Active profiling and polishing for efficient control of material removal from large precision surfaces with moderate asphericity

We present the development of an active fabrication technology for controlling material removal on large precision surfaces of moderate departure from a sphere. The underlying philosophy was established as an efficient solution to the challenging problem of fabricating secondary mirrors of up to nominally 2.5 m in diameter for modern 8 m class telescopes and beyond. The facility described comprises a CNC profiler, two contact profilometers, and a full size active polisher. The trial work-piece was a convex surface of 830 mm in diameter on a zero-expansion ceramic ('Cervit') blank - a 1/3 scale hyperbolic mirror for a proposed 2.5 m diameter f/7 secondary mirror for the 8 m Gemini telescope. Using software error-correction from profilometric metrology data, a factor of 2 improvement in generating the convex aspheric profile was achieved. An active loose-abrasive polishing process is also described, in which a full-size tool is configured to deliver variable, edgeless, sub-diameter removal-footprints. Real-time monitoring of process variables is described, and approximately 10% convergence in each polishing pass is reported.