Hexagonal cutting of pre-polished circular segments is one of the critical process step in the manufacturing of ELT-M1 mirrors. This enables edge-to-edge optical performance, and precise mechanical references used to align the segment during operation of the segmented primary mirror. This paper presents the novel technology developed by Safran REOSC to guarantee fast and precise referencing of all critical features, hexagonal shaping, edge sensor interface machining, cutouts handling, and throughput over one segment per day. We will analyse the machining performance over 100 mirrors, and the effect of cutting on optical surface.
Ion Beam Figuring is a key technology after polishing, hexagonal cutting and integration to obtain ELT-M1 hexagonal segments without edge effects. This process used at REOSC over 30 years offers an efficient solution for finishing these large freeform optical components. This paper presents a dedicated figuring process strategy to maximize throughput and process convergence as well as to limit temperature increase during processing. We analysed the results of optical surface improvement over 100 ELT-M1 segments. These results highlight the high accuracy of IBF technology to correct hexagonal surfaces all the way to the edge. The final surface figure error below 10nm RMS was obtained while keeping low surface roughness. This is achieved after less than two figuring iterations leading to a throughput over one segment per day.
An ultra precision large optics grinding machine, BoX®, was developed and produced at Cranfield University. BoX®
offers a rapid and economic solution for grinding large off-axis aspherical and free-form optical components. Grinding
high accuracy surfaces with low subsurface damage reduces subsequent polishing time. This efficient grinding process
provides the capacity to grind 1.5 m parts. This paper presents an analysis of Astrositall® optical ground parts: a
hexagonal 84 m radius of curvature mirror of 1 m across corners and an off-axis 350 mm diameter mirror. The 1 m
hexagonal part is representative of segments under study for making extremely large telescope (ELT) segmented mirrors.
The second part was machined off-axis to demonstrate free-form fabrication capability. These operations demonstrate
the scalability of the rapid grinding process developed for large free-form optics. The use of an error compensation
procedure improved an initial ground form accuracy to +/- 1 μm p-v over 1 metre surface. The results highlighted the
effect of grinding parameters and machine dynamics on form accuracy and fabrication time.
A new ultra precision large optics grinding machine, BoX (R) , has been developed at Cranfield University. This machine is
located at the UK's Ultra Precision Surfaces laboratory at the OpTIC Technium, North Wales. This machine offers a
rapid and economic solution for grinding large off-axis aspherical and free-form optical components.
This paper presents an analysis of surface and subsurface damage assessments of Zerodur(R) ground using diamond resin
bonded grinding wheels. Zerodur(R) was tested as it is one of the materials currently under study for making extremely
large telescope (ELT) segmented mirrors such as in the E-ELT project.
The grinding experiments have been conducted on the BoX(R) grinding machine using wheels with grit sizes of 76 μm, 46
µm and 25 μm. The highest material removal rate (187.5 mm3/s) used ensures that a 1 metre diameter optic can be
ground in less than 10 hours. The surface roughness and surface profile were measured using a Form Talysurf. The
subsurface damage was revealed using a sub aperture polishing process in combination with an etching technique on
small parts.
These results are compared with the targeted form accuracy of 1 μm p-v over a 1 metre part, surface roughness of 50-150
nm RMS and subsurface damage in the range of 2-5 μm. This process stage was validated on a 1 metre hexagonal
Zerodur(R) part.
A new ultra precision large optics grinding machine, BoX® has been developed at Cranfield University. BoX® is
located at the UK's Ultra Precision Surfaces laboratory at the OpTIC Technium. This machine offers a rapid
and economic solution for grinding large off-axis aspherical and free-form optical components.
This paper presents an analysis of subsurface damage assessments of optical ground materials produced using
diamond resin bonded grinding wheels. The specific materials used, Zerodur® and ULE® are currently under
study for making extremely large telescope (ELT) segmented mirrors such as in the E-ELT project.
The grinding experiments have been conducted on the BoX® grinding machine using wheels with grits sizes of
76 μm, 46 μm and 25 μm. Grinding process data was collected using a Kistler dynamometer platform. The
highest material removal rate (187.5 mm3/s) used ensures that a 1 metre diameter optic can be ground in less
than 10 hours. The surface roughness and surface profile were measured using a Form Talysurf. The subsurface
damage was revealed using a sub aperture polishing process in combination with an etching technique.
These results are compared with the targeted form accuracy of 1 μm p-v over a 1 metre part, surface roughness
of 50-150 nm RMS and subsurface damage in the range of 2-5 μm. This process stage was validated on a 400
mm ULE® blank and a 1 metre hexagonal Zerodur® part.
An ultra precision large optics grinder, which will provide a rapid and economic solution for grinding large off-axis
aspherical and free-form optical components, has been developed at Cranfield University. This paper presents
representative grinding experiments performed on another machine - a 5 axes Edgetek - in order to verify the proposed
BoX(r) grinding cycle. The optical materials assessed included; Zerodur(r), SIC and ULE(r), all three being materials are
candidates for extreme large telescope (ELT) mirror segments. Investigated removal rates ranged from 2mm3/s to
200mm3/s. The higher removal rate ensures that a 1 metre size optic could be ground in less than 10 hours. These
experiments point out the effect of diamond grit size on the surface quality and wheel wear. The power and forces for
each material type at differing removal rates are presented, together with subsurface damage.
Many hundreds of mirror segments of 1-2 metre size will be needed to realise the next generation ground based extra large telescopes (ELTs). This paper introduces the design of a new ultra precise large optics grinding machine; Big OptiX or simply 'BOXTM'. This machine has been conceived to have unprecedented dynamic loop stiffness enabling ultra precise large 'free-form' optics to be rapidly ground within a serial production environment. Form accuracy capability of this machine will be 1 um per metre aperture and low levels of induced sub-surface damage will minimise the processing time of subsequent 'polishing' processes.
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