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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样件,验证了所设计的反射镜满足增材制造的可制造性要求。对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,面密度为13.21 kg/m2。分析结果表明优化后的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 lightweight and high-performance silicon carbide (SiC) primary mirrors, the integration of topology optimization methods with ceramic additive manufacturing techniques provides an effective strategy. The lightweight and thin design method was designed with the back support structure of the primary mirror, with maximum stiffness as the design objective and mass as the constraint. Based on the Heaviside-function based directional growth topology parameterization (H-DGTP) method, a novel method was design while considering the ceramic manufacturability constraints. For typical SiC primary mirror specifications, a lightweight and thin configuration of the primary mirror was obtained that satisfies additive manufacturing requirements. The size optimization method is further adopted to reconstruct and fine-design the topologically optimized mirror structure. Furthermore, a sample primary mirror was fabricated using digital light processing (DLP) additive manufacturing technology, and its manufacturability of additive manufacturing was validated. Numerical simulations of the design scheme showed that the root mean square (RMS) values of the self-weight loads along the x, y and z directions normal to the mirrors were 3.27 nm, 3.27 nm, and 7.55 nm, respectively, with a surface density of 13.21 kg/m2. The analysis results demonstrate that the optimized silicon carbide primary mirror design achieves the target surface accuracy while significantly reducing weight. This study confirms the effectiveness of the proposed method for the lightweight and thin design of additively manufactured SiC space primary mirrors.

     

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