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中文核心期刊

基于拓扑优化的增材制造碳化硅反射镜轻薄化设计方法

TOPOLOGY OPTIMIZATION-BASED METHOD FOR LIGHTWEIGHT AND THIN DESIGN OF ADDITIVE MANUFACTURING SILICON CARBIDE PRIMARY MIRROR

  • 摘要: 拓扑优化方法和陶瓷增材制造技术的结合为开发轻质高性能的大口径碳化硅反射镜提供了一种有效的方法. 以反射镜背部支撑结构构型为设计对象, 以最大刚度为目标、反射镜质量为约束, 采用板筋布局与高度协同优化(Heaviside-function based directional growth topology parameterization, H-DGTP)方法建立了具备陶瓷可制造性约束的轻薄化设计方法. 该方法针对典型大口径碳化硅空间反射镜的实际需求, 设计了具有陶瓷可制造性的反射镜镜体轻薄化构型; 进一步采用尺寸优化方法对拓扑优化的反射镜镜体结构进行了重构和精细化设计; 利用 DLP 陶瓷增材制造技术成功制备了反射镜陶瓷样件, 验证了所设计的反射镜镜体轻薄化构型满足陶瓷增材制造的可制造性要求. 对轻薄化设计方案进行了数值仿真, 反射镜法向轴沿x、y和z向自重载荷的均方根RMS值分别为3.27 nm、3.27 nm和7.55 nm, 反射镜面密度为13.21 kg/m2. 分析结果表明优化后的大口径碳化硅空间反射镜在满足面形精度设计要求的同时大幅减轻了反射镜重量, 验证了本文方法在增材制造碳化硅反射镜轻薄化设计方面的有效性.

     

    Abstract: To develop the lightweight and high-performance large-aperture silicon carbide (SiC) space primary mirrors, the combination of topology optimization methods and ceramic additive manufacturing techniques provides an effective strategy. The lightweight and thin design method was designed with the back support structure of the silicon carbide space primary mirror, with the maximum stiffness as the design objective and the total mass of the silicon carbide space primary mirror as the constraint. Additionally, this novel method was designed while considering the ceramic manufacturability constraints, based on the Heaviside-function based directional growth topology parameterization (H-DGTP) method. Firstly, the lightweight and thin design method designed a lightweight and thin configuration of the silicon carbide space primary mirror body with ceramic manufacturability, based on the actual requirements of a typical large-diameter silicon carbide space primary mirror. Then, the size optimization method was used to reconstruct and refine the topology-optimized silicon carbide space primary mirror structure. Furthermore, the ceramic sample of the silicon carbide space primary mirror was successfully prepared by the digital light processing (DLP) ceramic additive manufacturing technology, which verified that the designed lightweight and thin configuration of the mirror body meets the manufacturability requirements of ceramic additive manufacturing. Numerical simulation was carried out for the design scheme of the lightweight and thin method. The root mean square (RMS) values of the silicon carbide space primary mirror normal axis along the x, y, and z directions under self-weight load are 3.27 nm, 3.27 nm, and 7.55 nm, respectively. Moreover, the area density of the silicon carbide space primary mirror is 13.21 kg/m2. The analysis results show that the optimized large-aperture silicon carbide space primary mirror meets the design requirements of surface accuracy and greatly reduces the weight of the mirror. The results verify the effectiveness of the proposed method for the lightweight and thin design of additive manufacturing silicon carbide space primary mirror.

     

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