solutions. At last, the periodical research result and the expected performance are given.
The stressed-lap technique has been proven to be an effective method to meet the challenge of polishing large mirrors
with highly aspheric figures. It has the advantage of high material removal and strong natural smoothing tendency over a
wide range of spatial frequencies, only round mirrors could be processed with this technology. A solution is put forward
in this paper by applying the CCOS (Computer controlled optical surfacing) removing strategy into the stressed lap
technology, employing the stressed lap as the removing tool but moving the lap in the CCOS fashion, naming the
stressed lap with orbital motion. With the new technology, almost any shape of mirror could be processed, the figuring
ability could be improved and the changing rate of the force imposed on the lap turn out to be only 1/6 of the stressed lap
with spinning motion based on simulation results, which conducing a lower response requirement of the lap with orbital
motion.
Wavefront coding (WFC) technology can extend the depth of focus of an optical system, which makes the application of this technology to space cameras extremely attractive. This paper introduces the application of wavefront coding to three-mirror anastigmatic optical systems. A transition model is established, in which the secondary mirror is regarded as the wavefront coding element and redesigned according to mathematical calculation. A comparison of modulation transfer function (MTF) behavior between the traditional system and the innovative system with wavefront coding technology is provided. The MTF behavior of both on-axis and off-axis field-of-view points remains the same in spite of the extended depth of focus. It is also observed that the system becomes very insensitive to aberration related to defocus through WFC technology. Errors in optical design and its improvement are discussed. The linear transition model is proven to be an acceptable one. Finally, an extension factor for the depth of focus is defined, and its effect is presented graphically.
Annular subaperture stitching interferometric technology can test large-aperture, high numerical aperture aspheric surfaces with high resolution, low cost and high efficiency without auxiliary null optics. In this paper, the basic principle and theory of the stitching method are introduced, the reasonable mathematical model and effective splicing algorithm are established based on simultaneous least-squares method and Zernike polynomial fitting. The translation errors are eliminated from each subaperture through the synthetical optimization stitching mode, it keeps the error from transmitting and accumulating. The numerical simulations have been carried on by this method. As results, the surface map of the full aperture after stitching is consistent to the input surface map, the difference of PV error and RMS error between them is -0.0074 λ and -0.00052 λ (λ is 632.8nm), respectively; the relative error of PV and RMS is -0.53% and -0.31%; and the PV and RMS of residual error of the full aperture phase distribution is 0.027 λ and 0.0023 λ, respectively. The results conclude that this splicing model and algorithm are accurate and feasible. So it provides another quantitive measurement for test aspheric surfaces especially for large aperture aspheres besides null-compensation.
Wavefront coding technology can extend the depth of focus of a well-corrected three-mirror anastigmatic optical system by about ten times, but the image obtained directly by charge-coupled devices blurs at the same time. An effective image restoration must be applied to these blurred images. This paper describes an innovative method that restores the blurred image, which combines the optical design software and mathematical software. The point spread function of system with wavefront coding technology is quite different from the usual and difficult to simulate by a disk function or other simple function in most cases. The commercial optical design software is applied to obtain the point spread function. If a 1×1-pixel image with brightness 255 is set as the point source of a optical system, the result of calculation software using a ray tracing algorithm will itself be the digital point spread function. This is proven to be a simple and effective way to acquire the complicated point spread functions of unusual optical systems such as those using wavefront coding technology. A regularization factor and contrast-adjusting factors are introduced into the classical Wiener filter, which achieves good restored images: the root-mean-square error is less than 0.0193, while the peak signal-noise ratio is higher than 23.7. Some parameters of the filter can be adjusted so that the restored image is more suitable for evaluation by eye. It is also shown that a single filter can restore all the images within the extended depth of focus.
CCOS (Computer Control Optical Surfacing) technology is widely used for making aspheric mirrors. For most
manufacturers, dwell time algorithm is usually employed to determine the route and dwell time of the small tools to
converge the errors. In this article, a novel damp iterative algorithm is proposed. We chose revolutions of the small tool
instead of dwell time to determine fabrication stratagem. By using resistance iterative algorithm, we can solve these
revolutions. Several mirrors have been manufactured by this method, all of them have fulfilled the demand of the
designers, a 1m aspheric mirror was finished within 3 months.
Reaction Bonded (RB) SiC mirrors due to their excellent specific stiffness and thermal properties have been widely used in space telescopes. However, polishing large SiC aspherical mirrors is difficult compared to other materials such as fused silica or Zerodu. In addition, surface roughness of the polished SiC mirrors is limited by the defects of the materials and needs to be improved by means of surface coating technique.
This paper introduces the current progress of large SiC aspherical mirrors manufacturing and testing in CIOMP. In particular, the procedures of making large off-axis aspherical mirrors were discussed in detail. A proprietary computer controlled optical surfacing (CCOS) technique was utilized to grind and polish the mirrors and the computer aided null test was used to measure the surface figure. As results, a 600mm class off-axis SiC aspherical mirrors was demonstrated with figure error less than 13nm rms.
The method of null test is widely used for testing an aspheric mirror. During optical manufacturing process, the mirror has to be moved up and down for testing and fabricating. Because the alignment of null test is difficult and time costing, the efficiency of making aspheric mirror is decreased greatly. In order to solve the problem, we developed a software based on polynomial fitting to calculate the misalignment parameters. By using the software and computer numeric controlled adjusting equipments, the efficiency of testing is increased and the accuracy of test has reached up to λ/40 RMS where λ equals to 632.8nm, which has fulfilled the demand of the designer.
The characteristics and effects of alignment error on test results are analysed in this paper. The mathematical model are established, the least square method is used to determine the misalignment. Procedures are presented that allow for separation of misalignment from misfigure in asphere testing. The misalignment-induced aberrations by corrector and the support of the mirror can be calculated and subtracted from segment interferogram so that only true misfigure remains. The accuracy of the system can reach up to 0.028λ(λ=632.8nm).
A method of fabricating an off-axis, lightweighting aspheric mirror is described, and its final results is given. The rectangle aperture of the mirror is 590mmx210mm, and its lightweighting rate is 50%. The final accuracy reached up to λ/40 RMS where λ equals to 632.8nm.
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