Fast manufacturing of E-ELT mirror segments using CNC polishing

C. Gray, I. Baker, G. Davies, R. Evans, N. Field, T. Fox-Leonard, W. Messelink, J. Mitchell, P. Rees, S. Waine, D. D. Walker, G. Yu

Research output: Chapter in Book/Report/Conference proceedingConference contribution

14 Citations (Scopus)

Abstract

We report on the first-ever demonstration of grinding and polishing full-size, off-axis aspheric, mirror segments as prototypes for an extremely large telescope, processed entirely in the final hexagonal shape. We first describe the overall strategy for controlling form and mid spatial frequencies, at levels in the vicinity of <10nm RMS surface. This relies first on direct CNC grinding of the base-form of these 1.4m segments, using the Cranfield BoX™ machine. The segments are then mounted on a custom designed (Optic Glyndwr Optoelectronic Engineering Group) three segment hydraulic support, and CNC polished on a Zeeko IRP 1600 machine using a variety of custom tooling. We overview the fullaperture and sub-aperture metrology techniques used to close the process-loop and certify quality, all of which operate with the segment in-situ on the IRP1600. We then focus on the pristine edge-definition achieved by the combination of tool-lift and smoothing operations; results never previously demonstrated on full-size pre-cut hexagonal segments. Finally, the paper discusses the feasibility of scaling the process to deliver 931 segments in seven years, as required for the E-ELT project.

Original languageEnglish
Title of host publicationOptical Manufacturing and Testing X
Volume8838
DOIs
Publication statusPublished - 28 Nov 2013
Externally publishedYes
EventOptical Manufacturing and Testing X - San Diego, United States
Duration: 26 Aug 201327 Aug 2013
Conference number: X
https://trove.nla.gov.au/work/194958874?q&versionId=213487214 (Link to Conference Details )

Conference

ConferenceOptical Manufacturing and Testing X
CountryUnited States
CitySan Diego
Period26/08/1327/08/13
Internet address

Fingerprint

Polishing
polishing
Telescopes
Optoelectronic devices
Optics
Mirror
Mirrors
Demonstrations
manufacturing
Manufacturing
Hydraulics
mirrors
Grinding
grinding
Hexagon
Extremely Large Telescopes
tooling
Optoelectronics
Metrology
smoothing

Cite this

Gray, C., Baker, I., Davies, G., Evans, R., Field, N., Fox-Leonard, T., ... Yu, G. (2013). Fast manufacturing of E-ELT mirror segments using CNC polishing. In Optical Manufacturing and Testing X (Vol. 8838). [88380K] https://doi.org/10.1117/12.2023475
Gray, C. ; Baker, I. ; Davies, G. ; Evans, R. ; Field, N. ; Fox-Leonard, T. ; Messelink, W. ; Mitchell, J. ; Rees, P. ; Waine, S. ; Walker, D. D. ; Yu, G. / Fast manufacturing of E-ELT mirror segments using CNC polishing. Optical Manufacturing and Testing X. Vol. 8838 2013.
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abstract = "We report on the first-ever demonstration of grinding and polishing full-size, off-axis aspheric, mirror segments as prototypes for an extremely large telescope, processed entirely in the final hexagonal shape. We first describe the overall strategy for controlling form and mid spatial frequencies, at levels in the vicinity of <10nm RMS surface. This relies first on direct CNC grinding of the base-form of these 1.4m segments, using the Cranfield BoX™ machine. The segments are then mounted on a custom designed (Optic Glyndwr Optoelectronic Engineering Group) three segment hydraulic support, and CNC polished on a Zeeko IRP 1600 machine using a variety of custom tooling. We overview the fullaperture and sub-aperture metrology techniques used to close the process-loop and certify quality, all of which operate with the segment in-situ on the IRP1600. We then focus on the pristine edge-definition achieved by the combination of tool-lift and smoothing operations; results never previously demonstrated on full-size pre-cut hexagonal segments. Finally, the paper discusses the feasibility of scaling the process to deliver 931 segments in seven years, as required for the E-ELT project.",
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Gray, C, Baker, I, Davies, G, Evans, R, Field, N, Fox-Leonard, T, Messelink, W, Mitchell, J, Rees, P, Waine, S, Walker, DD & Yu, G 2013, Fast manufacturing of E-ELT mirror segments using CNC polishing. in Optical Manufacturing and Testing X. vol. 8838, 88380K, Optical Manufacturing and Testing X, San Diego, United States, 26/08/13. https://doi.org/10.1117/12.2023475

Fast manufacturing of E-ELT mirror segments using CNC polishing. / Gray, C.; Baker, I.; Davies, G.; Evans, R.; Field, N.; Fox-Leonard, T.; Messelink, W.; Mitchell, J.; Rees, P.; Waine, S.; Walker, D. D.; Yu, G.

Optical Manufacturing and Testing X. Vol. 8838 2013. 88380K.

Research output: Chapter in Book/Report/Conference proceedingConference contribution

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AU - Baker, I.

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Gray C, Baker I, Davies G, Evans R, Field N, Fox-Leonard T et al. Fast manufacturing of E-ELT mirror segments using CNC polishing. In Optical Manufacturing and Testing X. Vol. 8838. 2013. 88380K https://doi.org/10.1117/12.2023475